Rapid fabrication of materials using directed light fabrication

Conference · Wed Oct 01 04:00:00 EDT 1997

OSTI ID:542062

Thoma, D J; Lewis, G K; Milewski, J O; Chen, K C; Nemec, R B

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 10{sup 4} K s{sup -1} and solidification growth rates (that scale with the beam velocity) ranging up to 10{sup 2} m s{sup -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 Mo{sub 5}Si{sub 3}. As a result, the rapid fabrication of conventional and advanced materials are possible.

• Research Organization: Los Alamos National Lab., NM (United States)
• Sponsoring Organization: USDOE Office of Energy Research, Washington, DC (United States)
• DOE Contract Number: W-7405-ENG-36
• OSTI ID: 542062
• Report Number(s): LA-UR--97-1385; CONF-9707101--; ON: DE98000267
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
COMPUTERIZED CONTROL SYSTEMS
COPPER ALLOYS
FABRICATION
LASERS
MICROSTRUCTURE
MOLYBDENUM SILICIDES
POWDERS
SILVER ALLOYS
SOLIDIFICATION