About this Abstract |
| Meeting |
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Symposium
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2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
|
| Presentation Title |
Metal Extrusion Additive Manufacturing of Thin-Walled Aluminum Alloys. |
| Author(s) |
Zefang Li, Rohit Berlia, Colin Goodman, Mark Foster, Timothy Weihs, Jochen Mueller |
| On-Site Speaker (Planned) |
Zefang Li |
| Abstract Scope |
Metal extrusion additive manufacturing (MEAM) directly extrudes molten metal from wire feedstock to produce near-net-shape parts, offering simple feedstock handling and reduced system complexity, which are advantageous for aluminum and other reactive alloys. However, nozzle clogging and part collapse, especially for higher-melting temperature alloys, limit reliable implementation. Here, we analyze thermal mechanisms driving these failures in thin-walled aluminum structures and identify the nozzle and the top of the previously deposited layer as critical thermal states for stability. We develop a thermally informed, simulation-guided framework that combines layer-wise print bed temperature control with practical time-based thermal criteria to prevent under- and over-heating during deposition. Applying this framework yields thin-walled aluminum parts with improved geometric fidelity and repeatability across build height. Microstructural characterization, mechanical testing, and demonstrations across multiple length scales and complex geometries illustrate the method’s effectiveness and limitations. |
| Proceedings Inclusion? |
Undecided |