Design and Operation of a Droplet Deposition System for Freeform Fabrication of Metal Parts
Source abstract
Abstract
A droplet generator has been designed and built to make wax and tin alloy droplets for freeform fabrication. The linear stability theory of liquid jets for forming droplets is first reviewed. The analytical formula for predicting droplet size and breakup length at optimal conditions are then developed. The suitability of the formulas to be used for the present droplet deposition system is studied by comparing its prediction with the more accurate numerical results and previously published experimental data. Only the suitable formulation is adopted for the design and operation of the droplet generator system. Experiments have been conducted at a wide range of operating conditions including different nozzle sizes, jet velocities, and frequencies. Good agreements are found between the predictions based on the adopted analytical formulation and the experimental results. It has been found that using the present design and procedure recommended, the droplet sizes can be controlled having a size deviation of less than 3 percent and the shape variation of the deposited layer can be managed within 3 percent of its deposited width.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Fluid Dynamics and Heat Transfer · Electrohydrodynamics and Fluid Dynamics · Surface Modification and Superhydrophobicity
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Mechanical and Aerospace Engineering, Arizona State University, Tempe, AZ 85287-5106
References (33)
Show source-provided references
1. Jacobs, P. F., 1996, Stereolithography and Other BP&M Technologies, Society of Manufacturing Engineers, Dearborn, MI.
2. Beaman, J. J., Barlow, J. W., Bourell, D. L., Crawford, R. H., Marcus, H. L., and McAlea, K. P., 1997, Solid Freeform Fabrication: A New Direction in Manufacturing, Kluwer Academic, Boston, MA.10.1007/978-1-4615-6327-3 ↗
3. Orme, M., Huang, C., and Courter, J., 1996, “Precision Droplet-Based Manufacturing and Material Synthesis: Fluid Dynamics and Thermal Control Issues,” Atomization Sprays, 6, pp. 305–329.10.1615/AtomizSpr.v6.i3.40 ↗
4. Kuhn, L., and Myers, R. A., 1979, “Ink-Jet Printing,” Sci. Am., 240, No. 4, Apr., pp. 162–178.10.1038/scientificamerican0479-162 ↗
5. Wallace, D. B. , 1989, “Automated Electronic Circuit Manufacturing Using Ink-Jet Technology,” ASME J. Electron. Packag., 111, pp. 108–111.10.1115/1.3226514 ↗
6. Lau, J., 1995, Ball Grid Array Technology, McGraw-Hill, New York.
7. Hayes, D. J., Wallace, D. B., Boldman, M. T., and Marusak, R. M., 1994, “Picoliter Solder Droplet Dispensing,” Int. J. Microcirc. Electron. Packag., 16, pp. 173–180.
8. Ju, T. H., Lin, W., Lee, Y. C., and Liu, J. J., 1994, “Effects of Ceramic Ball-Grid-Array Package’s Manufacturing Variations on Solder Joint Reliability,” ASME J. Electron. Packag., 116, pp. 242–248.10.1115/1.2905694 ↗
9. Lovelady, M. L., and Watts, J. D., 1999, “Closed Loop Feedback for Continuous Mode Materials Jetting,” 24 IEEE/CPMT Int. Electronics Manufacturing Technology Symposium, IEEE, pp. 189–195.10.1109/IEMT.1999.804817 ↗
