Advances in the Production of Infiltrated Aluminium Parts Using Selective Laser Sintering

Recent advances in a rapid freeform fabrication process for the production of aluminium parts are considered. The methodology involves the formation of an unconstrained, resin bonded aluminium powder part by Selective Laser Sintering, the burnout of the resin, the partial transformation of the aluminium into a rigid aluminium nitride skeleton by reaction with the atmosphere under a magnesium/alumina blanket and the subsequent infiltration with a second aluminium alloy. Here we describe the process and consider potential applications. Strategies for controlling the growth of the aluminium nitride are also to be discussed.Mechanical Engineerin

Distortion in a 7xxx aluminum alloy during liquid phase sintering

The distortion in a sintered 7xxx aluminum alloy, Al-7Zn-2.5Mg-1Cu (wt. pct), has been investigated by sintering three rectangular bars in each batch at 893 K (620 °C) for 0 to 40 minutes in nitrogen, followed by air or furnace cooling. They were placed parallel to each other, equally spaced apart at 2 mm, with their long axes being perpendicular to the incoming nitrogen flow. Pore evolution in each sample during isothermal sintering was examined metallographically. The compositional changes across sample mid-cross section and surface layers were analyzed using energy dispersive X-ray spectroscopy and X-ray photoelectron spectroscopy depth profiling, respectively. The two outer samples bent toward the middle one, while the middle sample was essentially distortion free after sintering. The distortion in the outer samples was a result of differential shrinkage between their outer and inner surfaces during isothermal sintering. The porous outer surface showed an enrichment of oxygen around the large pores as well as lower magnesium and zinc contents than the interior and inner surface of the same sample, while the inner surface was distinguished by the presence of AlN. The differential shrinkage was caused by different oxygen contents in local sintering atmosphere and unbalanced loss of magnesium and zinc between the outer and inner surfaces

The effects of sample position and gas flow pattern on the sintering of a 7xxx aluminum alloy

The effects of sample position and gas flow pattern on the sintering of a 7xxx aluminum alloy Al-7Zn-2.5Mg-1Cu in flowing nitrogen have been investigated both experimentally and numerically. The near-surface pore distribution and sintered density of the samples show a strong dependency on the sample separation distance over the range from 2 mm to 40 mm. The open porosity in each sample increases with increasing separation distance while the closed porosity remains essentially unchanged. A two-dimensional computational fluid dynamics (CFD) model has been developed to analyze the gas flow behavior near the sample surfaces during isothermal sintering. The streamlines, velocity profile, and volume flow rate in the cavity between each two samples are presented as a function of the sample separation distance at a fixed nitrogen flow rate of 6 L/min. The CFD modeling results provide essential details for understanding the near-surface pore distribution and density of the sintered samples. It is proposed that the different gas flow patterns near the sample surfaces result in variations of the oxygen content from the incoming nitrogen flow in the local sintering atmosphere, which affects the self-gettering process of the aluminum compacts during sintering. This leads to the development of different near-surface pore distributions and sintered densities

Modification of the alpha-Ti laths to near equiaxed alpha-Ti grains in as-sintered titanium and titanium alloys by a small addition of boron

A small addition of boron (B) changes the morphology of the α-Ti laths in as-sintered Ti-6Al-4V and Ti- 10 V-2Fe-3Al to near equiaxed α-Ti grains and increases the number density of the resulting α-Ti grains by up to six folds. TiB forms at about 700 °C during heating to the isothermal sintering temperature and more than 90% of the TiB particles were found inside the α-Ti grains. Transmission electron microscopy (TEM) was used to identify the orientation relationships (ORs) between the TiB and α-Ti phases. Their exact ORs are affected by both the chemistry of the alloy and the processing conditions. The modification of the α-Ti laths and the substantial increase in the number density of the α-Ti grains are attributed to the enhanced heterogeneous nucleation of α-Ti on TiB due to the identified specific ORs and excellent lattice matches between these two phases. In addition, there exists a unique peritectoid reaction between b-Ti and TiB during the subsequent cooling after isothermal sintering by which-Ti + TiB → α-Ti, which may have contributed to the enhanced heterogeneous nucleation of α-Ti on TiB

Powder metallurgy as a net shape processing technology

Powder metallurgy is a manufacturing process which uses metal powders as a feed stock. It is a net shape technology when these powders are shaped in a closed die and sintered. Although the mechanical properties are not as good as conventionally processed material, it is an inexpensive means to manufacture small, complicated shapes. This paper provides an introduction to the powder metallurgy process, including a description of the major steps in the fabrication of a part from powder production to post sintering operations. It also includes an analysis of new and developing powder techniques for net shape manufacturing, such as injection moulding and rapid prototyping. The world market and the Australian industry are briefly considered

Design of titanium alloy for efficient sintering to low porosity

Few Ti alloys have been designed for ease of sintering. This paper considers the design of alloys for processing using the mixed elemental technique, in which powders are mixed, cold pressed in a die to near net shape and sintered under vacuum at high temperature. The authors describe steps in the process of developing a Ti-Ni-Sn alloy, able to be sintered to near full density at a sintering temperature as low as 1100 degrees C without requiring unusually fine powder or high compaction pressure. Higher sintering temperature allows the Ni content of the alloy to be reduced, but swelling of the alloy probably imposes an upper limit on practical sintering temperature. The increase in green density, and hence sintered density, conferred by Sn in Ti-Sn alloys, and the increase in sintered density due to the high diffusivity of Ni in Ti-Ni alloys, are combined in Ti-Ni-Sn alloys