WO2002040744A1 - Laser fabrication of ceramic parts - Google Patents
Laser fabrication of ceramic parts Download PDFInfo
- Publication number
- WO2002040744A1 WO2002040744A1 PCT/US2001/015812 US0115812W WO0240744A1 WO 2002040744 A1 WO2002040744 A1 WO 2002040744A1 US 0115812 W US0115812 W US 0115812W WO 0240744 A1 WO0240744 A1 WO 0240744A1
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- ceramic
- powder
- substrate
- laser
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- 239000000919 ceramic Substances 0.000 title claims abstract description 138
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 239000000843 powder Substances 0.000 claims abstract description 92
- 239000000758 substrate Substances 0.000 claims abstract description 72
- 229910052751 metal Inorganic materials 0.000 claims abstract description 15
- 239000002184 metal Substances 0.000 claims abstract description 15
- 238000006243 chemical reaction Methods 0.000 claims abstract description 11
- 238000005336 cracking Methods 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 63
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 29
- 238000000151 deposition Methods 0.000 claims description 25
- 239000002245 particle Substances 0.000 claims description 16
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 10
- 230000008018 melting Effects 0.000 claims description 6
- 238000002844 melting Methods 0.000 claims description 6
- 238000007493 shaping process Methods 0.000 claims description 6
- 239000011225 non-oxide ceramic Substances 0.000 claims 2
- 229910052575 non-oxide ceramic Inorganic materials 0.000 claims 2
- 238000005137 deposition process Methods 0.000 abstract description 19
- 239000000203 mixture Substances 0.000 abstract description 4
- 229910010293 ceramic material Inorganic materials 0.000 description 22
- 239000000463 material Substances 0.000 description 22
- 230000008569 process Effects 0.000 description 12
- 229910052593 corundum Inorganic materials 0.000 description 8
- 229910001845 yogo sapphire Inorganic materials 0.000 description 8
- 239000007787 solid Substances 0.000 description 7
- 239000000155 melt Substances 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 5
- 230000008021 deposition Effects 0.000 description 5
- 238000005755 formation reaction Methods 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 239000007767 bonding agent Substances 0.000 description 2
- 238000011960 computer-aided design Methods 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 1
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910003112 MgO-Al2O3 Inorganic materials 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 229910033181 TiB2 Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 1
- 210000003850 cellular structure Anatomy 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007123 defense Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000005303 fluorophosphate glass Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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Definitions
- the present invention resides in the field of laser fabrication of parts, and more particularly relates to methods of shaping ceramic powder materials to form such parts.
- Conventional methods of producing parts from metals,, metal alloys, and/or ceramics include additive and subtractive methods.
- Subtractive methods teach subtracting material from a starting block to produce a more complex shape. Examples include milling, grinding, drilling, and lathe cutting.
- Conventional subtractive methods are deficient because they produce a large amount of waste material for disposal, involve a large initial expense in setting up the tooling, and result in significant tool wear which increases operating costs. Furthermore, such methods cannot produce parts with unique shapes or complicated internal formations.
- Bourell is directed to the production of parts from (1) powders mixed together, such as a mixture of fluorophosphate glass powders and alumina powders; and (2) coated ceramic powders, such as aluminum silicate or silica coated with a polymer (see Column 8, lines 45-60).
- powders mixed together such as a mixture of fluorophosphate glass powders and alumina powders
- coated ceramic powders such as aluminum silicate or silica coated with a polymer
- the selective sintering process of Bourell produces a ceramic part having a density of about 40% to about 65%.
- a further process/ step is required to remove the bonding layer (polymer/ wax) - otherwise the part would remain soft and unstable.
- the further processing step comprises placing the ceramic part in a furnace for post-deposition heating to remove the bonding layer. As the bonding layer is removed, the ceramic particles bond to themselves, but the particles are not melted together.
- Ceramic parts having a high density and good mechanical properties have not heretofore been produced using a single-step laser deposition method.
- a novel method and articles obtained by the method are disclosed, where a high density ceramic part is produced by melting together ceramic particles without the use of a bonding agent.
- the laser power is varied to allow sufficient bonding of the ceramic layer(s) together and to a substrate.
- the power is controlled in order to prevent plasma reactions which can occur in ceramic powders and cracking of the solid ceramic part.
- the method employing a laser deposition process, builds the part layer-by-layer in a predetermined configuration.
- the present invention utilizes the Laser Engineered Net Shaping (LENS) process, in conjunction with one or more ceramic powders, for direct fabrication of a high density ceramic structure or part.
