Rapid Fabrication of Materials Using Directed Light Fabrication
Rapid Fabrication of Materials Using Directed Light Fabrication

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Published: 1997

Total Pages: 9

ISBN-13:

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Directed light fabrication (DLF) is a rapid fabrication process that fuses gas delivered metal powders within a focal zone of a laser beam to produce fully dense, near-net shape, 3-dimensional metal components from a computer generated solid model. Computer controls dictate the metal deposition pathways, and no preforms or molds are required to generate complex sample geometries. The focal zone of the laser beam is programmed to move along or across a part cross-section, and coupled with a multi-axis sample stage, produces the desired part. By maintaining a constant molten puddle within the focal zone, a continuous liquid/solid interface is possible while achieving constant cooling rates that can be varied between 10 to 104 K s−1 and solidification growth rates (that scale with the beam velocity) ranging up to 102 m s−1. The DLF technique offers unique advantages over conventional thermomechanical processes in that many labor and equipment intensive steps can be avoided. Moreover, owing to the flexibility in power distributions of lasers, a variety of materials can be processed, ranging from aluminum alloys to rhenium, and including intermetallics such as Mo5Si3. As a result, the rapid fabrication of conventional and advanced materials are possible.

Directed Light Fabrication of Refractory Metals
Directed Light Fabrication of Refractory Metals

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Published: 1997

Total Pages: 9

ISBN-13:

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Directed Light Fabrication (DLF) is a metal, rapid fabrication process that fuses metal powders to full density into a solid replica of a computer modeled component. It has been shown feasible for forming nearly any metal and also intermetallics to near net shape with a single process. DLF of refractory pure metals is feasible, bypassing the extensive series of conventional processing steps used for processing these high melting point materials. Tungsten, tantalum, and rhenium were processed and show a continuous resolidified microstructure. Porosity was a problem for the tantalum and rhenium powders produced by chemical reduction processes but not for the tungsten powder spherodized in a plasma arc. Chemical analysis of powder compared to the DLF deposit showed reductions in carbon, oxygen and hydrogen, indicating that process parameters may also be optimized for evolution of residual gases in the deposits.

Free-form Processing of Near-net Shapes Using Directed Light Fabrication
Free-form Processing of Near-net Shapes Using Directed Light Fabrication

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Publisher:

Published: 1997

Total Pages: 9

ISBN-13:

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Directed light fabrication (DLF) is a rapid fabrication process that fuses gas delivered metal powders within a focal zone of a laser beam to produce fully dense, near-net shape, three-dimensional metal components from a computer generated solid model. Computer controls dictate the metal deposition pathways, and no preforms or molds are required to generate complex sample geometries with accurate and precise tolerances. The DLF technique offers unique advantages over conventional thermomechanical processes or thermal spray processes in that many labor and equipment intensive steps can be avoided to produce components with fully dense microstructures. Moreover, owing to the flexibility in power distributions of lasers, a variety of materials have been processed, ranging from aluminum alloys to tungsten, and including intermetallics such as Mo5Si3. Since DLF processing offers unique capabilities and advantages for the rapid fabrication of complex metal components, an examination of the microstructural development has been performed in order to define and optimize the processed materials. Solidification studies of DLF processing have demonstrated that a continuous liquid/solid interface is maintained while achieving high constant cooling rates that can be varied between 10 to 105 K s−1 and solidification growth rates ranging up to the 10−2 m s−1.

Laser-Induced Materials and Processes for Rapid Prototyping
Laser-Induced Materials and Processes for Rapid Prototyping

Author: Li Lü

Publisher: Springer Science & Business Media

Published: 2013-11-27

Total Pages: 278

ISBN-13: 146151469X

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The term rapid prototyping (RP) refers to a generic group of emerging technologies that enable very quick fabrication of engineering components primarily targeted for prototyping applications. With RP, very complex three dimensional parts or prototypes can be fabricated without the need of costly tooling and machining. This inevitably leads to much shorter design cycle time and lower cost of building a prototype. Its manifold benefits include significant productivity gains, cost saving, and shortened development time to introduce concept models. As such, RP technologies have attracted tremendous R&D interests from both academia and industry in the past decade. Many different processes and materials have been commercialized and used in industry primarily for the fabrication of physical prototypes. 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 processes and materials have been commercialized but are yet to be able to fulfill the aforementioned functional requirements because of limited mechanical strengths of the fabricated parts.

