A Novel Rapid Manufacturing Process for Metal Lattice Structure

Author(s):  
Bashir Khoda ◽  
A.M.M. Nazmul Ahsan

1— In certain metals such as Cu, hydrogen appears to be dissolved in the metal in the form of free protons, which do not affect the normal metal lattice, even when present at very considerable concentrations. In other metals such as Ti, definite metal hydrides are formed which have a different lattice structure from the pure metal. The metal Pd is intermediate since the hydrogen affects the lattice constant. It is the properties of the former group of metals which are first to be discussed here, since the fact that the normal metal lattice is (practically) unaffected seems to justify a very simple theoretical treatment of the solubility, and it is of some interest to examine how the theory compares with the facts. We shall find that we can bring the facts and the theory into satisfactory order together. The various types of solubility curve are shown in fig. 1. 2— From evidence such as the well-known p 1/2 law for the rate of diffusion of hydrogen through metals we may certainly assume that the hydrogen in the metal is atomic. For the present we shall neglect the difference between atoms of hydrogen and protons plus electrons, and merely assume that the atoms are present as such in the metal, without specific interaction with particular metallic atoms; the metal merely provides a region in which hydrogen atoms can exist and move in a definite field of potential energy. Specific contributions by the electrons of the hydrogen atoms will be considered later, when the hydrogen atoms in the metal will be considered as protons plus electrons.


2015 ◽  
Vol 21 (3) ◽  
pp. 340-350 ◽  
Author(s):  
Suryakumar Simhambhatla ◽  
K.P. Karunakaran

Purpose – This paper aims to develop build strategies for rapid manufacturing of components of varying complexity with the help of illustration. Design/methodology/approach – The build strategies are developed using a hybrid layered manufacturing (HLM) setup. HLM, an automatic layered manufacturing process for metallic objects, combines the best features of two well-known and economical processes, viz., arc weld-deposition and milling. Depending on the geometric complexity of the object, the deposition and/or finish machining may involve fixed (3-axis) or variable axis (5-axis) kinematics. Findings – Fixed axis (3-axis) kinematics is sufficient to produce components free of undercuts and overhanging features. Manufacture of components with undercuts can be categorized into three methods, viz., those that exploit the inherent overhanging ability, those that involve blinding of the undercuts in the material deposition stage and those that involve variable axis kinematics for aligning the overhang with the deposition direction. Research limitations/implications – Although developed using the HLM setup, these generic concepts can be used in a variety of metal deposition processes. Originality/value – This paper describes the methodology for realizing undercut features of varying complexity and also chalks out the procedure for their manufacture with the help of case studies for each approach.


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