Electrochemical Infiltration of Selective Laser Sintered Preforms

该奖项是根据2009年美国复苏和再投资法案（公法111-5）资助的。提出的研究目标是利用电沉积技术设计制造全致密金属-非金属选择性激光烧结零件的制造路线。该方法将适应和改进传统的电化学沉积/涂层技术，以应用于多孔预制体的内部沉积，以填充相互连接的孔隙。研究的一个重要部分是建立对多孔选择性激光烧结预制体中金属的电化学渗透/沉积的科学理解。如果成功，这项工作的好处将包括开发一种真正新颖的方法来有效地实现渗透。这将促进选择性激光烧结从快速成型方法向快速/增材制造技术的过渡。对于在室温下制造低成本、复杂几何形状的金属渗透复合材料的新制造路线来说，去除孔隙率是发展和成熟的主要科学障碍。电化学渗透的主要优点之一是处理温度较低。低温降低了能源消耗和相关的碳足迹，也最大限度地减少了不必要的结构变化。拟议的研究结果还将为低成本生产提供一种工具，从而影响国内各种零部件的竞争。提议的过程将显著降低工具和制造成本。

This award is funded under the American Recovery and Reinvestment Act of 2009 (Public Law 111-5).The research objective of the proposed research is to employ electrodeposition techniques in the design of a manufacturing route for creation of fully dense metal-nonmetallic selective laser sintered parts. The approach will be to adapt and modify conventional electrochemical deposition/coating techniques to apply to internal deposition on porous preforms to fill in interconnected porosity. A significant part of the research involves establishment of a sound scientific understanding for electrochemical infiltration/deposition of metal within porous selective laser sintered preforms.If successful, the benefits of this work will include the development of a truly novel method to effectively achieve infiltration. This will facilitate transition of selective laser sintering from a rapid prototyping method to a rapid/additive manufacturing technique. Porosity removal represents the major scientific barrier to development and maturation of a new manufacturing route for creating low-cost, metal-infiltrated composites with complex geometry at room temperature. One of the major advantages of electrochemical infiltration is the lower processing temperature. Low temperature reduces both energy consumption and associated carbon-footprint and also minimizes undesirable structural changes. The results of the proposed research will also impact domestic competition for a variety of parts in manufacture by providing a vehicle for low-cost production. The proposed process would significantly reduce tooling and manufacturing costs.