Abstract
The adoption of metal additive manufacturing into the production of passive microwave components is still in its relative infancy. However, it is of increasing interest due to the offer of geometrical design freedom and significant weight reduction. The electrical properties of additive manufactured components are still inferior to traditional manufacturing techniques owing to the poor surface finish, especially on overhanging surfaces, which are unavoidable in three-dimensional microwave components. In this paper we present experimental findings on the disparity in microwave surface resistance values between three common build orientations, as well as findings that establish a connection between increasing downskin laser power and a reduction in surface resistance for overhanging surfaces. Finally, additive manufactured rectangular waveguide sections are measured to assess the influence of combined upward and downward facing surfaces on surface resistance.
Highlights
Additive layer manufacturing (ALM) is of increasing interest within the aero/space industries due to its unique offering of unparalleled geometric design freedom
It is evident that a macro approach to testing microwave components produced by Powder bed fusion (PBF) is missing important information regarding the specific locations where loss contributions are occurring and overall performance will be heavily dependent on the build orientation of the part
In this study, additive manufactured sample plates orientated in three common build angles and several X-band waveguide sections have been manufactured from AlSi10Mg and evaluated for microwave loss
Summary
Additive layer manufacturing (ALM) is of increasing interest within the aero/space industries due to its unique offering of unparalleled geometric design freedom. Powder bed fusion (PBF), one form of ALM, uses spherical metal powder melted by a high power laser in successive layers to form three-dimensional components. PBF adoption is still in relative infancy [2], many studies have been performed on their application to microwave communication components [3]–[5]. A. MICROWAVE LOSS At microwave frequencies, the skin effect causes electrical current to be carried in only the outermost regions of material at a depth known as the skin depth δ= 1 πf μσ (1). R. Gumbleton et al.: Effect of Build Orientation and Laser Power on Microwave Loss. With the majority of current carried at the surface of the material, even micro-surface features can have a significant impact on microwave loss; the relationship between roughness and microwave loss is well established in literature [13]. Power dissipation in a conductor at microwave frequencies is defined by
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
