Support-Free Infiltration of Selective Laser Sintered (SLS) Silicon Carbide Preforms

Non-metallic objects are often difficult to manufacture due to high melting temperatures, poor sinterability, limited ductility, and difficulty in machining. Freeform fabrication techniques coupled with liquid infiltration offer a cost-effective and rapid manufacturing mechanism for composite parts with complex geometry and adequate properties. Selective laser sintered (SLS) silicon carbide (SiC) preforms infiltrated with liquid silicon develop localized infiltrant overextrusions onto surfaces and at surface irregularities. Several shrinkage mechanisms including densification were studied as possible causes of these overfilling extrusions, and the results are discussed below. This research was supported by NSF Grant Number DMI-0522176.Mechanical Engineerin

SLS Materials Development Method for Rapid Manufacturing

As soon as SFF technology development began to make Rapid Prototyping possible the interest in Rapid Manufacturing (RM) began to grow. The advantages in terms of functional integration, elimination of tooling and fixtures and mass customization make a compelling case for RM, leading some in the field to call it the next industrial revolution. Yet without the materials properties necessary to provide the function and variety currently available from mass production methods, the application of RM will remain limited. Developing new materials for the SLS process, one immediate step toward a larger portfolio of RM materials, is very challenging. The formation of high quality SLS parts relies on appropriate powder characteristics, thermal cycles and sintering behavior. Based on a brief examination of the key factors in SLS processing and a research project to develop a new binder material for Silicon Carbide composites, a systematic materials development method is proposed in this paper. The method provides guidance for introducing new SLS materials, support for educating new SLS users and researchers and direction for several future research projects.Mechanical Engineerin

Rapid Manufacturing of Silicon Carbide Composites

From the earliest days of SFF technology development, a viable technique for the direct manufacture of fully-functional parts has been a major technology goal. While direct metal methods have been demonstrated for a variety of metals including aluminum, steel and titanium, they have not reached wide commercial application due to processing speed, final material properties and surface finish. In this paper the development of an SLS-based rapid manufacturing (RM) platform is reviewed. The core of this platform is a thermosetting binder system for preform parts in contrast to the thermoplastic materials currently available for SLS. The preforms may include metal and/or ceramic powders. A variety of fully functional parts can be prepared from different combinations of materials and post processing steps including binder pyrolysis, free-standing alloy infiltration, room temperature polymer infiltration and machining. The main issues of these steps are reviewed followed by a discussion about the support of RM. This paper is an intermediate report additional materials, applications, process models and product design strategies will be incorporated into the project in the next year.Mechanical Engineerin

Instrumented Prototypes

Full scale prototyping can be expensive and time consuming. Virtual prototypes reduce costs and time but often cannot be relied on for full scale production. Instrumented SFF prototypes update virtual prototypes, reducing cycle times and costs for full scale production. Both single and multi-layer access, two different methods for embedding sensors, are investigated at the University of Texas at Austin. Sensors are first embedded in a simulated SLS process to determine if embedding off the shelf sensors is feasible. Foil strain gages are then embedded into cantilever beams using multi-layer techniques. Both foil strain gages and bead type thermocouples are also embedded using single layer techniques. The results of the single layer tests will be used to construct a proof-of-concept prototype for single layer embedding.Mechanical Engineerin

Selective Laser Sintering of High Performance High Temperature Materials

Hot Isostatic Pressing (HIP) of high performance metal parts is currently done using either a shaped metal container or a pre-fabricated ceramic mold depending on the part material and geometry. An alternative method of HIP encapsulation that allows complex part geometry, short cycle time and minima) potential for container-powder bed interaction is desired. Integral, fully dense metal skins with complex geometry can potentially be constructed by direct selective laser sintering (SLS). The advantages ofin-situ HIP encapsulation by direct SLS include the elimination of a secondary container material and any associated container-powder bed interaction, reduced pre-processing time and a short HIP cycle. Single and multi-layer specimens of Inconel625, Ti-6AI-4Vand 17-4 PH stainless steel were produced by direct SLS. Closed porosity in Inconel625 and 17-4 PH stainless steel samples ranged from 0 to 12% and area porosity from 0.5 to 20%, depending on the laser energy density. Direct SLS samples ofInconel 625 were subjected to helium leak testing and found to be impervious, with a leak rate less than lxl0-10 atm eels. These samples met the criteria for containerless hot isostatic pressing.Mechanical Engineerin

Environmental impacts of selective laser melting: do printer, powder, or power dominate?

