Ricoh Company, Ltd., based in Kanagawa, Japan, has developed an innovative diffusion bonding technology that improves the process of joining aluminium parts fabricated using Binder Jetting (BJT) to wrought aluminium alloys. This new technique not only allows for the production of larger parts but also has the potential to reduce manufacturing costs.

Overcoming Binder Jetting Limitations with Diffusion Bonding

Metal Binder Jetting (BJT) is a cost-effective Additive Manufacturing technology known for its high productivity, making it suitable for prototyping and mass production. However, due to the sintering process involved, achieving dimensional accuracy with larger parts can be challenging.

Ricoh’s diffusion bonding technology solves this problem by using a proprietary liquid-phase sintering method. This process enables the joining of sintered aluminium BJT parts to traditional wrought aluminium alloys like 6061 and 1050. The new bonding technology is particularly useful for applications such as high-efficiency heat exchangers, where both complex geometries and dimensional accuracy are required.

One key application involves fabricating complex fins using BJT and bonding them to an aluminium case made using traditional methods. The result is a component that offers highly efficient cooling performance thanks to the complex fin shapes, while the case’s machining accuracy ensures the overall component maintains its dimensional integrity.

Potential for Larger Components and Cost Reduction

Ricoh’s new diffusion bonding method has been successfully tested with components such as a large cooling part measuring 400 mm x 160 mm x 10 mm. By combining the bonding process with conventional brazing, the company can produce large components that were previously difficult to manufacture using BJT alone.

Ricoh’s technology is also compatible with various aluminium alloys, including 6063, and has been shown to work effectively for both the BJT fabrication and bonding processes. This innovation could lead to significant cost reductions in manufacturing and enable the production of larger, more complex components.

Takafumi Sasaki, head of Ricoh’s metal BJT project, emphasized the advantages of this technology, stating that it would improve cooling efficiency, reduce costs, and facilitate larger component sizes. Ricoh plans to further explore its feasibility in real-world applications through collaborations with customers.

www.ricoh.com