- the ceramic part is formed by transporting one or more ceramic materials in powder form to a laser device where the ceramic powder(s) are melted and deposited on a substrate to form a ceramic part of high density.
- the density of the ceramic part can be greater than about 90% to about 100%, and is preferably from about 96% to about 100% dense.
- Such a high density is achieved according to a method which provides for varying the power of the laser beam during the deposition process.
- a highly dense ceramic part can be produced by a single laser deposition process, without requiring further steps such as post-deposition heating of the ceramic part in a furnace.
- a substrate made of a metal, a metal alloy, or a ceramic serves as a base to support the formation of one or more layers of ceramic materials.
- the ceramic layers are formed by a laser deposition process, where one or more ceramic powders are fed from hopper(s) toward the substrate. A laser beam is directed at the substrate and the powder feed such that ceramic powder is deposited in the desired shape on the substrate. Successive layers of ceramic material are built upon the substrate and the laser beam is adjusted under CAD /CAM control to form a near net shape part in the desired shape. Custom designed cellular structures and complex geometric shapes can be formed.
- the laser power can be varied during the laser deposition process, in order to create a part having high density in which successive layers bond to one another and the substrate.
- the laser power is initially set at a high level to create a melt pool.
- the laser power is gradually reduced so that the powder melts but does not undergo a plasma reaction.
- the absorptivity of ceramic materials is significantly higher than the metal substrate, and thus reduced heat (and a lower laser power) is required to melt and bond the particles to form layers.
- the laser power can be selectively varied during the various steps of the laser deposition process.
- multiple ceramic powder feeds can be employed to create a hybrid ceramic part.
- a plurality of hoppers can feed different types of ceramic particles, and the hoppers can be selectively controlled to feed an appropriate amount of one or more types of ceramic powders.
- the multiple feeds can be selectively graded to form a hybrid part having different regions corresponding to different ceramic powders.
- FIG. 1 is a schematic representation of a laser fabrication process used to form ceramic parts according to the present invention
- FIG. 2 is an example of a failed ceramic part construction, where a ceramic substrate and ceramic layers were formed at a constant, high laser power;
- FIG. 3 is a solid, flat specimen made of Al O 3 according to the method of the present invention.
- FIG. 4 is a solid, tensile specimen made of Al 2 O 3 according to the method of the present invention.
- FIG. 5 is a hollow, flat specimen with a thin wall made of AI2O3 according to the method of the present invention
- FIG. 6 is a hybrid ceramic structure made of 50% Al 2 O 3 and 50% A1N according to the method of the present invention
- FIG. 7 is a schematic representation of a hybrid ceramic part graded from 100% AI2O3 gradually up to 100% A1N made according to the method of the present invention
- FIG. 8 is a hybrid ceramic part made according to the specifications of
- FIG. 7
- FIGS. 9(a) and 9(b) are schematic representations of two steps in a method of joining a ceramic deposited material to a hybrid substrate, using the laser deposition process;
- FIG. 10 is ⁇ a schematic representation of a particular arrangement for grading ceramic jnaterials : in a saw-tooth formation using the laser deposition process;
- FIG. 11 is a schematic representation of another arrangement for grading ceramic materials using the laser deposition process.
- Ceramic parts and structures with high density and good mechanical properties are provided according to a method of the present invention.
- One preferred method of forming the ceramic parts and structures is illustrated in FIG. 1.
- the method of the present invention is carried out using a laser fabrication apparatus 10 having a first hopper 12 containing ceramic powder 14, where the first hopper deposits the powder 14 in a feed zone 24 beneath a laser 16.
- a laser beam 18 is directed at the feed zone to heat and melt the powder to form a deposition in a structure or part 26.
- Material is added to previous depositions formed upon a substrate 30 to gradually build the structure/part.
- the substrate can be preheated before receiving depositions of the structure /part, but preheating is not required according to the present invention.
- the powder 14 comprises particles which are preferably of approximately uniform size and consisting of one type of ceramic.
- the appropriate size of the particles can be determined by one skilled in the art for the materials and equipment used in the laser deposition process.
- different ceramic powders can be mixed in the first hopper_12.
- Ceramic powders which are preferred for use in the present invention include aluminum oxide Al 2 O 3 (also known as "alumina") and aluminum nitride AIN.
- Other ceramics which can be used in the present invention are various oxides and non-oxides such as carbides, nitrides, and borides.
- the substrate 30 can be made of a metal, a metal alloy, or a ceramic.
- the substrate can include a hybrid of one or more of these materials.
