Additive Manufacturing of Transparent Soda-Lime Glass Using a Filament-Fed Process

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
Junjie Luo ◽  
Luke J. Gilbert ◽  
Chuang Qu ◽  
Robert G. Landers ◽  
Douglas A. Bristow ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Bubble Formation ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Correct Process ◽  
Transparent Glass ◽  
Optically Transparent ◽  
Transparent Parts

There are many scientific and engineering applications of transparent glass including optics, communications, electronics, and hermetic seals. However, there has been minimal research toward the additive manufacturing (AM) of transparent glass parts. This paper describes and demonstrates a filament-fed technique for AM of transparent glass. A transparent glass filament is melted by a CO2 laser and solidifies as the workpiece is translated relative to the stationary laser beam. To prevent thermal shock, the workpiece rests on a heated build platform. In order to obtain optically transparent parts, several challenges must be overcome, notably producing index homogeneity and avoiding bubble formation. The effects of key process parameters on the morphology and transparency of the printed glass are explored experimentally. These results are compared to a low-order model relating the process parameters to the temperature of the molten region, which is critical to the quality of the deposited glass. At lower temperatures, the glass is not fully melted, resulting in index variations in the final part, while at higher temperatures, phase separation introduces bubbles and other defects into the part. The correct process avoids these issues and deposits optically transparent glass.

Wire-Fed Additive Manufacturing of Transparent Glass Parts

2015 ◽  
Author(s):  
Junjie Luo ◽  
Luke Gilbert ◽  
Chuang Qu ◽  
Jacob Wilson ◽  
Douglas Bristow ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Work Piece ◽  
Powder Bed ◽  
Transparent Glass ◽  
Melt Pool ◽  
Final Sample ◽  
Scan Speed ◽  
Transparent Parts ◽  
A New Technique

This paper presents a new technique for additive manufacturing of transparent glass. In this process, transparent glass is wire-fed into a laser generated melt pool, which solidifies as the work piece is moved relative to a stationary laser beam. The key parameters are identified in terms of their effects on the morphology and transparency of printed walls. The relationship between these parameters is studied experimentally. It is demonstrated that the process parameters strongly affect the morphology and proper selection of the scan speed, feed rate and laser power can produce optimum results. A key advantage of this process relative to powder bed techniques is the ability to form optically transparent parts. The process parameters also determine the transmissivity of the final sample. The transmissivity is measured experimentally for builds with different process parameters.

Analysis of Cu(InGa)Se2 Alloy Film Optical Properties and the Effect of Cu Off-Stoichiometry

2005 ◽  
Vol 865 ◽  
Author(s):  
P. D. Paulson ◽  
S. H. Stephens ◽  
W. N. Shafarman
Keyword(s):  
Optical Constants ◽  
Soda Lime ◽  
Alloy Film ◽  
Relative Volume ◽  
Soda Lime Glass ◽  
Distinctive Features ◽  
Glass Substrates ◽  
Wide Range ◽  
Two Phases

AbstractVariable angle spectroscopic ellipsometry has been used to characterize Cu(InGa)Se2 thin films as a function of relative Ga content and to study the effects of Cu off-stoichiometry. Uniform Cu(InGa)Se2 films were deposited on Mo-coated soda lime glass substrates by elemental evaporation with a wide range of relative Cu and Ga concentrations. Optical constants of Cu(InGa)Se2 were determined over the energy range of 0.75–C4.6 eV for films with 0 ≤ Ga/(In+Ga) ≤ 1 and used to determine electronic transition energies. Further, the changes in the optical constants and electronic transitions as a function of Cu off-stoichiometry were determined in Cu-In-Ga-Se films with Cu atomic concentration varying from 10 to 25 % and Ga/(In+Ga) = 0.3. Films with Cu in the range 16–24 % are expected to contain 2 phases so an effective medium approximation is used to model the data. This enables the relative volume fractions of the two phases, and hence composition, to be determined. Two distinctive features are observed in the optical spectra as the Cu concentration decreases. First, the fundamental bandgaps are shifted to higher energies. Second, the critical point features at higher energies become broader suggesting degradation of the crystalline quality of the material.

scholarly journals Additive Manufacturing of Optically Transparent Glass

2015 ◽  
Vol 2 (3) ◽  
pp. 92-105 ◽  
Author(s):  
John Klein ◽  
Michael Stern ◽  
Giorgia Franchin ◽  
Markus Kayser ◽  
Chikara Inamura ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Transparent Glass ◽  
Optically Transparent

Optimizing the process parameters for additive manufacturing of glass components by selective laser melting: Soda-lime glass versus quartz glass

