Benchmarking of three processes for producing castings incorporating micro/mesoscale features with a high aspect ratio

Charmeux, Jean-Francois; Minev, Roussi; Dimov, Stefan Simeonov; Brousseau, Emmanuel Bruno Jean Paul; Minev, Ekaterin; Harrysson, Urban

doi:10.1243/09544054jem693

Cited by 13 publications

(6 citation statements)

References 16 publications

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“…Wu et al [60], Everton et al [61], and Fayazfar et al [62] conducted reviews of the use of stainless steel powder as the feedstock material in AM. Charmeux et al [63] investigated the performance of three process chains for vacuum investment casting of aluminum/zinc alloys and stainless steel parts. The property parameters considered were dimensional accuracy, surface quality, and production costs of the three process chains.…”

Section: Stainless Steel-based Alloysmentioning

confidence: 99%

Review of materials used in laser-aided additive manufacturing processes to produce metallic products

et al. 2018

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Rapid prototyping (RP) or layered manufacturing (LM) technologies have been extensively used to manufacture prototypes composed mainly of plastics, polymers, paper, and wax due to the short product development time and low costs of these technologies. However, such technologies, with the exception of selective laser melting and sintering, are not used to fabricate metallic products because of the resulting poor life, short cycle, poor surface finish, and low structural integrity of the fabricated parts. The properties endowed by these parts do not match those of functional parts. Therefore, extensive research has been conducted to develop new additive manufacturing (AM) technologies by extending existing RP technologies. Several AM technologies have been developed for the fabrication of metallic objects. These technologies utilize materials, such as Ni-, Al-, and Ti-based alloys and stainless steel powders, to fabricate high-quality functional components. The present work reviews the type of materials used in laserbased AM processes for the manufacture of metallic products. The advantages and disadvantages of processes and different materials are summarized, and future research directions are discussed in the final section. This review can help experts select the ideal type of process or technology for the manufacturing of elements composed of a given alloy or material (Ni, Ti, Al, Pb, and stainless steel).

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Section: Stainless Steel-based Alloysmentioning

confidence: 99%

Review of materials used in laser-aided additive manufacturing processes to produce metallic products

et al. 2018

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“…95 It was reported that a conventional vacuum casting process with minor changes can be employed to fabricate microstructures, high AR structures and submicrometer features. 96 Microprecision investment casting is adapted to parts smaller than 1 mm and to bigger ones with structural details in micrometer range (Figure 10). 85 It was shown that features with size less than 150 μm, ribs with AR higher than 50 and surface roughness around 5 μm could be reproduced with an accuracy of 10% or less.…”

Section: Microcastingmentioning

confidence: 99%

“…89 The capabilities of two different process chains, lost-wax process and direct shell process, for producing accurate castings having micro/mesoscale features have been compared. 96 The soundness, quality, microstructure and production cost of castings manufactured by employing these two processes are also discussed in detail.…”

Section: Microcastingmentioning

confidence: 99%

Micromanufacturing: A review—part II

Jain

Dixit

Paul

et al. 2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article discusses an overview of microforming, microcasting and microwelding processes. In the case of microforming, the processes reviewed are micro deep drawing, microforging, microextrusion, microrolling, microstamping, microhydroforming and incremental microforming. This section also throws some light on how the lasers have been used for microbending and micropunching purposes. The work done in the area of physics of microforming processes has also been discussed briefly. This article also deals with different types of microcasting processes particularly permanent mold and investment microcasting processes. The applications of these microcasting processes have been specified in different fields of engineering, biomedical and so on. Some areas in which further research work is needed have been identified. It includes both theoretical and experimental works which need attention. The last part of this article deals with microjoining in general and laser microjoining in particular. This section discusses the types of the lasers that are being used for microjoining purposes. The process parameters (laser, optics, system and material) have been explained, and some work done on the parametric analysis has been reported briefly. Various applications of laser microjoining have been elaborated before the last section on concluding remarks. This last section presents, in very brief, the areas in which further work is required in microjoining processes.

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“…Several analyses have been conducted to examine the molding accuracy of this process. The casting accuracy of microparts using aluminum/zinc alloys [5,6] and stainless steel [7] as well as low melting Au-Ag-based precious metal alloys was investigated [8]. According to these results, microparts with geometrical features in a range of 700-50 μm can be cast with acceptable geometrical variation and an average surface roughness between 0.5 and 1 μm.…”

Section: Introductionmentioning

confidence: 99%

Replication of specifically microstructured surfaces in A356-alloy via lost wax investment casting

Ivanov

Bührig–Polaczek

Vroomen

et al. 2011

J. Micromech. Microeng.

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A common way of realizing microstructural features on metallic surfaces is to generate the designated pattern on each single part by means of microstructuring technologies such as e.g. laser ablation, electric discharge machining or micromilling. The disadvantage of these process chains is the limited productivity due to the additional processing of each part. The approach of this work is to replicate microstructured surfaces from a master pattern via lost wax investment casting in order to reach a higher productivity. We show that microholes of different sizes (∅ 15–22 µm at depths of 6–14 µm) can be replicated in AlSi7Mg-alloy from a laser-structured master pattern via investment casting. However, some loss of molding accuracy during the multi-stage molding process occurs. Approximately 50% of the original microfeature's heights are lost during the wax injection step. In the following process step of manufacturing a gypsum-bonded mold, a further loss in the surface quality of the microfeatures can be observed. In the final process step of casting the aluminum melt, the microfeatures are filled without any loss of molding accuracy and replicate the surface quality of the gypsum mold. The contact angle measurements of ultrapure water on the cast surfaces show a decrease in wettability on the microstructured regions (75°) compared to the unstructured region (60°).

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Benchmarking of three processes for producing castings incorporating micro/mesoscale features with a high aspect ratio

Cited by 13 publications

References 16 publications

Review of materials used in laser-aided additive manufacturing processes to produce metallic products

Review of materials used in laser-aided additive manufacturing processes to produce metallic products

Micromanufacturing: A review—part II

Replication of specifically microstructured surfaces in A356-alloy via lost wax investment casting

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