Name: indirect fabrication of lattice metals with thin sections using centrifugal casting
Uploaded: 2016-05-14T14:00:00
Description: Watch this Scientific Journal Video about Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting at JoVE.com

Este estudo recebeu apoio da pesquisa de iniciação Grant (RIG) do Vice-Presidente de Pesquisa e Desenvolvimento Económico da Universidade do Norte do Texas (UNT). Os autores também agradecem KCIS Co. Ltd para suportar parcialmente este estudo. O apoio da PACCAR Instituto de Tecnologia da UNT para o sucesso desta publicação é muito apreciada.

1. Planejamento de Experimento <ol><li> Desenhar um padrão de sacrifício (uma estrutura de treliça octeto com um sistema de sprue), utilizando software computer aided design (CAD) como mostrado na Figura 1 e salvar o modelo CAD como um formato de arquivo STL. Nota: O padrão de sacrifício é um padrão integrado da estrutura de armação octeto com um sistema de canal de entrada que serão, eventualmente, derretida para a fundição. Uma vez que o padrão sacrificial inclui tanto a estrutur...

<ol>
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Trans. 46, (2015).</li><li>Chiras, S., et al. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=The+Structural+Performance+of+Near-Optimized+Truss+Core+Panels.">The Structural Performance of Near-Optimized Truss Core Panels.</a> Solids Struct. 39, 4093-4115 (2002).</li><li>Meisel, N. A., Williams, C. B., Druschitz, A. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Lightweight+Metal+Celluar+Structures+via+in+Direct+3D+Printing+and+Casting.">Lightweight Metal Celluar Structures via in Direct 3D Printing and Casting.</a> Proceedings of the 24th Solid Freeform Fabrication Symposium. , (2013).</li><li>Mun, J., Ju, J., Yun, B. -. G., Chang, B. -. M., Kim, D. -. 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Para fundição de metal convencional, é importante para manter o fluxo do metal fundido liso e racionalizado em &#39;laminar&#39; na cavidade do molde e prefere evitar fluxo irregular e agitado geralmente observado no fluxo turbulento 27. Por conseguinte, é importante desenhar adequadamente o sistema de entrada do canal de entrada associada com a velocidade de rotação de um braço centrífuga para manter o fluxo de metal fundido no interior da cavidade do molde treliça &quot;laminar&quot;. <p class=...

