Microcasting Shape-Deposition-Manufacturing is an approach to Solid-Freeform-Fabrication (SFF) process which is a novel method for rapid automated manufacturing of near-net-shape multi-material parts with complex geometries. By this method, objects are made by sequentially depositing molten metal droplets on a substrate and shaping by a CNC tool, layer by layer. Important issues are concerned w...

During rapid solidification, solute may be incorporated into the solid phase at a concentration significantly different from that predicted by equilibrium thermodynamics. This process, known as solute trapping, leads to a progressive reduction in the concentration change across the interface as the solidification rate increases. Theoretical treatments of rapid solidification using traditional s...

Here we show theoretically that the history of solid growth during ‘‘rapid’’ solidification must be S-shaped, in accord with the constructal law of design in nature. In the beginning the rate of solidification increases and after reaching amaximum it decreasesmonotonically as the volume of solid tends toward a plateau. The S-history is a consequence of four configurations for the flow of heat f...

A new finite element level set method is developed to simulate the interface motion. The normal velocity of the moving interface can depend on both the local geometry, such as the curvature, and the external force such as that due to the flux from both sides of the interface of a material whose concentration is governed by a diffusion equation. The key idea of the method is to use an interface-...

Laser Engineered Net Shaping (LENSTM) is a rapid-manufacturing process that involves complex thermal, mechanical, and metallurgical interactions. Due to process input parameter such as laser power , laser scanning velocity and feed rate, the effect on solidification of component to be produced must be understand. The finite element method (FEM) may be used to accurately model this process and s...

Related Articles Thermoelectric magnetic force acting on the solid during directional solidification under a static magnetic field Appl. Phys. Lett. 101, 251904 (2012) Structural features and high quasi-static strain rate sensitivity of Au49Cu26.9Ag5.5Pd2.3Si16.3 bulk metallic glass Appl. Phys. Lett. 101, 241905 (2012) First principle molecular dynamic simulation of the rapid solidification pro...

The rapid solidification microstructure of gas-atomized Al-Si powders of 15, 18, 25, and 50 wt pct Si were examined using scanning electron microscopy (SEM) and transmission electron microscopy (TEM). In order of increasing particle size, the powders exhibited microcellular Al, cellular/dendritic Al, eutectic Al, and primary Si growth morphologies. Interface velocity and undercooling were estim...

Optimizing fabrication parameters for rapid solidification of Re-Fe-B (Re = Rare earth) alloys can lead to nanocrystalline products with hard magnetic properties without any heat-treatment. In this work, we enhanced the magnetic properties of Ce17Fe78B₆ ribbons by engineering both the microstructure and volume fraction of the Ce₂Fe14B phase through optimization of the chamber pressure and the w...

The nucleation mechanism involving rapid solidification of undercooled La-Fe-Si melts has been studied experimentally and theoretically. The classical nucleation theory-based simulations show a competitive nucleation process between the α-(Fe,Si) phase (size approximately 10 to 30 nm) and the cubic NaZn13-type phase (hereinafter 1:13 phase, size approximately 200 to 400 nm) during rapid solidif...