Hostname: page-component-76fb5796d-5g6vh Total loading time: 0 Render date: 2024-04-26T19:18:05.134Z Has data issue: false hasContentIssue false
  • English
  • Français

Freeform Fabrication of Functional Silicon Nitride Components by Direct Photo Shaping

Published online by Cambridge University Press:  10 February 2011

S. Ventura ,
S. Narang ,
P. Guerit ,
S. Liu ,
D. Twait ,
P. Khandelwal ,
E. Cohen  and
R. Fish
S. Ventura
Affiliation:
SRI International, 333 Ravenswood Avenue, Menlo Park California 94025
S. Narang
Affiliation:
SRI International, 333 Ravenswood Avenue, Menlo Park California 94025
P. Guerit
Affiliation:
SRI International, 333 Ravenswood Avenue, Menlo Park California 94025
S. Liu
Affiliation:
SRI International, 333 Ravenswood Avenue, Menlo Park California 94025
D. Twait
Affiliation:
Honeywell Ceramic Components, 2525 West 190th Street, Torrance, California 90504
P. Khandelwal
Affiliation:
Rolls-Royce Allison, P.O. Box 420, Speed Code W-05, Indianapolis, Indiana 46206-0420
E. Cohen
Affiliation:
University of Utah, Department of Computer Science, 3190 Merrill Engineering Bldg., Salt Lake City, Utah 84112
R. Fish
Affiliation:
University of Utah, Department of Computer Science, 3190 Merrill Engineering Bldg., Salt Lake City, Utah 84112
Get access

Abstract

This paper describes a new multilayer solid freeform fabrication process, “Direct Photo Shaping” (DPS), where visible digital light projection is used as a maskless tool to build images on photocurable ceramic dispersions (ceramic powders in photopolymerizable liquid monomers) by flood exposure. For each layer, the projected image is changed according to the CAD data describing the object being built and solidification takes place by photocuring the exposed areas. Multiple layers are dispensed and photocured to fabricate the object of interest. A final rinse with a suitable solvent allows the removal of any uncured ceramic dispersion. The porous free formed “green” ceramic object can then be fired and sintered into a highly dense ceramic part. Digital Light Processing™ technology (developed by Texas Instruments) enables SRI International to project digital, high resolution, high brightness, high contrast visible light to photocure and form components with a good degree of accuracy. This paper describes the Direct Photo Shaping process and its advantages, and how DPS is being applied to the fabrication of ceramic (Honeywell AS800) gas turbine components for military and commercial applications. ASS00 test specimens with flexural strength in excess of 800MPa were fabricated by DPS. A first-stage AS800 turbine vane for the Rolls-Royce Allison Model 501-K industrial gas turbine was fabricated by DPS and tested in a gas-burner test rig at 1204°C. Initial tests show that ceramic samples with optimized surface finish (comparable to that achieved by ceramic bisque machining) can be fabricated by applying a pixel anti-aliasing filter along the boundaries of the sample projected slice images.

Type
Research Article
Information
MRS Online Proceedings Library (OPL) , Volume 625: Symposium Y – Solid Freeform & Additive Fabrication – 2000 , 2000 , 81
Copyright
Copyright © Materials Research Society 2000

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

1 Tompkins, J.V., Birminghan, B.R., and Marcus, H.L., Proceedings of the First International Symposium on Advanced Synthesis and Processing, Cocoa Beach, FL, January 1995.Google Scholar
2 Grau, J., Moon, J., Uhland, S., Cima, M., and Sachs, E., Proceedings of the Solid Freeform Fabrication Symposium (Austin, TX, August, 1997), pp.371–8.Google Scholar
3 Griffith, M.L. and Halloran, J.W., J. Am. Ceram. Soc., 79(10), 2601–8 (1996); T. Himmer, T. Nakagawa and H. Naguchi, “Stereolithography of Ceramics”, pp. 363–370.Google Scholar
4 Clancy, R., Jamalabad, V., Whalen, P., Bhargava, P., Dai, C., Rangarajan, R., Wu, W., Danforth, S., Langrana, N. and Safari, A., Proceedings of the Solid Freeform Fabrication Symposium (Austin, TX, August, 1997), pp.185–194.Google Scholar
5 Klosterman, D., Chartoff, R., Osborne, N., Groves, G., Lightman, A. and Han, G., Proceeding of the Seventh International Conference on Rapid Prototyping, San Francisco, CA, April 1997, pp.43–50.Google Scholar
6 Ventura, S., Narang, S., Sharma, S., Stotts, J., Annavajula, D., Ho, L., Lombardo, S., Hardy, A., Mangaudis, M., and Groseclose, L., Proceeding of the Seventh International Conference on Rapid Prototyping, San Francisco, CA, April 1997, pp.271–8.Google Scholar
7 Omatete, O.O., Janney, M.A., and Strehlow, R.A., Ceram. Bull. 70(10), 1991.Google Scholar
8 Roffey, C.G., Photopolymerizaion of Surface Coatings, edited by John Wiley & Sons Ltd. 1982.Google Scholar
9 Hornbeck, L.J., “Digital Light Processing for High Brightness, High-Resolution Applications”, Presented at “Electronic Imaging, El ‘97”, 10-12 February 1997, San Jose‘, California; L.J. Hornbeck, “Digital Light Processing and MEMS: Timely Convergence for a Bright Future”;Presented at Micromachining and Microfabrication ‘95, 23-24 October 1995, Austin, Texas.Google Scholar
10 Burns, M., Automated Fabrication: Improving Productivity in Manufacturing; edited by Prentice Hall, Englewood Cliffs, NJ, 1993.Google Scholar
11 Seibein, K. N. and Lovington, W. M., in Microstructural Science, vol.16, pp.319–329. Edited by Cialoni, H.J., Blum, M.E., Johnson, G.W.E., and VanderVoort, G.F., ASM International, Metals Park, OH, 1985 Google Scholar
12 “Standard Test Method for Flexural Strength of Advanced Ceramics at Ambient Temperature”, ASTM C 1161, Annual Book of ASTM Standards, Vol. 15.01, American Society for Testing and Materials, West Conshohocken, PA, 1999.Google Scholar
13 “Standard Test Method for Flexural Strength of Advanced Ceramics at Elevated Temperature”, ASTM C1211, Annual Book of ASTM Standards, Vol. 15.011, American Society for Testing and Materials, West Conshohocken, PA, 1999.Google Scholar