Additive Manufacturing of Functional and Energy Materials: Energy Materials
Sponsored by: TMS: Additive Manufacturing Committee
Program Organizers: Sneha Prabha Narra, Carnegie Mellon University; Markus Chmielus, University of Pittsburgh; Mohammad Elahinia, University of Toledo; Reginald Hamilton, Pennsylvania State University
Wednesday 8:30 AM
February 26, 2020
Room: 7B
Location: San Diego Convention Ctr
Session Chair: Sneha Narra, Worcester Polytechnic Institute
8:30 AM Invited
3D Printed Lithium Ion Batteries and Other Functional Devices: Mohammad Sadeq Saleh1; Jie Li2; Jonghyun Park2; Rahul Panat1; 1Carnegie Mellon University; 2Missouri University of Science and Technology
Additive manufacturing methods such as printing allows the fabrication of microstructures with rapid changes to design, use of a large number of functional materials, and novel device geometries. In this research, we develop a fabrication technique using printed electronics to create a new class of three-dimensional (3D) micro-architected materials without any support materials. The printed structures are then used to enhance the performance of energy storage devices. Microlattice electrodes with porous solid truss members are fabricated that leads to a significant improvement in the battery performance in terms of specific capacity and areal capacity when compared to a thin solid block electrode. These results indicate that the 3D printed structures enhance electrolyte transport through the electrode volume, increase the available surface area for electrochemical reaction, and relieve the intercalation-induced stress. Other 3D printed functional devices are also demonstrated.
9:00 AM
High Performance Zn-ion Batteries by Additive Manufacturing: Sanket Bhoyate1; Marcus Young1; Wonbong Choi1; 1University of North Texas
Batteries play significant role in powering modern electronic devices. Li-ion batteries are widely used in such applications. However, there are several factors such as scarcity of Li metal, major safety issues, cost and life cycle that affect the long-term applicability of Li-batteries. Hence, in this study we focus on alternative battery technology using Zn metal. Zinc is naturally abundant metal as compared to Lithium with high theoretical volumetric capacity, it is considerably safe and stable in ambient condition. In order to utilize maximum volumetric capacity of Zn, we used additive manufacturing technique to fabricate 3D Zn anode. Our results suggest, that 3D Zn anode show higher rate capability at high charge-discharge current as compared to commercial Zn foil. The higher performance owes to the porous surface area of designed 3D Zn anode and can be used for high-performance battery application.
9:20 AM
Multiscale-controlled Three-dimensional Electrodes for Lithium-ion Batteries: Jonghyun Park1; 1Missouri University of Science and Technology
This talk introduces multiscale-controlled electrodes for lithium-ion batteries. First, a hybrid electrode structure was fabricated by a 3D printed extrusion process, where hybrid means to combine the benefits of conventional laminated structure and 3D interdigitated structure. Then, an idea of self-assembly of particles via an electric field process along with 3D printed structures based on additive manufacturing proved the important roles of micro/macrostructure on battery performance. This synergistic control of micro-/macro-structures is a novel concept in energy material processing and has considerable potential for providing unprecedented control of electrode structures with enhancing performance. In addition, thin coated active particles through atomic layer deposition (ALD) have been integrated with a 3D electrode structure to achieve further performance. The nanoscale coating/doping provided enhanced fundamental properties, including transport and structural properties, while the mesoscale control could provide a better network of the nanostructured elements by decreasing the diffusion path between.
