STTR Phase I: Rapid Freeze Prototyping of Investment Cast Thin Wall Metal Matrix Composites

小型企业技术转移研究（STTR）第一阶段项目将确定通过快速冷冻成型（RFP）生产薄壁模型的可行性以及薄壁冰模型熔模铸造的可行性。该项目的总体目标是将RFP与熔模铸造相结合，生产薄壁金属基复合材料。RFP是一种新型的固体自由曲面制造工艺，通过逐层沉积和快速冻结水，根据CAD模型构建三维冰部件。与现有的商业固体自由成形制造工艺相比，RFP的优点包括：表面光洁度高，尺寸精度好，能耗低，在铸造和成型应用中易于去除图案。该研究将复合铸造技术从目前可用的0.4-0.6mm壁厚扩展到小于0.3mm。快速冷冻成型与熔模铸造相结合，生产薄壁金属基复合材料（MMC），与生产高刚度、轻量化、薄壁或形状复杂的小批量军事和商业应用部件的替代技术相比，将是一项具有竞争力的利基技术。

The Small Business Technology Transfer Research (STTR) Phase I project will determine the feasibility of thin-wall pattern production by rapid freeze prototyping (RFP) and the feasibility of investment casting with thin-wall ice patterns. The overall goal of the project then is to use RFP in conjunction with investment casting to produce thin-wall metal matrix composites. RFP is a novel solid freeform fabrication process that builds a three dimensional ice part according to a CAD model by depositing and rapidly freezing water in a layer-by-layer manner. Advantages of the RFP, when compared to existing commercial solid freeform fabrication processes include: fine surface finish, good dimensional accuracy, low energy consumption, and ease of pattern removal in casting and molding applications. The proposed research will extend composite casting technology from the currently available wall thickness of 0.4-0.6mm down to less than 0.3mm. Rapid freeze prototyping in conjunction with investment casting to produce thin-wall metal matrix composites (MMC) would be a competitive niche technology compared to alternatives for production of high stiffness, lightweight, and thin-walled or intricately shaped components in low volume for both military and commercial applications.