Metais celulares são os metais composta de uma rede interligada de suportes sólidos ou placas e têm micro-arquiteturas complexas com vazios 1. Exemplos incluem tanto i) as espumas estocásticas estruturados de forma aleatória e ii) periodicamente ordenada bidimensionais (2D) favos de mel e tridimensionais (3D estruturas de treliça) treliçadas. Eles têm recebido atenção devido à sua elevada rigidez específica e força 1-3 e alta resistência específica 4-5, excelente absorção de energia para a carga de impacto 6, isolamento acústico 7, possível desenho de dissipadores de calor e trocadores de calor 8. Especialmente, estruturas de rede cristalina periodicamente ordenadas têm o potencial para manipular as propriedades superiores com uma capacidade para controlar a geometria da rede porosa interna. Devido à sua geometria complexa rede porosa interna, é difícil de fabricar metais celulares usando o machinin subtractiva convencionalg. Como tal, os investigadores começaram a procurar métodos alternativos para fabricar metais celulares: formação de gás no metal líquido ou a mistura de pó de metal com agentes de expansão foram exploradas para a fabricação de formas de metal estocásticos 9. Devido à falta de controlo sobre a topologia de células, é difícil para adaptar as propriedades mecânicas. Alternativamente, os métodos de fabricação de metais celulares periodicamente pedidos foram exploradas: carimbar folhas finas de metal em uma forma ondulada seguido de juntá-las para criar estruturas periódicas 10, bonding fenda folhas de metal 11, extrusão 12, tecelagem e em chamas filamentos de metal para fabricar têxteis 13. Embora estes métodos de fabrico oferecem padrões repetitivos, os padrões são ainda limitados na direcção planar. Em um esforço para gerar padrão de repetição 3D, os pesquisadores começaram a usar fabricação aditiva (AM); por exemplo, Selective Laser de fusão (SLM) 14, Electron Beam Melting (EBM) <sup&gt; 15, e Direct-Metal Laser Sintering (LMG) 16. Apesar de sua capacidade para fabricar 3D ordenou geometrias de treliça complexos, ainda existem algumas limitações: dificuldade em utilizar metais com alta condutividade térmica e alta refletividade óptico 17, de alta tensão residual térmica 18, acabamento de superfície pobre com o fenômeno &quot;balling&quot; durante a laser ou de elétrons de fusão 19, propriedades anisotrópicas 20-21 de peças causadas por um efeito combinado da fabricação de camadas, formação anisotrópica de grãos, tamanho de pó, potência e velocidade de varredura de laser ou feixe de electrões 15, alto consumo de energia, etc. Combinando polímero AM base com fundição de metais pode fornecer um método alternativo para a fabricação de metais treliça. Pode-se chamar isso de &quot;AM indireta&quot;. Indirecta AM pode fornecer uma solução para superar os problemas técnicos de AM directa dos metais acima mencionados. Vários esforços têm sido made fabricar metais treliça usando indireta SOU combinando impressão 3D de polímeros com gravidade baseada fundição 22-25; por exemplo, uma carcaça de investimento combinado com modelagem por fusão e deposição (FDM) para fabricar uma liga de malha 22-25 ou areia de fundição combinado com um pó de areia com base AM 23. O casting base gravidade parece continuar a ser um desafio técnico para superar - misrun e porosidade causada por súbita solidificação de metais fundidos quando eles se encontram estruturas de rede com cantos afiados de moldes estruturais treliça 25-26. Relativamente grande área de superfície de moldes estruturais treliçadas também parece contribuir para arrefecimento brusco, resultando na solidificação prematura 25-26. Neste estudo, propomos uma AM indireta alternativa que pode superar a misrun durante a fabricação de metais treliça - Fundição centrífuga para uma cavidade do molde treliça feita por um padrão de polímero sacrificial estrutura 3D impresso. Nós usamos uma câmera digitalLight Processing (DLP) com base método de impressão 3D para construir um padrão sacrificial estrutural estrutura seguido de fundição centrífuga de ligas de Al e Cu. O objectivo deste estudo é o de proporcionar um protocolo detalhado na fabricação de metais treliça 3D que têm uma forma complexa e uma espessura de parede fina. A principal contribuição deste processo é fornecer uma oportunidade para alargar a selecção de materiais com baixo custo de produção para a fabricação de metais treliça.

