SFF-Oriented Modeling and Process Planning of Functionally Graded Materials Using a Novel Equal Distance Offset Approach

This paper deals with the modeling and process planning of solid freeform fabrication (SFF) of 3D functionally graded materials (FGMs). A novel approach of representation and process planning of FGMs, termed as equal distance offset (EDO), is developed. In EDO, a neutral arbitrary 3D CAD model is adaptively sliced into a series of 2D layers. Within each layer, 2D material gradients are designed and represented via dividing the 2D shape into several sub-regions enclosed by iso-composition contours. If needed, the material composition gradient within each of sub-regions can be further determined by applying the equal distance offset algorithm to each sub-region. Using this approach, an arbitrary-shaped 3D FGM object with linear or non-linear composition gradients can be represented and fabricated via suitable SFF machines.Mechanical Engineerin

A Theoretical Model for Optimization of SALD Parameters

This paper addresses the need to conduct theoretical work concerning an economical way of Solid Freeform Fabrication rendering by using selective Area Laser Deposition (SALD). The part in SALD rendering process is formed layer by layer that, in turn, is composed of stripes of material produced in the path of a laser. There are three situations in which such a stripe can be rendered: a) alone, b) with one neighbor on one side, and c) with neighbors on both sides. Residual thermal stresses in the part are expected to be affected by how a stripe is rendered. Furthermore, the residual thermal stress and the mechanical property of the part are also dictated by other processing variables such as laser scanning patters, laser input power, scanning speed, scanning spacing, deposition temperature, gas precursor pressure, intrinsic thermal conductivity and mechanical properties of the rendered material. A theoretical approach is proposed to address the minimization of residual thermal stresses and rendering times and the maximization of the strength of the part. It is proposed that such multiple optimizations that are dictated by many decision variables can be solved by minimizing and/or maximizing object functions dePending on the design criteria for each attribute of the rendered partMechanical Engineerin

Solid Freeform Fabrication of Artificial Human Teeth

In this paper, we describe a solid freeform fabrication procedure for human dental restoration via porcelain slurry micro-extrusion. Based on submicron-sized dental porcelain powder obtained via ball milling process, a porcelain slurry formulation has been developed. The formulation developed allows the porcelain slurry to show a pseudoplastic behavior and moderate viscosity, which permits the slurry to re-shape to form a near rectangular cross section. A well-controlled cross-section geometry of the extrudate is important for micro-extrusion to obtain uniform 2-D planes and for the addition of the sequential layers to form a 3-D object. Human teeth are restored by this method directly from CAD digital models. After sintering, shrinkage of the artificial teeth is uniform in all directions. Microstructure of the sintered teeth is identical to that made via traditional dental restoration processes.Mechanical Engineerin

Comparisons Between Thermal Modeling and Experiments in Laser-Densified Dental Powder Bodies

A three-dimensional thermal finite element model including the effect of the powder-tosolid transition has been developed to investigate the transient temperature distribution during laser densification of dental powder bed for the layer-by-layer fabrication. The model encompasses the effects of the temperature- and porosity-dependent thermal conduction and radiation as well as the temperature-dependent natural convection. The simulation result is compared with the experiments which establish the temperature dependence of the dental porcelain microstructure and utilize this dependence to construct the temperature distribution profile. It is found that the trend of the simulation result matches the experiments very well.The authors gratefully acknowledge financial support provided by the National Science Foundation under Grant Nos: DMI-9908249 and DMI-0218169.Mechanical Engineerin

Stereometric Design for Desk-Top SFF Fabrication

Solid Freeform Fabrication (SFF) technologies refer to the fabrication of physical parts directly from computer based solid models described by STL (Stereo Lithography) or VRML (Virtual Reality Modeling Language) files generated by Computer-Aided Design (CAD) systems. Most of the SFF processes produce parts by building them layer by layer using a row by row pattern, though it is possible to build the part using other patterns. The SFF technology represents a challenge to designers who, in addition to making decisions concerning optimum shape and functionality of the entire part, have'to take under consideration several other manufacturing factors. These factors cover a wide range of technical issues such as Computer-Aided Design model generation, part description and model slicing files, laser path files, precision of part design, rendering patterns, manufacturing tolerances, thermal expansion and residual stress phenomena. This paper investigates the effect of rendering patterns on the integrity, material characteristics and mechanical properties of the parts prepared by a desk-top SFF device using diode lasers. Fe - Bronze (Cu - Sn) premixed metal powders were used as the starting material. The particle size was about 100 /lm to 200 /lm. Density, tensile strength and microstructure of the parts prepared using different rendering patterns were characterized. The results were analyzed to seek optimal rendering patterns. It was noticed that the samples were strong along the laser scanning direction, while they were weak perpendicular to the scanning direction. These results suggest that the laser scanning patterns should be designed to minimize the warping and maximize the strength of the part in the direction depending on the part's function.Mechanical Engineerin

High energy and high power primary Li-CFx_x batteries enabled by the combined effects of the binder and the electrolyte

Several effective methods have been developed recently to demonstrate simultaneous high energy and high power density in Li - carbon fluoride (CF$_x$) batteries. These methods can achieve as high as 1000 Wh/kg energy density at 60-70 kW/kg power density (40-50 C rate) in coin cells and 750 Wh/kg energy density at 12.5 kW/kg power density (20 C rate) in pouch cells. This performance is made possible by ingenious nano-architecture design, controlled porosity, boron doping and electrolyte additives. In the present study, we show that a similarly great performance, 931 Wh/kg energy density at 59 kW/kg power density, can be achieved by using a polyacrylonitrile binder and a LiBF4 electrolyte in Li - graphite fluoride coin cells. We also demonstrate that the observed effect is the result of the right combination of the binder and the electrolyte. We propose that the mechanistic origin of the observed phenomena is an electro-catalytic effect by the polyacrylonitrile binder. While our proposed method has a competitive performance, it also offers a simple implementation and a scalable production of high energy and high power primary Li-CF$_x$ cells.Comment: 13 pages, 8 figures, 1 tabl

Control of the Cross Section Geometry of Extruded Dental Porcelain Slurries for Rapid Prototyping Applications

This study investigates the dependence of the cross section geometry of extruded dental porcelain slurries on the rheological property of the slurry and the extrusion conditions. It is found that a pseudoplastic slurry is a basic requirement for obtaining extruded lines with rectangular cross sections. The cross section geometry of the extrudate is also strongly affected by extrusion parameters including the extrusion nozzle height, nozzle moving speed, and extrusion rate. Proper combinations of these extrusion parameters are necessary in order to obtain extrudates with near rectangular cross sections. The results obtained have been explained in terms of the interactions among the rheological properties of the slurry, the shear rate imposed on the slurry during extrusion, the wettability of the slurry on the substrate, and the forced flow of the slurry during extrusion.The authors gratefully acknowledge financial support provided by the National Science Foundation under Grant Nos: DMI-9908249 and DMI-0218169.Mechanical Engineerin

SALDVI of SiC into Metal and Ceramic Powders

Selective Area Laser Deposition Vapor Infiltration (SALDVI) is the SFF technique using gas phase precursors to locally infiltrate a powder bed into a desired shape. Experiments were performed with a CO2 laser and the silicon carbide forming gas precursor Si(CH3)4. This paper will report on the microstructural aspects of SiC into a variety of metal and ceramic powders including Mo, SiC, ZrO2, and WC.The authors acknowledge the support for this research by the Office of Naval Research (grant #N00014-95-1-0978).Mechanical Engineerin