Direct manufacturing of net-shape functional componentstest-pieces for aerospace, automotive, and other applications

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DOIResolve DOI: http://doi.org/10.2351/1.3622200
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TypeArticle
Journal titleJournal of Laser Applications
ISSN1042-346X
Volume23
Issue4
Article number42004
SubjectCAD models; Computer aided design models; Conventional machining; Dimensional accuracy; Functional components; Functional parts; Green manufacturing; High performance material; Industrial materials; laser technique; Layer-by-layers; Manufacturing process; Metallic part; Mold inserts; National Research Council of Canada; Net-shape; Other applications; Rapid manufacturing; Computer aided design; Computer aided manufacturing; Industrial engineering; Industrial research; Manufacture; Materials; Production engineering; Spray nozzles; Tool steel; Laser applications
AbstractLaser consolidation (LC) is a novel computer-aided manufacturing process being developed by the Industrial Materials Institute of National Research Council of Canada (NRC-IMI). This rapid manufacturing process produces net-shape functional metallic parts layer-by-layer directly from a computer-aided design (CAD) model by using a laser beam to melt the injected powder and resolidifying 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 materials. In this paper, laser consolidation of various high performance materials (such as Ni-alloys, tool steels, etc.) will be demonstrated to manufacture functional components or test-pieces (such as shell-based mold inserts, impeller, intersected multihexagon tube, goblet shape, etc.) for potential aerospace, automotive, and other applications. In the paper, dimensional accuracy of various laser-consolidated test-pieces will be measured and compared with CAD models. In addition, an example will be given on laser consolidation to build complex cold spray nozzles that are difficult to make otherwise and significantly improve the performance. © 2011 Laser Institute of America.
Publication date
LanguageEnglish
AffiliationNational Research Council Canada (NRC-CNRC); NRC Industrial Materials Institute (IMI-IMI)
Peer reviewedYes
NPARC number21271265
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Record identifier1dc9c2f4-e192-4ae6-909c-8cc00af65a22
Record created2014-03-24
Record modified2016-05-09
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