- the substrate can be arranged such that one portion of the substrate comprises Material A and another portion of the substrate comprises Material B (see FIG. 9(a)).
- the laser 16 is preferably used in the Laser Engineered Net Shaping
- LENS process.
- the laser is guided under computer control to follow a predetermined pattern to build the structure or part.
- the laser is operated using computer aided design/ computer aided manufacture (CAD /CAM) techniques, where the two-dimensional plane of the substrate 30 contains imaginary x- and y-axes, and the laser moves longitudinally toward and away from the substrate along an imaginary z-axis under control of a computer 28.
- CAD /CAM computer aided design/ computer aided manufacture
- Laser fabrication provides for rapid cooling, as the laser beam 18 produces intense heat directed at relatively local regions of the deposited material. Due to the relatively large surface area of the melted material compared to its volume, energy can be removed rapidly and fast cooling is achieved. Fine grain structure is achieved in the part due to the rapid cooling. Because near net shape processing is obtained, the part requires minimal post machining. In fact, no additional steps or processes are required to produce a highly dense part.
- the substrate 30 is preferably made of a metal or a metal alloy.
- the substrate can comprise a well known titanium based alloy such as Ti-6A1-4V, also known as Ti64.
- the laser power is initially set sufficiently high to melt the metal material at the surface of the substrate, thereby creating a melt pool. Thereafter, a laser deposition process (e.g. the LENS process) is initiated.
- Ceramic powder 14 is dispensed through the hopper 12 in a controlled manner. As the powder is deposited in the feed area 24, the laser 14 is guided under computer control to heat and shape the powder in one or more layers, thereby building the ceramic part 26. During the laser deposition process, the laser power is varied and thus the amount of heat directed at the substrate and ceramic powder can be controlled. As discussed above, the laser power is initially set at a high level, generally in a range of about 150W to about 550W, at a level which can readily be determined by one skilled in the art to melt the substrate to thereby create a melt pool. It is important that a melt pool be created, in order for the ceramic material to bond with the substrate material.
- the ceramic material forms a layer of ceramic material and bonds with the substrate. Successive layers of ceramic material are deposited on each other and the substrate.
- the laser power is gradually reduced from the initially high level required to melt the metal substrate to a lower level for melting the ceramic material.
- the absorptivity of ceramic materials is significantly higher than the metal substrate, so a reduced laser power is required to melt the ceramic, powder without vaporizing it.
- the ceramic substrate is heated to a temperature sufficient to melt the substrate, and then the laser power is adjusted to an appropriate level to melt the ceramic powder as it is deposited.
- the laser power is reduced during deposition of the ceramic powder, to a level suitable for the type of ceramic powder to be deposited.
- the laser power should be set at a sufficient level to melt the ceramic powder without causing damage to the ceramic material.
- a high powered laser beam is directed at the ceramic powder, the powder turns a deep, dark color, indicating a plasma reaction has occurred which results in material evaporation and a porous structure.
- Such a reaction can be avoided by setting the laser power at a level only high enough to melt the ceramic powder to allow the ceramic powder to bond together.
- FIG. 2 illustrates an example of problems which can be encountered when attempting to use a laser deposition process to build a ceramic part upon a ceramic substrate.
- a ceramic substrate made of AI2O3 was used.
- the substrate was preheated to 500°F using a hot plate, in order to help prevent cracking of the substrate.
- a high laser power 375W
- the result was thermal shock due to the focus " of a high powered laser on a portion of the solid ceramic structure.
- the thermal shock caused cracking of the ceramic substrate.
- a ceramic powder made of Al O3 was fed to the substrate using a laser deposition process.
- the laser power was reduced to 130W, the substrate remained intact, but the deposited material turned to a dark color (black), indicating a plasma reaction had occurred.
- the laser power was further reduced to 60W, the deposited material appeared less dark.
- the deposited layers peeled off the substrate, as there was insufficient bonding between the ceramic substrate and the deposited ceramic material.
- both the high laser power required to initially create a melt pool on the substrate, and the lower laser power preferred to avoid a plasma reaction in the deposited ceramic material are taken into consideration in selecting reaction parameters.
- a minimum laser power of approximately 30W is typically required for the laser fabrication device described with reference to FIG. 1 to function properly.
- a solution to the above-described problems is to initially set the laser power at a high level and gradually reduce the power as the deposited ceramic material bonds to the substrate.
- a metallic substrate Ti-6A1-4V alloy, also known as "Ti64” was selected.
