Shape Deposition Manufacturing With Microcasting: Processing, Thermal and Mechanical Issues

[+] Author and Article Information
C. H. Amon, J. L. Beuth

Department of Mechanical Engineering, Carnegie Mellon University, Pittsburgh, PA 15213

L. E. Weiss

Robotics Institute, Carnegie Mellon University, Pittsburgh, PA 15213

R. Merz

Department of Mechanical Engineering and the Center for Design Research, Stanford University, Stanford, CA 94305

F. B. Prinz

Departments of Mechanical Engineering and Materials Science and Engineering, and the Center for Design Research, Stanford University, Stanford, CA 94305

J. Manuf. Sci. Eng 120(3), 656-665 (Aug 01, 1998) (10 pages) doi:10.1115/1.2830171 History: Received June 01, 1996; Revised September 01, 1997; Online January 17, 2008


Shape deposition manufacturing (SDM) is a solid freeform fabrication (SFF) methodology for automatically building up material layers to form three-dimensional, complex-shaped, multi-material structures. Microcasting is a molten metal droplet deposition process which is able to create fully dense metal layers with controlled microstructures. SDM combines microcasting with other intermediate processing operations, such as CNC machining and shot peening, to create high quality metal parts. In this paper, a description is given of SDM and the microcasting process. An overview of thermal and mechanical issues associated with SDM and microcasting is presented, including the control of interlayer metallurgical bonding through substrate remelting, the control of cooling rates of both the substrate and the deposited material and the minimization of residual thermal stress effects. Thermal models are used to study the issue of localized remelting of previously deposited material by newly deposited molten droplets to achieve metallurgical bonding. Mechanical modeling provides insight into residual stress build-up during part manufacture and residual stress-driven debonding between deposited layers.

Copyright © 1998 by The American Society of Mechanical Engineers
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