This life cycle assessment measured environmental impacts of selective laser melting, to determine where most impacts arise: machine and supporting hardware; aluminum powder material used; or electricity used to print. Machine impacts and aluminum powder impacts were calculated by generating life cycle inventories of materials and processing; electricity use was measured by in-line power meter; transport and disposal were also assessed. Impacts were calculated as energy use (megajoules; MJ), ReCiPe Europe Midpoint H, and ReCiPe Europe Endpoint H/A. Previous research has shown that the efficiency of additive manufacturing depends on machine operation patterns; thus, scenarios were demarcated through notation listing different configurations of machine utilization, system idling, and postbuild part removal. Results showed that electricity use during printing was the dominant impact per part for nearly all scenarios, both in MJ and ReCiPe Endpoint H/A. However, some low-utilization scenarios caused printer embodied impacts to dominate these metrics, and some ReCiPe Midpoint H categories were always dominated by other sources. For printer operators, results indicate that maximizing capacity utilization can reduce impacts per part by a factor of 14 to 18, whereas avoiding electron discharge machining part removal can reduce impacts per part by 25% to 28%. For system designers, results indicate that reductions in energy consumption, both in the printer and auxiliary equipment, could significantly reduce the environmental burden of the process

On the predominant mechanisms active during the high power diode laser modification of the wettability characteristics of an SiO2/Al2O3-based ceramic material

The mechanisms responsible for modifications to the wettability characteristics of a SiO2/Al2O3-based ceramic material in terms of a test liquid set comprising of human blood, human blood plasma, glycerol and 4-octonol after high power diode laser (HPDL) treatment have been elucidated. Changes in the contact angle, , and hence the wettability characteristics of the SiO2/Al2O3-based ceramic were attributed primarily to: modifications to the surface roughness of the ceramic resulting from HPDL interaction which accordingly effected reductions in ; the increase in the surface O2 content of the ceramic after HPDL treatment; since an increase in surface O2 content intrinsically brings about a decrease in , and vice versa and the increase in the polar component of the surface energy, due to the HPDL induced surface melting and resolidification which consequently created a partially vitrified microstructure that was seen to augment the wetting action. However, the degree of influence exerted by each mechanism was found to differ markedly. Isolation of each of these mechanisms permitted the magnitude of their influence to be qualitatively determined. Surface energy, by way of microstructural changes, was found to be by far the most predominant element governing the wetting characteristics of the SiO2/Al2O3-based ceramic. To a much lesser extent, surface O2 content, by way of process gas, was also seen to influence to a changes in the wettability characteristics of the SiO2/Al2O3-based ceramic, whilst surface roughness was found to play a minor role in inducing changes in the wettability characteristics

Multiple cardiovascular comorbidities and acute myocardial infarction: temporal trends (1990–2007) and impact on death rates at 30 days and 1 year

BACKGROUND: The objectives of this community-based study were to examine the overall and changing (1990-2007) frequency and impact on 30-day and 1-year death rates from multiple cardiovascular comorbidities in adults from a large central New England metropolitan area hospitalized with acute myocardial infarction (AMI). METHODS: The study population consisted of 9581 patients hospitalized with AMI at all 11 medical centers in the metropolitan area of Worcester, MA, during 10 annual periods between 1990 and 2007. The comorbidities examined included atrial fibrillation, diabetes, heart failure, hypertension, and stroke. RESULTS: Thirty-five percent of participants had a single diagnosed cardiovascular comorbidity, 25% had two, 12% had three, and 5% had four or more comorbidities. Between 1990 and 2007, the proportion of patients without any of these comorbidities decreased significantly, while the proportion of patients with multiple comorbidities increased significantly during the years under study. An increasing number of comorbidities was associated with higher 30-day and 1-year postadmission death rates in patients hospitalized with AMI. CONCLUSION: Patients hospitalized with AMI carry a significant burden of comorbid cardiovascular disease that adversely impacts their 30-day and longer-term survival. Increased attention to the management of AMI patients with multiple cardiovascular comorbidities is warranted

Direct Selective Laser Sintering of High Temperature Materials

Abstract Selective Laser Sintering (SLS) involving a coexisting liquid and particulate solid during the SLS processing can be used to produce freeform parts directly with high temperature materials. Factors such as scanning laser power density, residence time, scan line spacing, the interfacial energies between the liquid and solid phases, powder bed biasing temperature, and sintering atmosphere greatly affect the microstructure evolution in the SLS process. Direct SLS of high melting temperature mixed powder materials was demonstrated using a 1.1 kW C02 laser SLS system. The relationship between the microstructures and the process parameters will be described

Spatially resolved acoustic spectroscopy for rapid imaging of material microstructure and grain orientation

Measuring the grain structure of aerospace materials is very important to understand their mechanical properties and in-service performance. Spatially resolved acoustic spectroscopy is an acoustic technique utilizing surface acoustic waves to map the grain structure of a material. When combined with measurements in multiple acoustic propagation directions, the grain orientation can be obtained by fitting the velocity surface to a model. The new instrument presented here can take thousands of acoustic velocity measurements per second. The spatial and velocity resolution can be adjusted by simple modification to the system; this is discussed in detail by comparison of theoretical expectations with experimental data