Process and Properties Control in Laser Aided Direct Metal/Materials Deposition Process

Manufacturing ◽  
2002 ◽  
Author(s):  
J. Choi
Keyword(s):  
Solid Freeform Fabrication ◽  
Laser System ◽  
Deposition Process ◽  
Cad Model ◽  
Metal Powders ◽  
Influence Of Process Parameters ◽  
Freeform Fabrication ◽  
Material Deposition ◽  
Nc Machine ◽  
Metallic Parts

Laser aided direct metal/material deposition (DMD) process, one of the technologies based on laser cladding, has demonstrated the ability to make a metal component directly from a 3-D CAD model. DMD process is achieved with a laser system combined with a NC machine tool or laser-robot system. Making metallic parts directly, designer can reduce unnecessary steps such as mock-up and molding. In the sense, DMD process is rather a rapid production technique than a rapid prototyping process. With continued advancement, DMD process, one of the leading solid freeform fabrication techniques, has demonstrated the ability to make a metal part with heterogeneous components directly from a CAD model. One unique advantage of the process is that building different metallic parts in same object can be achieved alternating metal powders. The advantage gives designers better quality of products than others can offer. Another attractive point is that some features such as cooling channel, heat sinks, sensors, fibers, and even hard phases for composites can be embedded during the process. This paper summarizes the fundamentals of the process, process control and influence of process parameters, and reports some examples produced utilizing the technique with the characteristics of fabricated parts.

Distributed-Parameter Modeling for Geometry Control of Manufacturing Processes With Material Deposition

1998 ◽  
Vol 122 (1) ◽  
pp. 71-77 ◽  
Author(s):  
Charalabos Doumanidis ◽  
Eleni Skordeli
Keyword(s):  
Solid Freeform Fabrication ◽  
Surface Topology ◽  
Distributed Parameter ◽  
Surface Geometry ◽  
Mass Source ◽  
Freeform Fabrication ◽  
Geometry Model ◽  
Material Deposition ◽  
Solid Objects ◽  
3D Solid

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]

scholarly journals A Study of the Solid Freeform Fabrication (SFF) System with Dual Laser System

2006 ◽  
Vol 49 (4) ◽  
pp. 1215-1222 ◽  
Author(s):  
Dong Soo KIM ◽  
Young Jin AHN ◽  
Won Hee LEE ◽  
Sung Woo BAE ◽  
Kyung Hyun CHOI
Keyword(s):  
Solid Freeform Fabrication ◽  
Laser System ◽  
Freeform Fabrication ◽  
Dual Laser

Bone Tissue Scaffold Technologies Based on RP Adopted Droplet Assembly

2002 ◽  
Vol 758 ◽  
Author(s):  
Renji Zhang ◽  
Yongnian Yan ◽  
Feng Lin
Keyword(s):  
Tissue Engineering ◽  
Bone Tissue ◽  
Solid Freeform Fabrication ◽  
Deposition Process ◽  
Layer By Layer ◽  
Tissue Engineering Scaffolds ◽  
Molecular Scaffold ◽  
Tissue Scaffold ◽  
Freeform Fabrication ◽  
Assembly Technology

ABSTRACTTissue engineering tries to grow replacement tissues to repair damaged bones. In this paper, the fabrication technology of Multi-nozzle Deposition Manufacturing (MDM) was adopted to fabricate scaffolds of a tissue engineered bone at low temperature. The composite of poly(L-lactic acid) and tri-calcium phosphate (TCP) was chosen to form bone tissue engineering scaffolds. The new computer aided manufacturing process can make porous PLLA/TCP scaffolds. A new surface processing technology of apatite coating on bone tissue engineered scaffolds was also adopted. This digital forming technology was based on rapid prototyping (RP), in which a digital droplets assembly technology was introduced. The MDM technology of 4 nozzles was developed based on the layer-by-layer manufacturing principle of Solid Freeform Fabrication (SFF) in our laboratory. The bone scaffolds made by the multi-nozzle deposition process in the MDM system have good biocompatibility and bone conductive properties as a molecular scaffold for bone morphogenic protein (BMP) in the implantation experiment of repairing segment defects in rabbits' and dogs' radiuses.

