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

Nicole R. Harlan, David L. Bourell, Joseph J. Beaman, Reuben Reyes

    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.

    LanguageEnglish (US)
    Pages410-413
    Number of pages4
    JournalJournal of Materials Engineering and Performance
    Volume10
    Issue number4
    DOIs
    StatePublished - Jan 1 2001

    Fingerprint

    Titanium castings
    Molds
    Zirconia
    Binders
    Lasers
    Surface roughness
    Waxes
    Thermal shock
    Titanium
    Infiltration
    Bending strength
    Powders
    Molten materials
    Bone
    Casting
    Pyrolysis
    Sintering
    Copolymers
    Microstructure
    zirconium oxide

    Keywords

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

    ASJC Scopus subject areas

    • Materials Science(all)
    • Mechanics of Materials
    • Mechanical Engineering

    Cite this

    Titanium castings using laser-scanned data and selective laser-sintered zirconia molds. / Harlan, Nicole R.; Bourell, David L.; Beaman, Joseph J.; Reyes, Reuben.

    In: Journal of Materials Engineering and Performance, Vol. 10, No. 4, 01.01.2001, p. 410-413.

    Research output: Contribution to journalArticle

    Harlan, Nicole R. ; Bourell, David L. ; Beaman, Joseph J. ; Reyes, Reuben. / Titanium castings using laser-scanned data and selective laser-sintered zirconia molds. In: Journal of Materials Engineering and Performance. 2001 ; Vol. 10, No. 4. pp. 410-413
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