SGER: Metal Solid Free Form Fabrication

点击翻译按钮获取中文摘要

9528579 Eagar This small grant for exploratory research will investigate the equipment and control system needed for rapid solid freeform fabrication (SFF) of fully dense metal components. A nozzle deposits layers of metals in their mushy state. The nozzle position and orientation are computer controlled, allowing the freeform shape to be built-up. Using lead-tin alloys, this technique produces non-porous, fully dense freeform structures. When this approach is used with higher melting point alloys like those used for dies and molds, this becomes a viable rapid prototyping process to produce tooling. Exploratory research issues are: the suitability of higher melting point alloys like 6061 and 443 aluminum, models for heat transfer between the SFF surface and injection molded polymer materials, and surface coatings for molding applications. Other issues are controlling the position and orientation of the nozzle, and providing smooth motion and temperature control to achieve controlled material properties. This research will lead to a viable rapid prototyping process that can quickly produce tooling for short to medium runs of injection molded or die cast products. ***