Reducing porosity in AlSi10Mg parts processed by selective laser melting

Selective laser melting (SLM) is widely gaining popularity as an alternative manufacturing technique for complex and customized parts. SLM is a near net shape process with minimal post processing machining required dependent upon final application. The fact that SLM produces little waste and enables more optimal designs also raises opportunities for environmental advantages. The use of aluminium (Al) alloys in SLM is still quite limited due to difficulties in processing that result in parts with high degrees of porosity. However, Al alloys are favoured in many high-end applications for their exceptional strength and stiffness to weight ratio meaning that they are extensively used in the automotive and aerospace industries. This study investigates the windows of parameters required to produce high density parts from AlSi10Mg alloy using selective laser melting. A compromise between the different parameters and scan strategies was achieved and used to produce parts achieving a density of 99.8%

Cost estimation for rapid manufacturing - laser sintering production for low to medium volumes

Rapid manufacturing (RM) is a modern production method based on layer by layer manufacturing directly from a three-dimensional computer-aided design model. The lack of tooling makes RM economically suitable for low and medium production volumes. A comparison with traditional manufacturing processes is important; in particular, cost comparison. Cost is usually the key point for decision making, with break-even points for different manufacturing technologies being the dominant information for decision makers. Cost models used for traditional production methodologies focus on material and labour costs, while modern automated manufacturing processes need cost models that are able to consider the high impact of investments and overheads. Previous work on laser sintering costing was developed in 2003. This current work presents advances and discussions on the limits of the previous work through direct comparison. A new cost model for laser sintering is then proposed. The model leads to graph profiles that are typical for layer-manufacturing processes. The evolution of cost models and the indirect cost significance in modern costing representation is shown finally

An empirical laser sintering time estimator for Duraform PA

This paper presents work on the development of a build time estimator for Rapid Manufacturing (RM). A time estimator is required in order to develop a comprehensive costing tool for RM. An empirical method has been used to estimate build times utilising both simulated and actual builds for a Laser Sintering (LS) machine. The estimator presented here is based upon object geometry and therefore the fundamental data driving the model is obtainable from current three dimensional Computer Aided Design (3D-CAD) models. The aim of the paper is to define a model describing the build times for a laser sintering machine either for single or multiple objects

Robo-Soar: An Integration of External Interaction, Planning, and Learning using Soar

This chapter reports progress in extending the Soar architecture to tasks that involve interaction with external environments. The tasks are performed using a Puma arm and a camera in a system called Robo-Soar. The tasks require the integration of a variety of capabilities including problem solving with incomplete knowledge, reactivity, planning, guidance from external advice, and learning to improve the efficiency and correctness of problem solving. All of these capabilities are achieved without the addition of special purpose modules or subsystems to Soar

Learning in Tele-autonomous Systems using Soar

Robo-Soar is a high-level robot arm control system implemented in Soar. Robo-Soar learns to perform simple block manipulation tasks using advice from a human. Following learning, the system is able to perform similar tasks without external guidance. Robo-Soar corrects its knowledge by accepting advice about relevance of features in its domain, using a unique integration of analytic and empirical learning techniques

Nanoindentation shows uniform local mechanical properties across melt pools and layers produced by selective laser melting of AlSi10Mg alloy

Single track and single layer AlSi10Mg has been produced by selective laser melting (SLM) of alloy powder on a AlSi12 cast substrate. The SLM technique produced a cellular-dendritic ultra-fined grained microstructure. Chemical composition mapping and nanoindentation showed higher hardness in the SLM material compared to its cast counterpart. Importantly, although there was some increase of grain size at the edge of melt pools, nanoindentation showed that the hardness (i.e. yield strength) of the material was uniform across overlapping tracks. This is attributed to the very fine grain size and homogeneous distribution of Si throughout the SLM material

Rapid manufacturing facilitated customisation

This paper presents a novel method for the production of body-fitting customised seat profiles utilising the following digital methods: three dimensional laser scanning, reverse engineering and Rapid Manufacturing (RM). Seat profiles were manufactured in order to influence the comfort characteristics of an existing ejector seat manufactured by Martin Baker Aircraft Ltd. The seat, known as the Navy Aircrew Common Ejection Seat (NACES), was originally designed with a generic profile. This paper shows the replacement of this profile with shapes captured from fast jet pilots. Pressure mapping of occupied seats, has shown that the pressure distribution under the buttocks can be influenced using body-fitting design and thus comfort is directly affected. The paper discusses the relevance of RM with respect to mass customisation and personalisation and, in addition, recognises RM as a Next Generation Manufacturing System (NGMS) capable of satisfying increasingly diverse products and lower volume production. A generic customisation process is reviewed to identify areas of technical difficulty and key issues in the cost-effective customisation of products

Combined inkjet printing and infrared sintering of silver nanoparticles using a swathe-by-swathe and layer-by-layer approach for 3-dimensional structures

Despite the advancement of additive manufacturing (AM)/3-dimensional (3D) printing, single-step fabrication of multifunctional parts using AM is limited. With the view of enabling multifunctional AM (MFAM), in this study, sintering of metal nanoparticles was performed to obtain conductivity for continuous line inkjet printing of electronics. This was achieved using a bespoke three dimensional (3D) inkjet-printing machine, JETx®, capable of printing a range of materials and utilizing different post processing procedures to print multi-layered 3D structures in a single manufacturing step. Multiple layers of silver were printed from an ink containing silver nanoparticles (AgNPs) and infra-red sintered using a swathe-by-swathe (SS) and layer-by-layer sintering (LS) regime. The differences in the heat profile for the SS and LS was observed to influence the coalescence of the AgNPs. Void percentage of both SS and LS samples was higher towards the top layer than the bottom layer due to relatively less IR exposure in the top than the bottom. The results depicted a homogeneous microstructure for LS of AgNPs and showed less deformation compared to the SS. Electrical resistivity of the LS tracks (13.6 ± 1μΩ cm) was lower than the SS tracks (22.5 ± 1 μΩ cm). This study recommends the use of LS method to sinter the AgNPs to obtain a conductive track in 25% less time than SS method for MFAM

An Imidazolium-Based Supramolecular Gelator Enhancing Interlayer Adhesion in 3D Printed Dual Network Hydrogels

The variety of UV-curable monomers for 3D printing is limited by a requirement for rapid curing aftereach sweep depositing a layer. This study proposes to trigger supramolecular self-assembly during theprocess by a gemini imidazolium-based low-molecular-weight gelator, allowing printing of certainmonomers. The as-printed hydrogel structures were supported by a gelator network immobilising monomer:water solutions. A thixotropic hydrogel was formed with a recovery time of 8.1 kPa and yield stress = 18 Pa, processable using material extrusion 3D printing. Material extrusion 3Dprinted objects are usually highly anisotropic, but in this case the gelator network improved the isotropyby subverting the usual layer-by-layer curing strategy. The monomer in all printed layers was curedsimultaneously during post-processing to form a continuous polymeric network. The two networks thenphysically interpenetrate to enhance mechanical performance. The double network hydrogels fabricatedwith layers cured simultaneously showed 62–147% increases in tensile properties compared to layer-bylayercured hydrogels. The results demonstrated excellent inter- and intra-layered coalescence.</p

multifunctional bioinstructive 3d architectures to modulate cellular behavior

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