Product Code: ICA10_1403

Direct Manufacturing of Net-Shape Functional Components/Test-Pieces for Aerospace, Automotive and Other Applications
Authors:
Lijue Xue, Industrial Materials Institute, National Research Council of Canada; London ON Canada
Yangsheng Li, Industrial Materials Institute, National Research Council of Canada; London ON Canada
Shaodong Wang, Industrial Materials Institute, National Research Council of Canada; London Canada
Presented at ICALEO 2010

Laser consolidation is a novel computer-aided rapid manufacturing process that produces net-shape functional metallic parts layer-by-layer directly from a CAD model by using a laser beam to melt the injected powder and re-solidifying it on the substrate or previous layer. As an alternative to the conventional machining process, this novel manufacturing process builds net-shape functional parts or features on an existing part by adding instead of removing material. In this paper, laser consolidation of various high performance materials (such as Ni-alloys, Ti-alloys, Al-alloys, tool steels, etc.) will be demonstrated to manufacture functional components or test pieces (such as nozzles, combustor chamber, impeller, ducts, shell-based mold inserts, intersected multi-hexgon tube, goblet shape, etc.) for potential aerospace, automotive and other applications. In the paper, mechanical properties of laser-consolidated materials will be discussed and dimensions of various laser-consolidated test pieces will be measured and compared with CAD models. In addition, the impacts of this green manufacturing technology will be discussed in terms of reducing waste chips, minimizing tooling materials and recovering waste components.

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