2021 ◽  
pp. 1-10
Author(s):  
Sergey Grigoriev ◽  
Roman Khmyrov ◽  
Mikhail Gridnev ◽  
Tatiana Tarasova ◽  
Andrey Gusarov
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Quartz Glass ◽  
Soda Lime ◽  
High Viscosity ◽  
Residual Porosity ◽  
Soda Lime Glass ◽  
Laser Melting ◽  
Powder Consolidation ◽  
Preheating Temperature

Abstract Additive manufacturing by selective laser melting (SLM) is generally applicable to glasses while insufficient resistance of the material to thermal shocks due to local laser heating may result in cracking and a high viscosity of glass melt is responsible for incomplete powder consolidation related to residual porosity. The present work shows that preheating up to 350 °C is sufficient to avoid cracking of soda-lime glass. Preheating of quartz glass up to 730 °C considerably decreases the residual porosity, which is explained by acceleration of powder consolidation by the viscous-flow mechanism of glass particles' coalescence. Variation of the preheating temperature is an effective tool to control consolidation of glass powder and to avoid cracking.

scholarly journals n-i-p Nanocrystalline Hydrogenated Silicon Solar Cells with RF-Magnetron Sputtered Absorbers

Materials ◽  
2019 ◽  
Vol 12 (10) ◽  
pp. 1699
Author(s):  
Dipendra Adhikari ◽  
Maxwell M. Junda ◽  
Corey R. Grice ◽  
Sylvain X. Marsillac ◽  
Robert W. Collins ◽  
...  
Keyword(s):  
Solar Cells ◽  
Chemical Vapor ◽  
Soda Lime ◽  
Device Fabrication ◽  
Silicon Solar Cells ◽  
Soda Lime Glass ◽  
Hydrogenated Silicon ◽  
Glass Substrates ◽  
Collection Probability

Nanocrystalline hydrogenated silicon (nc-Si:H) substrate configuration n-i-p solar cells have been fabricated on soda lime glass substrates with active absorber layers prepared by plasma enhanced chemical vapor deposition (PECVD) and radio frequency magnetron sputtering. The cells with nanocrystalline PECVD absorbers and an untextured back reflector serve as a baseline for comparison and have power conversion efficiency near 6%. By comparison, cells with sputtered absorbers achieved efficiencies of about 1%. Simulations of external quantum efficiency (EQE) are compared to experimental EQE to determine a carrier collection probability gradient with depth for the device with the sputtered i-layer absorber. This incomplete collection of carriers generated in the absorber is most pronounced in material near the n/i interface and is attributed to breaking vacuum between deposition of layers for the sputtered absorbers, possible low electronic quality of the nc-Si:H sputtered absorber, and damage at the n/i interface by over-deposition of the sputtered i-layer during device fabrication.

scholarly journals The molten glass sewing machine

2017 ◽  
Vol 375 (2093) ◽  
pp. 20160156 ◽  
Author(s):  
P.-T. Brun ◽  
Chikara Inamura ◽  
Daniel Lizardo ◽  
Giorgia Franchin ◽  
Michael Stern ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Molten Glass ◽  
Building Blocks ◽  
Geometrical Model ◽  
Media Theory ◽  
Complex Media ◽  
Sewing Machine ◽  
Transparent Glass ◽  
Fluid Instability ◽  
Optically Transparent

We present a fluid-instability-based approach for digitally fabricating geometrically complex uniformly sized structures in molten glass. Formed by mathematically defined and physically characterized instability patterns, such structures are produced via the additive manufacturing of optically transparent glass, and result from the coiling of an extruded glass thread. We propose a minimal geometrical model—and a methodology—to reliably control the morphology of patterns, so that these building blocks can be assembled into larger structures with tailored functionally and optically tunable properties. This article is part of the themed issue ‘Patterning through instabilities in complex media: theory and applications’.

scholarly journals Study of the Surface and Dimensional Quality of the AlSi10Mg Thin-Wall Components Manufactured by Selective Laser Melting

2021 ◽  
Vol 5 (5) ◽  
pp. 126
Author(s):  
Muhammad Waqas ◽  
Dingyong He ◽  
Hassan Elahi ◽  
Saleem Riaz ◽  
Marco Eugeni ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Wall Thickness ◽  
Reference Value ◽  
Dimensional Accuracy ◽  
Thin Wall ◽  
Laser Melting ◽  
Anova Technique

Additive manufacturing (AM), a 3D printing technique that manufactures components by sequential addition of powder, has massively reshaped the manufacturing and engineering sectors from batch production to manufacturing customized, innovative, state-of-the-art, and sustainable products. Additive manufacturing of aluminum alloys by selective laser melting (SLM) is one of the latest research trends in this field due to the fact of its advantages and vast applications in manufacturing industries such as automobiles and aerospace. This paper investigated the surface and dimensional quality of SLM-built AlSi10Mg parts using a response surface method (RSM) and found the influence of the wall thickness and process parameters (i.e., laser power, scanning speed, hatch distance) on the pieces. Thin-walled test specimens of AlSi10Mg alloy were manufactured with different combinations of process parameters at three wall thicknesses: 1.0 mm, 2.0 mm, and 3.0 mm. The Minitab DOE module was used to create 27 different configurations of wall thickness and process parameters. The samples’ surface roughness and dimensional accuracy were investigated, and the findings were evaluated using the ANOVA technique. The regression model and the ANOVA technique showed high precision and had a particular reference value for practical engineering applications.

