P. Regenfuss, L. Hartwig, S. Klötzer, R. Ebert, Th. Brabant, T. Petsch and H. Exner
Examples are given for the technical applicability of a novel development of selective laser sintering called “laser micro sintering”.
Abstract
Purpose
Examples are given for the technical applicability of a novel development of selective laser sintering called “laser micro sintering”.
Design/methodology/approach
Together with a specific method to produce powder layers, the controlled application of pulsed radiation for the processing of sub‐μm grained metal powders was exploited to produce micro‐tools with a heretofore unattained structural resolution.
Findings
High resolution micro bodies are displayed. Instruments could be generated which proved to fulfil their designation as grip bits for micro manipulators. The micro‐bodies can be generated detachably from or firmly fixed to the construction substrate. The material of the generated bodies withstands the traction forces when used as an injection mold for polymer casts.
Research limitations/implications
Densities and structural resolutions can still be improved especially with a newly updated version of the equipment. Laser micro sintering of materials, other than metal (e.g. ceramics), has still to be developed. The introduction of the equipment and the technique into the market is on its way.
Practical implications
Micro‐tools can be generated with an overall structural resolution of 30 μm and with all the advantages of a freedom technique.
Originality/value
The paper informs the technical community on a new novel modification of the freeform technique selective laser sintering, demonstrating the solution of some problems that have hampered the progress of metal laser into resolution ranges below 100 μm. It also supplies evidence for the technical applicability.
Details
Keywords
P. Regenfuss, A. Streek, L. Hartwig, S. Klötzer, Th. Brabant, M. Horn, R. Ebert and H. Exner
The purpose of the paper is the elucidation of certain mechanisms of laser material processing in general and laser micro sintering in particular. One major intention is to…
Abstract
Purpose
The purpose of the paper is the elucidation of certain mechanisms of laser material processing in general and laser micro sintering in particular. One major intention is to emphasize the synergism of the various effects of q‐switched laser pulses upon metal and ceramic powder material and to point out the non‐equilibrium character of reaction steps.
Design/methodology/approach
Recent results and observations, obtained in development of “laser micro sintering,” are surveyed and analyzed. By breaking down the overall process into relevant steps and considering their possible kinetics, an approach is made towards interpreting specific phenomena of laser micro sintering. Thermodynamics upon heating of the material as well as its photo‐electronic response to the incident radiation are considered.
Findings
The findings corroborate a model whereby short pulses of high intensity provide non‐equilibrium pressure conditions at the location of incidence, that allow for the melting of metal powder with an almost immediate expansion of a plasma and/or vapor bulb. Thereby the molten material is condensed and propelled towards the substrate. A final boiling eruption after each pulse is the reason for the morphology of the laser micro‐sintered surfaces and can prevent oxidation when the process is conducted under normal atmosphere. In sintering of ceramics, the short pulsed and intensive radiation increases the chance to excite the material even with photon energies below the bandgap value and it lowers the risk of running into a destructive avalanche.
Research limitations/implications
Owing to the stochastic character of the respective sintering event, that is initiated by each individual pulse, the gathered data are not suitable yet for the formulation of an exact quantitative function between sintering behavior and laser parameters.
Practical implications
The qualitative findings yield a good rule of thumb for the choice of parameters in laser sintering on a micrometer scale and the model is conducive for advanced interpretation of other phenomena in laser material processing besides sintering.
Originality/value
The kinetics and thermodynamics of laser sintering with q‐switched pulses are approached by a qualitative explanation. The heterogeneous and non‐equilibrium character of the processes is taken into account; this character is often neglected by researchers in the area.
Details
Keywords
This paper presents a unified framework to model the sintering process of fine powders. The framework is based on classical virtual power principle and its corresponding…
Abstract
This paper presents a unified framework to model the sintering process of fine powders. The framework is based on classical virtual power principle and its corresponding variational principle. Firstly, the classical models of solid state, viscous and liquid phase sintering are reproduced assuming single matter re‐distribution mechanism and using the virtual power principle as the starting point. Then we demonstrate how to obtain the governing equations for microstructural evolution using the variational principle. These provide a common thread through the existing sintering models. Finally a numerical solution scheme is briefly outlined for computer simulation of microstructural evolution using the variational principle as the starting point. The computer simulation can follow the entire sintering process from powder compact to fully dense solid and deal with fully couple multi‐physics processes involving all the possible underlying matter re‐distribution mechanisms. Several examples are provided to demonstrate the deep insights that can be gained into the sintering process by using the numerical tool.
Details
Keywords
Swee Leong Sing, Wai Yee Yeong, Florencia Edith Wiria, Bee Yen Tay, Ziqiang Zhao, Lin Zhao, Zhiling Tian and Shoufeng Yang
This paper aims to provide a review on the process of additive manufacturing of ceramic materials, focusing on partial and full melting of ceramic powder by a high-energy laser…
Abstract
Purpose
This paper aims to provide a review on the process of additive manufacturing of ceramic materials, focusing on partial and full melting of ceramic powder by a high-energy laser beam without the use of binders.
Design/methodology/approach
Selective laser sintering or melting (SLS/SLM) techniques are first introduced, followed by analysis of results from silica (SiO2), zirconia (ZrO2) and ceramic-reinforced metal matrix composites processed by direct laser sintering and melting.
