Metal Micro-Droplet Based 3D Printing Technology

Foreword
Preface
Contents
1 Introduction
1.1 Classification and Characteristics of Uniform Metal Droplet Ejection Technology
1.1.1 Continuous-Ink-Jet Jetting Technology
1.1.2 Drop-On-Demand Jetting Technology
1.2 State-of-the-Art and Trends of the Uniform Metal Droplet Ejection Technology
1.2.1 State-of-the-Art of the Uniform Metal Droplet Ejection Technology
1.2.2 Trends in Uniform Metal Droplet Ejection 3D Printing Technology
References
2 Fundamental Theory of Uniform Metal Droplet Ejection and Deposition
2.1 Introduction
2.2 Theory of Continuous Uniform Metal Droplet Ejection and Mechanism of Droplet Charging and Deflection
2.2.1 Theory of Continuous Uniform Metal Droplet Ejection (Theory of Rayleigh Jet Instability)
2.2.2 Mechanism of Charging and Deflection of Uniform Droplets
2.3 Drop-On-Demand Ejection of Metal Droplets
2.3.1 Theory of Pneumatic Pulse-Driven Drop-On-Demand Ejection
2.3.2 Theory of Piezoelectric Pulse-Driven Drop-On-Demand Ejection
2.3.3 Model of Stress Wave-Driven Drop-On-Demand Ejection
2.4 Dynamics and Thermodynamic Theory of Uniform Metal Droplet Flight Process
2.4.1 Flight Dynamics of Metal Droplets
2.4.2 Temperature History of Metal Droplets During Flight
2.5 Fundamental Theory for Uniform Metal Droplet Deposition
2.5.1 Non-Dimensional Analysis of Metal Droplet Impact Behavior
2.5.2 Non-Isothermal Impact and Spreading Behaviors of Metal Droplets
References
3 Devices and Equipment for Uniform Droplet Ejection
3.1 Introduction
3.2 Brief Introduction of Equipment for Uniform Metal Droplet Ejection
3.3 Device for Continuous Uniform Droplet Streams Ejection, Charging, and Deflection
3.3.1 Device for Ejecting Continuous Uniform Droplet Streams
3.3.2 Charging and Deflection Device for the Continuous Uniform Droplet Stream
3.4 Design and Implementation of the Pneumatic Pulse-Driven Drop-On-Demand (DOD) Droplet Ejection System
3.4.1 Pneumatic Pulse-Driven DOD Droplet Generator for Tin Solder
3.4.2 Pneumatic Pulse-Driven DOD Droplet Generator for Aluminum Alloy
3.5 Piezoelectric Pulse-Driven DOD Droplet Generator
3.6 Stress Wave-Driven DOD Droplet Generator
3.7 Parameter Acquisition and Control System of the Metal Droplet Ejection and Deposition
3.7.1 Control System for Uniform Metal Droplet Ejection and Deposition
3.7.2 Key Parameters Acquisition System of the Droplet Ejection and Deposition
References
4 Uniform Metal Droplet Continuous Ejection and Printing Process Control Technology
4.1 Introduction
4.2 Research on Uniform Droplet Continuous Ejection Behavior and Its Influencing Factors
4.2.1 Numerical Simulation of Continuous Uniform Droplet Ejection Process and Research on Influencing Factors
4.2.2 The Influence of the Experimental Parameters on the Metal Jet Breakup Process
4.3 Charging and Deflection Control of Uniform Metal Micro Droplet Stream
4.3.1 Control of Droplet Charge of Uniform Metal Micro Droplets
4.3.2 Study on the Dispersion Behavior of Charged Uniform Droplet Stream
4.3.3 Implementation and Control of Deflected Flight of Charged Uniform Micro Droplets
4.3.4 Temperature History of Uniform Metal Droplets During the Deflection Flight
4.4 Free Forming by Continuous Ejection of Uniform Metal Droplets and Its Controlling Method
4.4.1 Influencing Factors and Research Methods for Free Forming by Continuous Droplet Ejection
4.4.2 Parameter Control of Free Forming by Continuous Ejection of Uniform Metal Droplets
References
5 On-Demand Ejection and Control of Uniform Metal Droplets
5.1 Introduction
5.2 On-Demand Ejection Behavior of Metal Droplets Driven by Pneumatic Pulse and the Influence of Parameters
