Additive Manufacturing of Functional and Energy Materials: Novel Applications
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
Thursday 2:00 PM
February 27, 2020
Room: 7B
Location: San Diego Convention Ctr
Session Chair: Amir Mostafaei, Illinois Institute of Technology
2:00 PM
Polycrystal-inspired Hierarchical Lattice Materials: Jedsada Lertthanasarn1; Chen Liu1; Everth Hernández-Nava2; Iain Todd2; Minh-Son Pham1; 1Imperial College London; 2The University of Sheffield
Lattice materials contain complex porous structures that offer an outstanding strength to weight ratio, but often suffer from post-yield instability. We propose a novel approach to lattice design to overcome this limitation based on mimicking crystal microstructure. Here, boundary hardening was employed to control the propagation of deformation bands in lattice materials. Such boundaries were introduced via tailoring the misorientations between adjacent lattice domains, resulting in a marked increase in strength and toughness. Moreover, fabricating such polycrystal-inspired lattices with Ti-6Al-4V leads to metamaterials that consist of a hierarchical lattice structure. Such metamaterials, termed meta-crystals, feature a BCC/HCP dual-phase microstructure characteristic of Ti-6Al-4V at the micro-scale, coupled with the FCC polygrain-like structure of the architected lattices at the meso-scale. With AM’s unique ability to control the micro- and meso-structure, we can optimise meta-crystals through different combinations of polycrystal microstructure and meso-lattice architecture to achieve the desired mechanical properties.
2:20 PM
Development of an Austenitic/Martensitic Gradient Steel by Additive Manufacturing: Flore Villaret1; Xavier Boulnat2; Pascal Aubry1; Damien Fabrčgue2; Yann de Carlan1; 1CEA; 2Université de Lyon, INSA de Lyon
In this study, we focused on a gradient from a 316L austenitic stainless steel to a 9Cr-1Mo martensitic steel. These steels are widely used for nuclear applications. Due to their chemical composition differences, welding them is uneasy, requiring nickel based filling metal and post-welding heat treatments. It is possible to consider the construction of a coupling sleeve between 316L and 9Cr-1Mo by additive manufacturing. Direct Metal Deposition (DMD) technique allows to gradually change the chemical composition from 316L to 9Cr-1Mo, allowing homogeneous welding at each end and thus simplifying the assembly step.Additive manufactured graded samples were built without major defects. Microstructural study of the transition by SEM/EBSD shows very good metallurgical bonding with a smooth transition from the 316L austenite to the 9Cr-1Mo martensite. Tensile tests shows that bonding in graded part is strong. Thermodynamic calculation and thermal cycle modelling are used to explain the observed microstructures.
2:40 PM
3D Printed Nanocomposites of Silicon Elastomer and Multiferroic Nanoparticles: Felicia Horne1; Naga Srinivas Korivi1; Vijay Rangari1; 1Tuskegee University
There is great interest in composites of polymers and multiferroic nanoparticles for advanced electronic applications. There has been very little work done in the rapid prototyping of such composites. We report the fabrication of composites of silicone elastomer, and barium titanate/iron oxide nanoparticles. The process first involves a sonochemical reaction of iron acetate, urea, barium titanate nanoparticles in a solvent. This results in iron oxide nanoparticles formed on and near the barium titanate nanoparticles. A subsequent sintering process improves the crystalline nature of the iron oxide. The barium titanate/iron oxide nanoparticles are combined with a moldable silicone elastomer (Dowsil MS-4007) at 5% weight ratio and loaded onto an extrusion head of a commercial 3D printer. Printing on a base maintained at 100 °C results in the formation of solid nanocomposite layers. Observations will be presented from characterization of these layers by electrical and magnetic studies, microscopy, mechanical and thermal studies.
