scholarly journals Challenges and Opportunities for Integrating Dealloying Methods into Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3706
Author(s):  
A. Chuang ◽  
J. Erlebacher
Keyword(s):  
Material Processing ◽  
Additive Manufacturing ◽  
Composite Materials ◽  
Material Properties ◽  
Functional Materials ◽  
Challenges And Opportunities ◽  
Integral Role ◽  
Nanoporous Metals ◽  
Processing Techniques ◽  
Nanoscale Features

The physical architecture of materials plays an integral role in determining material properties and functionality. While many processing techniques now exist for fabricating parts of any shape or size, a couple of techniques have emerged as facile and effective methods for creating unique structures: dealloying and additive manufacturing. This review discusses progress and challenges in the integration of dealloying techniques with the additive manufacturing (AM) platform to take advantage of the material processing capabilities established by each field. These methods are uniquely complementary: not only can we use AM to make nanoporous metals of complex, customized shapes—for instance, with applications in biomedical implants and microfluidics—but dealloying can occur simultaneously during AM to produce unique composite materials with nanoscale features of two interpenetrating phases. We discuss the experimental challenges of implementing these processing methods and how future efforts could be directed to address these difficulties. Our premise is that combining these synergistic techniques offers both new avenues for creating 3D functional materials and new functional materials that cannot be synthesized any other way. Dealloying and AM will continue to grow both independently and together as the materials community realizes the potential of this compelling combination.

Additive Manufacturing (AM)

2022 ◽  
pp. 27-48
Author(s):  
Kamardeen Olajide Abdulrahman ◽  
Rasheedat Modupe Mahamood ◽  
Esther T. Akinlabi
Keyword(s):  
Material Processing ◽  
Additive Manufacturing ◽  
Material Properties ◽  
Titanium Aluminide ◽  
High Performance ◽  
Industrial Revolution ◽  
Weight Ratio ◽  
Microstructural Development ◽  
Structural Applications ◽  
Lightweight Metals

The need for less weight and high-performance materials in manufacturing industries has continuously led to the development of lightweight materials through the use of advanced additive manufacturing (AM). The race of lightweight and high-performance metals continue to evolve as this continuously provides better understanding about connection existing between material processing, microstructural development, and material properties. AM technique is an interesting manufacturing process that is employed in production of engineering components with improved properties. The choice of titanium and its alloys in structural applications are attributed to their superior strength-to-weight ratio and high corrosion resistance. This chapter looked at different additive manufacturing (AM) techniques developed for the processing of lightweight metals, their strengths, and limitations. The chapter also looked at the role and contribution of AM to the 4th industrial revolution, processing, and application of titanium aluminide for high temperature applications.

scholarly journals Unconventional Materials Processing Using Spark Plasma Sintering

Ceramics ◽  
2021 ◽  
Vol 4 (1) ◽  
pp. 20-40
Author(s):  
Ambreen Nisar ◽  
Cheng Zhang ◽  
Benjamin Boesl ◽  
Arvind Agarwal
Keyword(s):  
Spark Plasma Sintering ◽  
Real Life ◽  
Functional Materials ◽  
Research Field ◽  
Advanced Materials ◽  
Plasma Sintering ◽  
Challenges And Opportunities ◽  
Future Challenges ◽  
Gas Quenching ◽  
Spark Plasma

Spark plasma sintering (SPS) has gained recognition in the last 20 years for its rapid densification of hard-to-sinter conventional and advanced materials, including metals, ceramics, polymers, and composites. Herein, we describe the unconventional usages of the SPS technique developed in the field. The potential of various new modifications in the SPS technique, from pressureless to the integration of a novel gas quenching system to extrusion, has led to SPS’ evolution into a completely new manufacturing tool. The SPS technique’s modifications have broadened its usability from merely a densification tool to the fabrication of complex-shaped components, advanced functional materials, functionally gradient materials, interconnected materials, and porous filter materials for real-life applications. The broader application achieved by modification of the SPS technique can provide an alternative to conventional powder metallurgy methods as a scalable manufacturing process. The future challenges and opportunities in this emerging research field have also been identified and presented.

