Assessment of non-uniform shrinkage in the laser sintering of polymer materials

Laser sintering technologies are well established in the rapid prototyping and rapid manufacturing industries, producing a wide range of products for an ever-increasing number of industry sectors. In theory, these processes facilitate direct digital fabrication from 3D CAD models, creating items that have very sophisticated geometries with high levels of quality and accuracy. However, the laser sintering fabrication process is susceptible to part shrinkage which in turn may lead to dimensional inaccuracies (and therefore quality degradation) of the finished item. This paper reviews the issue of shrinkage for laser sintering in the z-axis, and using an EOS P700 machine operating with polyamide-12 material, demonstrates a technique for the assessment of this problem. The experimental results quantify the magnitude of z-axis shrinkage, finding it to be both non-linear and linked to thermal inconsistencies in the build chamber. The study shows that z-axis non-linear shrinkage is likely in all builds; however, its linearity may be improved through placement of products in the centre of the build chamber. The data presented highlight that current operational practices of factorial adjustment for each axis of the build chamber are inadequate and demonstrates the implications of these inaccuracies across different size build components.     

陶瓷粉末选择性激光烧结及聚合物纳米复合材料的研究现状及前景

介绍选择性激光烧结技术(SLS)的原理、特点。评述国内外选择性激光烧结普通陶瓷粉末、纳米陶瓷粉末及聚合物纳米复合材料的研究进展,并对以后的研究方向提出建议。     

A finite element model of thermal evolution in laser micro sintering

Laser micro sintering (LMS) is a promising technique for micro-additive manufacturing. During LMS of metallic powder, the material property variation and the heat input energy profile are important to understand physical phenomena involved. This paper presents a finite element temperature distribution profile in LMS of nickel powder on 304 stainless steel substrate. The simulation considered the transition of powder-to-dense sub-model which involves effective thermal conductivity, volumetric enthalpy, and absorptance change; and a moving volumetric Gaussian distribution heat source sub-model. It is found that, for a specified cross section, the mechanism of preheating the nickel powder changes for the heat source from previous laser-irradiated substrate region to molten nickel as the laser beam approaches, while the center of molten pool slice is slightly shifted toward the reverse direction of laser scanning when the laser moves away due to the thermal accumulation effect. Simulated sintered widths showed very good agreement with experimental measurement, and relative prediction errors are below 16 % within the process window.     

选择性激光烧结激光能量密度与温度补偿规律研究

选择性激光烧结（SLS）成型预热温度从成型缸中间到缸壁呈降低趋势,由于预热温度不均匀,导致SLS成型件密度不均匀。针对这一问题,通过增加激光能量密度对预热温度不足进行了补偿。通过试验建立了激光能量密度差△E与预热温差△T的经验公式,并比较了温度补偿前后烧结件的机械强度。实验结果表明,通过增加激光能量密度对预热温度不足进行补偿,提高了产品机械强度。     

Melt pool temperature control using LabVIEW in Nd:YAG laser blown powder cladding process

Employing automatic gauges is one of the fundamental steps in advanced manufacturing system not only for assuring product quality, but also monitoring process stability. Statistical process control (SPC), therefore, is developed to detect the occurrence of assignable causes so that unnecessary quality costs can be avoided. However, it is necessary to provide a practical way to evaluate the monitoring capability of an automatic gauge for its application. That is, the monitoring capability study should be conducted before applying any automatic gauge on SPC application. The economic SPC chart then can be properly designed. Rather than conventionally considering the relationship between both manufacturing cappability and control limits, gauge capability is further and concurrently considered to analyze the monitoring error of an automatic gauge in this paper. After interpreting the effect of manufacturing capability, gauge capability, and control limits to construct the monitoring error model, furthermore, the engineer can then distinctly evaluate monitoring capability by the expected cost incurred in the SPC process. Also, genetic algorithm is successfully applied to determine the economic design of X-bar control chart with the realistic monitoring error model embedded.     

