Freeform fabrication of functional aluminium prototypes using powder metallurgy

摘要

Freeform fabrication methods allow the directformation of parts built layer by layer, under the control of a CADdrawing. Most of these methods form parts in thermoplastic orthermoset polymers, but there would be many applications forfreeform fabrication of fully functional metal or ceramic parts. Wedescribe here the freeforming of sinterable aluminium alloys. Inaddition, the building approach allows different materials to bepositioned within a monolithic part for an optimal combination ofproperties. This is illustrated here with the formation of analuminium gear with a metal-matrix composite wear surface.