Precision LCVD System Design with Real Time Process Control

A Laser Chemical Vapor Deposition (LCVD) system was designed using a fixed 100 Watt C02 laser focused on a moveable substrate. Temperature and height measurement devices monitor the reaction at the point of deposition to provide feedback for controlling the process. The LCVD system will use rapid prototyping technology to directly fabricate fully threedimensional ceramic, metallic, and composite parts of arbitrary shape. Potential applications include high temperature structures, electronic/photonic devices, and orthopaedic implants.Mechanical Engineerin

Fabrication of Advanced Thermionic Emitters Using Laser Chemical Vapor Deposition-Rapid Prototyping 498

Laser Chemical Vapor Deposition-Rapid Prototyping (LCVD-RP) is a relatively new manufacturing process. Its capabilities are ideally suited for the manufacturing of a type of electron emitter called an integrated-grid thermionic emitter. The integrated-grid thermionic emitter is composed of wagon wheel-like structures of alternating layers of boron nitride and molybdenum on tungsten. The goal of this paper is to determine the feasibility of using LCVDRP technology to manufacture advanced thermionic emitters.Mechanical Engineerin

Heat Transfer Analysis of a Gas-Jet Laser Chemical Vapor Deposition (LCVD) Process 461

This paper describes the development of a computer model used to characterize the heat transfer properties of a gas-jet LCVD process. A commercial software package was used to combine heat transfer finite element analysis with the capabilities of computational fluid dynamic software (CFDS). Such a model is able to account for both conduction and forced convection modes of heat transfer. The maximum substrate temperature was studied as a function of laser power and gas-jet velocity.Mechanical Engineerin

Fabrication of Multi-Layered Carbon Structures Using LCVD

Others have used Laser Chemical Vapor Deposition (LCVD) to create 3-D fibrous structures and helical springs. Current research efforts focus on the creation of more advanced three-dimensional carbon objects through the use of multi-layered deposition. Multi-layered structures require an understanding of interlayer adhesion and the propagation of geometric anomalies through multiple layers. An important aspect in minimizing these shape anomalies is the implementation of closed loop temperature control. Several laminated carbon structures are presented with discussions and observations about the fabrication process and visual characteristics of each. The major issues in using LCVD to create multi-layer carbon structures are addressed.McDonald Observator

Decontamination Strategy for Large Area and/or Equipment Contaminated with Chemical and Biological Agents using a High Energy Arc Lamp (HEAL)

A strategy for the decontamination of large areas and or equipment contaminated with Biological Warfare Agents (BWAs) and Chemical Warfare Agents (CWAs) was demonstrated using a High Energy Arc Lamp (HEAL) photolysis system. This strategy offers an alternative that is potentially quicker, less hazardous, generates far less waste, and is easier to deploy than those currently fielded by the Department of Defense (DoD). For example, for large frame aircraft the United States Air Force still relies on the combination of weathering (stand alone in environment), air washing (fly aircraft) and finally washing the aircraft with Hot Soapy Water (HSW) in an attempt to remove any remaining contamination. This method is laborious, time consuming (upwards of 12+ hours not including decontamination site preparation), and requires large amounts of water (e.g., 1,600+ gallons for a single large frame aircraft), and generates large amounts of hazardous waste requiring disposal. The efficacy of the HEAL system was demonstrated using diisopropyl methyl phosphonate (DIMP) a G series CWA simulant, and Bacillus globigii (BG) a simulant of Bacillus anthracis. Experiments were designed to simulate the energy flux of a field deployable lamp system that could stand-off 17 meters from a 12m2 target area and uniformly expose a surface at 1360 W/m2. The HEAL system in the absence of a catalyst reduced the amount of B. globigii by five orders of magnitude at a starting concentration of 1.63 x 107 spores. In the case of CWA simulants, the HEAL system in the presence of the catalyst TiO2 effectively degraded DIMP sprayed onto a 100mm diameter Petri dish in 5 minutes

Comparing Mechanical and Geometrical Properties of Lattice Structure Fabricated Using Electron Beam Melting

To design lattice structure, a uniform voxel based approach is widely used which divides a part into unit volumes (e.g., cubes) and maps lattice topology into those volumes. In contrast, conformal lattice structures represent a second design method for constructing lattices in which unit cells are constructed parallel to the surface to be reinforced and are deformed in a manner that enables them to conform to the surface. In this paper, the strength of lattice structures designed using these two methods (uniform voxel based and conformal) are compared based on additive manufacturing (AM) process effects. For this purpose, spheres filled with three types of lattice structure are fabricated using electron beam melting technology and tested in compression. Effects of AM processes are studied in two ways – volumetric and structural performance equivalence. Struts in lattice structures are observed through a microscope to examine volume-equivalence and tests are simulated numerically and compared to identify structural equivalence.Mechanical Engineerin

Precision Carbon Deposition Using Pyrolytic Laser Chemical Vapor Deposition (LCVD) 73

Laser Chemical Vapor Deposition (LCVD) can be used to rapid prototype many different metals and ceramics. The spatial resolution is potentially very fine, depending on the accuracy of stage or laser movement, and the size of the laser spot used for the localized heating. This paper describes a set of experiments performed using an LCVD system powered with a 100 Watt CO2 laser. The laser was focused to 200 mm onto a graphite substrate to deposit pyrolytic carbon. The morphologies of the carbon deposits were studied while varying laser power, reagent concentration, scanning speeds, and scanning patterns.Mechanical Engineerin

Wide Area Thermal Processing of Light Emitting Materials

Laboratory laser materials synthesis of wide bandgap materials has been successfully used to create white light emitting materials (LEMs). This technology development has progressed to the exploration on design and construction of apparatus for wide area doping and phase transformation of wide bandgap material substrates. The objective of this proposal is to develop concepts for wide area doping and phase transformation based on AppliCote Associates, LLC laser technology and ORNL high density pulsed plasma arc technology