Micro laser welding of polymer microstructures using low power laser diodes

The use of laser welding for joining micro parts has experienced a substantial increase in popularity during recent years. Specifically translucent microfluidic devices are assembled using laser welding; however, a major issue is the laser beam size of commercially available laser-welding equipment and thus the resulting welding seam size, which may be orders of magnitude larger than microfluidic channels and structures. We have successfully achieved extremely small welding seams using focussed low-power laser diodes. Commercial laser welding stations for polymer assembly will typically operate in the power-region 15–50 Watts. The focussed laser beam will have a size of typically 500 μm × 500 μm and may, depending on optical configuration, be up to several mm². The resulting welding-seam will thus be in the area of 300–600 μm depending on beam energy distribution; additionally the melt will spread to unheated areas due to capillary forces. As microfluidic channels are in 20–100 μm regions, even a very limited amount of stray melt may completely fill a part of a channel and thus render it useless. We have used commercially available “single-die” laser-diodes of optical power 200–500 mW. The beam has been focussed and directed using simple optical installations, resulting in a beam-size in the area of 50 μm × 5 μm full width half maximum (FWHM) We have achieved firm welding seams of width <10 μm, with a welding speed of 15 mm/s and with virtually no noticeable spread of melt.     

Rough-cut fast numerical investigation of temperature fields in selective laser sintering/melting

The surface micro/nano-topographical modifications have been widely used in improving the biocompatibility of biomedical implants. In this paper, the feasibility of the micro-milling process for construction of micro-grooves without burrs on titanium alloy materials was investigated. Low melting point alloy was selected as supporting material to extend the boundary of the workpiece, so the burrs produced on the surface of supporting material. A novel hierarchical micro/nano-topography with micro-grooves and TiO₂ nanotubes was fabricated on titanium alloy surface combining micro-milling and anodic oxidation. The scanning electron microscope, energy-dispersive spectroscopy, laser scanning microscope, and contact angle tester were used in characterizing surface features of machined workpieces. Results showed that the micro-grooves with dimension of 40 μm in depth were machined using V-shaped cutting tool, and the TiO₂ nanotubes with dimension of 70 nm in diameter were superimposed on the surfaces of micro-grooves by anodic oxidation. In addition, the hydrophilicity of micro/nano-structured surface was significantly enhanced with the water contact angle decreasing from 114.8° to 60.3°. It is concluded that this hybrid method combining micro-milling technology and anodic oxidation can be used in improving the biological activity of biomedical implants through changing surface topographies.     

Fabrication of porous bioactive structures using the selective laser sintering technique

Hydroxyapatite, a ceramic with which natural bone inherently bonds, has been incorporated into a polymer matrix to enhance the bioactivity of implant materials. In order to manufacture custom-made bioactive implants rapidly, selective laser sintering has been investigated to fabricate hydroxyapatite and polyamide composites and their properties investigated. One objective of this research was to identify the maximum hydroxyapatite content that could be incorporated into the matrix, which was sintered at various parameters. The study focused on investigating the control of porosity and pore size of the matrix by manipulating the selective laser sintering parameters of the laser power and laser scan speed. The interception method was used to analyse the internal porous morphology of the matrices which were cross-sectioned through the vertical plane. Most notably, all structures built demonstrated interconnection and penetration throughout the matrix. Liquid displacement was also used to analyse the porosity of the matrices. The laser power showed a negative relationship between porosity and variation in parameter values until a critical power value was reached. However, the same relationship for laser scan speed matrices was inconsistent. The effects of the laser power and laser scanning speed on the features of porous structures that could influence cell spreading, proliferation, and bone regeneration are presented.     

激光焊接接头的质量控制研究

激光焊接高强度镀锌钢时,采用引弧板和接弧板的方法,可以避免不稳定的熔宽变化造成的不良影响。由于激光焊接时工件表面镀锌层的蒸发而影响接头的耐蚀性,为此采用浓度为3%的盐水对不同激光焊接工艺的焊接件进行腐蚀试验,获得了腐蚀前后的焊接接头的质量变化量和金相图。研究表明,在不同工艺参数的条件下,激光焊接高强度镀锌钢焊接接头的腐蚀速度不同,其平均速度与母材的腐蚀速度大体相当,不会影响接头的抗腐蚀性能。     

