Binder jetting in gears

Abstract Due to near netshape production, powder metallurgically manufactured (PM) gears have a high potential to increase cost and resource efficiency. Compared to conventionally machined gears, the advantages of PM gears are the different local density distribution in the component and the potential integration of secondary design elements. These advantages are accompanied by the reduction of weight and the possibility of optimizing the NVH-behavior of a gear. PM gears may be manufactured by both, die pressing and additive manufacturing (AM). The powder bed-based additive manufacturing processes for metals can be classified into binder-based (e.g. Binder Jetting, BJT) and beam-based thermal processes (e.g. Laser Powder Bed Fusion, LPBF). Due to the specific process technology, the manufacturing of PM gears by die pressing is only economical for large batch sizes in series production. For small batches, AM offers an approach to manufacture gears that meet the requirements in terms of quality, strength, acoustics and economic efficiency of the manufacturing process. This report describes the potential of BJT gears made of stainless steel 17-4PH (X5CrN-CuNb16-4) with a relative density of ρ 0,rel ≈ 99% regarding the tooth bending strength. The reliability of the process and thus the tooth bending strength can be increased further by a specific adjustment of process parameters. Subsequently, the gears are tested with regard to the tooth bending strength on the pulsator test rig. The results are summarized in a SN-curve.