Laser-Induced Materials and Processes for Rapid Prototyping

By: Li LÃ¼, J. Fuh, Yoke-San Wong

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Hardcover | 30 June 2001

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288 Pages

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The term rapid prototyping (RP) refers to a generic group of emerging technologies that enable very quick fabrication of engineering components primarily targeted for prototyping applications. With RP, very complex three dimensional parts or prototypes can be fabricated without the need of costly tooling and machining. This inevitably leads to much shorter design cycle time and lower cost of building a prototype. Its manifold benefits include significant productivity gains, cost saving, and shortened development time to introduce concept models. As such, RP technologies have attracted tremendous R&D interests from both academia and industry in the past decade. Many different processes and materials have been commercialized and used in industry primarily for the fabrication of physical prototypes. More recent interests in RP technologies are towards functional applications of the fabricated parts, such as in rapid tooling applications and replacements of damaged components. Many processes and materials have been commercialized but are yet to be able to fulfill the aforementioned functional requirements because of limited mechanical strengths of the fabricated parts.

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Preface	p. XI
Acknowledgements	p. XV
Introduction	p. 1
Overview of rapid prototyping and manufacturing	p. 1
Laser-induced rapid prototyping	p. 2
Laser-lithography (LL) process	p. 2
Selective laser sintering process	p. 3
RP process characterization and modeling	p. 5
RP technology trends	p. 6
References	p. 7
Fundamentals of Laser-lithography Processes	p. 9
Laser-lithography	p. 9
Laser scanning in LL process	p. 9
Laser-lithography systems	p. 10
Laser systems	p. 11
Control software	p. 13
Fundamental relationships	p. 13
Working curve	p. 13
Intensity profile	p. 15
Process parameters	p. 17
Profile of scan lines	p. 21
Single-scan line	p. 21
Multi-scan line and layer	p. 25
Characteristics of photo-polymerization	p. 28
Properties of photo-polymer	p. 28
Photo-polymerization	p. 29
Over-curing and over-penetration	p. 30
Focus effect on the curing profile	p. 34
Summary	p. 37
References	p. 37
Material Characterization of Laser-lithography Built Parts	p. 39
Mechanical properties of LL parts	p. 39
Properties at green state	p. 40
Properties after post-curing	p. 42
Density change	p. 43
Shrinkage and distortion	p. 43
Thermal post-curing	p. 45
UV post-curing	p. 47
Analyses of degree of curing	p. 49
Raman spectrum analysis	p. 49
DSC analysis	p. 51
Processes	p. 52
Analyses	p. 53
Distortion analysis by Moire method	p. 57
Principles	p. 57
Formation of Moire fringes	p. 58
Displacement-field method for Moire-fringe pattern analysis	p. 59
Processes	p. 60
Analyses	p. 61
Summary	p. 64
References	p. 64
Improvements of Mechanical Properties by Reinforcements	p. 67
Introduction	p. 67
Fiber-reinforced photo-polymer	p. 67
Basic principles and theory	p. 68
Modeling of short fiber composite	p. 70
Young's modulus and strength	p. 72
AEROSIL-mixed photo-polymer	p. 75
Support-less modeling	p. 76
Layer coating process	p. 76
Improvements in LL-process	p. 77
Mechanical properties	p. 77
Fiber-reinforced LL parts	p. 77
AEROSIL-mixed LL parts	p. 80
Shrinkage and distortion	p. 81
Reduction of support and build time	p. 84
Summary	p. 87
References	p. 87
Selective Laser Sintering	p. 89
Principle of laser sintering	p. 89
Fundamentals of laser processing	p. 89
Absorptance of laser energy	p. 89
Process of selective laser sintering	p. 91
Process	p. 92
Types of SLS	p. 93
Indirect SLS	p. 93
Direct SLS	p. 94
Deoxidization	p. 97
Effect of laser sintering parameters	p. 97
Liquid phase sintering in SLS	p. 99
Fundamentals of liquid-phase sintering	p. 99
Binding mechanisms for liquid-phase sintering	p. 100
Influence of solubility	p. 104
Commercial applications	p. 104
Development of SLS	p. 104
DTM's RapidSteel and copper polyamide material	p. 106
EOS process	p. 106
EOSINT M	p. 106
EOS materials	p. 108
EOSINT M 250 sintering process	p. 109
