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Design and Thermal Comparison of Random Structures Realized by Indirect Additive Manufacturing

Dipartimento di Ingegneria dell’Impresa “Mario Lucertini”, Università di Roma “Tor Vergata”, Via del Politecnico 1, 00133 Rome, Italy
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Materials 2019, 12(14), 2261; https://doi.org/10.3390/ma12142261
Received: 18 June 2019 / Revised: 6 July 2019 / Accepted: 11 July 2019 / Published: 13 July 2019
(This article belongs to the Section Manufacturing Processes and Systems)
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Abstract

Additive manufacturing (AM) processes are used to fabricate three-dimensional complex geometries. There are several technologies that use laser or electron beam over metal powder beds. However, the direct AM processes have inconveniences such as specific set of materials, high thermal stress traced, high local energy absorbed, poor surface finish, anisotropic properties, high cost of material powder, and manufacturing with high-power beams. In this paper, an alternative process was developed. An indirect additive manufacturing (I-AM) combining a 3D print of castable resin and metal casting in order to obtain a cellular structure similar in shape to commercial metal foams but completely definable as design features was developed. Design of the cellular structure was made by the graphical algorithm editor Grasshopper®. Designed structures were realized by a lost-wax casting process and compared with commercial foam specimens by a system designed for this work. The designed metal foams showed a performance superior to that of commercial metal foam; in particular, the heat thermal coefficient of designed metal foams in the better case was 870 W/m2·K, almost doubled in comparison with the commercial foam tested in this work. View Full-Text
Keywords: metal foam; additive manufacturing; open cell; thermal test; random structure metal foam; additive manufacturing; open cell; thermal test; random structure
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Almonti, D.; Ucciardello, N. Design and Thermal Comparison of Random Structures Realized by Indirect Additive Manufacturing. Materials 2019, 12, 2261.

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