Laser consolidation is an emerging novel computer-aided manufacturing process that produces net-shape functional metallic parts layer by layer directly from a CAD model by using a laser beam to melt the injected powder and re-solidifying it on the substrate or previous layer. As an alternative to the conventional machining process, this novel manufacturing process builds net-shape functional parts or features on an existing part by adding instead of removing material.

In this paper, laser consolidation of IN-625 and Ti-6Al-4V alloys has been investigated to build several generic shapes representing parts that may have potential rocket engine applications. Laser consolidation produces components with good surface finish, dimensional accuracy and mechanical properties, and demonstrates the potential for direct manufacturing of functional net-shape components and tooling. In addition, some preliminary results demonstrate that the laser consolidation, in combination with solid-state, net-shape powder metallurgy processing, may provide a unique manufacturing capability to make very complex components for the rocket engines.

1.
Xue
,
L.
 &
Islam
,
M.U.
 (
2000
)
Free-Form Laser Consolidation for Producing Metallurgically Sound and Functional Components
,
Journal of Laser Applications
,
12
(
4
),
160
–
165
.
https://doi.org/10.2351/1.521927
Google Scholar
Crossref
Search ADS
 
2.
Xue
,
L.
,
Chen
,
J.-Y.
,
Islam
,
M.U.
,
Pritchard
,
J.
,
Manente
,
D.
 &
Rush
,
S.
 (
2000
)
Laser Consolidation of IN-738 Alloy for Repairing Cast IN-738 Gas Turbine Blades
, in
Proceedings of 20th ASM Heat Treating Society Conference, St.-Louis, Missouri, USA
,
1063
–
1071
.
Google Scholar
 
3.
Xue
,
L.
,
Chen
,
J.-Y.
, &
Theriault
,
A.
 (
2002
)
Laser Consolidation of Ti-6Al-4V Alloy for the Manufacturing of Net-Shape Functional Components
, in
Proceedings of 21st International Congress on Applications of Lasers and Electro-Optics (ICALEO 2002
),
Scottsdale, USA
,
169
–
178
.
Google Scholar
Crossref
Search ADS
 
4.
Xue
,
L.
,
Chen
,
J.-Y.
,
Wang
,
S.-H.
 &
Li
,
Y.
 (
2006
)
Laser Consolidation of Al 4047 Alloy for Making Net-Shape Functional Components
, in
Proceedings of the 15th International Symposium on Processing and Fabrication of Advanced Materials (PFAM XV)
,
Materials Science and Technology (MS&T’06), Cincinnati
,
Ohio, USA
,
465
–
477
.
Google Scholar
 
5.
Xue
,
L.
,
Theriault
,
A.
,
Rubinger
,
B.
 &
Parry
,
D.
 (
2003
)
Investigation of Laser Consolidation Process for Manufacturing Structural Components for Advanced Robotic Mechatronics System
”, in
Proceedings of 22nd International Congress on Applications of Lasers and Electro-Optics (ICALEO 2003
),
Jacksonville, Florida, USA
,
134
–
143
.
Google Scholar
Crossref
Search ADS
 
6.
Xue
,
L.
,
Theriault
,
A.
,
Islam
,
M.U.
,
Jones
,
M.
 &
Wang
,
H.P.
 (
2004
)
Laser Consolidation of Ti-6Al-4V Alloy to Build Functional Net-Shape Airfoils with Embedded Cooling Channels
, in
Proceedings of the 23rd International Congress on Applications of Lasers and Electro-Optics 2004 (ICALEO’ 2004
),
San Francisco, California, USA
,
34
–
40
.
Google Scholar
Crossref
Search ADS
 
7.
Xue
,
L.
 &
Purcell
,
C.
 (
2006
)
Laser Consolidation of Net-Shape Shells for Flextensional Sonar Projectors
, in
Proceedings of the 25th International Congress on Applications of Lasers and Electro-Optics (ICALEO 2006
),
Scottsdale, Arizona, USA
,
686
–
694
.
Google Scholar
Crossref
Search ADS
 
8.
Erickson
,
G.L.
 (
1990
)
Polycrystalline Cast Superalloys, Metals Handbook
10th Edition, Vol.
1
,
ASM International
,
Ohio
,
984
.
Google Scholar
 
9.
Morral
,
F.R.
 (
1980
)
Wrought Superalloys, Metals Handbook
, 9th Edition, Vol.
3
,
American Society for Metals
,
Ohio
,
219
.
Google Scholar
 
10.
Reed-Hill
,
R.E.
 (
1973
)
Physical Metallurgy Principles
, 2nd Edition,
D. Van Nostrand Company
,
New York
,
581
.
Google Scholar
 
11.
Newman
,
J.R.
 (
1980
)
Titanium Castings, Metals Handbook
9th Edition, Vol.
3
,
American Society for Metals
,
409
.
Google Scholar
 
12.
ASM Committee on Titanium and Titanium Alloys
(
1980
)
Properties of Titanium and Titanium Alloys, Metals Handbook
9th Edition, Vol.
3
,
American Society for Metals
,
388
–
389
.
13.
Davis
,
J.R.
 (
1997
)
Titanium and Titanium Alloys, ASM Specialty Handbook: Heat-Resistant Materials
,
ASM International
,
347
–
360
.
Google Scholar
 
14.
Teifke
,
F.C.
,
N.H.
Marshall
,
D.
Eylon
 and
F.H.
Froes
, (
1982
)
Effects of Processing on Fatigue Life of Ti-6Al-4V Casting
,
Advanced Processing Methods for Titanium
, pp.
147
–
159
.
Google Scholar
 
15.
Thériault
,
A.
,
Xue
,
L.
 &
Chen
,
J.-Y.
 (
2005
)
Laser Consolidation of Ti-6Al-4V Alloy
, in
Proceedings of the 5th International Workshop on Advanced Manufacturing Technologies
,
London, Canada
,
267
–
272
.
Google Scholar
 
16.
Bampton
,
C.
,
Goodin
,
W.
,
Van Daam
,
T.
,
Creeger
,
G.
 &
James
,
S.
 (
2005
)
Net-Shape HIP Powder Metallurgy Components for Rocket Engines
, in
Proceedings of 2005 International Conference on Hot Isostatic Pressing
,
Paris, France
,
53
.
Google Scholar
 
17.
Samarov
,
V.
 (
2006
)
HIP of Net Shape Parts for Critical Applications from Advanced Powder Materials
, in
Proceedings of NATO AVT-139 Specialists’ Meeting on Cost Effective Manufacture via Net Shape processing
,
Amsterdam, Netherlands
,
4-1
–
4-8
.
Google Scholar
 
This content is only available via PDF.
© 2007 Laser Institute of America.
2007
Laser Institute of America
You do not currently have access to this content.