Gao and Sonin (1994) have proposed a method for rapid prototyping and microfabrication by precise deposition and solidification of molten microdrops. Objects can be fabricated by a drop-on-demand, computer-controlled droplet generator. To understand the fundamentals of droplet deposition and solidification, experiments have been conducted using microcrystalline wax droplets (Schiaffino and Soni...

Using the calculation of phase diagrams approach and Scheil solidification modeling, Al-2.5Mg-1.0Ni-0.4Sc-0.1Zr alloy was designed, intentionally with an extraordinarily high cracking susceptibility, making it prime for during laser powder bed fusion. This study demonstrates ability to mitigate even most extreme tendencies in aluminum alloys only minor alloying additions Sc Zr, 0.5 wt.% max. Fu...

Heterogeneous Al–Si microstructure comprising of sub-micron-scale Al dendrites and nanoscale fibrous eutectic was fabricated by processing as-cast Al-20wt.%Si alloy using laser rapid solidification. In situ tension tests explored high tensile strength (∼600 MPa) ductility (∼10%) strain hardening rate (∼7 GPa). Microstructural characterization revealed the plastic co-deformation mechanisms betwe...

Solidification rate of the casting affects greatly on the microstructure, quality as well as the mechanical properties of the casting. In centrifugal castings solidification rate is faster compared to gravity casting but still solidification depends on various process parameters like, die wall temperature, pouring temperature of the molten metal, wall thickness of the die and also rotational sp...

Recent years have witnessed increasing demand for selective laser melting (SLM) in practical applications; however, determining the appropriate process parameter range remains challenging. In this study, a framework was developed to determine considering occurrence of defects and cracks by conducting single-track test thermal elastoplastic analysis. Keyholing, balling, residual unmelted regions...

  Abstract:   The aims of this research were to investigate the effects of semisolid metal (SSM) processing parameters (i.e., shear rates –times – temperatures combinations) on the primary solidification products and isothermal holding duration, subsequent to cessation of stirring on the secondary solidification of Al-Si (A356) alloy.   The dendrite fragmentation was found to be the governing m...

Metal matrix syntactic foams (MMSFs) are advanced lightweight materials constituted by a metallic and dispersion of hollow/porous fillers. Physical mechanical properties can be fitted regarding filler processing parameters. Their make them potential for sectors where density is limiting parameter, such as transport, marine, defense, aerospace, engineering applications. MMSFs mainly manufactured...

Solidification cracks are among the most deteriorating defects observed in Remote Laser Welding (RLW) of 6xxx aluminium alloys. This research has been designed to study solidification crack susceptibility during RLW AA6005 alloy using Adjustable Ring mode (ARM) laser technology. The experimental setup included a high-speed camera on self-restraint test rig, and strains near root front were iden...