Direct metal writing: Controlling the rheology through microstructure

Chen, Wen; Thornley, Luke; Coe, Hannah G.; Tonneslan, Samuel J.; Vericella, John J.; Zhu, Cheng; Duoss, Eric B.; Hunt, Ryan M.; Wight, Michael J.; Apelian, Diran; Pascall, Andrew J.; Kuntz, Joshua D.; Spadaccini, Christopher M.

doi:10.1063/1.4977555

Title: Direct metal writing: Controlling the rheology through microstructure

Journal Article · Mon Feb 27 00:00:00 EST 2017 · Applied Physics Letters

DOI:https://doi.org/10.1063/1.4977555· OSTI ID:1353155

Chen, Wen ^[1]; Thornley, Luke ^[1]; Coe, Hannah G. ^[1];

^[1]; Vericella, John J. ^[1]; Zhu, Cheng ^[1]; Duoss, Eric B. ^[1];

^[1]; Wight, Michael J. ^[2]; Apelian, Diran ^[2]; Pascall, Andrew J. ^[1]; Kuntz, Joshua D. ^[1]; Spadaccini, Christopher M. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Worcester Polytechnic Institute, Worcester, MA (United States)

Most metal additive manufacturing approaches are based on powder-bed melting techniques such as laser selective melting or electron beam melting, which often yield uncontrolled microstructures with defects (e.g., pores or microcracks) and residual stresses. Here, we introduce a proof-of-concept prototype of a 3D metal freeform fabrication process by direct writing of metallic alloys in the semi-solid regime. This process is achieved through controlling the particular microstructure and the rheological behavior of semi-solid alloy slurries, which demonstrate a well suited viscosity and a shear thinning property to retain the shape upon printing. Furthermore, the ability to control the microstructure through this method yields a flexible manufacturing route to fabricating 3D metal parts with full density and complex geometries.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC52-07NA27344; Laboratory Directed Research and Development 14-SI-004

OSTI ID:: 1353155

Alternate ID(s):: OSTI ID: 1349372

Report Number(s):: LLNL-JRNL-716017

Journal Information:: Applied Physics Letters, Vol. 110, Issue 9; ISSN 0003-6951

Publisher:: American Institute of Physics (AIP)Copyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 40 works

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