SGER: Metal Solid Free Form Fabrication

小行星9528579 这项探索性研究的小额赠款将调查完全致密金属部件的快速固体自由成形制造（SFF）所需的设备和控制系统。 一个喷嘴沉积成糊状的金属层。 喷嘴的位置和方向是由计算机控制的，允许自由成形的形状。 使用铅锡合金，这种技术产生无孔，完全致密的自由形式的结构。当这种方法用于高熔点合金时，如用于模具和模具的合金，这成为一种可行的快速原型制造工艺。 探索性研究问题包括：高熔点合金如6061和443铝的适用性，SFF表面和注塑聚合物材料之间的热传递模型，以及模塑应用的表面涂层。 其他问题是控制喷嘴的位置和方向，并提供平滑的运动和温度控制，以实现受控的材料特性。 这项研究将导致一个可行的快速成型工艺，可以快速生产模具的短期到中期运行的注塑或压铸产品。 ***

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. ***