10. Lee, H. C. , 1974, “Drop Formation in a Liquid Jet,” IBM J. Res. Develop., 18, pp. 173–180.10.1147/rd.184.0364 ↗
11. Chun, J., and Passow, C. H., 1993, “Production of Charged Uniformly Sized Metal Droplets,” U. S. Patent 5,266,098.
12. Rayleigh, J. W. S. , 1878, “On the Stability of Jets,” Proc. London Math. Soc., 10, pp. 4–13.10.1112/plms/s1-10.1.4 ↗
13. Weber, C. , 1931, “The Decomposition of a Liquid Jet,” Z. Angew. Math. Mech., 11, pp. 136–154.10.1002/zamm.19310110207 ↗
14. Donnelly, R. J., and Glaberson, W., 1966, “Experimental on the Capillary Instability of a Liquid Jet,” Proc. R. Soc. London, Ser. A, 290, pp. 547–556.10.1098/rspa.1966.0069 ↗
15. McCarthy, M. J., and Molloy, N. A., 1974, “Review of Stability of Liquid Jets and the Influence of Nozzle Design,” Chem. Eng. J., 7, pp. 1–20.10.1016/0300-9467(74)80021-3 ↗
16. Orme, M., and Muntz, E. P., 1987, “New Technique for Producing Highly Uniform Droplet Streams over an Extended Range of Disturbance Wave Number,” Rev. Sci. Instrum., 58, pp. 279–284.10.1063/1.1139322 ↗
17. Sterling, A. M., and Sleicher, C. A., 1975, “The Instability of Capillary Jets,” J. Fluid Mech., 68, pp. 477–495.10.1017/S0022112075001772 ↗
18. Reitz, R. D. , 1987, “Modeling Atomization Processes in High-pressure Vaporizing Sprays,” Atom. Spray Technol., 3, pp. 309–337.
19. Lin, S. P., and Reitz, R. D., 1998, “Drop and Spray Formation from a Liquid Jet,” Annu. Rev. Fluid Mech., 30, pp. 85–105.10.1146/annurev.fluid.30.1.85 ↗
20. Orme, M. , 1994, “Rapid Solidification Materials Synthesis with Nano-Liter Droplets,” SAE Trans. J. Aerospace, 102, pp. 1876–1881.10.4271/932566 ↗
21. Yim, P. W., 1996, “The Role of Surface Oxidation in the Break-up of Laminar Liquid Metal Jets,” Ph.D. thesis, M.I.T, Cambridge, MA.
22. Harmon, Jr., D. B. , 1955, “Drop Sizes from Low Speed Jets,” J. Franklin Inst., 259, pp. 519–523.10.1016/0016-0032(55)90098-3 ↗
23. Middleman, S., and Gavis, J., 1961, “Expansion and Contraction of Capillary Jets of Newtonian Liquids,” Phys. Fluids, 4, No. 3, pp. 355–359.10.1063/1.1706332 ↗
24. Clift, R., Grace J. R., and Weber, M. E., 1978, Bubble, Drops and Particles, Academic, New York, pp. 333–340.
25. Fox, R. W., and McDonald, A. T., 1985, Introduction to Fluid Mechanics, Wiley, New York, pp. 356–373.
26. Brandes, E. A., and Brook, G. B., ed., 1992, Smithells Metals Reference Book, Section 14.2, Butterworth-Heinemann, Oxford, England.
27. Manko, H. H., 1979, Solders and Soldering, McGraw-Hill, New York, pp. 120–121.
28. Wittenberg, L. J., and Ofte, D., 1970, “Viscosity of Liquid Metals,” Physicochemical Measurements in Metals Research, Part 2, R. A. Rapp, ed., Wiley, New York.
29. Boyer, H. E., and Gall, T. L., ed., 1985, Metals Handbook, Desk Ed., American Society for Metals, Metal Park, OH, pp. 1.46–1.49.
30. Warth, A. H., 1956, The Chemistry and Technology of Waxes, Reinhold, New York, NY.10.1097/00010694-195610000-00013 ↗
31. Gao, F. Q., and Sonin, A. A., 1994, “Precise Deposition of Molten Microdrops: the Physics of Digital Microfabrication,” Proc. R. Soc. London, Ser. A, 444, pp. 533–554.10.1098/rspa.1994.0037 ↗
32. Incropera, F. P., and DeWitt, D. P., 1985, Fundamentals of Heat and Mass Transfer, 2nd ed., Wiley, New York, pp. 774–775.
33. Rocha, J. C., 1997, “Control of the UDS Process for the Production of Solder Balls for BGA Electronics Packaging,” S.M. thesis, Massachusetts Institute of Technology, Cambridge, MA.