Directed Light Fabrication
Directed Light Fabrication

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Published: 1994

Total Pages: 11

ISBN-13:

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Directed Light Fabrication (DLF) is a rapid prototyping process being developed at Los Alamos National Laboratory to fabricate metal components. This is done by fusing gas delivered metal powder particles in the focal zone of a laser beam that is, programmed to move along or across the part cross section. Fully dense metal is built up a layer at a time to form the desired part represented by a 3 dimensional solid model from CAD software. Machine ''tool paths'' are created from the solid model that command the movement and processing parameters specific to the DLF process so that the part can be built one layer at a time. The result is a fully dense, near net shape metal part that solidifies under rapid solidification conditions.

Additive Manufacturing Applications for Metals and Composites
Additive Manufacturing Applications for Metals and Composites

Author: Balasubramanian, K.R.

Publisher: IGI Global

Published: 2020-06-19

Total Pages: 348

ISBN-13: 1799840557

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Additive manufacturing (AM) of metals and composites using laser energy, direct energy deposition, electron beam methods, and wire arc melting have recently gained importance due to their advantages in fabricating the complex structure. Today, it has become possible to reliably manufacture dense parts with certain AM processes for many materials, including steels, aluminum and titanium alloys, superalloys, metal-based composites, and ceramic matrix composites. In the near future, the AM material variety will most likely grow further, with high-performance materials such as intermetallic compounds and high entropy alloys already under investigation. Additive Manufacturing Applications for Metals and Composites is a pivotal reference source that provides vital research on advancing methods and technological developments within additive manufacturing practices. Special attention is paid to the material design of additive manufacturing of parts, the choice of feedstock materials, the metallurgical behavior and synthesis principle during the manufacturing process, and the resulted microstructures and properties, as well as the relationship between these factors. While highlighting topics such as numerical modeling, intermetallic compounds, and statistical techniques, this publication is ideally designed for students, engineers, researchers, manufacturers, technologists, academicians, practitioners, scholars, and educators.

Laser Fabrication and Machining of Materials
Laser Fabrication and Machining of Materials

Author: Narendra B. Dahotre

Publisher: Springer Science & Business Media

Published: 2008-01-25

Total Pages: 565

ISBN-13: 0387723447

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This book covers the fundamental principles and physical phenomena behind laser-based fabrication and machining processes. It also gives an overview of their existing and potential applications. With laser machining an emerging area in various applications ranging from bulk machining in metal forming to micromachining and microstructuring, this book provides a link between advanced materials and advanced manufacturing techniques. The interdisciplinary approach of this text will help prepare students and researchers for the next generation of manufacturing.

Virtual Modelling and Rapid Manufacturing
Virtual Modelling and Rapid Manufacturing

Author: Paulo Jorge da Silva Bartolo

Publisher: CRC Press

Published: 2005-09-15

Total Pages: 656

ISBN-13: 9780415390620

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Virtual Modelling and Rapid Manufacturing presents essential research in the area of Virtual and Rapid Prototyping. It contains reviewed papers that were presented at the 2nd International Conference on Advanced Research in Virtual and Rapid Prototyping, held at the School of Technology and Management of the Polytechnic Institute of Leiria, Portugal, from September 28 to October 1, 2005. The volume covers a wide range of topical subjects, such as medical imaging, reverse engineering, virtual reality and prototyping, biomanufacturing and tissue engineering, advanced rapid prototyping technologies and micro-fabrication, biomimetics and materials, and concurrent engineering

Rapid Prototyping and the ASME B5.54 Standard for Evaluation of Machine Tool Performance
Rapid Prototyping and the ASME B5.54 Standard for Evaluation of Machine Tool Performance

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Publisher:

Published: 1998

Total Pages: 7

ISBN-13:

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The Directed Light Fabrication (DLF) process has shown feasibility for rapid fabrication of metal to full density. Structural properties equivalent to those of conventionally processed material have been achieved. The process is performed without the use of stereolithography files using a more conventional CNC approach to developing the motion path from the CAD solid model and using multi-axis positioning to deposit material in any plane, not just the horizontal plane used in many current processes. The important criteria for evaluating a solid free-form deposit were suggested and used to evaluate a part produced by DLF example presented here.

Free Form Fabrication of Metallic Components Using the Directed Light Fabrication Process
Free Form Fabrication of Metallic Components Using the Directed Light Fabrication Process

Author:

Publisher:

Published: 1998

Total Pages: 9

ISBN-13:

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The Directed Light Fabrication (DLF) process uses a laser beam and metal powder, fed into the laser focal zone, to produce free standing metal components that are fully dense and have structural properties equivalent to conventional metal forming processes. The motion of the laser focal zone is precisely controlled by a motion path produced from a 3 dimensional solid model of a desired component. The motion path commands move the focal zone of the laser such that all solid areas of the part are deposited and the part can be built (deposited) in its entirety to near net shape, typically within " 0.13 mm. The process is applicable to any metal or intermetallic. Full density and mechanical properties equivalent to conventionally processed material are achieved.