Research on the solidified morphologies of successive pileup metal droplets
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DOI 10.1007/s12206-020-0711-5
Journal of Mechanical Science and Technology 34 (8) 2020 Original Article DOI 10.1007/s12206-020-0711-5 Keywords: · Metal droplet · Successive pileup · Pillar structure · 3D numerical model
Correspondence to: Jieguang Huang [email protected] Congping Chen [email protected] Hao Yi [email protected]
Citation: Chen, C., Huang, J., Yi, H., Zhang, Y. (2020). Research on the solidified morphologies of successive pileup metal droplets. Journal of Mechanical Science and Technology 34 (8) (2020) ?~?. http://doi.org/10.1007/s12206-020-0711-5
Research on the solidified morphologies of successive pileup metal droplets Congping Chen1, Jieguang Huang2, Hao Yi3 and Yi Zhang1 1
2
School of Mechanical Engineering, Changzhou University, Changzhou 213164, China, School of Me3 chanical Engineering, Northwestern Polytechnical University, Xi'an 710072, China, College of Mechanical Engineering, Chongqing University, Chongqing 400030, China
Abstract
Metal micro-droplet 3D printing is an effective additive manufacturing technique to form micro pillar structures. However, the control mechanism of the pillar contour is still unclear. To form a pillar with uniform radius, it is essential to investigate the dependence of processing parameters on pillar contours. In this study, a 3D numerical model was employed to simulate and analyze the successive pileup processes of multiple droplets. The solidification angle of solidified new-coming droplets is defined to characterize the pillar contour. An analytic equation of solidification angle was established. In this case, the solidified morphology of the droplets could be feasibly predicted through thermophysical parameters and initial conditions. This work provides good physical understanding of the complicated mechanisms for fabricating a pillar structure by means of the successive pileup of molten metal droplets, and paves the way for pillar contour control.
Received August 30th, 2019 Revised
April 13th, 2020
Accepted May 19th, 2020 † Recommended by Editor Chongdu Cho
© The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2020
1. Introduction Pillar structures have drawn tremendous interest in field emission devices [1], hierarchical pillar arrays [2], surface patterning [3], and fine-pitch copper pillar bump [4], of which the processing technology is complex, costly, and not allowing customization. To break through these limitations, metal micro-droplet 3D printing [5, 6] was proposed. With wide material applicability, high material usage efficiency, inexpensive equipment and fewer machining steps than conventional manufacturing techniques, metal micro-droplet 3D printing is a very promising additive manufacturing technique to form such pillar structures. Luo [7] and Visser [8] fabricated pins in microelectronics manufacturing and large aspect ratio functional parts by this technique, in which understanding the effects of parameters associated with the pillar contour is essential to obtain high printing a
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