<table>
	<tbody>
		<tr>
			<td>Motorized centrifugal casting machine</td>
			<td>Rey Motorized Centrifugal Casting Machine, Rey Industries Inc.</td>
			<td></td>
			<td>Made in U.S.A. by Rey industries, Inc. Dallas, TX 75220</td>
		</tr>
		<tr>
			<td>Gypsum powder</td>
			<td>Satin Cast 20, FindingKing Kerr</td>
			<td>7960</td>
			<td>Gypsum powder is used to make the investment mixture</td>
		</tr>
		<tr>
			<td>Ployjet 3D printer</td>
			<td>Projet HD3500 Plus, 3D Systems</td>
			<td></td>
			<td>This polymer based 3D printer to print out sacrificial pattern for casting.</td>
		</tr>
		<tr>
			<td>Cartridge materials - UV curable and castable acrylic plastic</td>
			<td>VisiJet Procast, 3D Systems</td>
			<td></td>
			<td>This is castable material that is going to be burn out before casting</td>
		</tr>
		<tr>
			<td>Cartridge materials- support material</td>
			<td>VijiJet S300, 3D Systems</td>
			<td></td>
			<td>This is support material that is going to be removed before pattern assemble</td>
		</tr>
		<tr>
			<td>Ancient Bronze Casting Grain</td>
			<td>Rio Grande</td>
			<td>706051</td>
			<td>This true bronze grain contains no zinc. Highly fluid, it melts quickly, casts cleanly and provides a good balance between strength and durability. The warm, deep-bronze color has rich red undertones, and the alloy takes a good patina. 
			Composition is 90% copper with an amount of tin; fits into the CDA#90700 category. This grain is sold in 1-lb. packages.</td>
		</tr>
		<tr>
			<td>Aluminum Round Wire, 1/8&#34;, 1-Lb. Spool, Dead Soft</td>
			<td>Rio Grande</td>
			<td>134700</td>
			<td>Lightweight and strong, aluminum wire is an economical and versatile choice. Not as bright-white as silver, aluminum offers a warmer tone much like that of platinum. Solder ONLY with low-temp solders such as Stay-Brite; suitable for both pulse-arc and laser welding. This quality aluminum wire is packaged on 1-lb. spools.</td>
		</tr>
		<tr>
			<td>Computer aided design software (Pro-e)</td>
			<td></td>
			<td></td>
			<td>This software can be replaced with the others such as Auto CAD, Catia, and so on.</td>
		</tr>
		<tr>
			<td>ProJet Finisher 1-A</td>
			<td>3D Systems</td>
			<td></td>
			<td>This machine is used to melt the support material.</td>
		</tr>
		<tr>
			<td>160 Watt 2.5 Liters Digital Ultrasonic Cleaner with Timer Heater Rings Tools</td>
			<td>Chicago, Electric, Power Tools</td>
			<td></td>
			<td>85 oz. capacity, Five cleaning cycles: 90, 180, 280, 380 and 480 seconds, Clean with or without heat, Easy-to-read LED digital timer, Clear-view window</td>
		</tr>
		<tr>
			<td>Fan&#160;</td>
			<td>Honeywell Inc.&#160;</td>
			<td>HT-800</td>
			<td>120V A.C., 60Hz., 0.85A. TP</td>
		</tr>
		<tr>
			<td>Paraffin wax for wax sheet - Modeler&#39;s Pink Wax Sheet, 3&#34; by 6&#34;, 24-Ga.</td>
			<td>Rio Grande</td>
			<td>700075</td>
			<td>Sheet wax is flexible and can be cut or formed into any shape. It&#8217;s ideal for designing since you can draw or trace directly onto the sheet; choose green or pink depending on which will best show your designs. High manufacturing standards ensure exceptional consistency and significant price savings. Value is enhanced by larger package quantities at the same price as the smaller packages available elsewhere. Each 8-oz. package contains approximately 30 sheets.</td>
		</tr>
		<tr>
			<td>Paraffin wax for wax stick - Modeler&#39;s Medium Red Sprue Wax, 8-Ga</td>
			<td>Rio Grande</td>
			<td>700741</td>
			<td>A pliable, softer sprue wax than the firm blue. Good for forming gates and sprues and burns out cleanly with no residue.</td>
		</tr>
		<tr>
			<td>Alcohol Lamp</td>
			<td>Rio Grande</td>
			<td>700008</td>
			<td>Use this lamp to heat wax-working tools or as a flame polisher. The heavy glass reservoir has faceted sides to allow it to be tipped for angling the flame. A screw adjustment for the 7&#34; x 3/16&#34; wick controls the height of the flame. A safety cap snuffs the flame and prevents fuel evaporation. For the best flame, use methyl alcohol fuel. Replacement wicks available. Reservoir holds 5 oz. (150ml) of fuel.</td>
		</tr>
		<tr>
			<td>Wax carving tool set - Soft Grip Wax Carvers, Set of 10</td>
			<td>Rio Grande</td>
			<td>700329</td>
			<td>This boxed set offers the best in cutting and shaping technology. Each of these ten high-quality steel wax-carving tools features a 5/16&#34; PVC covered handle that ensures a sure, comfortable grip through hours of work and all have sharp edges for shaping and fine detailing. Sharpen or custom-shape each tool to fit your needs. These tools provide exceptional tool strength and deliver excellent results. This set comes in a hinged, foam-lined wood box.</td>
		</tr>
		<tr>
			<td>Rubber Mixing Bowl, 1-1/2 Qt.</td>
			<td>Rio Grande</td>
			<td>702131</td>
			<td>This highly-flexible vulcanized rubber bowl is easy to grip, will not be marred by a spatula and cleans with ease.</td>
		</tr>
		<tr>
			<td>Pyrex Beaker, 1,000ml</td>
			<td>Rio Grande</td>
			<td>335040</td>
			<td>Ideal for holding and heating bath plating solutions, this genuine Pyrex glass beaker is sturdy and durable.</td>
		</tr>
		<tr>
			<td>Rio Premium Stainless Steel Flask, 2-1/2&#34; dia.</td>
			<td>Rio Grande</td>
			<td>70201514</td>
			<td>This solid, #304-quality stainless steel flask is corrosion-resistant, durable for a long service life and performs under extreme temperature without distortion.</td>
		</tr>
		<tr>
			<td>CAST/T Ceramic Casting Crucible, 450g</td>
			<td>Rio Grande</td>
			<td>705047</td>
