The extrusion-based additive manufacturing (EAM) technique is recently being employed for rapid production of metals and ceramic components. This technique involves extruding the metal or ceramic material in solid pow...The extrusion-based additive manufacturing (EAM) technique is recently being employed for rapid production of metals and ceramic components. This technique involves extruding the metal or ceramic material in solid powder form mixed with a binder (i.e., an expendable viscous fluid), which is removed from the part after 3D printing. These technologies rely on the large design freedom allowed and the cost efficiency advantage over alternative metal additive manufacturing processes that are based on high energy beams, such as laser or electron beams. The EAM of metals and ceramics is not yet widespread, but published scientific and technical literature on it is rapidly growing. However, this literature is still less extensive than that on the fused deposition modeling (FDM) of plastics or the selective laser melting (SLM) of metals. This paper aims at filling this gap. FDM and powder injection molding are identified as preceding or enabling technologies for EAM. This paper systematically reviews all aspects of the feedstock EAM processes used for production of complex-shaped parts. The unique characteristics and advantages of these processes are also discussed with respect to materials and process steps. In addition, the key process parameters are explained to illustrate the suitability of the EAM process for diverse application domains.展开更多
Ceramic structural parts are one of the most widely utilized structural parts in the industry. However, they usually contain defects following the pressing process, such as burrs. Therefore, additional trimming is usu...Ceramic structural parts are one of the most widely utilized structural parts in the industry. However, they usually contain defects following the pressing process, such as burrs. Therefore, additional trimming is usually required, despite the deformation challenges and difficulty in positioning. This paper proposes an ultrafast laser processing system for trimming complex ceramic structural parts. Opto-electromechanical cooperative control software is developed to control the laser processing system. The trimming problem of the ceramic cores used in aero engines is studied. The regional registration method is introduced based on the iterative closest point algorithm to register the path extracted from the computer-aided design model with the deformed ceramic core. A zonal and layering processing method for three-dimensional contours on complex surfaces is proposed to generate the working data of high-speed scanning galvanometer and the computer numerical control machine tool, respectively. The results show that the laser system and the method proposed in this paper are suitable for trimming complex non-datum parts such as ceramic cores. Compared with the results of manual trimming, the method proposed in this paper has higher accuracy, efficiency, and yield. The method mentioned above has been used in practical application with satisfactory results.展开更多
文摘The extrusion-based additive manufacturing (EAM) technique is recently being employed for rapid production of metals and ceramic components. This technique involves extruding the metal or ceramic material in solid powder form mixed with a binder (i.e., an expendable viscous fluid), which is removed from the part after 3D printing. These technologies rely on the large design freedom allowed and the cost efficiency advantage over alternative metal additive manufacturing processes that are based on high energy beams, such as laser or electron beams. The EAM of metals and ceramics is not yet widespread, but published scientific and technical literature on it is rapidly growing. However, this literature is still less extensive than that on the fused deposition modeling (FDM) of plastics or the selective laser melting (SLM) of metals. This paper aims at filling this gap. FDM and powder injection molding are identified as preceding or enabling technologies for EAM. This paper systematically reviews all aspects of the feedstock EAM processes used for production of complex-shaped parts. The unique characteristics and advantages of these processes are also discussed with respect to materials and process steps. In addition, the key process parameters are explained to illustrate the suitability of the EAM process for diverse application domains.
基金the National Key R&D Program of China(Grant No.2016YFB1102500)the Key R&D Project in Shaanxi Province(Grant No.2019ZDLGY01-07)the Science and Technology Program of Jiangsu Province,China(Grant No.SBK2019041271).
文摘Ceramic structural parts are one of the most widely utilized structural parts in the industry. However, they usually contain defects following the pressing process, such as burrs. Therefore, additional trimming is usually required, despite the deformation challenges and difficulty in positioning. This paper proposes an ultrafast laser processing system for trimming complex ceramic structural parts. Opto-electromechanical cooperative control software is developed to control the laser processing system. The trimming problem of the ceramic cores used in aero engines is studied. The regional registration method is introduced based on the iterative closest point algorithm to register the path extracted from the computer-aided design model with the deformed ceramic core. A zonal and layering processing method for three-dimensional contours on complex surfaces is proposed to generate the working data of high-speed scanning galvanometer and the computer numerical control machine tool, respectively. The results show that the laser system and the method proposed in this paper are suitable for trimming complex non-datum parts such as ceramic cores. Compared with the results of manual trimming, the method proposed in this paper has higher accuracy, efficiency, and yield. The method mentioned above has been used in practical application with satisfactory results.
