Fundamentals of selective laser sintering of metals

A model describing the primary mechanism for achieving high density metal parts during Selective Laser Sintering (SLS) has been developed. The model was verified using low melting temperature alloys and the concepts of the model were used to select a higher melting temperature alloy that produced high density SLS single layers. For successful SLS processing of metal powders, the individual components must be selected carefully to assure that the low melting temperature component will have a lower surface tension ({dollar}gammarmsb{lcub}lv{rcub}{dollar}) than the solid ({dollar}gammarmsb{lcub}sv{rcub}{dollar}), and have a low viscosity so that the liquid will rapidly wet the solid and infiltrate into the pores of the solid network, displace the vapor, and produce a dense SLS layer. Understanding the fundamentals of SLS processing of metals, ceramics and polymeric materials will lead to better process control and materials selection.