Enhanced Aluminum Properties by Means of Precise Droplet Deposition

[+] Author and Article Information
Melissa Orme, Robert F. Smith

Department of Mechanical and Aerospace Engineering, University of California, Irvine, CA 92697-3975

J. Manuf. Sci. Eng 122(3), 484-493 (Sep 01, 1999) (10 pages) doi:10.1115/1.1285914 History: Received November 01, 1998; Revised September 01, 1999
Copyright © 2000 by ASME
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Conceptual schematic precision droplet-based net-form manufacturing
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Illustration of droplet formation from capillary streams
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Schematic of aluminum droplet generation and deposition facility
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Schematic of cartridge, heater, and plunger assembly
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(a) SEM photograph of a 100 μm diameter natural diamond orifice which was jetted for two hours; (b) enlarged view which illustrates the rough region on the right which was exposed for two hours, and the smoother region on the left which was exposed for one hour
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189 μm diameter molten aluminum droplets generated from a 100 μm diameter orifice after traveling approximately 0.4 meters in an inert environment
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Three optical microscope images of the microstructure of a droplet deposited aluminum component at various distances from the substrate. Left: Image is a vertical cut 1.0 mm from the substrate. Center: 5.0 mm from the substrate. Right: 25 mm from the substrate (please note the different length scales).
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Micrographs of droplet deposited aluminum clinders. Field of view in both images is 160×190 μm. Splat boundaries are not evident in either image. Left: melt was unfiltered. Oxidation and pores are evident around the grains; Right: melt was filtered. Grain boundaries are not encapsulated with an oxide film.
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Zoomed out micrographs of droplet deposited aluminum structures. Field of view in both images is 800×970 μm. Splat boundaries do not exist in either image. Left: melt was unfiltered. Oxidation and pores are evident around the grains; Right: melt was filtered. Oxide grain boundaries are not present.
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Plot of temperature increase of the top surface of the deposited component as a function of number of splat delivered for a splat delivery rate of 24,000 Hz and a splat thickness of 10 μm
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Plot of the solid/liquid interface through a two-splat system for various values of the temperature difference ratio




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