3:00 PM
Energy Absorbing Functional Composites with Negative Stiffness: Al-ZrO2 Fabricated by Additive Friction Stir Deposition: Hunter Rauch1; Hang Yu1; 1Virginia Polytechnic Institute and State University
Granular doped zirconia packings have recently been shown to exhibit continuous martensitic phase transformation. This, combined with the large actuation stress and volumetric strain, makes the material appealing as a damping medium or as a tunable actuator. In this talk, we present the first aluminum-matrix composites with functional zirconia particles as the reinforcement phase, which display good static properties and significant stress-induced stiffening thanks to zirconia’s phase transformation. These composites are of superior quality thanks to their processing technique: Additive Friction Stir Deposition, a solid-state additive manufacturing technology that uses intense plastic deformation to incite material flow, leading to well dispersed secondary particles. Because there is no melting, wetting angles are a non-issue and the interface between aluminum and zirconia is excellent. Analysis of this critical interface, as well as the composites’ macro- and microscopic mechanical properties, are presented here in depth with results from microscopy, XRD, DSC, and nano-indentation.
3:20 PM
3D Printed Polymer Multiferroic Composites: Emery Utterback1; Naga Srinivas Korivi1; Vijay Rangari1; 1Tuskegee University
Composites of polydimethylsiloxane (PDMS), and nano-particles of barium titanate, cobalt ferrite and iron oxide have been fabricated by 3D printing for applications in advanced multiferroic devices. The fabrication involved nano-particle synthesis by sonochemical method, followed by mechanically blending liquid PDMS pre-polymer and its curing agent with the nanoparticles. The blend was loaded onto an extrusion printing head of a commercial 3D printer and printed on a base plate maintained between 75 – 90 °C to yield solid composite layers. Characterization of these composite layers by electrical and magnetic studies, and observations from scanning electron microscopy, transmission electron microscopy, x-ray diffraction, differential scanning calorimetry, thermogravimetry will be presented. To the best of our knowledge, this is the first report of a 3D printing approach to developing polymer multiferroic composites and constitutes a facile route to achieving such functional composites.
3:40 PM Break
4:00 PM
Additive Manufacturing of Multifunctional Continuous Carbon Fiber Composites via Coextrusion: Aditya Thakur1; Xiangyang Dong1; 1Missouri University of Science and Technology
Structural lithium-ion batteries are capable of storing electrical energy and meeting mechanical requirements simultaneously. In this study, a coextrusion-based additive manufacturing process was applied to directly print a newly designed multifunctional structural lithium-ion battery structure with continuous carbon fibers. Individually coated carbon fiber tows as both electrolyte and separator were printed with photopolymers infused with active and conductive materials. This study demonstrated that the proposed printing processes successfully printed various types of multifunctional composites with compliant fiber-reinforced structures, circuit-imbedded composites, and carbon fiber structural batteries. Both mechanical properties as a function of structural components and electrical properties were characterized and investigated for the additively fabricated multifunctional structures. The printed structural batteries showed the promising results with decent battery capacities and strong mechanical strength. In particular, the printed multifunctional batteries were demonstrated with great potentials in the efficient use of the structural battery materials and thus significant weight reduction.
4:20 PM
Characterization of as Selected Laser Melting Built and Vacuum Heat Treated NiTa Alloy for Hard Disc Applications: Cheng-Tse Wu1; Michael Wu2; Gary Chung3; C.Y. Ma2; Feng Xu4; Kinnor Chattopadhyay1; 1University of Toronto; 2Solar Applied Materials Technology Corp; 3Solar Applied Materials Technology Corporation; 4Farsoon Technologies Corporation
The semiconductor industry applies an amorphous Nickel-tantalum (NiTa) thin film on disc substrate through sputtering deposition process of a crystalline alloy target. The current Hard Disc storage drive has a layer of amorphous NiTa thin film between the magnetic soft underlayer and the disc substrate. Traditionally, target manufacturers employ a hot-pressing process followed by a hot isostatic press process to form alloy powder (with <25-micrometre size) into a uniform, dense, and crystalline alloy structure. However, the HIP treatment is sophisticated and tends to deform parts resulting in significant costs and material loss. This study investigates a concept of combining an optimized selected laser melting process parameter and a vacuum heat treatment process as an alternative process. The concept aims to reduce cost and to enhance the microstructure of alloy Target. As-printed and post-vacuum heat treated alloy samples will be characterized under optical microscopy and scanning electron microscopy for comparative analysis.