Additive Manufacturing and Innovative Powder/Wire Processing of Multifunctional Materials: Poster Session
Sponsored by: TMS Functional Materials Division, TMS Materials Processing and Manufacturing Division, TMS: Magnetic Materials Committee, TMS: Additive Manufacturing Committee, TMS: Powder Materials Committee
Program Organizers: Daniel Salazar, BCMaterials; Markus Chmielus, University of Pittsburgh; Emily Rinko, Honeywell Fm&T; Emma White, DECHEMA Forschungsinstitut; Kyle Johnson, Sandia National Laboratories; Andrew Kustas, Sandia National Laboratories; Iver Anderson, Iowa State University Ames Laboratory
Monday 5:30 PM
March 20, 2023
Room: Exhibit Hall G
Location: SDCC
Session Chair: Daniel Salazar, BCMaterials
A-1: 3D Ink-Extrusion Printing of NbFeSb Thermoelectric Legs with Complex Shape: Alexander Proschel1; Duncan Zavanelli1; Jeffery Snyder1; David Dunand1; 1Northwestern University
Current manufacturing processes for brittle, thermoelectric (TE) materials limit material shape and device geometry, limiting both performance and utility. Also, current processes such as ball milling and hot pressing are time consuming and unsuitable for continuous processing and they require subsequent slicing steps increasing cost due to kerf loss of high purity TE material. Thus, the development of additive manufacturing synthesis techniques for TE legs is important for widespread implementation. This talk will present a 3D ink-extrusion procedure for printing NbFeSb, one of the highest performing p-type half Heusler thermoelectric based on inexpensive Fe, and with excellent mechanical stability. This synthesis approach utilizes metallic precursor powders suspended in a polymer ink, which is 3D printed at ambient temperature and subsequently sintered at high temperature, allowing for manufacturing of geometrically-complex NbFeSb legs with minimal material loss, and without issues of evaporation, cracking and lack of fusion associated with laser-based additive manufacturing.
A-2: Additive Manufacturing of Iron and Iron-Alloy Lattices for Magnetic Nanoparticle Capture: Sammy Shaker1; Juyeon Won2; Daniel Shoemaker2; Steven Hetts3; Vitaliy Rayz4; Julia Greer1; 1California Institute of Technology; 2University of Illinois Urbana-Champaign; 3University of California-San Francisco; 4Purdue University
Magnetic nanoparticles have recently been applied to facilitate in vivo capture of small molecule chemotherapeutics. Removal of these nanoparticles after chemotherapeutic capture is an unresolved problem. In particular, capture devices must be magnetizable, have high surface areas for particle uptake, and minimize flow disruption. A potential solution to this issue involves additive manufacturing (AM) of magnetic alloys. A recent method developed for metal AM, hydrogel infusion AM (HIAM), has demonstrated the ability to form lattices with a range of metal alloy compositions. The magnetic and microstructural properties of materials synthesized through this pathway are still poorly understood. To further the knowledge of these properties as well as generate biocompatible magnetic lattices, we use HIAM to form iron, iron-nickel, and copper-nickel-iron lattices. We characterize the magnetic properties of these samples by vibrating sample magnetometry and perform microstructural analysis via powder X-ray diffraction, energy dispersive X-ray spectroscopy, and electron backscatter diffraction.
A-3: Comparison of Laser Wire and Powder Blown Directed Energy Deposition for C103: Daniel Palacios1; Aaron Stebner1; 1Georgia Institute of Technology
Coaxial laser wire directed energy deposition (DED) has become increasingly common in recent years. Laser wire DED provides some advantages over the more common powder blown DED in terms of speed and material usage. However, more work is needed exploring the quality differences between parts manufactured using the two processes. This work covers the development of optimal parameters for the additive manufacture of C103, a niobium alloy, using a powder blown DED system and a coaxial laser wire DED system. A design of experiments approach is used to explore the parameter space by varying process parameters such as laser power, scan speed, and material flow rate. The printed parts are evaluated in terms of density, surface roughness, and porosity to compare between the two processes. These results, together with work on microstructure characterization, are presented in this poster.
A-4: FeSiBCCr Amorphous Fine Powders with High Saturation Magnetization Based on Particle Size Classification and Its Magnetic Powder Cores with Low Core Loss: Yan-nan Dong1; Zheng-qu Zhu1; Jia-qi Liu1; Huan Zhao2; Jing Pang2; Pu Wang1; Jia-quan Zhang1; 1University of Science & Technology Bejing; 2Qingdao Yunlu Advanced Materials Technology Co., Ltd.
FeSiBCCr gas-water combined atomization amorphous powders were divided into five size groups (1#: ≥104 μm; 2#: 74~104 μm; 3#: 48~74 μm; 4#: 38~48 μm; 5#: ≤38 μm) to study the relationship between powder properties and size distribution, and then to prepare high-performance magnetic powder cores (MPCs) through particle size classification. The results of powder characterization show that the circularity of the powders increases with the decrease of the particle size. Due to the finest particle size, the comprehensive properties of 5# powders are better than other powders, with the saturation magnetization of 144.2 emu·g–1 and the coercivity of 0.13 Oe. MPCs prepared by cold pressing process using 5# powders show excellent soft magnetic properties. The effective permeability is 19.62, and the core losses are 224.10 mW·cm–3 (Bm=0.05 T, f=100 kHz) and 1441.5 mW·cm–3 (Bm=0.02 T, f=1 MHz), respectively.
