Titanium castings using laser-scanned data and selective laser-sintered zirconia molds

N. R. Harlan, R. Reyes, D. L. Bourell, J. J. Beaman

Research output: Contribution to journalArticle

  • 13 Citations

Abstract

Titanium casting molds, made of stabilized and unstabilized zirconium oxide, were created using a combination of selective laser sintering (SLS) and colloidal infiltration. The mold material system was chosen for its thermal shock resistance and low reactivity with molten titanium. The starting material, stabilized zirconia powder mixed with a copolymer binder, was laser sintered into the desired green shape. The binder was removed during pyrolysis and replaced by unstabilized zirconia. As infiltrant weight gain increased, the density, flexural strength, and surface roughness improved to levels adequate for titanium casting trials. A half-scale casting mold for the ball of a human femur bone was produced from laser-scanned data and cast with Ti-6Al-4V alloy. The castings exhibited an as-cast surface roughness (Ra) of 8 μm and a typical microstructure. This work demonstrates a feasible method of producing complex titanium castings for one-of-a-kind and custom components without the necessity of part-specific tooling or wax patterns.

Original languageEnglish (US)
Pages (from-to)410-413
Number of pages4
JournalJournal of Materials Engineering and Performance
Volume10
Issue number4
DOIs
StatePublished - Aug 2001

Fingerprint

Lasers
Cytotoxins
Titanium castings
Zirconia
Molds
Binders
Surface roughness
Alginates
Orthostatic Hypotension
Traffic Accidents
Phobic Disorders
Thermal shock
Waxes
Infiltration
Bending strength
Molten materials
Bone
Casting
Pyrolysis
Sintering

Keywords

  • Selective laser sintering
  • Ti-6-Al-4V alloy
  • Titanium casting molds
  • Zirconia

ASJC Scopus subject areas

  • Materials Science(all)

Cite this

Titanium castings using laser-scanned data and selective laser-sintered zirconia molds. / Harlan, N. R.; Reyes, R.; Bourell, D. L.; Beaman, J. J.

In: Journal of Materials Engineering and Performance, Vol. 10, No. 4, 08.2001, p. 410-413.

Research output: Contribution to journalArticle

Harlan, N. R.; Reyes, R.; Bourell, D. L.; Beaman, J. J. / Titanium castings using laser-scanned data and selective laser-sintered zirconia molds.

In: Journal of Materials Engineering and Performance, Vol. 10, No. 4, 08.2001, p. 410-413.

Research output: Contribution to journalArticle

@article{262aa61eb2154ffc801136793a263e60,
title = "Titanium castings using laser-scanned data and selective laser-sintered zirconia molds",
abstract = "Titanium casting molds, made of stabilized and unstabilized zirconium oxide, were created using a combination of selective laser sintering (SLS) and colloidal infiltration. The mold material system was chosen for its thermal shock resistance and low reactivity with molten titanium. The starting material, stabilized zirconia powder mixed with a copolymer binder, was laser sintered into the desired green shape. The binder was removed during pyrolysis and replaced by unstabilized zirconia. As infiltrant weight gain increased, the density, flexural strength, and surface roughness improved to levels adequate for titanium casting trials. A half-scale casting mold for the ball of a human femur bone was produced from laser-scanned data and cast with Ti-6Al-4V alloy. The castings exhibited an as-cast surface roughness (Ra) of 8 μm and a typical microstructure. This work demonstrates a feasible method of producing complex titanium castings for one-of-a-kind and custom components without the necessity of part-specific tooling or wax patterns.",
keywords = "Selective laser sintering, Ti-6-Al-4V alloy, Titanium casting molds, Zirconia",
author = "Harlan, {N. R.} and R. Reyes and Bourell, {D. L.} and Beaman, {J. J.}",
year = "2001",
month = "8",
doi = "10.1361/105994901770344818",
volume = "10",
pages = "410--413",
journal = "Journal of Materials Engineering and Performance",
issn = "1059-9495",
publisher = "Springer New York",
number = "4",

}

TY - JOUR

T1 - Titanium castings using laser-scanned data and selective laser-sintered zirconia molds

AU - Harlan,N. R.

AU - Reyes,R.

AU - Bourell,D. L.

AU - Beaman,J. J.

PY - 2001/8

Y1 - 2001/8

N2 - Titanium casting molds, made of stabilized and unstabilized zirconium oxide, were created using a combination of selective laser sintering (SLS) and colloidal infiltration. The mold material system was chosen for its thermal shock resistance and low reactivity with molten titanium. The starting material, stabilized zirconia powder mixed with a copolymer binder, was laser sintered into the desired green shape. The binder was removed during pyrolysis and replaced by unstabilized zirconia. As infiltrant weight gain increased, the density, flexural strength, and surface roughness improved to levels adequate for titanium casting trials. A half-scale casting mold for the ball of a human femur bone was produced from laser-scanned data and cast with Ti-6Al-4V alloy. The castings exhibited an as-cast surface roughness (Ra) of 8 μm and a typical microstructure. This work demonstrates a feasible method of producing complex titanium castings for one-of-a-kind and custom components without the necessity of part-specific tooling or wax patterns.

AB - Titanium casting molds, made of stabilized and unstabilized zirconium oxide, were created using a combination of selective laser sintering (SLS) and colloidal infiltration. The mold material system was chosen for its thermal shock resistance and low reactivity with molten titanium. The starting material, stabilized zirconia powder mixed with a copolymer binder, was laser sintered into the desired green shape. The binder was removed during pyrolysis and replaced by unstabilized zirconia. As infiltrant weight gain increased, the density, flexural strength, and surface roughness improved to levels adequate for titanium casting trials. A half-scale casting mold for the ball of a human femur bone was produced from laser-scanned data and cast with Ti-6Al-4V alloy. The castings exhibited an as-cast surface roughness (Ra) of 8 μm and a typical microstructure. This work demonstrates a feasible method of producing complex titanium castings for one-of-a-kind and custom components without the necessity of part-specific tooling or wax patterns.

KW - Selective laser sintering

KW - Ti-6-Al-4V alloy

KW - Titanium casting molds

KW - Zirconia

UR - http://www.scopus.com/inward/record.url?scp=0035421331&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=0035421331&partnerID=8YFLogxK

U2 - 10.1361/105994901770344818

DO - 10.1361/105994901770344818

M3 - Article

VL - 10

SP - 410

EP - 413

JO - Journal of Materials Engineering and Performance

T2 - Journal of Materials Engineering and Performance

JF - Journal of Materials Engineering and Performance

SN - 1059-9495

IS - 4

ER -