Laser-Induced Materials and Processes for Rapid Prototyping,9780792374008

Laser-Induced Materials and Processes for Rapid Prototyping

by ; ;
ISBN13: 9780792374008
ISBN10: 0792374002
Format: Hardcover
Pub. Date: 2001-06-01
Publisher(s): Kluwer Academic Pub
List Price: $169.99

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Summary

Rapid Prototyping (RP) and tooling (RT) technologies have attracted tremendous R&D interests from both academia and industry in the past decade. More recent interests in RP technologies are towards functional applications of the fabricated parts, such as in rapid tooling applications and replacements of damaged components. Many RP processes and materials have been commercialized but are yet to be able to fulfill the functional requirements because of limited mechanical strengths of fabricated parts. This book thus focuses on the fundamental issues of the laser-induced RP materials and processes. The remedies and possible solutions to RP/RT pertaining to materials and processes are included. The highlighted research issues and presented results are not only informative, but will also be very useful for future commercial developments.

Table of Contents

Preface xi
Acknowledgements xv
Introduction
1(8)
Overview of rapid prototyping and manufacturing
1(1)
Laser-induced rapid prototyping
2(3)
Laser-lithography (LL) process
2(1)
Selective laser sintering process
3(2)
RP process characterization and modeling
5(1)
RP technology trends
6(1)
References
7(2)
Fundamentals of Laser-lithography Processes
9(30)
Laser-lithography
9(1)
Laser scanning in LL process
9(4)
Laser-lithography systems
10(1)
Laser systems
11(2)
Control software
13(1)
Fundamental relationships
13(15)
Working curve
13(2)
Intensity profile
15(2)
Process parameters
17(4)
Profile of scan lines
21(1)
Single-scan line
21(4)
Multi-scan line and layer
25(3)
Characteristics of photo-polymerization
28(9)
Properties of photo-polymer
28(1)
Photo-polymerization
29(1)
Over-curing and over-penetration
30(4)
Focus effect on the curing profiile
34(3)
Summary
37(1)
References
37(2)
Material Characterization of Lawer-lithography Built Parts
39(28)
Mechanical properties of LL parts
39(10)
Properties at green state
40(2)
Properties after post-curing
42(1)
Density change
43(1)
Shrinkage and distortion
43(2)
Thermal post-curing
45(2)
UV post-curing
47(2)
Analyses of degree of curing
49(8)
Raman spectrum analysis
49(2)
DSC analysis
51(1)
Processes
52(1)
Analyses
53(4)
Distortion analysis by Moire method
57(7)
Principles
57(1)
Formation of Moire fringes
58(1)
Displacement-field method for Moire-fringe pattern analysis
59(1)
Processes
60(1)
Analyses
61(3)
Summary
64(1)
References
64(3)
Improvements of Mechanical Properties by Reinforcements
67(22)
Introduction
67(1)
Fiber-reinforced photo-polymer
67(8)
Basic principles and theory
68(2)
Modeling of short fiber composite
70(2)
Young's modulus and strength
72(3)
AEROSIL-mixed photo-polymer
75(2)
Support-less modeling
76(1)
Layer coating process
76(1)
Improvements in LL-process
77(10)
Mechanical properties
77(1)
Fiber-reinforced LL parts
77(3)
AEROSIL-mixed LL parts
80(1)
Shrinkage and distortion
81(3)
Reduction of support and build time
84(3)
Summary
87(1)
References
87(2)
Selective Laser Sintering
89(54)
Principle of laser sintering
89(2)
Fundamentals of laser processing
89(1)
Absorption of laser energy
89(2)
Process of selective laser sintering
91(8)
Process
92(1)
Types of SLS
93(1)
Indirect SLS
93(1)
Direct SLS
94(3)
Deoxidization
97(1)
Effect of laser sintering parameters
97(2)
Liquid phase sintering in SLS
99(5)
Fundamentals of liquid-phase sintering
99(1)
Binding mechanisms for liquid-phase sintering
100(4)
Influence of solubility
104(1)
Commercial applications
104(6)
Development of SLs
104(2)
DTM's RapidSteel and copper polyamide material
106(1)
EOS process
106(1)
EOSINT M
106(2)
EOS materials
108(1)
EOSINT M 250 sintering process
109(1)
Post process
109(1)
Metal powders for laser sintering
110(19)
Development of laser sintering powder in general