热管理技术在紫外成像光谱仪热控制中的应用

研究了紫外成像光谱仪热控制的特点,指出采用常规热设计理念对紫外成像光谱仪散热容易造成散热面面积大、主动加热功耗高等问题。基于热管理技术,提出采用统一收集和综合管理仪器热源产生热量的方法来解决紫外成像光谱仪的热控制问题。对紫外成像光谱仪的热设计验证试验表明:低温工况下整机平均温度变化为18～20℃,最大轴向温差变化为1.0～2.4℃;高温工况下整机平均温度变化为18～24.5℃,最大轴向温差变化为1.2～3.3℃;均满足热控指标要求。结果显示:采用热管理技术综合收集和管理热量能够提高能量利用率、有效降低热控系统规模。提出的方法对其它空间光学遥感器的热控制具有一定参考意义。     

Influence of target grit count and sintering temperature on pulsed laser deposition of SiC thin films

A pulsed laser deposition (PLD) technique for depositing SiC on Si(100) substrates using Nd³⁺:YAG laser at 355 nm is studied. The influence of substrate temperature, ambient pressure, and SiC powder grit size on both structure and morphology of SiC thin film is investigated. Further, the influence of the target preparation on the reduction of droplet formation during Nd³⁺:YAG laser-assisted pulsed laser deposition of SiC thin films is investigated. Experimental studies show that multicrystalline SiC film can be obtained with temperature ranging from 600 to 700 °C and at an ambient pressure of about 5.5 × 10^?3 Pa. Further, droplet formation on the deposited film was reduced significantly by selecting the grit count of SiC powder 500 and the pressure of 2 × 10^?2 Pa. SiC target sintered at 1,600 °C showed a reduced wear during the laser ablation. The X-ray diffraction (XRD) and the Raman spectroscopy studies on deposited films clearly show the multicrystalline (combined 3C-SiC and 4H-SiC) nature of SiC films. I-V characteristics of deposited SiC film on n-type c-Si substrate also indicated that SiC thin film possesses P-type semiconductor properties.     

模糊自适应在真空烧结炉温度控制中的应用

硬质合金真空烧结炉的动态特性具有非线性、时变性和不对称性等特点，采用通用智能温控器控温时效果不尽人意。本文提出一种将PID参数插值自适应控制与模糊控制相结合的自适应控制算法，仿真结果表明，该控制方案简单、有效，满足硬质合金真空烧结炉温度的控制要求。     

水质自动监测系统的质量保证与质量控制

质量保证和质量控制是水环境监测工作的重要组成部分,本文主要介绍水质自动监测全过程的质量保证与质量控制方法。     

FEA simulation of thermal processes during the direct metal laser sintering of Ti64 titanium powder

With regard to the fact that laser sintering belongs to the high-temperature processes in which metal particles are sintered by a high-power laser, forming a homogenous structure, it is necessary and important to know the characteristics and the mechanism of these thermal processes. A high-power laser system produces three forms of heat that include convection, conduction, and radiation. These thermal processes affect the formation of internal stresses and tension that lead to deformations and rapidly influence the resulting quality, dimensions, density, micro-structure, and mechanical properties of fabricated parts. In response to this fact, it was important to analyse these heat transfer methods instantly during the direct metal laser sintering (DMLS) process simulation and subsequently monitor the parameters and settings of the sintering equipment in order to obtain acceptable manufacture outputs intended for further use. This work is focused on the creation of a FEA simulation model and the simulation of thermal processes across an object during and after the sintering process in the cooling stage, when it is important to consider a laser beam trajectory, temperatures of individual elements affected by the laser beam, and current laser energy in time. A 3D FEA simulation model was created in order to represent actual behaviour of a part during the sintering process. The simulation model consisted of two sub-models, particularly the building platform model with the dimensions of 250 mm × 250 mm × 22 mm, with stainless steel as the selected material, and the model of individual layers of sintered titanium powder with the dimensions of 10 mm × 10 mm × 0.03 mm. The total number of used layers was 12, which represents the total thickness of 0.36 mm. Applied power was P = 170 W. The simulation as such was carried out using the FEA software, Simulia Abaqus supported on the Windows x86-64 platform, which uses an integrated solver to make thermal and mechanic calculations. The calculations included also the impact of the protective argon atmosphere located in the process chamber. Mutual impact between individual layers was also considered. The simulation results were confronted with the results of already performed experimental studies of other scientific works, with the compliance and confirmation of assumptions being on a very good level.     

