研究目的
To manufacture functionally gradient materials (FGM) with composition variation from a copper alloy to a soda-lime glass using a proprietary nozzle-based multi-material selective laser melting (MMSLM) system and to examine the mechanical properties of the FGM.
研究成果
The bonding mechanism of metal and glass was that melted glass penetrated into the CMC phase, which played a role to anchor the glass. Both horizontal gradient and vertical gradient structures were achieved. The weakest part of the FGM structure occurred at the interface between transition phase and the CMC, which was also the interface between the ductile and brittle phases.
研究不足
The thickness of the glass part was limited, which should be improved by further research. The oxide layer between materials may be much thinner, probably in the nano scale, which requires further investigation.
1:Experimental Design and Method Selection:
A new, in situ powder mixing system was developed to mix two different powders (Cu10Sn copper-alloy and soda-lime glass) at selective ratios. The mixed powders were dispensed with an ultrasonic vibration powder feeding system. Laser parameters for different powder mixing ratios were optimized.
2:Sample Selection and Data Sources:
Cu10Sn copper-alloy spherical powders and spherical soda-lime powders were used. Different ratios of glass powders were prepared from 5 wt.% to 65 wt.% of the mixture.
3:List of Experimental Equipment and Materials:
A 500 W ytterbium single-mode, continuous wave (CW) fibre laser, an Intelli SCAN x-y galvo, and an ultrasonic vibration powder feeding system were used. Powders were Cu10Sn copper-alloy and soda-lime glass.
4:Experimental Procedures and Operational Workflow:
Powders were mixed and dispensed onto the work platform. The laser selectively scanned the powder layer to melt powders. The process was repeated layer by layer until the 3D printed part was completed.
5:Data Analysis Methods:
Microstructural analysis was carried out using an SEM and optical microscopy. Mechanical properties were examined through indentation, tensile, and shear tests.
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ytterbium single-mode, continuous wave (CW) fibre laser
YLR-500-WC
IPG Photonics (UK) Ltd.
Used for scanning over the powder bed in a designed pattern.
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Intelli SCAN x-y galvo
SCANLAB GmbH
Used for controlling the laser scanning pattern.
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electronic balance
Ek-300i
A&D Instruments Ltd.
Used for measuring the powder flow rates.
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optical microscopes
VHX-5000 and VHX-500F
KEYENCE Corporation
Used for observing morphological characteristics of the surfaces and cross sections of the samples.
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scanning electron microscopy
Zeiss Sigma VP FEG SEM
Used for observing microstructures.
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energy dispersive spectroscopy
Oxford Instruments X-maxN 150
Used for measuring the chemical element distribution.
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Durascan-80 hardness tester
Used for measuring the Vickers microhardness.
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Vickers indenter
No. 2005-6608
Calibrations Ltd.
Used for hardness measurements with a 30 kg load.
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