Additive Manufacturing and Innovative Powder/Wire Processing of Multifunctional Materials: Multifunctional Materials
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
Wednesday 2:00 PM
March 22, 2023
Room: 23C
Location: SDCC
Session Chair: Markus Chmielus, University of Pittsburgh
2:00 PM Invited
The Accelerated Development of Additively Manufactured Multifunctional Components: Raju Ramanujan1; Varun Chaudhary1; Srinivas Mantri2; Rajarshi Banerjee2; 1Nanyang Technological University; 2University of N. Texas
The next generation of high-performance components require multifunctional materials with spatially optimized properties. For example, future high frequency, large torque, extreme service environment rotating electrical conversion machines demand next-gen components. Additive manufacturing (AM) can produce such components, fabricated from multiple material compositions. A directed energy deposition technique, LENS, was deployed to produce compositionally graded Fe-Co-Ni based samples. The process parameters were optimized to produce structurally sound samples. The materials library intrinsic to such samples was utilized to rapidly develop composition-structure- multiple property relationships. Alloy compositions possessing attractive magnetic, mechanical, and electrical properties were pinpointed. Novel compositions, e.g., Co30Fe60Ni10, Co10Fe80Ni10, etc., with an optimum property set were identified. Such compositions were used to produce multi-material, spatially optimized, AM prototypes. This rapid development of AM multifunctional components will be elucidated. This work is supported by the AME Programmatic Fund by the Agency for Science, Technology and Research, Singapore under Grant No. A1898b0043.
2:25 PM
3D Ink-Extrusion Printing of La3Te4 Thermoelectric Legs with Complex Geometries: Alexander Proschel1; Yunjia Zhang1; Araseli Cortez2; Jeffery Snyder1; David Dunand1; 1Northwestern University; 2NASA Jet Propulsion Laboratory
Thermoelectric (TE) La3Te4 is one of the best performing n-type high temperature TEs but traditional synthesis techniques and intrinsic brittleness restrict TE leg design to cuboidal shapes fabricated by slicing larger ingots. Implementation of a 3D-ink extrusion manufacturing procedure would enable geometrical freedom and continuous processing with minimal loss of expensive TE material caused by traditional slicing while avoiding complications such as Te evaporation and cracking present in laser-based additive manufacturing processes. Here we present a 3D-ink extrusion process for synthesizing La3Te4 utilizing elemental powders and a polymer-based ink which can be printed at ambient temperature into complex geometries. Subsequent heat treatments decompose polymer binder and sinter powders to form densified, high purity La3Te4 enabling cheaper and better performing TE devices for deep space and power generation applications.
2:45 PM
3D Ink-extrusion Printing and Sintering of Thermoelectric Yb14MnSb11: Ming Chen1; Alexander Proschel1; Araseli Cortez2; Jeffrey Snyder1; David Dunand1; 1Northwestern University; 2NASA Jet Propulsion Laboratory, California Institute of Technology
Yb14MnSb11 is a high-performance, high-temperature thermoelectric (TE) material, but its brittleness and poor formability prevents manufacturing of TE devices with complex geometries. For Yb14MnSb11, traditional additive manufacturing approaches based on laser melting/sintering induce cracking and evaporation of Mn and Sb, due to high temperatures and thermal gradients. Here, we apply 3D ink-extrusion printing technique to fabricate Yb14MnSb11, enabling complex geometries with high fill factor and aspect ratio footprint to maximize heat transfer and conversion. Precursor powders are suspended together with binder into an ink with sufficiently low viscosity that it can be 3D-extruded into thin struts, in air at ambient temperature. Printed green body is sintered at elevated temperatures to decompose binder and densify powders. We discuss various approaches to achieve high density and high purity Yb14MnSb11 during the sintering process (including transient liquid phase sintering with Sb-rich melts), we describe the resulting microstructures and we report on TE properties.
3:05 PM
Process-Structure-Property Relationships for Laser Powder Bed Fusion of Thermoelectric Materials for Low and High Temperature Applications: Saniya Leblanc1; Yahya Oztan1; Ryan Welch1; Bengisu Sisik1; Vijayabarathi Ponnambalam1; 1George Washington University
We report on experimental and computational investigation of process-structure-property relationships for laser powder bed fusion of thermoelectric materials including bismuth telluride (for applications near 100°C) and silicon germanium (for applications near 1000°C). Strategies for non-spherical powders were developed, and the process parameters that lead to conduction mode melting were determined. The process has been demonstrated on multiple tools, both custom setups and commercial tools. The structure of both single melt tracks and bulk parts were characterized at nano-, micro-, and meso-scales. Simulations compared the predicted transition between equiaxed and columnar grains to the experimentally observed grain morphology. Thermoelectric properties (Seebeck coefficient, electrical and thermal conductivities) were measured and indicate a link between the process-dependent nanostructure and the Seebeck coefficient, including a transition between n- and p-type behavior. Finally, the performance impact of unique device shapes enabled by additive manufacturing was modeled, and selected promising shapes were fabricated.
