Development of a Low Coefficient of Thermal Expansion Composite Tooling via 3D Printing

2018 ◽  
Author(s):  
Michael Maravola ◽  
Pedro Cortes ◽  
Michael Juhasz ◽  
Douglas Rutana ◽  
Bridger Kowalczyk ◽  
...  
Keyword(s):  
Thermal Expansion ◽  
3D Printing ◽  
Coefficient Of Thermal Expansion ◽  
Low Cost ◽  
Ceramic Materials ◽  
Silica Sand ◽  
Direct Energy ◽  
Carbon Fiber Reinforced Composites ◽  
Unique Approach ◽  
Composite Tooling

The use of additive manufacturing (AM) provides an opportunity to fabricate composite tooling rapidly and cost effectively. This project appears to have demonstrated the use of an additive technology for the production of composite processing tools. In particular, this work has addressed tooling that is functional in the range of autoclave temperatures around 300–350°F. This has led to the use of Invar and ceramic materials for use in composite molding tools because of their relatively low coefficient of thermal expansion (CTE) performance, which is in range to that commonly displayed by carbon fiber reinforced composites during their solidifying-curing process. In this project, two main approaches have been considered. The first approach consisted on using binder jetting for 3D printing sand molds to cast molten Invar to produce the composite tooling. Indeed, 3D sand printing offers the ability to cast complex geometries without the geometric limitations associated with conventional pattern making. The second innovative approach was based on printing a mold based on silica sand and infiltrating it with a polymer to yield a robust ceramic composite tooling. An additional technology using a Hybrid Direct Energy Deposition (DED) System for cladding Invar upon a steel molding structure has also been considered for producing potential composite tooling. Indeed, this unique approach could represent a promising technology for producing low cost composite tooling since only a small layer of Invar would be printed upon a non-expensive substrate. The results have shown that the aforementioned processes have successfully resulted on low CTE composite tooling molds. This work presents innovative AM processes by initially investigating 3D ceramic systems for composite tooling.

scholarly journals The Use of Recycled Carpet in Low-Cost Composite Tooling Materials

Recycling ◽  
2019 ◽  
Vol 4 (1) ◽  
pp. 12 ◽  
Author(s):  
Kunal Mishra ◽  
Sarat Das ◽  
Ranji Vaidyanathan
Keyword(s):  
Mechanical Properties ◽  
Thermal Expansion ◽  
Material Properties ◽  
Coefficient Of Thermal Expansion ◽  
Low Cost ◽  
Value Engineering ◽  
Compressive Properties ◽  
Structural Composites ◽  
Environmental Deterioration ◽  
Composite Tooling

More than 250,000 metric tons (600 million pounds) of carpet are dumped in landfills every year. That creates a significant concern regarding environmental deterioration and economic liability. It is therefore imperative to develop sustainable post-consumer carpet-based products for high-value engineering applications such as composite tooling. To be considered as an acceptable composite tooling material, the composite needs to meet certain required properties such as a low coefficient of thermal expansion, excellent compressive properties, and high a hardness value after repeated exposure to curing cycles. The tooling composites must also exhibit the ability to endure several curing cycles, without deteriorating the mechanical properties. In the present investigation, post-consumer carpet has been recycled in the form of structural composites for tooling applications. The recycled carpet composites have been reinforced with 0.5 wt.% of graphene nanoplatelets to modify the material properties of the carpet composites. The results from compressive and hardness experiments demonstrate that the recycled carpet preserved its mechanical integrity even after several curing cycles. This indicates that recycled carpet composites have the potential to be a low-cost composite tooling alternative for the industry.

