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

Denna studie fick stöd från forsknings Initiation Grant (RIG) vice ordförande för forskning och ekonomisk utveckling vid University of North Texas (UNT). Författarna tackar också KCIS Co Ltd för att delvis stödja denna studie. Stödet från PACCAR Technology Institute vid UNT till framgång för denna publikation är mycket uppskattat.

1. Planering av experiment <ol><li> Rita en offermönster (en oktett fackverksstruktur med ett inloppssystem) med användning av datorstödd konstruktion (CAD) program som visas i figur 1 och spara CAD-modellen som en STL-filformat. Anmärkning: Offer mönstret är ett integrerat mönster av oktettfackverksstruktur med ett inloppssystem som kommer att så småningom smältas för gjutning. Eftersom offer mönstret innefattar både oktetten fackverksstrukturen och inloppssystemet, inte exakt rep...

<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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Process. 17, 28-40 (2015).</li><li>Challapalli, A., Ju, J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Continuum+Model+for+Effective+Properties+of+Orthotropic+Octet-Truss+Lattice+Materials.">Continuum Model for Effective Properties of Orthotropic Octet-Truss Lattice Materials.</a> Proceedings of the ASME International Mechanical Engineering Congress and Exposition. , (2014).</li><li>Taylor, H. F., Flemings, M. 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För konventionell metallgjutning, är det viktigt att hålla den smälta metallens flöde slät och rationaliseras i &quot;laminärt&quot; i formrummet och snarare undvika oregelbunden och upprörd flöde allmänt förekommer i turbulent flöde 27. Följaktligen är det viktigt att kunna utforma inloppet hos inloppssystemet associerad med rotationshastigheten hos en centrifugal arm för att upprätthålla flödet av smält metall inuti galler formhåligheten &#39;laminärt&#39;. ...

Cellulära metaller är metallerna består av ett sammanhängande nätverk av fasta stöttor eller plattor och har komplexa mikroarkitekturer med hålrum 1. Exempel innefattar både i) slumpmässigt strukturerade stokastiska skum och ii) periodiskt ordnade tvådimensionella (2D) bikakor och tredimensionella (3D) gitter fackverksstrukturer. De har fått uppmärksamhet på grund av deras höga specifika styvhet och hållfasthet 1-3 och hög specifik motståndskraft 4-5, utmärkt energiabsorption för stötbelastning 6, akustisk isolering 7, möjlig utformning av värme dissipaters och värmeväxlare 8. Speciellt regelbundet ordnade gitterstrukturer har potential att konstruera de egenskaper som är överlägsna med en förmåga att reglera den inre poröst nätverk geometri. På grund av deras komplicerade interna poröst nätverk geometri, är det svårt att tillverka cellulära metaller med användning av den konventionella subtraktiv machining. Som sådan, forskare har börjat leta efter alternativa metoder för att fabricera cellulära metaller: bildande gas i flytande metall eller blandning av metallpulver med jäsmedel undersöktes för tillverkning av stokastiska metallformer 9. På grund av bristande kontroll över cell topologi, är det svårt att skräddarsy mekaniska egenskaper. Alternativt har tillverkningsmetoder för period beställda cellulära metaller utforskas: stämpling tunna blad av metall i en korrugerad form, följt av att gå dem för att skapa periodiska strukturer 10, slitsade bindningsmetallplåtar 11, extrudering 12, vävning och glödande metalltrådar för att tillverka textilier 13. Även om dessa tillverknings metoder ger upprepningsbara mönster är mönstren fortfarande begränsad i den plana riktningen. I ett försök att skapa 3D mönster upprepning, forskare börjat använda additiv tillverkning (AM), t.ex. Selective Laser Melting (SLM) 14, Electron Beam Melting (EBM) <sup&gt; 15, och Direct-Metal Laser Sintring (DML) 16. Trots att de har förmåga att tillverka 3D beordrade komplexa gittergeometrier, finns det fortfarande vissa begränsningar: svårt att använda metaller med hög värmeledningsförmåga och hög optisk reflektivitet 17, hög termisk restspänning 18, dålig ytfinish med &quot;balling&quot; -fenomen under laser eller elektron smältning 19 anisotropa egenskaper 20-21 av delar till följd av en kombinerad effekt av den skiktade tillverkning, anisotropisk bildandet av korn, pulver storlek, makt och skanningshastighet av laser eller elektronstråle 15, hög energiförbrukning, osv. Kombinera polymerbaserad AM med metallgjutning kan ge en alternativ metod för att tillverka gitter metaller. Man kan kalla detta &quot;indirekt AM&quot;. Indirekt AM kan vara en lösning för att övervinna de tekniska problemen med direkt AM av metaller som nämns ovan. Flera insatser har varit made att tillverka gitter metaller med hjälp av indirekt AM kombinera 3D-utskrifter av polymerer med allvar baserade gjutning 22-25, t ex, en investering gjutning i kombination med smält nedfall modellering (FDM) för att tillverka ett galler legering 22-25 eller sandgjutning i kombination med en sand pulver baserade AM 23. Allvaret baserad gjutning tycks förbli en teknisk utmaning att övervinna - misrun och porositet orsakad av plötslig solidifiering av smälta metaller när de möter nätstrukturer med skarpa hörn av gitterstruktur formar 25-26. Relativt stor ytarea av gitterstrukturformar verkar också för att bidra till plötslig kylning, vilket resulterar i för tidig stelning 25-26. I denna studie, föreslår vi ett alternativ indirekt AM som kan övervinna misrun under tillverkning av fackverks metall - centrifugalgjutning till ett galler formkavitet gjord av en 3D tryckt gallerofferpolymermönster. Vi använder en digitalLight Processing (DLP) baserad 3D-utskrifter metod för att bygga en galler strukturell offer mönster följt av centrifugal gjutning av Al- och Cu-legeringar. Syftet med denna studie är att ge ett detaljerat protokoll för tillverkning av 3D-gitter metaller med en komplex form och en tunn väggtjocklek. Det viktigaste bidraget i denna process är att ge en möjlighet att utöka urvalet av material med låg tillverkningskostnad för tillverkning av gitter metaller.