			<td>Made exclusively for the CAST/T centrifugal casting machine, this crucible is designed with an angled base that slides into the hinged bracket on top of the casting machine. This brings the crucible into perfect alignment with the center of the flask ring to ensure an error-free pour.</td>
		</tr>
		<tr>
			<td>MyWeigh iBalance 300 Digital Scale</td>
			<td>Rio Grande</td>
			<td>116850</td>
			<td>This scale is used to measure the weight of the sacrificial and sprue system for metal which is going to be used for centrifugal casting.</td>
		</tr>
		<tr>
			<td>Rubber bottom - CAST/T Flask Ring Base</td>
			<td>Rio Grande</td>
			<td>705025</td>
			<td>Specially made for the CAST/T centrifugal casting machine, this rubber base accommodates all Table King flask ring styles, creating a secure, airtight seal throughout the investment process. The center post fits either of the wax disc styles for complete versatility.</td>
		</tr>
		<tr>
			<td>Scotch&#174; Colored Duct Tape, 1 7/8&#34; x 20 Yd., Blue</td>
			<td>OfficeMax&#160;</td>
			<td>22353766</td>
			<td>This scotch tape is used to make sure that the gypsum-water mixture fully covers the assembled sacrificial pattern inside the flask by allowing for extra material above the flask height</td>
		</tr>
		<tr>
			<td>Vacuum casting machine - V.I.C. 12 Tabletop Solid- and Perforated-Flask Casting Machine with The Rio Assistant, 110-Volt</td>
			<td>Rio Grande</td>
			<td>70511814</td>
			<td>The V.I.C. 12 casting machine offers all the latest technical innovations for efficient, productive vacuum investing and casting. Designed to meet the demands of medium-sized casting operations, this machine includes a powerful 1/2hp, 5cfm vacuum pump for effective vacuuming and outstanding casting results. The V.I.C. 12 casts small or large flasks. Includes an adapter table that accepts standard solid flasks up to 5&#34; x 7&#34; high and is mounted on rubber feet for stability.</td>
		</tr>
		<tr>
			<td>Furnace for burn out sacrificial pattern -Rio Model 1000 Enameling Kiln with Nine Program Controller</td>
			<td>Rio Grande</td>
			<td>703121</td>
			<td>The Rio enameling kiln features three pre-set firing temperatures for enamels and six that you can define. Use the exclusive Rio controller to set and maintain firing temperatures. Perfect for all types of enameling, including tall pieces. Includes ample space for firing and an easy-latch door that will not jar your enamels when opening and closing. Also suitable for metal clay, glass and ceramics. Galvanized steel case with high-temperature insulating firebrick keeps them cool. Element protected in recessed groove. Includes user instructions.</td>
		</tr>
		<tr>
			<td>Smith Complete Little Torch Acetylene and Oxygen System</td>
			<td>Rio Grande</td>
			<td>500030</td>
			<td>Get everything you need to equip your shop for soldering and brazing. Use Little Torch systems for gold 
			or silver soldering, brazing and casting applications. Complete every soldering and melting job with confidence and ease! This system accepts all Little Torch accessory tips for melting, brazing and large soldering jobs and is a staple for every jeweler.</td>
		</tr>
		<tr>
			<td>Heat-Resistant Safety Apron</td>
			<td>Rio Grande</td>
			<td>750160</td>
			<td>The specially designed apron has an 800&#176;F (427&#176;C) temperature resistance. Its reflective finish repels hot metal splashes and helps insulate the wearer from heat.</td>
		</tr>
		<tr>
			<td>Radnor Heat-Resistant Gloves</td>
			<td>Rio Grande</td>
			<td>350050</td>
			<td>These flexible, heat-resistant gloves are ideal for enameling projects, allowing you to grip even small tongs securely. Blue, shoulder-split leather gloves are made of tough cowhide and lined with cotton and foam, and have reinforced thumb wings.</td>
		</tr>
		<tr>
			<td>Platinum Soldering Glasses, #7</td>
			<td>Rio Grande</td>
			<td>113914</td>
			<td>Protect yourself and your employees when soldering platinum. Comfortable glasses feature adjustable earpieces and 52mm IR green polycarbonate #7 lenses. The #7 lens is approved by The Platinum Guild.</td>
		</tr>
		<tr>
			<td>Economy Light-Duty Flask Tongs</td>
			<td>Rio Grande</td>
			<td>704026</td>
			<td>Constructed of bent steel, these tongs are designed to handle flasks 3-1/2&#34; or less in diameter. The small-angle notches grip smaller flask sizes and the larger, rounded contour area securely holds larger flasks.</td>
		</tr>
		<tr>
			<td>Separating Screen Bucket</td>
			<td>Rio Grande</td>
			<td>201360</td>
			<td>15&#34;-diameter, 11-1/2&#34;-deep</td>
		</tr>
		<tr>
			<td>Sand blaster - Econoline - 101701CB-A - Free-Standing Cabinets Workspace Width (Inch): 60 Workspace Depth (Inch): 48</td>
			<td>MSC industrial supply Co.&#160;</td>
			<td>223818</td>
			<td>Ree-Standing Cabinets; Workspace Width (Inch): 60; Workspace Depth (Inch): 48; Workspace Height (Inch): 40; Air Requirement: 12 CFM @ 80 psi; Overall Cabinet Width (Inch): 65; Maximum Cabinet Depth (Inch): 86</td>
		</tr>
		<tr>
			<td>Johnson&#39;s Baby Oil Shea &#38; Cocoa Butter&#160;</td>
			<td>Wal-Mart</td>
			<td>260074132</td>
			<td>This baby&#160; oil is used for removing the residue of the support material for the castable sacrificial pattern using Digital Ultrasonic Cleaner.</td>
		</tr>
		<tr>
			<td>German 4&#34; Saw Frame and Saw Blade Kit</td>
			<td>Rio Grande</td>
			<td>110112</td>
			<td>Quality, German-made frames are our most popular saw frames, and this frame includes a sampler pack of Rio German saw blades! The adjustable saw frame allows you to achieve the blade tension you want. Throat depth is 102mm (4&#34;). Saw blades have rounded backs that make cutting curves and corners easy and are made from hardened, tempered steel.</td>
		</tr>
	</tbody>
</table>

