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Sequential Solidification of Metal Powder by a Scanning Microwave Applicator.

Yoav Shoshani1, Tal Weinstein1, Zahava Barkay2

  • 1Faculty of Engineering, Tel Aviv University, Ramat Aviv 6997801, Israel.

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|February 11, 2023
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Summary

Localized microwave heating (LMH) offers a novel approach for continuous metal powder solidification in additive manufacturing (AM). This study demonstrates its feasibility for 3D printing metal parts with properties comparable to laser-based systems.

Keywords:
3D printingadditive manufacturinghotspotslocalized microwave-heatingmetal powdersmicrowave processingthermal runaway

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Microwave Engineering

Background:

  • Traditional additive manufacturing (AM) methods like laser-based systems face limitations in speed and cost.
  • Localized Microwave Heating (LMH) has previously shown potential for incremental metal powder solidification.
  • A continuous, lateral scanning approach for LMH in AM has not been fully explored.

Purpose of the Study:

  • To investigate the fundamental feasibility of continuous, lateral metal powder solidification using localized microwave heating (LMH).
  • To evaluate LMH as a potential alternative for additive manufacturing (AM) and 3D printing (3DP) of metal parts.
  • To compare the properties of LMH-processed metal parts with those produced by conventional laser-based AM systems.

Main Methods:

  • Utilizing a scanning, all-solid-state microwave applicator for localized microwave heating (LMH).
  • Implementing a continuous lateral scanning process, layer by layer, analogous to laser scanning in powder beds.
  • Conducting experiments on bronze powder with controlled scanning rates (~1 mm³/s) and microwave power (~0.25 kW).
  • Mechanically confining the solidified layers to dimensions of approximately 1-4 mm thickness and 2-4 mm width.

Main Results:

  • Achieved LMH solidification in bronze powder at scanning rates of ~1 mm³/s using ~0.25-kW microwave power.
  • Produced imperfect solid bars (~20×4×5 mm³) with rough surfaces, demonstrating successful lateral solidification.
  • Successfully demonstrated the joining of solidified metal parts in an L-shape configuration.
  • Experimental solidified products exhibited hardness and density properties comparable to laser-based AM products.

Conclusions:

  • The continuous lateral LMH scanning concept shows fundamental feasibility for metal powder solidification in AM.
  • LMH offers a potential solid-state alternative for additive manufacturing of metal parts.
  • Further research is needed to optimize the process and overcome limitations such as surface roughness and mechanical confinement.