Solid Freeform Fabrication of Ceramics Using Selective Laser Sintering and Selective Area Laser Deposition

1991 ◽  
Vol 249 ◽  
Author(s):  
Uday Lakshminarayan ◽  
Guisheng Zong ◽  
W. Richards Thissell ◽  
Harris L. Marcus
Keyword(s):  
Gas Phase ◽  
Solid Freeform Fabrication ◽  
Laser System ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Laser Deposition ◽  
Powder Materials ◽  
Freeform Fabrication ◽  
Selective Area

ABSTRACTSolid Freeform Fabrication (SFF) is a new computer fabrication technique that does not require any part specific tooling. The starting material can be either solid, liquid or gaseous. The part can be made from metallic, ceramic, polymeric or a composite material. The concept is to use a solid modeling system to define the part of interest and to reduce the model to a set of toggle point data that totally define the geometry. In Selective Laser Sintering the sectioned component is then combined with a rastered laser system that impinges on the precursor powder materials in a layered reconstruction of the three dimensional CAD designed part. The part is then formed in this manner. This approach to producing the part involves a great deal of understanding of the laser materials interactions, the appropriate choice of materials specific to this processing and how the total process integrates. Application to ceramic powders will be described. An alternative approach to SFF is Selective Area Laser Deposition where the three dimensional part is made from the gas phase. The initial gas deposition studies involving deposition of carbon from hydrocarbons will be discussed. For both of the above SFF approaches the laser beam powder and gas phase interactions and the microstructure of the resulting three dimensional forms as a function of system parameters will be described.

A Process Map for Consistent Build Conditions in the Solid Freeform Fabrication of Thin-Walled Structures

2000 ◽  
Vol 123 (4) ◽  
pp. 615-622 ◽  
Author(s):  
Aditad Vasinonta ◽  
Jack L. Beuth ◽  
Michelle L. Griffith
Keyword(s):  
Solid Freeform Fabrication ◽  
Numerical Models ◽  
Thermal Control ◽  
Process Map ◽  
Freeform Fabrication ◽  
Thin Walled Structures ◽  
Melt Pool ◽  
Material Deposition ◽  
Thin Walled ◽  
Net Shaping

In solid freeform fabrication (SFF) processes involving thermal deposition, thermal control of the process is critical for obtaining consistent build conditions and in limiting residual stress-induced warping of parts. In this research, a nondimensionalized plot (termed a process map) is developed from numerical models of laser-based material deposition of thin-walled structures. This process map quantifies the effects of changes in wall height, laser power, deposition speed and part preheating on melt pool length, which is an essential process parameter to control in order to obtain consistent build conditions. The principal application of this work is to the Laser Engineered Net Shaping (LENS) process under development at Sandia Laboratories; however, the general approach and a subset of the presented results are applicable to any SFF process involving a moving heat source. Procedures are detailed for using the process map to predict melt pool length and predictions are compared against experimentally measured melt pool lengths for stainless steel deposition in the LENS process.

Laser Cladding Based Solid Freeform Fabrication and Direct Metal Deposition

2006 ◽  
Author(s):  
Huan Qi ◽  
Jyotirmoy Mazumder
Keyword(s):  
Laser Beam ◽  
Laser Cladding ◽  
Solid Freeform Fabrication ◽  
Three Dimensional ◽  
High Energy ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Effective Control ◽  
Metal Powders ◽  
Freeform Fabrication

Three-dimensional additive manufacturing or solid freeform fabrication (SFF) techniques, originated in the rapid fabrication of non-functional physical prototypes in polymers (Rapid Prototyping), have matured to the manufacture of functional prototypes, short-run production products, and now even advanced engineering designs. Laser-based material deposition or laser cladding has been used as a SFF technique, in which a laser beam is used as a precise high-energy thermal source to melt preplaced or pneumatically delivered metal powders and make solidified deposits on a substrate. By using laser cladding techniques, three-dimensional fully dense components can be built line-by-line and layer-by-layer directly from a CAD model with tailored material properties. Laser cladding is essentially a fusion and solidification (thermal) process, which involves complicated interactions between the laser beam, metal powders, the base material (substrate), and processing gases. Maintaining a stable and uniform melt pool during laser cladding is critical to produce dimensional accuracy and material integrity. An effective control of energy (laser power) spatial and temporal distributions in either an open-loop or closed-loop laser cladding process is essential to achieve the high quality results. This paper reviews, from a laser-material interaction point of view, various laser cladding based SFF processes, and particularly the direct metal deposition technique.

