A new three-dimensional (3D) printing process designated as shockwave-induced freeform technique (SWIFT) is explored for fabricating microparts from nanopowders. SWIFT consists of generating shockwaves using a laser beam, applying these shocks to pressure sinter nanoparticles at room temperature, and creating structures and devices by the traditional layer-by-layer formation. Shockwave cold compaction of nanoscale powders has the capability to overcome limitations, such as shrinkage, porosity, rough surface, and wide tolerance, normally encountered in hot sintering processes, such as selective laser sintering. In this study, the window of operating parameters and the underlying physics of SWIFT were investigated using a high-energy Q-switched Nd: YAG laser and nanodiamond (ND) powders. Results indicate the potential of SWIFT for fabricating high-performance diamond microtools with high aspect ratios, smooth surfaces, and sharp edges. The drawback is that the SWIFT process does not work for micro-sized powders.
Issue Section:
Research Papers
References
1.
Isaza
, J. F.
, and Aumund-Kopp
, P. C.
, 2014
, “Additive Manufacturing With Metal Powders: Design for Manufacture Evolves Into Design for Function
,” Powder Metall. Rev.
, 3
(2
), pp. 41
–50
.2.
Kumar
, S.
, 2003
, “Selective Laser Sintering: A Qualitative and Objective Approach
,” J. Met.
, 55
(10
), pp. 43
–47
.3.
Regenfuss
, P.
, Streek
, A.
, Hartwig
, L.
, Klotzer
, S.
, Brabant
, T.
, Horn
, M.
, Ebert
, R.
, and Exner
, H.
, 2007
, “Principles of Laser Microsintering
,” Rapid Prototyping J.
, 13
(4
), pp. 204
–212
.4.
Exner
, H.
, Horn
, M.
, Streek
, A.
, Ullmann
, F.
, Hartwig
, L.
, Regenfuss
, P.
, and Ebert
, R.
, 2008
, “Laser Micro Sintering: A New Method to Generate Metal and Ceramic Parts of High Resolution With Sub-Micrometer Powder
,” Virtual Phys. Prototyping
, 3
(1
), pp. 3
–11
.5.
Simchi
, A.
, 2004
, “The Role of Particle Size on the Laser Sintering of Iron Powder
,” Metall. Mater. Trans. B
, 35
(5
), pp. 937
–947
.6.
Hu
, J.
, Chou
, Y. K.
, Thompson
, R. G.
, Burgess
, J.
, and Street
, S.
, 2007
, “Characterizations of Nano-Crystalline Diamond Coated Cutting Tools
,” Surf. Coat. Technol.
, 202
(4–7
), pp. 1113
–1117
.7.
Williams
, O. A.
, and Nesladek
, M.
, 2006
, “Growth and Properties of Nanocrystalline Diamond Films
,” Phys. Status Solidi A
, 203
(13
), pp. 3375
–3386
.8.
Jiang
, W.
, Nair
, R.
, and Molian
, P.
, 2005
, “Functionally Graded Mold Inserts by Laser-Based Flexible Fabrication: Processing, Modeling, Structural Analysis, and Performance Evaluation
,” J. Mater. Proc. Technol.
, 166
(2
), pp. 286
–293
.9.
Nair
, R.
, Jiang
, W.
, and Molian
, P.
, 2004
, “Nanoparticle Additive Manufacturing of Ni/H13 Steel Injection Molds
,” ASME J. Manuf. Sci. Eng.
, 126
(3
), pp. 637
–639
.10.
Jiang
, W.
, Stock
, M.
, and Molian
, P.
, 2002
, “Production of Aluminum Extrusion Dies Using a Laser-Based Flexible Fabrication Technique
,” Society of Manufacturing Engineers, Dearborn, MI, Technical Paper No. MF02-132
, pp. 17
–24
.11.
Jiang
, W.
, and Molian
, P.
, 2002
, “Laser Based Flexible Fabrication of Functionally Graded Dies and Mold Inserts
,” Int. J. Adv. Manuf. Technol.
, 19
(9
), pp. 646
–654
.12.
Jiang
, W.
, and Molian
, P.
, 2007
, “Nanocrystalline TiC Alloying and Glazing of Die-Casting Dies Using a CO2 Laser for Improved Life and Performance
,” Surf. Coat. Technol.
, 135
(2–3
), pp. 139
–149
.13.
Engstrom
, D. S.
, Porter
, B.
, Pacios
, M.
, and Bhaskaran
, H.
, 2014
, “Additive Nanomanufacturing—A Review
,” J. Mater. Res.
, 29
(17
), pp. 1
–25
.14.
Thadhani
, N.
, 1988
, “Shock Compression Processing of Powders
,” Mater. Manuf. Proc.
, 3
(4
), pp. 493
–549
.15.
Vreeland
, T.
, Jr., Kasiraj
, P.
, Ahrens
, T.
, and Schwarz
, R.
, 1983
, “Shock Consolidation of Powders—Theory and Experiment
,” MRS
Proceedings, Vol. 28.16.
Akashi
, T.
, and Sawaoka
, A.
, 1987
, “Shock Consolidation of Diamond Powders
,” J. Mater. Sci.
, 22
(9
), pp. 3276
–3286
.17.
Kanel
, G.
, Razorenov
, S.
, and Fortov
, V.
, 2004
, Shock-Wave Phenomena and the Properties of Condensed Matter
, Springer
, New York
, Chap. 1.18.
