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Journal of Materials Engineering and Performance

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16-06-2022 | Technical Article

Engineering the Surface Melt for In-Space Manufacturing of Aluminum Parts

Authors: Kasra Momeni, Sara Neshani, Chukwudalu Uba, Huan Ding, Jonathan Raush, Shengmin Guo

Published in: Journal of Materials Engineering and Performance | Issue 8/2022

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Abstract

Aluminum alloys are among the top candidate materials for in-space manufacturing (ISM) due to their lightweight and relatively low melting temperature. A fundamental problem in printing metallic parts using available ISM methods, based on the fused deposition modeling (FDM) technique, is that the integrity of the final printed components is determined mainly by the adhesion between the initial particles. Engineering the surface melt can pave the way to improve the adhesion between the particles and manufacture components with higher mechanical integrity. Here, we developed a phase-field model of surface melting, where the surface energy can directly be implemented from the experimental measurements. The proposed model is adjusted to Al 7075-T6 alloy feedstocks, where the surface energy of these alloys is measured using the sessile drop method. Effect of mechanics has been included using transformation and thermal strains. The effect of elastic energy is compared here with the corresponding cases without mechanics. Two different geometric samples (cylindrical and spherical) are studied, and it is found that cylindrical particles form a more disordered structure upon size reduction compared to the spherical samples.

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Title: Engineering the Surface Melt for In-Space Manufacturing of Aluminum Parts
Authors: Kasra Momeni
Sara Neshani
Chukwudalu Uba
Huan Ding
Jonathan Raush
Shengmin Guo
Publication date: 16-06-2022
Publisher: Springer US
Published in: Journal of Materials Engineering and Performance / Issue 8/2022
Print ISSN: 1059-9495
Electronic ISSN: 1544-1024
DOI: https://doi.org/10.1007/s11665-022-07054-2

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