Improving the Binder Jetting Gear Performance Through Shot Peening

Additive manufacturing through Binder Jetting (BJT) has emerged as a promising technique for the production of complex metallic components, including gears.However, its inherent porosity and heterogeneous densification pose significant challenges for surface integrity and contact strength.This work investigates the use of post-processing strategies to improve the load-carrying capacity of BJT parts, focusing on the application of shot peening as a dual action technique: increasing surface densification and inducing compressive residual stresses.An experimental campaign was conducted, covering the manufacture, postprocessing and mechanical testing of specimens subjected to different process chains.Surface and subsurface characterizations, including porosity and residual stress profiles, were carried out to evaluate the effects of post-processing.The mechanical response was assessed using rolling contact fatigue tests .Weibull statistical analysis was used to compare the contact strength between the routes.The results show that shot peening significantly improves fatigue life by closing surface pores and introducing beneficial residual stress states, even in samples with relatively low initial density.This study contributes to a better understanding of the failure mechanisms associated with BJT and proposes a replicable post-processing strategy aimed at extending the service life of functional components manufactured in sub-optimal density conditions.VII.Improving the Binder Jetting Gear Performance Through Shot Peening -Matheus Rubik, M.Sc.(ITA) VII -2 Outlooks 4.