<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

En av de typiska metoder för att tillverka 3D gitter metaller är direkt metall additiv tillverkning (AM) process såsom Selective Laser Melting (SLM) och elektronstrålesmältning (EBM). Trots dess potentiella bearbetningskapacitet, har den direkta AM metod flera nackdelar såsom höga kostnader, dålig ytfinish slutprodukter, begränsning i materialval, hög termisk stress och anisotropiska egenskaper delar. Vi föreslår en kostnadseffektiv metod att tillverka 3D-gitter metaller. Syftet med denna studie är att ge ett detaljerat protokoll för tillverkning av 3D-gitter metaller med en komplex form och en tunn väggtjocklek, t.ex. oktett fackverk tillverkade av Al- och Cu-legeringar som har en enhetscelllängd 5 mm och en cellväggtjocklek på 0,5 mm. En övergripande experimentella förfarande är indelad i åtta avsnitt: (a) 3D-utskrifter av offer mönster (b) smält av stödmaterial (c) avlägsnande av rester av stödmaterial (d) mönster assembly (e) investeringar (f) utbrändhet av offermönster (g) centrifugalgjutning (h) efterbehandling för slutprodukter. Den föreslagna indirekta AM teknik ger möjlighet att tillverka extremt lätta gitter metaller;. T.ex. fackverkskonstruktioner med Al-legeringar. Det verkar som om processparametrarna bör kontrolleras ordentligt beroende på material och gitter geometri, observera slutprodukterna från oktett fackverks metaller genom den indirekta AM tekniken.

Använda additiv tillverkning indirekt beskrivs i protokollet avsnittet var Al- och Cu-legeringar som används för tillverkning oktett stötta metaller, som visas i figur 1 Hela gjutningsförfarande sammanfattas i figur 2 Förfarandet består av åtta avsnitt:.. (A) offer mönster utskrift (b) smält av bärarmaterial (c) avlägsnande av rester av bärarmaterial (d) mönsterenhet (e) investeringar (f) utbrändhet av offermönster (g) centrifugalgjutning...

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

En indirekt additiv tillverkningsmetod som kombinerar en 3D tryckning av polymerer med en centrifugalgjutning skisseras för tillverkande 3D oktettfackverks metaller (Al och Cu-legeringar) som har en enhetscelllängd av 5 mm med en väggtjocklek av 0,5 mm.

Indirekt Tillverkning av Lattice metaller med tunna sektioner Använda centrifugalgjutning

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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Detection and Recovery of Palladium, Gold and Cobalt Metals from the Urban Mine Using Novel Sensors/Adsorbents Designated with Nanoscale Wagon-wheel-shaped Pores

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Fabrication of Low Temperature Carbon Nanotube Vertical Interconnects Compatible with Semiconductor Technology

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Capillary-based Centrifugal Microfluidic Device for Size-controllable Formation of Monodisperse Microdroplets

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Here, we demonstrate a simple method for the rapid production of size-controllable, monodisperse, W/O microdroplets using a capillary-based centrifugal ...

Fabrication of White Light-emitting Electrochemical Cells with Stable Emission from Exciplexes

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Fabrication of Ultra-thin Color Films with Highly Absorbing Media Using Oblique Angle Deposition

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