Solid Freeform Fabrication of Intermetallics and Their Ceramic Composites by Reactive Rapid Prototyping

Author(s):  
Kiyotaka Matsuura ◽  
Masayuki Kudoh ◽  
Soshu Kirihara ◽  
Yoshinari Miyamoto
Author(s):  
Noshir Langrana ◽  
Dan Qiu ◽  
Guohua Wu ◽  
Kathryn Higgins ◽  
Cheng Tiao Hsieh

Abstract Development of Solid Freeform Fabrication (SFF) systems has created the opportunity for new approaches in design of functional components, which leverages the inherent strengths of both experiment and numerical simulation. This paper describes an approach in which the computational models are integrated with the rapid prototyping fabrication processes. The parts are fabricated using different materials including wax, PZT, silicone nitride, and 17-4PH stainless steel powders for the SFF hardware (Langrana et al, 2000, Qiu et al, 1999, Danforth et al, 1998) and Ciba-Geigy SL-resin for SLA hardware (Higgins and Langrana, 1998, Higgins and Langrana 1999). The components such as turbine blades, actuators, and fixtures have been designed, simulated and fabricated. The properties of parts have been and are being quantified in terms of accuracy and quality.


2012 ◽  
Vol 710 ◽  
pp. 101-109 ◽  
Author(s):  
Pulak M. Pandey

Material removal, forming, casting and joining are the established manufacturing approaches and processes based on these approaches are being practiced even in modern industries with appropriate automation. Layer by layer material deposition method to produce prototypes from a solid model is relatively new and was developed during last 10-15 years of 20th century. These processes were named as Rapid Prototyping (RP) or Solid Freeform Fabrication (SFF). Today there are many commercial RP system and most of these able to deposit liquid or solid/powder polymer based materials. Some systems are also able to deposit blends of polymer and metal or ceramic. Latest trend in this area is to deposit metals or alloys with variable composition and hence to produce functionally graded material. This paper describes in general the details related to RP processes, data preparation, and various commercial RP technologies. The article also discusses applications these processes.


Author(s):  
Harald E. Otto ◽  
Fumihiko Kimura ◽  
Ferruccio Mandorli ◽  
Umberto Cugini

Abstract Due to life cycles of artifacts, which become shorter, rapid prototyping development and tight feedback among product requirements, design, and manufacturing are gaining increasing importance. Classical rapid prototyping technologies such as computer-numerically-controlled (CNC) machinery, which remain still time consuming and expensive, are getting superseded by a growing propensity to apply new solid freeform fabrication (SFF) technologies, which became commercially available since 1987. Although, being on the market for only less than a decade, remarkable progress in various directions such as accuracy, used materials, through-put, and equipment costs, has been achieved in SFF technologies. However, there are still several technological as well as methodological problems left. Within given scope, we would like to tackle some, taken from the methodological field, which seems still weakly developed compared to existing technology. Within our approach we apply feature-based models and techniques, realized within typed attributed entity (TAE) structures. In particular, we are interested in the handling of additional fabrication relevant form structures and the automatic determination of fabrication parameters. To verify developed methodologies and to demonstrate the applicability of our taken approach, several selected parts, taken from precision machinery engineering and aerospace engineering were modeled and processed. An implemented prototype environment and a stereolithography apparatus (SLA) were used for integrated knowledge handling, computation and SFF fabrication.


2001 ◽  
Author(s):  
D. L. Bourell ◽  
J. J. Beaman ◽  
Jr

1998 ◽  
Vol 122 (1) ◽  
pp. 71-77 ◽  
Author(s):  
Charalabos Doumanidis ◽  
Eleni Skordeli

Recent solid freeform fabrication methods generate 3D solid objects by material deposition in successive layers made of adjacent beads. Besides numerical simulation, this article introduces an analytical model of such material addition, using superposition of unit deposition distributions, composed of elementary spherical primitives consistent with the mass transfer physics. This real-time surface geometry model, with its parameters identified by in-process profile measurements, is used for Smith-prediction of the material shape in the unobservable deposition region. The model offers the basis for a distributed-parameter geometry control scheme to obtain a desired surface topology, by modulating the feed and motion of a moving mass source. The model was experimentally tested on a fused wire deposition welding station, using optical sensing by a scanning laser stripe. Its applications to other rapid prototyping methods are discussed. [S0022-0434(00)02301-7]


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