- a minimum power of about 150W is required to melt the Ti64, which is beyond the acceptable range of laser power for heating the ceramic powder.
- FIGS. 3-5 Parts fabricated according to this method are shown in FIGS. 3-5.
- FIG. 3 is a photograph of a solid, flat bar which was fabricated from AI2O3 ceramic powder.
- FIG. 4 is a photograph of a solid, tensile cylindrical bar also fabricated from AI2O3 ceramic powder. The part depicted in FIG. 4 shows that the laser deposition process can be used to produce parts with complex geometric shapes. Parts with delicate geometries can also be produced, as shown in FIG. 5.
- FIG. 5 is a hollow, flat specimen made from AI2O3 ceramic powder, the final part having external dimensions of 3in. x 0.5in. x O.OSin. with a thin wall less than 1mm thick prepared using the laser deposition process.
- the density of the above fabricated parts was measured using the standard water absorption method (ASTM designation: C373-56) well known in the art for obtaining accurate and reliable density calculations.
- the average density of the above fabricated Al 2 O 3 parts is 3.80 gx 3 which indicates 0.962 densification of the theoretical density of AI2O3 (3.95g-cm 3 ).
- the finished ceramic parts were, on average, about 96% dense.
- the density of parts or structures fabricated according to the present invention are preferably greater than about 90%, and are up to about 100% dense, but preferably in the range of from about 96% to about 100% dense.
- the high density of ceramic parts produced according to this method is achieved by using a metallic substrate and varying the power of the laser beam as .-discussed herein. Ceramic powder comprising AI2O3 is useful with the present invention, because AI2O3 powders generally have good fluidity and are commonly used for a variety of applications.
- AI2O3 is one preferred type of ceramic powder suitable for use in the present invention
- other types of ceramic powders can also be used, either alone or in conjunction with Al O 3 .
- Another preferred ceramic powder is AIN, which often includes some fine particulates which tend to clog up the hoppers and feed system.
- AIN powder when using AIN powder, the powder can be filtered and treated with a sufficient amount of fluid and dispersant to remove the fine particles. The remaining powder has a much better fluidity and can be successfully used in the laser fabrication device. Referring back to FIG. 1, a multiple feed laser fabrication apparatus is shown, where the apparatus includes a second hopper 20 containing a second ceramic powder 22 which can be controllably released toward the feed area 24.
- the second hopper can contain the same type of ceramic powder as the first hopper 12, in order to allow for continuous part fabrication when building, e.g., a large part or a plurality of unifonn parts.
- the second hopper 20 can also be used to store particles corresponding to a different type of ceramic powder from that stored in the first hopper 12.
- FIG. 6 is a photograph of a part produced by this method. As shown in FIG. 6, approximately the first one-half of the length of the part was fabricated using AI2O3 powder; the other half was fabricated using a dual feed mixture of about 50% AI2O3 and about 50% AIN. As described herein, the graded structures are made from powders with approximately the stated percentage of the material. It is possible that a small amount of impurities can be present in the finished part.
- the first hopper 12 contained AI 2 O 3 powder and the second hopper 20 contained AIN powder.
- the fabrication process involved feeding exclusively from the first hopper, while approximately the other half was produced with simultaneous feeding from the first and second hoppers.
- the result was a solid graded part with no visible defects and a smooth interface. between the 100% AI2O3 and the 50% A1 2 O 3 /50% AIN sections. More complex variations of the above graded part have been produced.
- FIG. 7 depicts a specification for a part graded from 100% AI2O 3 gradually to 100% AIN.
- the specification calls for a 100% Al 2 O 3 section, followed by a 50% A1 2 O 3 /50% AIN section, and then a 25% Al 2 O3/ 5% AIN section, where each of these sections is produced using a laser power of 125W.
- the next section is 100% A ⁇ N produced under a laser power of 145W.
- the change in laser power for the AIN section is motivated by the different physical properties of AIN.
- Aluminum nitride has a higher thermal conductivity and a lower laser energy absorption than alumina. Accordingly, a higher laser power is required to melt and bond together the layers of aluminum nitride.
- FIG. 7 depicts a specification for a part graded from 100% AI2O 3 gradually to 100% AIN.
- FIG. 8 is a photograph of a graded ceramic part produced according- to the specification of FIG. 7. As seen in FIG. 8, the transitions between the various graded sections are smooth. Only the 25% Al 2 O3/75% AIN experienced some bonding problems, which was likely due to insufficient laser power caused by the higher percentage of AIN as compared to the other sections having AI2O3.