9:40 AM
Porous Lithium Ion Battery Cathodes Prepared Using Selective Laser Sintering Exhibit Complex Microstructure and Dual Phase State: Katherine Acord1; Alexander Dupuy1; Umberto Scipioni Bertoli1; Baolong Zheng1; William West2; Qian Chen2; Andrew Shapiro2; Julie Schoenung1; 1Department of Materials Science and Engineering, University of California, Irvine, CA; 2Jet Propulsion Laboratory, California Institute of Technology, Pasadena, CA
Three-dimensional (3D) printing is a promising manufacturing technique for the development of thick, complex geometry lithium ion battery (LIB) cathodes with enhanced energy and power density. We utilized selective laser sintering (SLS) to fabricate 3D lithium nickel cobalt aluminum oxide (NCA) cathodes without the use of electrochemically inactive components (e.g., binders, solvents). A parametric single-track study was performed to develop successful deposition conditions for 3D NCA components. Crystal structure transformations, known to influence electrochemical performance, were investigated using X-ray diffraction. The 3D NCA samples exhibit high geometric complexity, open porosity, good structural stability (i.e., crack-free), and dual phase states, that include the trigonal layered structure (R3 ̅m) and disordered rock salt (Fm3 ̅m) structure. The presence of the electrochemically active trigonal layered structure in the complex geometry NCA cathodes prepared using SLS is promising for the development of next generation LIBs.
10:00 AM Break
10:20 AM Invited
Laser Processing of Bismuth Telluride Thermoelectric Materials for Solid-State Energy Conversion: Saniya Leblanc1; Haidong Zhang1; Ryan Welch1; George Nolas2; Yohann Thimont3; 1George Washington University; 2University of South Florida; 3Universite Paul SABATIER CIRIMAT
Our work expands the materials capability in additive manufacturing to enable new thermoelectric energy conversion devices. We apply selective laser melting (also known as laser powder bed fusion) to thermoelectric materials, semiconductors which convert heat to electricity with a solid-state process. This approach could enable new geometries and architectures, nano- to meso-scale structuring, and material-to-device integration. This talk will present the process-structure-property relationships for laser-processed bismuth telluride. We characterize the microstructure and phases, and we measure key thermoelectric properties (Seebeck coefficient, electrical resistivity, thermal conductivity) as a function of temperature. We also demonstrate the impact novel geometries can have on thermoelectric device performance using multiphysics modeling.
10:50 AM Invited
3D Ink Printing of Thermoelectric Materials: Christoph Kenel1; David Dunand1; 1Northwestern University
Additive manufacturing of thermoelectric materials enables the production of shape conforming, geometrically complex and intricate components. With ongoing material development, Bi2Te3 remains among the most efficient materials for temperatures close to room temperature. Here, an ink-based approach is presented, where a powder-loaded ink containing binders is 3D ink extruded in the desired shape. After printing, the binders are thermally removed and the powders are sintered to yield a fully intermetallic part. The initial ink can be loaded with pre-alloyed Bi2Te3 powders, that are then directly sintered, or by blends of Bi2O3+3TeO2, that are co-reduced and reacted to form Bi2Te3 in situ during thermal treatment in a reducing H2 atmosphere. In-situ synchrotron x-ray diffraction elucidates the complex co-reduction of Bi2O3 and TeO2 requiring precise process control to obtain the desired Bi2Te3 phase. The presented approach is cost effective, versatile and foreseen to widen the range of 3D-printable thermoelectrics in the future.
11:20 AM
Solid-state Additively Manufactured Thermal Energy Storage Materials: Darin Sharar1; Asher Leff1; Adam Wilson1; Kadri Atli1; Alaa Elwany2; Ibrahim Karaman2; 1US Army Research Laboratory; 2Texas A&M
Solid-liquid phase change materials require engineering measures in the form of encapsulants and fin structures to provide mechanical support, prevent liquid phase leakage, and enhance thermal conductivity. We report here the use of Additively Manufactured NiTi and NiTi-based shape memory alloys (SMAs) as ultrahigh performance metallic solid-state PCMs. This development will allow the fabrication of complex thermal designs and topology optimization schemes without the design constraints imposed by standard PCMs and traditional manufacturing processes. In addition to design freedom, this newly-identified class of metallic PCM offers a two-order-of-magnitude figure-of-merit improvement over traditional PCMs with excellent tunability, both through additive process parameters and post-processing heat treatment. The ultrahigh performance of reversible martensitic transformations in NiTi-based alloys, in conjunction with its excellent structural properties and additive manufacturability presents an opportunity for a combination of innovative materials science, thermal engineering, and AM solutions to meet the extreme demands of emerging energy storage systems.