From Photopolymerization of Metal Suspension to Practical and Economical Additive Manufacturing of Haynes 214 Alloy for High Temperature Application

Abstract

Haynes 214 high temperature heat exchanger assembly with enclosed heat flow channels and internal fin structures was successfully fabricated using our scalable and expeditious additive manufacturing (SEAM) process, a new metal additive manufacturing (AM) technology developed at Michigan State University (MSU). Three dimensional green objects can be fabricated by selectively photopolymerizing Haynes 214 metal suspension on a powder bed system in a layer-by-layer fashion. An innovative strategy to attain a complete binder removal and high density as well as dimensional accuracy were developed and employed to achieve final metal parts with relative density above 99.5% and no geometrical distortion.

Novel Process Modeling of Magnetic-Field Assisted Finishing (MAF) with Rheological Properties

“…The flexible nature of the brush makes MAF one of the most suitable candidates for polishing complex geometries such as cylindrical [1] and freeform surfaces [2], cavities [3], and internal grooves [4]. With the development of metal additive manufacturing (AM) [5][6][7][8][9], which is capable of producing various complex designs and shapes that are not feasible with any conventional subtractive manufacturing, there has been an increasing demand for viable finishing technologies for complex AM-fabricated geometries. Although there are other advanced finishing processes that can improve the surface quality of the parts to a fine scale such as elastic emission machining (EEM) [10] and chemical-mechanical polishing (CMP) [11], thanks to the shape-adaptive flexible polishing brush, MAF has garnered much interest regarding the post processing of additively manufactured components [12][13][14].…”