Production of Low Coefficient of Thermal Expansion Composite Tooling Manufactured Via 3D Printing

2019 ◽  
Author(s):  
Pedro Cortes ◽  
Michael Maravola ◽  
Brett Conner ◽  
Stephen Szaruga ◽  
Brian Hetzel ◽  
...  
Keyword(s):  
Thermal Expansion ◽  
3D Printing ◽  
Coefficient Of Thermal Expansion ◽  
Composite Tooling

scholarly journals Sintering Behavior, Thermal Expansion, and Environmental Impacts Accompanying Materials of the Al2O3/ZrO2 System Fabricated via Slip Casting

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3365
Author(s):  
Justyna Zygmuntowicz ◽  
Magdalena Gizowska ◽  
Justyna Tomaszewska ◽  
Paulina Piotrkiewicz ◽  
Radosław Żurowski ◽  
...  
Keyword(s):  
Thermal Expansion ◽  
Life Cycle ◽  
Coefficient Of Thermal Expansion ◽  
Raw Materials ◽  
Slip Casting ◽  
Ceramic Materials ◽  
Sintering Behavior ◽  
Environmental Loads ◽  
Practical Applications ◽  
Technical Ceramics

This work focuses on research on obtaining and characterizing Al2O3/ZrO2 materials formed via slip casting method. The main emphasis in the research was placed on environmental aspects and those related to the practical use of ceramic materials. The goal was to analyze the environmental loads associated with the manufacturing of Al2O3/ZrO2 composites, as well as to determine the coefficient of thermal expansion of the obtained materials, classified as technical ceramics. This parameter is crucial in terms of their practical applications in high-temperature working conditions, e.g., as parts of industrial machines. The study reports on the four series of Al2O3/ZrO2 materials differing in the volume content of ZrO2. The sintering process was preceded by thermogravimetric measurements. The fabricated and sintered materials were characterized by dilatometric study, scanning electron microscopy, X-ray diffraction, and stereological analysis. Further, life cycle assessment was supplied. Based on dilatometric tests, it was observed that Al2O3/ZrO2 composites show a higher coefficient of thermal expansion than that resulting from the content of individual phases. The results of the life cycle analysis showed that the environmental loads (carbon footprint) resulting from the acquisition and processing of raw materials necessary for the production of sinters from Al2O3 and ZrO2 are comparable to those associated with the production of plastic products such as polypropylene or polyvinyl chloride.

scholarly journals Unusually Small Thermal Expansion of Ordered Perovskite Oxide CaCu3Ru4O12 with High Conductivity

Materials ◽  
2018 ◽  
Vol 11 (9) ◽  
pp. 1650 ◽  
Author(s):  
Akihiro Tsuruta ◽  
Katsuhiro Nomura ◽  
Masashi Mikami ◽  
Yoshiaki Kinemuchi ◽  
Ichiro Terasaki ◽  
...  
Keyword(s):  
Thermal Expansion ◽  
Coefficient Of Thermal Expansion ◽  
Ceramic Materials ◽  
Vital Role ◽  
Perovskite Oxide ◽  
Conducting Composite ◽  
Conducting Oxides ◽  
Jahn Teller ◽  
Jahn Teller Effect ◽  
A Site

We measured the coefficient of thermal expansion (CTE) of conducting composite ceramics 30 vol.% CuO-mixed CaCu3Ru4O12 together with CaCu3Ru4O12 and CuO. Although conducting ceramics tend to show higher CTE values than insulators, and its CTE value does not match with other ceramic materials, the CTE of CaCu3Ru4O12 (7–9 × 10−6/K) was as small as those of insulators such as CuO (9 × 10−6/K), alumina (8 × 10−6/K), and other insulating perovskite oxides. We propose that the thermal expansion of CaCu3Ru4O12 was suppressed by the Cu-O bond at the A-site due to the Jahn–Teller effect. This unusually small CTE of CaCu3Ru4O12 compared to other conducting oxides plays a vital role enabling successful coating of 30 vol.% CuO-mixed CaCu3Ru4O12 thick films on alumina substrates, as demonstrated in our previous study.

scholarly journals 3D printing of CF/nylon composite mold for CF/epoxy parabolic antenna

