Titanium castings using laser-scanned data and selective laser-sintered zirconia molds |
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Authors: | Nicole R Harlan David L Bourell Joseph J Beaman Reuben Reyes |
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Affiliation: | (1) Laboratory for Freeform Fabrication, USA;(2) Aerospace Engineering/Engineering Mechanics Learning Resource Center, The University of Texas at Austin, 78712 Austin, TX |
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Abstract: | Titanium casting molds, made of stabilized and unstabilized zirconium oxide, were created using a combination of selective
laser sintering (SLS) and colloidal infiltration. The mold material system was chosen for its thermal shock resistance and
low reactivity with molten titanium. The starting material, stabilized zirconia powder mixed with a copolymer binder, was
laser sintered into the desired green shape. The binder was removed during pyrolysis and replaced by unstabilized zirconia.
As infiltrant weight gain increased, the density, flexural strength, and surface roughness improved to levels adequate for
titanium casting trials. A half-scale casting mold for the ball of a human femur bone was produced from laser-scanned data
and cast with Ti-6Al-4V alloy. The castings exhibited an as-cast surface roughness (R
a
) of 8 μm and a typical microstructure. This work demonstrates a feasible method of producing complex titanium castings for
one-of-a-kind and custom components without the necessity of part-specific tooling or wax patterns. |
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Keywords: | selective laser sintering Ti-6-Al-4V alloy titanium casting molds zirconia |
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