Layerless Additive Manufacturing of Metal Alloy Lattices Using Immiscible-Interface Assisted Direct Metal Drawing
Layerless Additive Manufacturing of Metal Alloy Lattices Using Immiscible-Interface Assisted Direct Metal Drawing
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DOI：
10.1016/j.promfg.2019.06.106
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发表时间：
2019
期刊：
影响因子：
--
通讯作者：
Li He;F. Fei;Wenbo Wang;Xuan Song
中科院分区：
文献类型：
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作者：
Li He;F. Fei;Wenbo Wang;Xuan Song
最新的金属合金添加剂制造(AM)技术通过烧结或熔化干金属粉末逐层构建三维结构，这通常会导致最终结构中出现几个AM特有的问题，如阶梯效应、残余应力和高度取向的微观组织。本文提出了一种新的基于挤压的金属AM工艺，称为非混溶界面辅助直接金属拉拔(II-DMD)，它以无层的方式制造金属合金结构，特别是晶格结构。在II-DMD工艺中，金属晶格结构是通过在第二个不相容的基质胶体悬浮液中连续挤压金属胶体悬浮液来制备的。由于两个胶体悬浮液体系之间存在不相容的界面，金属胶体悬浮液的形状稳定。通过对自稳定的金属基体系进行二次固结，包括液态干燥和金属相烧结，可以获得致密的金属晶格结构。介绍了II-DMD工艺，研究了不相容界面辅助自稳定机理。讨论了固结后的处理过程。制作了几个测试用例，并对其进行了表征。
State-of-the-art metal alloy additive manufacturing (AM) techniques construct a three-dimensional structure through sintering or melting dry metal powders in a layer-by-layer fashion, which typically results in several AM-specific issues in the final structure, such as staircase effect, residual stress and highly-orientated microstructures. In this paper, we present a new extrusion-based metal AM process, named Immiscible-interface assisted Direct Metal Drawing (II-DMD), which fabricates metal alloy structures, in particular lattice structures, in a layerless manner. In the II-DMD process, metal lattice structures are fabricated by continuously extruding a metal colloidal suspension within a second immiscible matrix colloidal suspension. The shape of the metal colloidal suspension is stabilized due to the presence of an immiscible interface between the two colloidal suspension systems. Dense metal lattice structures can be achieved via post-consolidation of the self-stabilized metal-matrix systems, including liquid-phase drying and metal-phase sintering. The II-DMD process is presented and the immiscible-interface-assisted self-stabilization mechanism is studied. The post-consolidation processes are discussed. Several test cases were fabricated and characterized.