2020 ◽  
Vol 15 ◽  
pp. 155892502096948
Author(s):  
Yi Chen ◽  
Jiang Lu ◽  
Qing Guo ◽  
Lei Wan
Keyword(s):  
3D Printing ◽  
Satellite Communication ◽  
Coefficient Of Thermal Expansion ◽  
Low Cost ◽  
High Gain ◽  
High Profile ◽  
Parabolic Antenna ◽  
3D Printed ◽  
Point To Point ◽  
Nylon Composite

Parabolic antennas, which are wildly used as high-gain antennas for point-to-point communications, need many iterations of design-fabrication-test in parabolic antenna development. However, traditional molding via mechanical processing takes a long manufacturing cycle and high cost. In this paper, a 3D-printed CF/nylon composite parabolic mold for CF/epoxy parabolic antenna is studied. It’s found that the coefficient of thermal expansion (CTE) of 3D-printed CF/nylon composite is usually anisotropic due to the low adhesion between printed layers and the aligned short carbon fiber along the printing trace. Here an inclined mode of 3D printing could uniform the CTE of the antenna mold and solve the problems of large printing steps and the separation of supports and mold occurred in horizontal and vertical modes, respectively. The parabolic mold also reveals high profile precision with a low root mean square (RMS) deviation of 0.14 mm. Utilizing the 3D-printed CF/nylon composite mold, parabolic antenna skin with low surface RMS deviation of 0.16 mm was successfully fabricated by laying CF/epoxy prepreg and curing in autoclave. This research about isotropic and smooth 3D-printed CF/nylon mold may support the low-cost and rapid mold development for microwaves relay links on ground and satellite communication antennas.

scholarly journals Packaged For The Road

2001 ◽  
Vol 123 (07) ◽  
pp. 56-59 ◽  
Author(s):  
Robert R. Irving
Keyword(s):  
Thermal Expansion ◽  
Coefficient Of Thermal Expansion ◽  
Low Cost ◽  
Pyrolytic Graphite ◽  
Iron Alloy ◽  
The Road ◽  
Nickel Cobalt ◽  
Cobalt Iron ◽  
Materials Used ◽  
Carbide Content

This article discusses use of metal matrix composite materials in electronic packaging. Composites can have higher thermal conductivity than traditional materials, low thermal stress, and tailorable coefficients of thermal expansion. They can reduce weight by as much as 80% and size by as much as 65%. They can also be used in low-cost, net-shape fabrication processes. The silicon carbide content can be adjusted to differing percentages to vary the composite's coefficient of thermal expansion. Traditional microelectronic packaging materials used to achieve low coefficients of thermal expansion include blends of copper and tungsten or of copper and molybdenum, and a nickel–cobalt–iron alloy called Kovar, a trademark owned by CRS Holdings Inc., a subsidiary of Carpenter Technology Corp. of Wyomissing, Pennsylvania. A key firm involved in promoting pyrolytic graphite in packaging is Advanced Ceramics Corp. of Cleveland. An expert predicts that, in the future, many of these materials will also be used in the optoelectronics industry. This will be a new market for the materials, but one with enormous potential.

Redesign of an innovative new extrusion system for a printing machine for ceramics

2021 ◽  
Author(s):  
Jihad EL Mesbahi ◽  
Irene Buj Corral ◽  
Abdelilah EL Mesbahi
Keyword(s):  
3D Printing ◽  
Mechanical Design ◽  
Low Cost ◽  
Ceramic Materials ◽  
Physicochemical Characteristics ◽  
Performance Criteria ◽  
Free Form ◽  
Direct Ink Writing ◽  
3D Printers ◽  
Printing Machine