Deng
, C.
, and Molian
, P.
, 2013
, “Nanodiamond Powder Compaction via Laser Shockwaves: Experiments and Finite Element Analysis
,” Powder Technol.
, 239
, pp. 36
–46
.19.
Deng
, C.
, and Molian
, P.
, 2012
, “Laser Shock Wave Treatment of Polycrystalline Diamond Tool and Nano-Diamond Powder Compact
,” Int. J. Adv. Manuf. Technol.
, 63
(1–4
), pp. 259
–267
.20.
Baerga
, V.
, and Molian
, P.
, 2012
, “Laser Shockwave Sintering of Nanopowders of Yttria-Stabilized Zirconia
,” Mater. Lett.
, 73
, pp. 8
–10
.21.
Melookaran
, R.
, Melaibari
, A.
, Deng
, C.
, and Molian
, P.
, 2012
, “Laser Shock Processing on Microstructure and Hardness of Polycrystalline Cubic Boron Nitride Tools With and Without Nanodiamond Powders
,” Mater. Design
, 35
, pp. 235
–242
.22.
Molian
, P.
, and Baerga
, V.
, 2011
, “Laser Shock Wave Consolidation of Micro-Powder Compacts of Fully Stabilized Zirconia With Addition of Nano-Particles
,” Adv. Appl. Ceram.
, 110
(2
), pp. 120
–123
.23.
Molian
, P.
, Molian
, R.
, and Nair
, R.
, 2009
, “Laser Shock Wave Consolidation of Nanodiamond Powders on Aluminum 319
,” Appl. Surf. Sci.
, 255
(6
), pp. 3859
–3867
.24.
Zhyrovetsky
, V.
, Kovalyuk
, B.
, Mocharskyi
, V.
, Nikiforov
, Y.
, Onisimchuk
, V.
, Popovych
, D.
, and Serednytski
, A.
, 2013
, “Modification of Structure and Luminescence of ZnO Nanopowder by the Laser Shock-Wave Treatment
,” Phys. Status Solidi
, 10
(10
), pp. 1288
–1291
.25.
Irifune
, T.
, Kurio
, A.
, Sakamoto
, S.
, Inoue
, T.
, and Sumiya
, H.
, 2003
, “Materials: Ultrahard Polycrystalline Diamond From Graphite
,” Nature
, 421
, pp. 599
–600
.26.
Prawer
, S.
, Nugent
, K.
, Jamieson
, D.
, Orwa
, J.
, Bursill
, L.
, and Peng
, J.
, 2000
, “The Raman Spectrum of Monocrystalline Diamond
,” Chem. Phys. Lett.
, 332
, pp. 93
–97
.27.
Ferrari
, A.
, and Robertson
, J.
, 2004
, “Raman Spectroscopy of Amorphous, Nanostructured, Diamond-Like Carbon, and Nanodiamond
,” Phil. Trans. R. Soc. Lond. A
, 362
(1824
), pp. 2477
–2512
.28.
Arato
, P.
, Bartha
, L.
, Porat
, R.
, Berger
, S.
, and Rosen
, A.
, 1998
, “Solid or Liquid Phase Sintering of Nanocrystalline WC/Co Hard Metals
,” Nanostruct. Mater.
, 10
(2
), pp. 245
–249
.29.
Zhu
, H.
, and Averback
, R.
, 1996
, “Sintering Processes of Two Nanoparticles: A Study by Molecular-Dynamics Simulations
,” Philos. Mag. Lett.
, 73
(1
), pp. 27
–32
.30.
Vereshchagin
, A.
, 2002
, “Phase Diagram of Ultrafine Carbon
,” Combust., Explo., Shock Waves
, 38
(3
), pp. 358
–359
.31.
Qian
, C.
, Pantea
, J.
, Huang
, T.
, and Zhao
, Y.
, 2004
, “Graphitization of Diamond Powders of Different Sizes at High Pressure-High Temperature
,” Carbon
, 42
(12–13
), pp. 2691
–2696
.32.
Tersoff
, J.
, 1988
, “Empirical Interatomic Potential for Carbon, With Applications to Amorphous Carbon
,” Phys. Rev. Lett.
, 61
(25
), pp. 2879
–2882
.33.
Tersoff
, J.
, 1988
, “New Empirical Approach for the Structure and Energy of Covalent Systems
,” Phys. Rev. B
, 37
(12
), pp. 6991
–6998
.34.
Brenner
, D.
, 1990
, “Empirical Potential for Hydrocarbons for Use in Simulating the Chemical Vapor Deposition of Diamond Films
,” Phys. Rev. B
, 42
(15
), pp. 9458
–9464
.35.
Wang
, X.
, and Xu
, X.
, 2002
, “Molecular Dynamics Simulation of Heat Transfer and Phase Change During Laser Material Interaction
,” ASME J. Heat Transfer
, 124
(2
), pp. 265
–270
.36.
Plimpton
, S.
, 1995
, “Fast Parallel Algorithms for Short-Range Molecular Dynamics
,” J. Comput. Phys.
, 117
(1
), pp. 19
–24
.37.
Zhong
, Z.
, Wang
, X.
, and Feng
, X.
, 2007
, “Effects of Pressure and Temperature on sp3 Fraction in Diamondlike Carbon Materials
,” J. Mater. Res.
, 22
(10
), pp. 2770
–2775
.Copyright © 2015 by ASME
You do not currently have access to this content.