Development of Industrial SFF System Using a New Selective Dual-Laser Sintering Process

2006 ◽  
Vol 326-328 ◽  
pp. 123-126 ◽  
Author(s):  
Won Hee Lee ◽  
Dong Soo Kim ◽  
Young Jin Ahn ◽  
Byung Oh Choi ◽  
Kyung Hyun Choi
Keyword(s):  
Solid Freeform Fabrication ◽  
Laser System ◽  
Selective Laser Sintering ◽  
Great Influence ◽  
Laser Sintering ◽  
Beam Power ◽  
Sintering Process ◽  
Large Area ◽  
Freeform Fabrication ◽  
Dual Laser

In order to develop more elaborate and speedy system for large objects than existing selective laser sintering (SLS), this study applies a new selective dual-laser sintering process. It contains a 3-axis dynamic focusing scanner system for scanning large area instead of the existing fθ lens. As sintering parameters, the sintering temperature, the laser beam power and the layer thickness have a great influence on sintering of the polymer and metal powder. This paper will address the development of a solid freeform fabrication (SFF) system employing the dual laser system. Experiments were performed to evaluate the effect of a scanning path and to fabricate the large-sized object.

A Network Based Modelling Approach Using the Dimensional Analysis Conceptual Modeling (DACM) Framework for Additive Manufacturing Technologies

2016 ◽  
Author(s):  
Hossein Mokhtarian ◽  
Eric Coatanéa ◽  
Henri Paris ◽  
Tuomas Ritola ◽  
Asko Ellman ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Dimensional Analysis ◽  
System Architecture ◽  
Conceptual Modeling ◽  
Deposition Process ◽  
Illustrative Case ◽  
Influence Of Process Parameters ◽  
Modelling Framework ◽  
Material Deposition ◽  
Manufacturing Technologies

The application of additive manufacturing technologies in the industry is growing fast. This leads to an increasing need for reliable modeling techniques in the field of additive manufacturing. A methodology is proposed to systematically assess the influence of process parameters on the final characteristics of additively manufactured parts. The current study aims at presenting a theoretical framework dedicated to the modeling of the additive manufacturing technology. More specifically, the framework is used in the context of the study to plan and optimize the experimental process to minimize the amount of experiments required to populate the model. The framework presented is based on the Dimensional Analysis Conceptual Modelling framework (DACM). DACM is an approach supporting the production of models. This approach is designing networks representing a system architecture and behavior using an approach sharing similarities with neural networks. Based on the proposed approach, it is possible to detect where supplementary experimental data have to be collected to complete the model generated by the DACM approach. The modeling of the Direct Material Deposition process is conducted as an illustrative case study. The scope of the approach is vast and supported by validated scientific methods combined to form the core of the DACM method. The DACM framework is step by step extracting information from a description of the system architecture to create semi-automatically a model that can be simulated and used for multiple types of analyses associated for example with innovation and design improvement. The current paper will focus on the usage of the DACM framework, recently developed in a project, in the field of additive manufacturing.

On the Rapid Prototyping Technologies and Applications in Product Design and Manufacturing

2012 ◽  
Vol 710 ◽  
pp. 101-109 ◽  
Author(s):  
Pulak M. Pandey
Keyword(s):  
Rapid Prototyping ◽  
Material Removal ◽  
Solid Freeform Fabrication ◽  
Functionally Graded ◽  
Layer By Layer ◽  
Data Preparation ◽  
Freeform Fabrication ◽  
Material Deposition ◽  
Design And Manufacturing ◽  
Graded Material

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.

Sign in / Sign up

Export Citation Format

Share Document