5.2.1 Research on On-Demand Ejection of Uniform Tin–Lead Alloy Droplets
5.2.2 Research on Ejection of Uniform Aluminum Droplets On-Demand Driven by Pneumatic Pressure Pulse
5.3 Ejection Behaviors of Metal Droplets On-Demand Driven by a Stress-Wave Pulse and the Influence of Parameters on Droplet Ejection
5.3.1 Influence of Parameters of Experiment Device on Metal Droplet Ejection
5.3.2 Effect of Stress Wave Pulse Parameters on Metal Droplet Ejection
5.4 Comparison of Various Metal Drop-On-Demand Technologies
References
6 Uniform Solder Droplet Deposition and Its 3D Printing Technology
6.1 Introduction
6.2 Deposition Behaviors of Uniform Solder Droplet Deposition and Effect Factors of the Morphology of Deposited Droplets
6.2.1 Deposition and Spreading Behaviors of Uniform Solder Droplets
6.2.2 Effect of Experimental Parameters on Final Shapes of Solidified Micro Droplets
6.2.3 The Method to Reduce the Height Deviation of Solder Bumps and the Analysis of the Height Accuracy
6.3 Printing Path Planning of the Metal Droplet and the Effect Factor
6.3.1 Effect of Sequential Printing Parameters on the Morphology of Printed Traces
6.3.2 Line Formation Experiment by Using the Alternate Printing
6.3.3 Controlling of the Deposition Path of Micro Metal Parts by Using Uniform Metal Droplet-Based Printing
6.4 Fabrication of Micro Metal Parts by Drop-On-Demand Printing
6.4.1 Fabrication of Micro-Finned Heat Sinks
6.4.2 Fabrication of Micro-Honeycomb Parts
6.4.3 Fabrication of Micro-Squared Parts
6.4.4 Fabrication of Micro Gears
6.4.5 Fabrication of Micro Racks
6.5 Electronic Packaging via Uniform Micro Lead–Tin Alloy Droplet 3D Printing Technology
6.5.1 Rapid Printing of Ball Grid Array and Solder Column Array
6.5.2 Rapid Printing and Soldering of Electronic Circuits
References
7 Uniform Aluminum Droplet Deposition Manufacturing and Its Controlling Technique
7.1 Introduction
7.2 Deposition Behaviors of Uniform Aluminum Droplets
7.2.1 Impact Behaviors of Aluminum Droplets
7.2.2 Effect of Process Parameters on the Profile of Deposited Aluminum Droplets
7.3 Deposition of Aluminum Lines by Uniform Droplets
7.3.1 Effect of Platform Velocity on Printed Lines
7.3.2 Effect of Substrate Temperature on Printed Lines
7.4 Drop-On-Demand Printing of Aluminum Pillars by Uniform Droplets
7.4.1 Temperature Change During the Deposition of Aluminum Droplets
7.4.2 Morphology Features of Deposited Pillars
7.4.3 Pillar Forming by Drop-On-Demand Printing of Aluminum Droplets
7.4.4 Forming of Thin-Walled Aluminum Parts
7.5 Forming of Aluminum Solid Parts
References
8 Microstructure Evolution and Interface Bonding of Uniform Aluminum Droplet Deposition Manufacturing
8.1 Introduction
8.2 Microstructure Evolution of Uniform Aluminum Droplet Deposition
8.2.1 Microstructure Evolution of Uniform Aluminum Droplets During the Vertical Pileup
8.2.2 Microstructure Evolution of Lines Deposited by Uniform Aluminum Droplets
8.3 Influence of Interface Bonding Between Metal Droplets on Printed Aluminum Parts
8.3.1 Effect of Interface Bonding on the Microstructure of Aluminum Parts
8.3.2 Effect of Interface Bonding on the Mechanical Properties of Aluminum Parts
8.4 Internal Defects and Their Influencing Factors of As-Deposited Aluminum Components
8.4.1 Hole Defects Inside Printed Aluminum Parts
8.4.2 Internal Cracks of Printed Aluminum Parts
References
9 Application Prospect of Uniform Metal Droplet-Based 3D Printing
9.1 Introduction
9.2 Preparation of Mono-Sized Spherical Metal Particles
9.3 Printing and Packaging of Microcircuits
9.4 Micron Scaled Metal Parts Printing
9.5 Micro Thin-Wall Parts Printing
9.6 3D Printing for Functional Parts
References