scholarly journals Influence of Variable Radius of Cutting Head Trajectory on Quality of Cutting Kerf in the Abrasive Water Jet Process for Soda–Lime Glass

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4277 ◽  
Author(s):  
Marzena Sutowska ◽  
Wojciech Kapłonek ◽  
Danil Yurievich Pimenov ◽  
Munish Kumar Gupta ◽  
Mozammel Mia ◽  
...  
Keyword(s):  
Brittle Material ◽  
Experimental Studies ◽  
Soda Lime ◽  
Water Jet ◽  
Soda Lime Glass ◽  
Abrasive Water Jet ◽  
Total Height ◽  
Cutting Head ◽  
The Impact

The main innovation of this article is the determination of the impact of curvature of a shape cut out in a brittle material using an abrasive water jet (AWJ) process as an important factor of the machined surfaces. The curvature of a shape, resulting from the size of the radius of the cutting head trajectory, is one of the key requirements necessary for ensuring the required surface quality of materials shaped by the abrasive water jet process, but very few studies have been carried out in this regard. An important goal of the experimental studies carried out here and presented in this work was to determine its influence on the quality of the inner and outer surfaces of the cutting kerf. This goal was accomplished by cutting the shape of a spiral in soda–lime glass. For such a shape, the effect of radius of the trajectory of the cutting head on selected parameters of the surface texture of the inner surface of the cutting kerf (IS) and the outer surface of the cutting kerf (OS) was studied. The obtained results of the experimental studies confirmed that the effect of the curvature of the cut shape is important from the point of view of the efficiency of the glass-based brittle material-cutting process using AWJ. Analyses of the surface textures of the areas located in the upper part of the inner and outer surfaces separated by the use of AWJ machining showed that the OS surfaces are characterized by worse technological quality compared with IS surfaces. Differences in the total height of surface irregularities (given by St amplitude parameter), determined on the basis of the obtained results of the measurements of both surfaces of the cutting kerf, were as follows: ΔStr = 50 = 0.6 μm; ΔStr = 35 = 1 μm; ΔStr = 15 = 1.3 μm. The analysis of values measured in areas located in the more sensitive zone of influence of the AWJ outflow proved that the total height of irregularities (St) of the OS was higher. Differences in the total heights of irregularities for inner and outer surfaces of the cutting kerf were as follows: ΔStr = 50 = 2.1 μm; ΔStr = 35 = 3 μm; ΔStr = 15 = 14.1 μm, respectively. The maximum difference in the total heights of irregularities (St), existing between the surfaces considered in a special case (radius 15 mm), was almost 20%, which should be a sufficient condition for planning cutting operations, so as to ensure the workpiece is shaped mainly by internal surfaces.

scholarly journals Effect of loose abrasive mixed electrolyte on the aspect ratio of blind holes drilled in soda-lime glass by ECDM process

2020 ◽  
Vol 7 ◽  
pp. 37
Author(s):  
Vijaya Vani Vemula ◽  
Sanjay Kumar Chak
Keyword(s):  
Aspect Ratio ◽  
Process Parameters ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Machining Accuracy ◽  
Outer Diameter ◽  
Machining Performance ◽  
Mixed Electrolyte ◽  
Micro Holes ◽  
The Impact

Electro-Chemical Discharge Machining (ECDM) process has the potential to machine various features and 3D surfaces on glass. However, machining of high aspect ratio micro holes is a challenging problem in ECDM process. In ECDM process, the machining rate mainly depends on the availability of the electrolyte at the electrode tip. Machining accuracy like taper, entry and exit diameter of the hole at high depths is rigorously affected due to lack of electrolyte at the machining zone resulting in more taperness. Low surface qualities (i.e. more over cut and tapered micro holes) are few limitations of the process. To enhance the machining capabilities a novel approach of PMECDM has been conducted. Present study is mainly focused on behavior of abrasive particles while machining soda lime glass, also studied effect of process parameters on the responses such as machining depth, outer diameter and aspect ratio. Also, the study led to analyze the effect of thermal properties of abrasives on machining performance of ECDM process. The maximum machined depth achieved was 2.31 mm in 5 min, and tremendous reduction of outer diameter from 1237.37 μm to 712.8 μm. Response surface methodology has been used to plan the experiments and ANOVA has been used to analyze the impact of each process parameters on machined depth and outer diameter of the micro holes.

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