indirect fabrication of lattice metals with thin sections using centrifugal casting

Um dos métodos típicos para a fabricação de metais treliça 3D é o processo em metal direta manufatura aditiva (AM), tais como Selective Laser de fusão (SLM) e Electron Beam Melting (EBM). Apesar da sua potencial capacidade de processamento, o método directo AM tem várias desvantagens tais como elevado custo, acabamento de superfície pobre de produtos finais, limitação na selecção de materiais, o stress térmico elevado, e propriedades anisotrópicas de peças. Propomos um método de baixo custo para a fabricação de metais treliça 3D. O objectivo deste estudo é o de proporcionar um protocolo detalhado na fabricação de metais treliça 3D que têm uma forma complexa e uma espessura de parede fina, por exemplo, fardo octeto feito de ligas de Al e Cu possuindo um comprimento de célula unitária de 5 mm e uma espessura de parede celular de 0,5 mm. Um procedimento experimental geral é dividido em oito seções: (a) a impressão 3D de padrões de sacrifício (b) derreter-out de materiais de apoio (c) a remoção de resíduos de materiais de apoio (d) assembl padrãoy (e) investimentos (f) burn-out de padrões de sacrifício (g) de fundição centrífuga (h) de pós-processamento para os produtos finais. A técnica AM indireta sugeriu oferece o potencial para a fabricação de metais treliça ultra-leves;., Por exemplo, estruturas de rede com ligas de alumínio. Verifica-se que os parâmetros do processo devem ser adequadamente controlada dependendo dos materiais e da geometria da estrutura, observando-se os produtos finais de metais octeto do fardo através da técnica indirecta AM.

Usando o fabrico aditivo indirecta descrito na secção protocolo, Al e Cu ligas foram usadas para metais fabricação octeto do fardo, como se mostra na Figura 1 O procedimento de moldagem inteira é resumido na Figura 2 O procedimento consiste em oito secções:.. (A) sacrificial padrão de impressão (b) fusão-out de material de apoio (c) a remoção de resíduos de material de apoio (d) O conjunto padrão (e) investimentos (f) burn-out de padrões d...

Watch this Scientific Journal Video about Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting at JoVE.com

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

Um método de fabrico aditivo indirecta combinando uma impressão em 3D de polímeros com uma fundição centrífuga é delineado para o fabrico de metais treliça octeto 3D (Al e Cu ligas) com um comprimento de célula unitária de 5 mm com uma espessura de parede de 0,5 mm.

Fabrication indireta de Malha Metals com cortes finos Usando Fundição

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) ...

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