- the laser power can be varied according to the present invention to allow for an increase in laser power for the 25% Al 2 O3/75% AIN section, where the applied laser power would be in the range of approximately 125W- 145W.
- FIGS. 9(a) and 9(b) illustrate two steps in a process of depositing a ceramic material on a hybrid substrate.
- the starting substrate material comprises "Material A” and "Material B” which can be metals, metal alloys, or ceramic materials. Metals or metal alloys are preferred, in order to provide sufficient bonding with the deposited ceramic material, for reasons stated above.
- the "deposited material” can be a ceramic material deposited by the aforementioned laser deposition process.
- the ceramic material can also comprise a graded ceramic structure.
- the ceramic materials graded in a structure or part can be deposited in a variety of formations.
- FIG. 10 illustrates a saw tooth formation with "Ceramic C” on one side and “Ceramic D” on the other side of the structure.
- the grading can be arranged using interlocking teeth, with "Ceramic E” on one side and “Ceramic F” on another side of the structure.
- the method and article produced according to the present invention are not limited to the above-mentioned graded parts or structures.
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- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Composite Materials (AREA)
- Physics & Mathematics (AREA)
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Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AU2001261662A AU2001261662A1 (en) | 2000-11-16 | 2001-05-16 | Laser fabrication of ceramic parts |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2000/031675 WO2001045882A2 (en) | 1999-11-16 | 2000-11-16 | Laser fabrication of discontinuously reinforced metal matrix composites |
USPCT/US00/31675 | 2000-11-16 |
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Publication Number | Publication Date |
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WO2002040744A1 true WO2002040744A1 (en) | 2002-05-23 |
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Application Number | Title | Priority Date | Filing Date |
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PCT/US2001/015812 WO2002040744A1 (en) | 2000-11-16 | 2001-05-16 | Laser fabrication of ceramic parts |
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WO (1) | WO2002040744A1 (en) |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2009132782A1 (en) | 2008-04-30 | 2009-11-05 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Process for producing ceramic objects by means of selective laser melting |
CN101817121A (en) * | 2010-04-15 | 2010-09-01 | 华中科技大学 | Deposition forming composite manufacturing method of part and mould and auxiliary device thereof |
WO2011018463A1 (en) | 2009-08-10 | 2011-02-17 | BEGO Bremer Goldschlägerei Wilh. Herbst GmbH & Co. KG | Ceramic or glass-ceramic article and methods for producing such article |
EP2529694A1 (en) * | 2011-05-31 | 2012-12-05 | Ivoclar Vivadent AG | Method for generative production of ceramic forms by means of 3D jet printing |
CN103031555A (en) * | 2011-10-10 | 2013-04-10 | 深圳富泰宏精密工业有限公司 | Shell preparation method and shell prepared by using same |
EP2671717A1 (en) * | 2007-11-23 | 2013-12-11 | SorTech AG | Functional composite material |
EP2781617A1 (en) * | 2013-03-19 | 2014-09-24 | Alstom Technology Ltd | Method for coating a component of a turbomachine and coated component for a turbomachine |
CN105002492A (en) * | 2015-07-27 | 2015-10-28 | 西安交通大学 | Method for preparing ceramic particle enhanced metal matrix composite coating in laser cladding mode through asynchronous powder feeding method |
WO2015185001A1 (en) * | 2014-06-05 | 2015-12-10 | 华中科技大学 | Incremental manufacturing method for part or mold |
CN105689712A (en) * | 2016-02-04 | 2016-06-22 | 上海航天精密机械研究所 | Method and device for laser direct manufacturing for metal-matrix composite structural part |
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CN101817121B (en) * | 2010-04-15 | 2012-03-28 | 华中科技大学 | Deposition forming composite manufacturing method of part and mould and auxiliary device thereof |
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EP2529694A1 (en) * | 2011-05-31 | 2012-12-05 | Ivoclar Vivadent AG | Method for generative production of ceramic forms by means of 3D jet printing |
CN103031555A (en) * | 2011-10-10 | 2013-04-10 | 深圳富泰宏精密工业有限公司 | Shell preparation method and shell prepared by using same |
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CN105002492A (en) * | 2015-07-27 | 2015-10-28 | 西安交通大学 | Method for preparing ceramic particle enhanced metal matrix composite coating in laser cladding mode through asynchronous powder feeding method |
CN105689712A (en) * | 2016-02-04 | 2016-06-22 | 上海航天精密机械研究所 | Method and device for laser direct manufacturing for metal-matrix composite structural part |
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