Establishing fundamental knowledge
Identifying process–microstructure–property relationships
Such studies would allow manufacturers not only to optimize additive manufacturing materi- als and techniques but also to develop effective methods for inspecting their products. The stud- ies conducted to date have resulted in the use of additive manufacturing for the manufacture of critical components, such as turbine blades, medical devices, and even complex structural parts.
Enterprising fabricators are producing 3D printed functional clocks, guns, robots, and even parts for a 3D printer. A most important and developing trend for additive manufacturing is its use for personal consumer purposes.
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49
2 Additive Manufacturing Using Free Space
Deposition in Metals
Experiment and Theory
Abinand Rangesh
AbstrACt
Additive manufacturing has the capability to build three-dimensional objects directly from a computer model to create complex internal or external geometries. The aim of this research was to design the foundations of a new additive manufacturing technology that could deposit shapes directly in free space without the use of any support structures and eliminate the limitation of Contents
2.1 Introduction ...50 2.2 Modeling Deposition of Tracks in Free Space ... 51 2.2.1 Experimental Apparatus ... 51 2.2.2 Classification of Results ... 52 2.2.3 Experimental Methodology ... 53 2.2.3.1 Effect of Varying Material Feed Rate ... 53 2.2.3.2 Effect of Varying Temperature ... 53 2.2.3.3 Effect of Varying Initial Volume of Material Fed ... 53 2.2.3.4 Effect of Varying Velocity ... 53 2.2.4 Results ...54 2.2.4.1 Effect of Material Feed Rate ...54 2.2.4.2 Effect of Varying Soldering Iron Temperature ...54 2.2.4.3 Effect of Varying Initial Volume of Material Fed to Electrode...54 2.2.4.4 Effect of Varying Velocity ... 56 2.2.5 Discussion ... 56 2.3 Modeling Free Space Deposition ... 58 2.3.1 Experimental Methodology ...60 2.3.1.1 Estimating the Track Profile ...60 2.3.1.2 Effect of Initial Operating Settings on Track Taper ... 61 2.3.2 Results ... 61 2.3.2.1 Estimating the Track Profile ... 61 2.3.2.2 Effect of Initial Operating Conditions on Track Taper ... 62 2.3.3 Discussion ...64 2.4 Conclusions ...65 Acknowledgments ...68 References ...68
deposition in the x-y plane that most current technologies utilize. The contribution of this research is the use of a heated tool as a temporary moving support structure during material solidification to deposit tracks in free space. Notable results in free space track deposition were that the initial track diameter and volume affected the repeatability and quality of tracks. The amount of material fed to the soldering iron before commencing deposition affected the taper of tracks. At an initial volume of 7 mm3 and an initial track diameter of 0.8 mm, none of the ten tracks deposited broke or showed taper > ~1°. The maximum deposition velocity for free space track deposition using lead-free solder was limited to 1.5 mm s–1. Finite element modeling showed that the initial volume within the melt boundary, initial track radius, and distance between the soldering iron and the solidification front could be used to inform future experimental design. Selection of initial operating settings may be used to produce tracks profiles with standard deviations < 30% of initial track width.
2.1 IntroduCtIon
Additive manufacturing has the capability to build three-dimensional objects directly from a com- puter design by selectively depositing material. It allows the construction of parts with complete internal or external geometries. However, most conventional metal additive manufacturing technol- ogies are limited in their ability to build overhanging structures. Kruth et al.1 and Thomas and Bibb2 found that selective laser melting (SLM) was limited in its ability to build overhanging structures with an angle less than 40° to 45° from the horizontal without building fixed support structures.
Fixed support structures provide a means to support tracks and features during solidification and are usually removed during post-processing of parts. If the individual tracks are supported during solidification it may be possible to create overhanging tracks or tracks that start on a substrate but stretch into free space, as shown in Figure 2.1. Overhanging features can be built by layering indi- vidual overhanging tracks. After solidification it may not be necessary to continue supporting the track which would allow deposition in any plane or straight into free space.
10 mm
fIgure 2.1 Photograph of track deposition in free space. (Top) Manual build of the letters “Science” built using free space deposition. (Bottom) Various shapes in the process of being deposited.