Meld manufacturing3/23/2023 ![]() ![]() Chawla, Metal Matrix Composites, Springer, New York, 2013 Frazier, Metal Additive Manufacturing: A Review, J. Babu, The Metallurgy and Processing Science of Metal Additive Manufacturing, Int. Zhang, Additive Manufacturing of Metallic Components-Process, Structure and Properties, Prog. Rubenchik, Laser powder bed fusion additive manufacturing of metals physics, computational, and materials challenges, Appl. Wicker, Characterization of Ceramic Components Fabricated Using Binder Jetting Additive Manufacturing Technology, Ceram. Kruth, Composites by Rapid Prototyping Technology, Mater. Stucker, Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing, Springer, New York, 2015 Finally, we compare the benefits and limitations of MELD with other composite fabrication processes such as powder bed fusion, friction stir processing, stir casting, and powder processing. We also discuss the limitations of MELD for composite fabrication, with issues related to maximum reinforcement loading, tool wear, and in-plane resolution. In addition to the high quality of produced composites, its ease of use, versatility of feed materials, and scalability all make MELD an attractive tool for additive manufacturing of aluminum matrix composites. These properties stem from the extensive material flow and mixing during the deposition process. Using complementary characterization tools, we show that this process results in aluminum matrix composites with no observed porosity and homogeneous particle distribution. ![]() Thanks to its solid-state nature, MELD is uniquely suited for the use of high-strength aluminum alloys as matrix material, which would suffer from hot cracking problems in liquid-state processes. Here, we discuss its potential for fabricating aluminum matrix composites by showing examples of Al-SiC, Al 6061-Mo, and Al 6061-W composites. MELD, previously known as additive friction stir, is an emerging solid-state process that enables additive manufacturing of a broad range of metals and metal matrix composites. ![]()
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