3:25 PM
The Control of Tailored Microstructure and Thermoelectric Properties in Additively Manufactured Materials: Connor Headley1; Roberto Herrera del Valle1; Ji Ma1; Prasanna Balachandran1; Vijayabarathi Ponnambalam2; Saniya LeBlanc2; Dylan Kirsch3; Joshua Martin3; 1University of Virginia; 2George Washington University; 3National Institute of Standards and Technology
The implementation of additive manufacturing promises to create thermoelectric devices with increased efficiency and lowered production costs. Through the integration of machine learning techniques alongside well-curated additive manufacturing experimentation, we quickly drew vital connections between processing parameters, melt pool geometries, and defects to produce highly dense, geometrically complex bismuth telluride parts. Further, a system of high throughput sample fabrication and characterization was devised to rapidly determine the connections between processing conditions, material structure, and resulting thermoelectric properties. With the aid of machine learning, key characteristics such as composition, porosity, and microstructural features were accurately predicted and mapped across the processing parameter space. The microstructure and thermoelectric properties of the bismuth telluride builds could then be intentionally altered using the additive manufacturing process. Ultimately, this understanding of the processing-structure-property relationships has allowed us to deliberately vary the character of these samples from n-type to p-type through processing parameter modifications.
3:45 PM Break
4:00 PM
Rapid 3D Printing of AlN Ceramic Green Bodies for Heat Dissipation Devices: Luyang Liu1; Xiangfan Chen1; 1Arizona State University
In this study, a new approach for fabricating green bodies of heat dissipation devices by using custom-made micro-continuous liquid interface printing (μCLIP) is presented. Aluminum nitride (AlN) ceramic with high thermal conductivity is selected as the functional material and poly (1,6-hexanediol diacrylate) is selected as the polymer matrix. 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 AlN green bodies efficiently. Characterization results show that the thermal conductivity of the green bodies increases as the concentration of AlN ceramic increases. Besides, the sophisticated 3D structures of the printed green bodies can be preserved after pressureless sintering. We believe that with an appropriate post heat treatment process, AlN based heat dissipation devices with customized, sophisticated 3D structures can be fabricated by this new approach.
4:20 PM
Manufacturability and Reliability of Additively Manufactured Planar Transformer Windings Using Silver-based Pastes: He Yun1; F. McCluskey1; 1University of Maryland
Additive manufacturing (AM) techniques are increasingly being employed in electronics packaging. In particular, AM can be used to create planar magnetics with complex designs that can improve power module efficiency. In this presentation, we will focus on two aspects: (1) Utilizing a paste-based AM technique, syringe-printing, to fabricate planar transformer windings on ceramic substrates using silver-based pastes. This will include a discussion of manufacturing considerations including printable trace width, gaps, and heights; the effect of the sintering process on electrical resistivity; and the adhesion at the metal/ceramic interface. (2) Conducting a series of accelerated life tests on the AM-printed silver-based windings, including temperature-humidity exposure, thermal aging, and thermal cycling, to identify and characterize the failure modes and mechanisms.
4:40 PM
High Resolution Three-Dimensional Printing of Piezoelectric Composites for Sensing Applications: Siying Liu1; Wenbo Wang1; Luyang Liu1; Xiangfan Chen1; 1Arizona State University
Piezoelectric composites are thriving in the field of self-sustainable wearable electronics owning to their intrinsic capability of converting mechanical energy to electrical energy and vice versa. Additive manufacturing (AM), also known as 3D printing, refers to as a category of robust techniques in manufacturing 3D architected piezoelectric structures. Nonetheless, most of the 3D printing techniques often face the inherent speed-accuracy trade-off. Herein, we report rapid, high-resolution 3D printing of architected piezoelectric composite structures using micro continuous liquid interface production (CLIP). Resins with chemically functionalized piezo nanoparticles, including barium titanate (BTO) and lead zirconate titanate (PZT), were prepared and printed continuously at high printing speeds. Quantitative studies on the 3D printed BTO and PZT composites reveal their piezoelectric performance comparable to other stereolithography-based works but come at >10 times faster speeds. Proof-of-concept demonstrations further validate its capability in a variety of flexible and wearable sensing applications.
5:00 PM
The Development of (CoCrFeMnCu)1-xCrx High Entropy Alloy by arc-DED Additive Manufacturing Process: Sertaç Altınok1; Koray Yurtışık2; Eren Kalay2; 1TAI; 2Middle East Technical University
Additive manufacturing enables the production of parts showing locally different properties by altering the incremental motive design – such as FCC or BCC mimicking lattices, on the geometry to maximize the exploitation of their performances for structural purposes. The changes at the smaller scales can further alter the properties by changing the local composition, resulting in functionally graded materials. For this purpose, we have investigated the transition of crystal structure by adding Cr element to the equimolar CoCrFeMnCu alloy using arc type of direct energy deposition (arc-DED) additive manufacturing process. We have used empirical and CALPHAD models to predict the transition behavior; XRD, EBSD, TEM, and SEM analyses for the characterization of phases and microstructure on the compositional-graded geometry build by arc-DED. The microstructural hierarchy and functional mechanical properties of the arc-DED process parameters will be discussed in detail.
5:20 PM
In-Situ Alloying of Nb-47Ti Superconductors Using Laser Powder Bed Fusion: Tugrul Ersoz1; Moataz Attallah1; 1University of Birmingham
Additive Manufacturing of superconductors may provide a more economic manufacturing route that can produce complex superconductor components for advanced applications. In this study, in-situ alloying of Nb-47Ti alloy was performed using Laser Powder Bed Fusion, combined with extensive characterisation to assess the impact of the process on the microstructure and superconducting behaviour. To improve the superconducting behaviour, post-processing treatments and blending of submicron/nano-sized oxides were used to create a more chemically homogeneous microstructure and artificial pinning centres to improve the current density, respectively. Generally, high temperature heat treatments were required to fully dissolve the unmelted Nb, although a better control of the powder size in the blend is essential to ensure the build chemical homogeneity. Flux pinning using the fine oxides adds another complexity to the process but can potentially generate superior critical current density compared to the alpha-Ti pinning centres in conventional superconductors.