In spite of recent advances in materials science, there is no widely commercialized technology for the rapid fabrication of metal components other than standard milling. There is a need for such technology, as the delivery time for metal dies or large-sized, low volume castings can exceed two to three months or more. This project will combine the features of semi-solid metal, a mixture of molten metal and metal particles, with an advanced deposition technique to produce large metal components. The technology will deposit layers of metal "paste" to build up three-dimensional metal parts. Phase I will focus on aluminum, and Phase II will address ferrous alloys. The Phase I project will construct and demonstrate the capability of the technology by depositing shapes from a semi-solid aluminum alloy.
Commercial Applications and Other Benefits as described by the awardee: There are many large components, including special piping, elbows, valves, flanges, and reducers that are made in small quantities with a months-long delivery time. This technology should provide the ability to produce these components within weeks, either as final components or as interim components. In addition, this technology may provide the ability to rapidly produce tool dies.
