Get This Paper

Production of Low Coefficient of Thermal Expansion Composite Tooling Manufactured Via 3D Printing


Title: Production of Low Coefficient of Thermal Expansion Composite Tooling Manufactured Via 3D Printing

Authors: Pedro Cortes, Michael Maravola, Brett Conner, Stephen Szaruga, Brian Hetzel, and Eric MacDonald

DOI: 10.33599/nasampe/s.19.1556

Abstract: Additive manufacturing enables the ability to produce composite tooling molds in a rapidly and cost effective manner. This work has produced low coefficient of thermal expansion composite tooling based on Invar, ceramics and metal-ceramic composites that are functional in the temperature range of 180°C. Here, four main approaches have been considered. The first approach consisted on using a binder jetting technology to 3D print sand molds to cast molten Invar to produce tooling. The second approach consisted on printing a mold based on both silica and zirconia sand and infiltrating them with a polymer to yield a robust tooling. The third approach was based on transforming a SLA printed ceramic mold into a metal-composite system. The fourth technology was based on a Direct Energy Deposition System for attaching Invar upon a steel molding structure. This last approach could represent a promising technology for producing low cost composite tooling since only a small layer of Invar would be added to a non-expensive substrate. The results have shown that the aforementioned processes have successfully resulted on low CTE tooling molds and successful composite materials.

References: 1. Kruth, J.-P. et al. “Progress in Additive Manufacturing and Rapid Prototyping”. CIRP Annals. vol. 47, no 2, 1998, pp. 525-540, doi: 10.1016/S0007-8506(07)63240-5. 2. ASTM. F2792-12a. Standard Terminology for Additive Manufacturing Technologies. 3. E. MacDonald and R. Wicker. “Multiprocess3D Printing for increasing component functionality”. Science, vol. 353, no 6307, Sep 2017, doi: 10.1126/science.aaf2093. 4. Thompson, Mary Kathryn, et al. “Design for Additive Manufacturing: Trends, Opportunities, Considerations, and Constraints.” CIRP Annals, vol. 65, no. 2, Jan. 2016, pp. 737–60, doi:10.1016/j.cirp.2016.05.004. 5. Li, Yingguang, et al. “Tooling Design and Microwave Curing Technologies for the Manufacturing of FiberReinforced Polymer Composites in Aerospace Applications.” The International Journal of Advanced Manufacturing Technology, vol. 70, no. 1, Jan. 2014, pp. 591–606, doi:10.1007/s00170-013-5268-3 6. Athanasopoulos, N., et al. “Temperature Uniformity Analysis and Development of Open Lightweight Composite Molds Using Carbon Fibers as Heating Elements.” Composites Part B: Engineering, vol. 50, July 2013, pp. 279–89, doi:10.1016/j.compositesb.2013.02.038. 7. Laureijs, Rianne E., et al. “Metal Additive Manufacturing: Cost Competitive Beyond Low Volumes.” Journal of Manufacturing Science and Engineering, vol. 139, no. 8, May 2017, pp. 081010-081010-9, doi:10.1115/1.4035420. 8. Zocca Andrea, et al. “Additive Manufacturing of Ceramics: Issues, Potentialities, and Opportunities.” Journal of the American Ceramic Society, vol. 98, no. 7, July 2015, pp. 1983–2001, doi:10.1111/jace.13700. 9. Maleksaeedi, S., et al. “Property Enhancement of 3DPrinted Alumina Ceramics Using Vacuum Infiltration.” Journal of Materials Processing Technology, vol. 214, no. 7, July 2014, pp. 1301–06, doi:10.1016/j.jmatprotec.2014.01.019. 10. Carroll, Beth E., et al. “Functionally Graded Material of 304L Stainless Steel and Inconel 625 Fabricated by Directed Energy Deposition: Characterization and Thermodynamic Modeling.” Acta Materialia, vol. 108, Apr. 2016, pp. 46–54, doi:10.1016/j.actamat.2016.02.019. 11. 12. 13. Abberger, Advanced Composite Molds—A New Use for Invar, The Invar Effect: A Centennial Symposium, J. Wittenauer, Ed., 7-8 Oct 1996 (Cincinnati, OH), The Minerals, Metals & Materials Society, 1997, p 317-325.

Conference: SAMPE 2019 - Charlotte, NC

Publication Date: 2019/05/20

SKU: TP19--1556

Pages: 13

Price: FREE

Get This Paper