Advances in the Production of Infiltrated Aluminium Parts Using Selective Laser Sintering

Recent advances in a rapid freeform fabrication process for the production of aluminium parts are considered. The methodology involves the formation of an unconstrained, resin bonded aluminium powder part by Selective Laser Sintering, the burnout of the resin, the partial transformation of the aluminium into a rigid aluminium nitride skeleton by reaction with the atmosphere under a magnesium/alumina blanket and the subsequent infiltration with a second aluminium alloy. Here we describe the process and consider potential applications. Strategies for controlling the growth of the aluminium nitride are also to be discussed.