A multi-component Cu-based metal powder was chosen for direct laser sintering. The powder consists of a mixture of high-purity Cu powder, pre-alloyed CuSn and CuP powder. Liquid phase sintering with complete melting o...A multi-component Cu-based metal powder was chosen for direct laser sintering. The powder consists of a mixture of high-purity Cu powder, pre-alloyed CuSn and CuP powder. Liquid phase sintering with complete melting of the binder (CuSn) but non-melting of the cores of structural metal (Cu) proves to be a feasible mechanism for laser sintering of this powder system. The microstructural evolution of the sintered powder with variation of laser processing parameters was presented. High sintering activities and sound densification response were obtained by optimizing the laser powers and scan speeds. Using a high laser power accompanied by a high scan speed gives rise to balling effect. At a high laser power with a slow scan speed the sintering mechanism may change into complete melting/solidification, which decreases the obtainable sintered density. The role of additive phosphorus in the laser sintering process is addressed. Phosphorus can act as a fluxing agent and has a preferential reaction with oxygen to form phosphatic slag, protecting the Cu particles from oxidation. The phosphatic slag shows a concentration along grain boundaries due to its light mass as well as the short thermal cycle of SLS.展开更多
A three-dimensional finite element thermal model in direct metal laser sintering(DMLS) including the effect of powder-to-solid transition were established to predict sintering zone, which benefited the determination o...A three-dimensional finite element thermal model in direct metal laser sintering(DMLS) including the effect of powder-to-solid transition were established to predict sintering zone, which benefited the determination of suitable process parameters in DMLS. The nonlinear transient model of the metals thermal conductivity for powder-to-solid transition was developed. The model uses solid thermal properties of material in liquid-phase zone, transitional ones in sintering or sintered zone and powder ones in unsintered zones of powder bed to predict, respectively. Sintering zone boundary was estimated by maximum temperature history profile. Experiments were carried out using multi-component Cu-based metal powder. Compared experimental and predicted results, the mean error of sintering depth and width are 7.8% and 14.4%, respectively, which confirms the accuracy of the FEM prediction.展开更多
Direct Laser Sintering (DSL), a technology enabling the production of dense metal components directly from 3D CAD data, was used for the first time to produce a Metal Matrix Composite (MMCp) based on Al-Si-Cu alloy in...Direct Laser Sintering (DSL), a technology enabling the production of dense metal components directly from 3D CAD data, was used for the first time to produce a Metal Matrix Composite (MMCp) based on Al-Si-Cu alloy in view of its application in different fields, in particular for aeronautics. The porosity of the material obtained so was investigated by using optical and electron microscopy and, in particular, X-ray computed microtomography techniques. DSL is a unique technique to produce complex components in an economical way while computed microtomography is a unique technique to evaluate the porosity and pore and cracks distribution in a not destructive way. A near homogeneous distribution of the porosity and pore sizes was observed both comparing different regions of the same specimen and also by comparing different samples obtained by using the same DLS production method. A quantitative analysis of the damage in the composite is also reported.展开更多
文摘A multi-component Cu-based metal powder was chosen for direct laser sintering. The powder consists of a mixture of high-purity Cu powder, pre-alloyed CuSn and CuP powder. Liquid phase sintering with complete melting of the binder (CuSn) but non-melting of the cores of structural metal (Cu) proves to be a feasible mechanism for laser sintering of this powder system. The microstructural evolution of the sintered powder with variation of laser processing parameters was presented. High sintering activities and sound densification response were obtained by optimizing the laser powers and scan speeds. Using a high laser power accompanied by a high scan speed gives rise to balling effect. At a high laser power with a slow scan speed the sintering mechanism may change into complete melting/solidification, which decreases the obtainable sintered density. The role of additive phosphorus in the laser sintering process is addressed. Phosphorus can act as a fluxing agent and has a preferential reaction with oxygen to form phosphatic slag, protecting the Cu particles from oxidation. The phosphatic slag shows a concentration along grain boundaries due to its light mass as well as the short thermal cycle of SLS.
文摘A three-dimensional finite element thermal model in direct metal laser sintering(DMLS) including the effect of powder-to-solid transition were established to predict sintering zone, which benefited the determination of suitable process parameters in DMLS. The nonlinear transient model of the metals thermal conductivity for powder-to-solid transition was developed. The model uses solid thermal properties of material in liquid-phase zone, transitional ones in sintering or sintered zone and powder ones in unsintered zones of powder bed to predict, respectively. Sintering zone boundary was estimated by maximum temperature history profile. Experiments were carried out using multi-component Cu-based metal powder. Compared experimental and predicted results, the mean error of sintering depth and width are 7.8% and 14.4%, respectively, which confirms the accuracy of the FEM prediction.
文摘Direct Laser Sintering (DSL), a technology enabling the production of dense metal components directly from 3D CAD data, was used for the first time to produce a Metal Matrix Composite (MMCp) based on Al-Si-Cu alloy in view of its application in different fields, in particular for aeronautics. The porosity of the material obtained so was investigated by using optical and electron microscopy and, in particular, X-ray computed microtomography techniques. DSL is a unique technique to produce complex components in an economical way while computed microtomography is a unique technique to evaluate the porosity and pore and cracks distribution in a not destructive way. A near homogeneous distribution of the porosity and pore sizes was observed both comparing different regions of the same specimen and also by comparing different samples obtained by using the same DLS production method. A quantitative analysis of the damage in the composite is also reported.