110(2)
Bronze-Ni powder
112(1)
Cu-Sn powder
113(2)
EOS powder
115(1)
Powder
115(1)
Role of Cu3P in DMLS of Cu-Ni materials
115(1)
Hot isostatic pressing of DMLS bronze-Ni parts
116(1)
DirectSteel 50V 1 (Steel-based powder)
116(1)
Tungsten carbide-cobalt powder
117(1)
Steel powder
117(1)
Carbon steel
118(1)
P20 and H13 steels
119(1)
Fe-based powder
120(1)
Stainless steel
120(1)
Stainless steel powder
120(1)
17-4PH
120(1)
DTM powder
121(1)
Copper polyamide
122(1)
RapidSteel 1.0 metal
123(1)
RapidSteel 2.0 metal
123(1)
Process
124(1)
Mareco's R&D powder
125(1)
Nickel alloy
125(1)
Inconel 625 superalloy
125(1)
Titanium alloy
126(3)
Densification
129(8)
Post sintering
129(2)
Infiltration
131(2)
Cu and bronze infiltration
133(1)
Epoxy infiltration
134(1)
Hot isostatic pressing
134(3)
Mechanical property
137(1)
Summary
138(1)
References
139(4)
Metal-Based System via Laser Melting
143(44)
Selective laser melting process
143(10)
Selective laser cladding
143(1)
Rapid prototyping using selective laser cladding process
143(2)
Design of nozzle
145(1)
Selective laser melting
146(1)
Rapid prototyping using selective laser melting process
146(1)
Process control
147(1)
Laser powder and energy density
147(1)
Scan speed
148(3)
Scan pitch
151(1)
Thickness of track
152(1)
Metal powders
153(18)
Ti system
153(2)
Iron-based system
155(5)
Copper-based system
160(1)
Cu-Ni system
160(3)
Cu-W system
163(3)
Influence of Ni on Cu-W system
166(5)
Composites
171(13)
Composite system using ex-situ processing
171(1)
Principle of ex-situ process
171(2)
Composite system using in-situ processing
173(1)
Principle of in-situ reaction
173(1)
Formation of TIC via element reaction
174(2)
Influence of addition of Ni
176(2)
Formation of TiC and TiB2
178(6)
Summary
184(1)
References
185(2)
Laser Sintering of Ceramics
187(14)
Fabrication of ceramic parts using SLS
187(3)
Process
188(2)
SLS of ceramic parts
190(7)
SLS with infiltration
190(3)
SLS with reactive binder
193(1)
SLS with infiltration reaction
194(1)
Selective laser reaction sintering
195(1)
SLS of ceramics with metal binder
196(1)
SLS nano-sized powder
196(1)
Summary
197(1)
References
198(3)
Characterization, Modeling and Optimization
201(40)
Introduction
201(1)
Modeling of RP part fabrication
202(13)
RP processes
203(1)
Surface roughness of a green part
204(2)
Surface roughness due to staircase effect
206(3)
Part fabrication time
209(2)
Part fabrication cost
211(4)
Optimal orientation
215(10)
Orientation candidates for RP part fabrication
215(1)
Single-criterion optimal orientation
216(2)
Quantification of building inaccuracy
218(4)
Part stability during the building process
222(1)
Effect of part orientation on manufacturing time
223(1)
Multi-criterion optimization techniques
223(2)
Direct slicing of CAD models
225(11)
Adaptive thickness slicing and cusp height tolerance
225(2)
Maximum allowable layer thickness based on curvature
227(1)
Surface normal curvature
227(1)
Surface normal curvature along the building direction
228(1)
Computing the maximum layer thickness at a point on the surface
229(1)
Optimallayer thickness at reference height
229(1)
One-dimension search problem
230(1)
Genetic algorithm for one-dimensional search
231(1)
Implementation of adaptive slicing algorithm
232(4)
Decision support for process optimization and selection
236(2)
Knowledge-based RP material/machine selection
237(1)
Knowledge-based systems and RP part fabrication
237(1)
Summary
238(1)
References
238(3)
Rapid Tooling and Its Applications
241(22)
Rapid tooling development
241(1)
Rapid tooling techniques and applications
242(7)
Direct tooling
243(3)
Indirect tooling
246(2)
Comparison of RT techniques
248(1)
RT for injection molding - a case study
249(7)
Design and fabrication processes
251(3)
Performance evaluation
254(2)
Application to EDM electrode fabrication
256(5)
Indirect sintered or formed electrodes
257(2)
Direct laser-sintered electrodes
259(2)
Summary
261(1)
References
261(2)
Index 263

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