Development of Nanocomposites for Solid Freeform Fabrication

Nanocomposites in which the constituents are mixed on a nanorneter scale can provide important advantages in the Selective Laser Sintering (SLS) and Selective Laser Reactive Sintering (SLRS) processes. The larger surface area and grain boundaries in the nanocolnposites compared to that in the conventional microcomposites are expected to enhance the solid state diffusion during laser irradiation as well as during any other subsequent processes. Our strategy is to design and develop nanocomposites in which one nanosize cOlnponent has a lower melting point than the other nanosize component, either of which can serve as the matrix phase. The nanoscale dispersion of the low melting component can aid the sintering process during SLS or SLRS. Nanocomposite powders of AI203-COOx, Ab03-NiO, A1203-CO and A1203-Ni have been synthesized by sol-gel processing and are evaluated by SLS.