Cancelled
Laser Powder Bed Fusion of the LaCe(Fe,Mn,Si)13 Magnetocaloric Material: Kun Sun1; Abdelmoez Hussein1; Moataz Attallah1; 1University of Birmingham
The aim of this study is to assess the printability of LaCe(Fe,Mn,Si)13 magneto-caloric material using laser powder bed fusion (LPBF) to create room temperature high surface-area-to-volume magnetic refrigeration media. LPBF process optimisation was performed on block samples, and lattice samples, focusing on the homogeneity, the microstructural development, and the crack propagation. Through optimising the parameters to avoid lack of fusion and keyhole porosity, samples with lower density of defects were achieved, although it was difficult to fully eliminate the defects, especially cracking. Different heat treatments were applied to homogenise the chemical composition and increase the magneto-caloric properties. By performing X-ray diffraction, it was found that the build is predominately made of the NaZn13 structure, α(Fe,Si), CeSi, La5Si3 and LaFeSi.
A-5: New Aluminium-based Composite Powders Dedicated for Additive Manufacturing: Krzysztof Pecak1; Marcin Lis1; Adriana Wrona1; Adrian Kukofka2; Jacek Mazur1; Anna Janoszka1; Małgorzata Osadnik1; 1Lukasiewicz Research Network - Institute of Non-Ferrous Metals; 2Progresja New Materials Sp. z o.o.
One of the most limiting factors of Additive Manufacturing, specifically Laser Powder Bed Fusion, is low availability of different materials. This is most visible when it comes to light alloy powders, standard compositions of which are often not printable due to several factors. In this work we present a new aluminium based composite powder. The powder was modified with the use of powder metallurgy methods to simultaneously achieve printability, superior powder flow properties and high strength of the end product. Samples produced by means of Selective Laser Melting have not undergone hot cracking and exhibit exceptionally low porosity. Results of chemical, phase and morphology investigations of powders and printed samples are presented.
A-81: Rapid 3D Printing of Nd:YAG Ceramic for Lasing Media: Luyang Liu1; Xiangfan Chen1; 1Arizona State University
Polycrystalline transparent yttrium aluminum garnet (YAG, Y3Al5O12) ceramic doped with rare-earth metals such as neodymium (Nd: YAG) has broad applications as a lasing medium. In this study, we developed a new fabrication method for Nd: YAG based lasing media by solvent-gelation reaction, micro-continuous liquid interface printing (μCLIP) with post heat treatment processes. With the resolution of 5.8 μm·pixel–1 and the printing speed of 10 μm·s–1, the μCLIP system can fabricate multi-scaled Nd: YAG green bodies efficiently. Characterization results show that after the post heat treatment processes the fabricated samples photoluminesce at 1064 nm pumped by 532 nm laser. This new approach is beneficial for developing lasing media with customized, sophisticated 3D structures within a shorter timescale.
A-83: Role of Additive Manufacturing (AM) in Developing Iron-Silicon Electric Steels for Soft Magnetic Applications: SaiSree Varahabhatla1; Kiran Nartu1; Sameehan Joshi1; Srinivas Mantri1; Narendra Dahotre1; Raj Banerjee1; 1University of North Texas
Over the past few years there has been substantial effort on developing Fe-3.8wt%Si grain oriented electric steels using laborious conventional techniques which include multi-step rolling for applications in transformers. Further, high silicon Fe-6.5wt%Si electric steels have gained significant traction because of their excellent magnetic properties. The brittle nature of the high silicon steels resulted difficulty in manufacturing via conventional techniques. In the present study, we explored the possibilities of producing Goss oriented Fe-3.8wt%Si and Fe-6.5wt%Si high silicon electric steels using Direct Energy Deposition (DED) and Laser Powder Bed Fusion (LPBF) additive manufacturing techniques. The DED and LPBF processed Fe-3.8wt%Si steels exhibited <001>BCC texture along the build direction which resulted in better magnetic properties compared to the conventionally processed counterpart. On the other hand, the DED deposited Fe-6.5wt%Si steel exhibited a single phase DO3 ordered microstructure which led to good soft magnetic and decent mechanical properties.
A-6: Study on the Optimization of Fe Content of FeSiBC Amorphous Powders: Zheng-qu Zhu1; Yan-nan Dong1; Jia-qi Liu1; Jing Pang2; Pu Wang1; Jia-quan Zhang1; 1University of Science & Technology Bejing; 2Qingdao Yunlu Advanced Materials Technology Co., Ltd.
In this paper, four types of amorphous spherical powders with different Fe contents were produced by a novel gas-water combined atomization process, and the corresponding magnetic powder cores (MPCs) were fabricated. It was found that as Fe content was increased from 92.66 to 94.55 wt.%, both the D50 and enthalpy of crystallization of the powders decreased and then increased, while the coercivity increased and then decreased together with a linearly enhanced saturation magnetization. Among them, Fe94.55Si1.05B4.3C0.1 amorphous powders have smaller particle size (D50=31.67 μm), excellent sphericity (0.95), good thermal stability (∆T=46 K) and highest saturation magnetization (172 emu·g-1), thus showing the most excellent overall properties. The core loss and the permeability of the corresponding MPCs for the Fe94.55Si1.05B4.3C0.1 amorphous powders is 79.76 kW·m-3 (0.02 T, 100 kHz) and 25.95, respectively, which shows the possibility to develop amorphous powders and MPCs with high Fe content through the present gas-water combined atomization.