Jet on demand—A pneumatically driven molten metal jetting method for printing crack-free aluminum components

IF 4.2 Q2 ENGINEERING, MANUFACTURING Additive manufacturing letters Pub Date : 2024-09-17 DOI:10.1016/j.addlet.2024.100240
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Abstract

Additive manufacturing (AM) of many traditional aluminum alloys is difficult due to hot cracking during cooling, which motivates investigating alternative AM methods that can mitigate this challenge. Here we demonstrate a new pneumatically driven molten metal jetting (MMJ) AM technique which uses a longer pressure pulse width to produce a jet of liquid metal that reaches the heated build plate. The “jet on demand” technique is utilized to build Al-6061 parts on heated build plates. Due to the large thermal mass contained in each jet, excellent adhesion is observed between droplets and layers while still maintaining dimensional control to produce parts with high relative densities (>98%). While as-printed parts exhibit different microstructure and hardness than traditional Al-6061, both microstructure and hardness are restored to traditionally processed values through a traditional T6 heat treatment. Microhardness values of 104 HV were obtained for printed Al-6061, which compares well to wrought properties. We observe that high build plate temperatures allow for lower solidification rates and eliminate hot cracking. These results point to a method for additively manufacturing traditional aluminum or other alloys that cannot currently be additively manufactured due to hot cracking.
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按需喷射--用于打印无裂纹铝制部件的气动驱动熔融金属喷射方法
由于冷却过程中的热裂纹,许多传统铝合金的增材制造(AM)都很困难,这促使我们研究能够减轻这一挑战的替代性增材制造方法。在这里,我们展示了一种新型气动驱动熔融金属喷射(MMJ)AM 技术,该技术使用较长的压力脉冲宽度产生液态金属喷流,喷射到加热的构建板上。这种 "按需喷射 "技术用于在加热的构建板上构建 Al-6061 零件。由于每次喷射都含有大量热量,因此液滴和层之间的附着力极佳,同时还能保持尺寸控制,从而生产出相对密度高(98%)的零件。虽然压印零件的显微结构和硬度与传统的 Al-6061 不同,但通过传统的 T6 热处理,显微结构和硬度都恢复到了传统的加工值。印刷后的 Al-6061 的显微硬度值为 104 HV,与锻造后的性能相当。我们观察到,较高的印制板温度可降低凝固速率并消除热裂纹。这些结果表明,这种方法适用于传统铝材或其他因热裂纹而无法进行添加式制造的合金。
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来源期刊
Additive manufacturing letters
Additive manufacturing letters Materials Science (General), Industrial and Manufacturing Engineering, Mechanics of Materials
CiteScore
3.70
自引率
0.00%
发文量
0
审稿时长
37 days
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