Abstract Today, the introduction of ceramic materials in the medical field is becoming a vital necessity because of its stable physicochemical characteristics, high biocompatibility, and good osteoconductivity. On the other hand, machining of ceramic components is difficult, owing to their extreme hardness and brittleness. Additive Manufacturing (AM) technologies are an appropriate alternative to obtain the complex shapes of implants, which can have porous structures. Thus, since the development of 3D printing, Direct Ink Writing (DIW) is one of the most promising and inexpensive techniques for shaping free-form ceramic medical components such as prostheses or dental implants from liquids or pastes. However, the assurance of performance criteria of the extrusion system for simultaneous usage becomes the major challenge for most Direct Ink Writing (DIW) platforms, for instance for printing large parts, for multi-material printing, to decrease printing time, and to increase efficiency in terms of motor usage and weight of the extruders. To address the current deficiencies, a new extrusion system is redesigned for a 3D printing machine for ceramics that is compatible with different low-cost, open-source 3D printers. The proposed extrusion model enables printing with a loader with different syringes simultaneously, without stopping the operational process while switching the syringe. Pugh concept analysis was used to select the optimum design shape. After that, the 3D CAD environment was used to combine the strength of Pugh’s method and the design space. This brings a new concept into the mechanical design field for 3D printers, which is in line with the technological trends prevalent in industry.

Effect of elevated temperatures and applied pressure on the tribological properties of LM30/sillimanite aluminium alloy composites

2018 ◽  
Vol 53 (11) ◽  
pp. 1521-1539 ◽  
Author(s):  
Sandeep Sharma ◽  
Tarun Nanda ◽  
OP Pandey
Keyword(s):  
Thermal Expansion ◽  
Cast Iron ◽  
Elevated Temperatures ◽  
Coefficient Of Thermal Expansion ◽  
Operating Temperature ◽  
Low Cost ◽  
Applied Pressure ◽  
Reinforcement Particle ◽  
Aluminum Matrix Composites ◽  
Brake Rotor

The present study focuses on the development of low-cost, lightweight and highly wear resistant composites for brake rotor applications. Sillimanite mineral reinforced aluminum matrix composites were stir cast using three distinct reinforcement particle sizes. Reinforcement level was varied in the range of 3–15 wt%. The influence of operating temperature (50℃–300℃) and applied pressure (0.2–1.0 MPa) on the wear/friction behaviour of composites was observed. Optical micrographs showed homogenous particle distribution throughout the matrix. The high nanohardness obtained for interface regions signifies good particle–matrix bonding of processed composites. Dilatometry studies showed that the increase in sillimanite content decreased the coefficient of thermal expansion of the composites. Maximum improvement of 33% in coefficient of thermal expansion (over base alloy) was observed for 15 wt% fine composites. Wear analysis revealed that the developed composites provided adequate wear resistance till an operating temperature of 200℃, beyond which wear rate increased significantly. For the high operating temperature of 200℃, the steady-state wear of composites was comparable (only 6.62% higher) to the commercial cast iron alloy used in brake rotor applications. The aluminium-based composites developed in the present research are low cost (sillimanite is a naturally occurring mineral sand) and lightweight (60% lighter than cast iron) and can be used as an alternate material for brake rotors in light vehicles. Finally, SEM of worn out surfaces divulged the dominance of adhesive wear for material removal.

NILO ALLOY 36

Alloy Digest ◽  
1987 ◽  
Vol 36 (8) ◽  
Keyword(s):  
Thermal Expansion ◽  
Corrosion Resistance ◽  
High Temperature ◽  
Physical Properties ◽  
Surface Treatment ◽  
Constant Coefficient ◽  
Coefficient Of Thermal Expansion ◽  
Heat Treating ◽  
Temperature Performance ◽  
Iron Nickel

Abstract NILO alloy 36 is a binary iron-nickel alloy having a very low and essentially constant coefficient of thermal expansion at atmospheric temperatures. This datasheet provides information on composition, physical properties, elasticity, and tensile properties. It also includes information on high temperature performance and corrosion resistance as well as forming, heat treating, machining, joining, and surface treatment. Filing Code: Fe-79. Producer or source: Inco Alloys International Inc..

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