Findings
At the current state of technology, it is still a challenge to fabricate dense ceramic components directly using SLS/SLM. Critical challenges encountered during direct laser melting of ceramic will be discussed, including deposition of ceramic powder layer, interaction between laser and powder particles, dynamic melting and consolidation mechanism of the process and the presence of residual stresses in ceramics processed via SLS/SLM.
Originality/value
Despite the challenges, SLS/SLM still has the potential in fabrication of ceramics. Additional research is needed to understand and establish the optimal interaction between the laser beam and ceramic powder bed for full density part fabrication. Looking into the future, other melting-based techniques for ceramic and composites are presented, along with their potential applications.
Details
Keywords
‘Information needs’ are defined in terms of conceptual incongruities, the paramaters of which are described by a number of constructs originating in the fields of cognitive and…
Abstract
‘Information needs’ are defined in terms of conceptual incongruities, the paramaters of which are described by a number of constructs originating in the fields of cognitive and social psychology. The ‘satisfaction’ of such needs are discussed in terms of access to varying ranges of information sources, from individual learning resources to large‐scale data bases, which may contain information appropriate to the resolving of such conceptual incongruities. From a review of systems designated to satisfy information needs of higher education students, it is concluded that generally, the wider the range of of information that an individual has access to, (i) the more restricted to the names of ‘topics’ and ‘subjects’ have been the parameters of information needs catered for by the system; and (ii) the less the individual has been able to know about the suitability of the sources to other parameters of his information needs, as proposed, at the time of searching. Implications are drawn, for students working in the context of relatively independent access to wide ranges of information sources, in terms of the need to develop effective information handling skills; assessment procedures; and information accessing systems.
Linda Ke, Haihong Zhu, Jie Yin and Xinbing Wang
– The purpose of this paper is to report the influence of the peak laser power on laser micro sintering 4-μm nickel powder using Q-switched 1064-nm Nd:YAG laser.
Abstract
Purpose
The purpose of this paper is to report the influence of the peak laser power on laser micro sintering 4-μm nickel powder using Q-switched 1064-nm Nd:YAG laser.
Design/methodology/approach
Experimental study has been performed. Nickel powder with grain size of 4 μm has been utilized. A Q-switching duration of 20-25 μs and rate of 20-40 kHz have been used.
Findings
The peak power intensity is so high that the metal particles and molten pool are blown away, leading to laser micro sintering not being successfully proceeded. The scanning line obtained by continuous-wave (CW) laser looks like a rod owing to balling effect. Using a suitable peak power intensity, a good-shaped sintering line can be obtained because the plasma can protect the molten metal from oxidation, and improve the wettability of the system. In addition, the plasma flattening effect may also contribute to the form of the good-shaped sintering line in pulsed laser sintering regime.
Originality/value
The role of plasma induced by pulsed laser with high peak power intensity has been found during pulsed laser sintering under an ambient environment.
Details
Keywords
Haihong Zhu, Linda Ke, Wenjuan Lei, Cheng Dai and Baijin Chen
The purpose of this paper is to investigate the effect of the Q‐switching parameters on the sintering behavior of laser micro sintering Cu‐based metal powder, using Q‐switched…
Abstract
Purpose
The purpose of this paper is to investigate the effect of the Q‐switching parameters on the sintering behavior of laser micro sintering Cu‐based metal powder, using Q‐switched 1064 nm Nd‐YAG laser.
Design/methodology/approach
An experimental study has been performed. Metal powder mixture with Cu and Cu‐P alloy powders has been utilized. Q‐switching duration of 15 μs∼25 μs, rate of 25 kHz∼45 kHz have been used.
Findings
The results show that as the Q‐switching rate and duration increases, the peak laser power decreases and the densification enhances. However, an optimal peak laser power exists and if the peak laser power is too low, the density of the sample is also low. The densification regime of laser micro‐sintering is not only caused by the liquid phase filling the pores, but is also caused by the Cu powder migrating and by coalescence, e.g. including initial stage and intermediate stage of the traditional furnace liquid phase sintering. However, the degree of these stages depends on the peak power and input laser energy.
Originality/value
The effect of the Q‐switching parameters on sintering behavior of laser micro sintering Cu‐based metal powder using Q‐switched 1064 nm Nd‐YAG laser has been obtained. It is found that the densification behavior is Q‐switching parameters dependent, although the average laser power is same. The densification regime of laser micro‐sintering includes initial stage and intermediate stage of the traditional furnace liquid phase sintering, but the degree is Q‐switching parameters dependent.
Details
Keywords
Reviews some of the chemistry and environmental hazards associatedwith chlorine and bromine compounds when used as water disinfectants inmany industrial processes. Lays emphasis…
Abstract
Reviews some of the chemistry and environmental hazards associated with chlorine and bromine compounds when used as water disinfectants in many industrial processes. Lays emphasis on the oxidation of bromide by chlorine to bromate, a suspected genotoxin. A risk assessment of the predicted presence is detailed. In view of the formation of haloforms and other noxious substances derived from chlorine, some of the advantages of the use of chlorine dioxide are detailed. Proposes recommendations for water regulators to consider the inclusion of bromine‐containing substances, and in particular bromate, in forthcoming legislation.