Post process	p. 109
Metal powders for laser sintering	p. 110
Development of laser sintering powder in general	p. 110
Bronze-Ni powder	p. 112
Cu-Sn powder	p. 113
EOS powder	p. 115
Powder	p. 115
Role of Cu[subscript 3]P in DMLS of Cu-Ni materials	p. 115
Hot isostatic pressing of DMLS bronze-Ni parts	p. 116
DirectSteel 50V 1 (Steel-based powder)	p. 116
Tungsten carbide-cobalt powder	p. 117
Steel powder	p. 117
Carbon steel	p. 118
P20 and H13 steels	p. 119
Fe-based powder	p. 120
Stainless steel	p. 120
316L Stainless steel powder	p. 120
17-4PH	p. 120
DTM powder	p. 121
Copper polyamide	p. 122
RapidSteel 1.0 metal	p. 123
RapidSteel 2.0 metal	p. 123
Process	p. 124
Mareco's RandD powder	p. 125
Nickel alloy	p. 125
Inconel 625 superalloy	p. 125
Titanium alloy	p. 126
Densification	p. 129
Post sintering	p. 129
Infiltration	p. 131
Cu and bronze infiltration	p. 133
Epoxy infiltration	p. 134
Hot isostatic pressing	p. 134
Mechanical property	p. 137
Summary	p. 138
References	p. 139
Metal-Based System via Laser Melting	p. 143
Selective laser melting process	p. 143
Selective laser cladding	p. 143
Rapid prototyping using selective laser cladding process	p. 143
Design of nozzle	p. 145
Selective laser melting	p. 146
Rapid prototyping using selective laser melting process	p. 146
Process control	p. 147
Laser power and energy density	p. 147
Scan speed	p. 148
Scan pitch	p. 151
Thickness of track	p. 152
Metal powders	p. 153
Ti system	p. 153
Iron-based system	p. 155
Copper-based system	p. 160
Cu-Ni system	p. 160
Cu-W system	p. 163
Influence of Ni on Cu-W system	p. 166
Composites	p. 171
Composite system using ex-situ processing	p. 171
Principle of ex-situ process	p. 171
Composite system using in-situ processing	p. 173
Principle of in-situ reaction	p. 173
Formation of TiC via element reaction	p. 174
Influence of addition of Ni	p. 176
Formation of TiC and TiB[subscript 2]	p. 178
Summary	p. 184
References	p. 185
Laser Sintering of Ceramics	p. 187
Fabrication of ceramic parts using SLS	p. 187
Process	p. 188
SLS of ceramic parts	p. 190
SLS with infiltration	p. 190
SLS with reactive binder	p. 193
SLS with infiltration reaction	p. 194
Selective laser reaction sintering	p. 195
SLS of ceramics with metal binder	p. 196
SLS nano-sized powder	p. 196
Summary	p. 197
References	p. 198
Characterization, Modeling and Optimization	p. 201
Introduction	p. 201
Modeling of RP part fabrication	p. 202
RP processes	p. 203
Surface roughness of a green part	p. 204
Surface roughness due to staircase effect	p. 206
Part fabrication time	p. 209
Part fabrication cost	p. 211
Optimal orientation	p. 215
Orientation candidates for RP part fabrication	p. 215
Single-criterion optimal orientation	p. 216
Quantification of building inaccuracy	p. 218
Part stability during the building process	p. 222
Effect of part orientation on manufacturing time	p. 223
Multi-criterion optimization techniques	p. 223
Direct slicing of CAD models	p. 225
Adaptive thickness slicing and cusp height tolerance	p. 225
Maximum allowable layer thickness based on curvature	p. 227
Surface normal curvature	p. 227
Surface normal curvature along the building direction	p. 228
Computing the maximum layer thickness at a point on the surface	p. 229
Optimal layer thickness at reference height	p. 229
One-dimension search problem	p. 230
Genetic algorithm for one-dimensional search	p. 231
Implementation of adaptive slicing algorithm	p. 232
Decision support for process optimization and selection	p. 236
Knowledge-based RP material/machine selection	p. 237
Knowledge-based systems and RP part fabrication	p. 237
Summary	p. 238
References	p. 238
Rapid Tooling and Its Applications	p. 241
Rapid tooling development	p. 241
Rapid tooling techniques and applications	p. 242
Direct tooling	p. 243
Indirect tooling	p. 246
Comparison of RT techniques	p. 248
RT for injection molding--a case study	p. 249
Design and fabrication processes	p. 251
Performance evaluation	p. 254
Application to EDM electrode fabrication	p. 256
Indirect sintered or formed electrodes	p. 257
Direct laser-sintered electrodes	p. 259
Summary	p. 261
References	p. 261
Index	p. 263
Table of Contents provided by Syndetics. All Rights Reserved.

Laser-Induced Materials and Processes for Rapid Prototyping

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