Engineering Research Equipment: Development of a Prototype Laser Shaping System for Advanced Ceramic Material Components

9500545 Todd This Engineering Research Equipment Grant allows for the purchase of a versatile, automated, laser-based rapid Prototyping system, (comprised of a laser, positioning system, beam scanner, non-contacting positioning system, beam conditioner and Computer Aided Design and Manufacturing system) capable of producing shapes through controlled layer ablation/deposition of ceramic, metallic or polymeric materials. The equipment will support research projects including: (a) Laser Shaping of Advanced Ceramic Composite Materials; (b) Laser Shaping of Si3N4 Components; (c) Studies of Ceramic Airfoils for solar turbines; and (d) Laser Shaping Graphite Fuel Cell Stacks. Expected outcomes are (1) models relating machine parameters such as scan rate, feed, beam power and polarization of process measurables such as material removal rate and surface roughness; (2) strategies for optimizing processing of Si3N4,SiC, carbon and A12O3-based ceramics; and (3) comparison of laser shaping with alternative ceramic shaping technologies such as diamond grinding, ultrasonic and waterjet machining. Rapid prototyping manufacturing is a fast moving technology that the industrial sector has started to take advantage of, particularly form and fit model making with easy to produce plastic parts. In order to move the technology to higher temperature structural components such as ceramics and metals, laser shaping process has the potential to drive down the cycle time from design to commercialization giving the end user a competitive edge in the market introduction of new products.