粉末薄层选区激光烧结温度场数值模拟与实验研究

单层粉末的激光烧结温度场对三维结构熔结成型有着直接影响。通过对工程塑料粉末选区激光烧结过程能量作用形式的分析,构建了粉体与金属基板界面接触热阻的导热模型和扫描烧结的移动热源模型;利用有限元法对功率为10～25W,光斑直径为0.24mm的激光逐行扫描烧结过程的温度场进行了数值模拟;通过温度场分布模拟和激光烧结实验得到了单层厚度为0.5mm的PA6粉末行扫描间距的优化区间为0.3～0.4mm,获得了熔结质量较好、厚度均匀的平板形烧结物,为进一步优化工艺参数提供了基础。     

High-precision temperature control and stabilization using a cryocooler

We describe a method for precisely controlling temperature using a Gifford-McMahon (GM) cryocooler that involves inserting fiber-reinforced-plastic dampers into a conventional cryosystem. Temperature fluctuations in a GM cryocooler without a large heat bath or a stainless-steel damper at 4.2 K are typically of the order of 200 mK. It is particularly difficult to control the temperature of a GM cryocooler at low temperatures. The fiber-reinforced-plastic dampers enabled us to dramatically reduce temperature fluctuations at low temperatures. A standard deviation of the temperature fluctuations of 0.21 mK could be achieved when the temperature was controlled at 4.200?0 K using a feedback temperature control system with two heaters. Adding the dampers increased the minimum achievable temperature from 3.2 to 3.3 K. Precise temperature control between 4.200?0 and 300.000 K was attained using the GM cryocooler, and the standard deviation of the temperature fluctuations was less than 1.2 mK even at 300 K. This technique makes it possible to control and stabilize the temperature using a GM cryocooler.     

激光金属沉积成形基板预热温度的控制

为了降低激光金属沉积成形过程中试样和基板间的温度梯度,减小和抑制成形过程的热应力,提高试样的成形质量,提出并设计了一种用于激光金属沉积成形的基板预热系统.其中基板预热温度的控制由智能比例微分积分控制器以及计算机串口温度采集反馈控制来完成.利用自行研制的激光金属沉积成形设备和基板预热系统进行了成形实验,实验结果表明该基板预热系统温度控制良好,可以满足实际应用的需要.     

Fabrication of porous polymeric matrix drug delivery devices using the selective laser sintering technique

New techniques in solid freeform fabrication (SFF) have prompted research into methods of manufacturing and controlling porosity. The strategy of this research is to integrate computer aided design (CAD) and the SFF technique of selective laser sintering (SLS) to fabricate porous polymeric matrix drug delivery devices (DDDs). This study focuses on the control of the porosity of a matrix by manipulating the SLS process parameters of laser beam power and scan speed. Methylene blue dye is used as a drug model to infiltrate the matrices via a degassing method; visual inspection of dye penetration into the matrices is carried out. Most notably, the laser power matrices show a two-stage penetration process. The matrices are sectioned along the XZ planes and viewed under scanning electron microscope (SEM). The morphologies of the samples reveal a general increase in channel widths as laser power decreases and scan speed increases. The fractional release profiles of the matrices are determined by allowing the dye to diffuse out in vitro within a controlled environment. The results show that laser power and scan speed matrices deliver the dye for 8-9 days and have an evenly distributed profile. Mercury porosimetry is used to analyse the porosity of the matrices. Laser power matrices show a linear relationship between porosity and variation in parameter values. However, the same relationship for scan speed matrices turns out to be rather inconsistent. Relationships between the SLS parameters and the experimental results are developed using the fractional release rate equation for the infinite slab porous matrix DDD as a basis for correlation.