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Advanced manufacturing—A transformative enabling capability for fusion

Fusion Engineering and Design

Nygren, Richard E.; Dehoff, Ryan R.; Youchison, Dennis L.; Katoh, Yutai; Wang, Y.M.; Spadaccini, Charles M.; Henager, Charles H.; Schunk, Randy; Keicher, David M.; Roach, R.A.; Smith, Mark F.; Buchenauer, D.A.

Additive Manufacturing (AM) can create novel and complex engineered material structures. Features such as controlled porosity, micro-fibers and/or nano-particles, transitions in materials and integral robust coatings can be important in developing solutions for fusion subcomponents. A realistic understanding of this capability would be particularly valuable in identifying development paths. Major concerns for using AM processes with lasers or electron beams that melt powder to make refractory parts are the power required and residual stresses arising in fabrication. A related issue is the required combination of lasers or e-beams to continue heating of deposited material (to reduce stresses) and to deposit new material at a reasonable built rate while providing adequate surface finish and resolution for meso-scale features. Some Direct Write processes that can make suitable preforms and be cured to an acceptable density may offer another approach for PFCs.

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TYPE Conference Poster YEAR 2018
ScopusOSTIDOI

Thermal spray and cold spray analysis of density, porosity, and tensile Specimens for use with LIGA applications

Decker, Merlin K.; Smith, Mark F.

This analysis provides a preliminary investigation into using Twin-Wire Arc Thermal Spray and Cold Spray as material deposition processes for LIGA applications. These spray material processes were studied to make an initial determination of their potential as alternatives to producing mechanical parts via the electroplating process. Three materials, UltraMachinable{reg_sign} Stainless Steel, BondArc{reg_sign}, and aluminum, were sprayed using Thermal Spray. Only aluminum was sprayed using the Cold Spray process. Following the spray procedure, the test specimens were released from a copper mold and then tested. Three tests, density, tensile strength, and porosity, were performed on the specimens to determine the spray effect on material properties. Twin-Wire Arc Thermal Spray did not demonstrate adequate deposition properties and does not appear to be a good process candidate for LIGA. However, Cold Spray yielded better density results and warrants further investigation to analyze the minimum feature size produced by the process.

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TYPE Report YEAR 2000
OSTIDOI
32 Results
32 Results