Special Section: Micromanufacturing

Fabrication of High Aspect Ratio Porous Microfeatures Using Hot Compaction Technique

[+] Author and Article Information
Peng Chen, Jun Ni

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109

Gap-Yong Kim

Department of Mechanical Engineering, Iowa State University, Ames, IA 50011

J. Manuf. Sci. Eng 130(3), 031103 (May 05, 2008) (8 pages) doi:10.1115/1.2917308 History: Received May 28, 2007; Revised March 09, 2008; Published May 05, 2008

High aspect ratio porous microfeatures are becoming more important in the modern industry. However, the fabrication of such features under a mass production environment remains a challenge when robustness, cost effectiveness, and high productivity requirements are required. In this study, the forming of such porous microfeatures using hot compaction was investigated. A hot compaction experimental setup was designed and fabricated that is capable of performing high temperature operation (700°C), quick heatup, and avoiding oxidation. 3D thermal simulation of the experimental setup was conducted to investigate the heat transfer performance and internal temperature distribution, which was then used as a reference for the experiment. Hot compaction experiments were carried out, and the effects of compression force and temperature on the quality in terms of powder consolidation strength and porosity were investigated. In addition, the achievable aspect ratio and taper angle were also discussed.

Copyright © 2008 by American Society of Mechanical Engineers
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Figure 2

Experimental setup: (a) whole setup; (b) compaction assembly (front view); (c) compaction assembly (section view)

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Figure 3

Die insert 1: (a) Insert 1; (b) profile measurement of the microchannels at different cross sections

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Figure 7

450°C case: (a) heat flux input; (b) validation of the simulation with experiment

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Figure 8

Temperature distribution of the powder (450°C case).

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Figure 9

Hot compacted part: (a) successfully formed microfeatures; (b) magnified cross-sectional view (Insert 1)

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Figure 10

Interconnected porous structure of the formed microfeatures (Insert 1).

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Figure 11

Effects of design factors on the hardness: (a) response surface; (b) main effect plot

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Figure 12

Effects of design factors on the porosity: (a) response surface; (b) main effect plot.

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Figure 13

Magnified cross-sectional view (Insert 2).

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Figure 14

Interconnected porous structure of the formed microfeatures (Insert 2).

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Figure 15

Successfully formed microprotrusions with different taper angles (Insert 3).



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