Surface Structuring Of Advanced Materials At Room Temperature On A Benchtop

Currently, near-net shaping of advanced materials, such as Inconel 718, is performed using energy-intensive methods that require specialized and costly equipment. Additionally, the most advanced additive manufacturing methods can only process one workpiece at a time, leading to longer work times that are not suitable for large-scale production. This study proposes a method for forming a green body of Inconel 718 powder through the use of polyvinyl alcohol (PVA) via homogeneous coagulation in water. The as-prepared green body has a dough-like rheology and it could be shaped by hand or pushed into a mold eliminating the hurdles, such as waiting for the evaporation of water in slip casting. Furthermore, the dough-like rheology allows the application of patterns onto the metal surface via stamps, wheels, or rollers with forces that are on the order of 10 N. The use of self-standing and malleable metal dough systems enables the creation of customized geometries with high fidelity in a short time, without the need for specialized and costly equipment, at room temperature and atmospheric pressure. This study establishes a foundational basis for this method and paves the way for further advancements in the process, rendering it accessible even in frugal environments for individuals and SMEs without domain knowledge and with limited equipment.