scholarly journals Improving surface quality in selective laser melting based tool making

2021 ◽  
Author(s):  
Filippo Simoni ◽  
Andrea Huxol ◽  
Franz-Josef Villmer
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Melting Process ◽  
Laser Remelting ◽  
Laser Melting ◽  
Great Cost ◽  
Starting Point ◽  
Processing Techniques

AbstractIn the last years, Additive Manufacturing, thanks to its capability of continuous improvements in performance and cost-efficiency, was able to partly replace and redefine well-established manufacturing processes. This research is based on the idea to achieve great cost and operational benefits especially in the field of tool making for injection molding by combining traditional and additive manufacturing in one process chain. Special attention is given to the surface quality in terms of surface roughness and its optimization directly in the Selective Laser Melting process. This article presents the possibility for a remelting process of the SLM parts as a way to optimize the surfaces of the produced parts. The influence of laser remelting on the surface roughness of the parts is analyzed while varying machine parameters like laser power and scan settings. Laser remelting with optimized parameter settings considerably improves the surface quality of SLM parts and is a great starting point for further post-processing techniques, which require a low initial value of surface roughness.

scholarly journals 3D Plotting of Silica/Collagen Xerogel Granules in an Alginate Matrix for Tissue-Engineered Bone Implants

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 830
Author(s):  
Sina Rößler ◽  
Andreas Brückner ◽  
Iris Kruppke ◽  
Hans-Peter Wiesmann ◽  
Thomas Hanke ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Bone Regeneration ◽  
Material Properties ◽  
Viscoelastic Properties ◽  
Viscoelastic Behavior ◽  
Matrix Phase ◽  
Patient Specific ◽  
Active Player ◽  
Alginate Concentration ◽  
Alginate Matrix

Today, materials designed for bone regeneration are requested to be degradable and resorbable, bioactive, porous, and osteoconductive, as well as to be an active player in the bone-remodeling process. Multiphasic silica/collagen Xerogels were shown, earlier, to meet these requirements. The aim of the present study was to use these excellent material properties of silica/collagen Xerogels and to process them by additive manufacturing, in this case 3D plotting, to generate implants matching patient specific shapes of fractures or lesions. The concept is to have Xerogel granules as active major components embedded, to a large proportion, in a matrix that binds the granules in the scaffold. By using viscoelastic alginate as matrix, pastes of Xerogel granules were processed via 3D plotting. Moreover, alginate concentration was shown to be the key to a high content of irregularly shaped Xerogel granules embedded in a minimum of matrix phase. Both the alginate matrix and Xerogel granules were also shown to influence viscoelastic behavior of the paste, as well as the dimensionally stability of the scaffolds. In conclusion, 3D plotting of Xerogel granules was successfully established by using viscoelastic properties of alginate as matrix phase.

scholarly journals Multiscale additive manufacturing of polymers using 3D photo-printable self-assembling ionic liquid monomers

2019 ◽  
Vol 4 (3) ◽  
pp. 580-585 ◽  
Author(s):  
Bineh G. Ndefru ◽  
Bryan S. Ringstrand ◽  
Sokhna I.-Y. Diouf ◽  
Sönke Seifert ◽  
Juan H. Leal ◽  
...  
Keyword(s):  
Ionic Liquid ◽  
Additive Manufacturing ◽  
Self Assembly ◽  
Low Cost ◽  
Low Resolution ◽  
Top Down ◽  
Bottom Up ◽  
Cost Approach ◽  
Self Assembling ◽  
Nanoscale Features

Combining bottom-up self-assembly with top-down 3D photoprinting affords a low cost approach for the introduction of nanoscale features into a build with low resolution features.

scholarly journals Mechanics of the small punch test: a review and qualification of additive manufacturing materials

2021 ◽  
Vol 56 (18) ◽  
pp. 10707-10744
Author(s):  
Jonathan Torres ◽  
Ali P. Gordon
Keyword(s):  
Additive Manufacturing ◽  
Material Properties ◽  
Materials Science ◽  
Contemporary Literature ◽  
The Body ◽  
Small Punch Test ◽  
Small Punch ◽  
Punch Test ◽  
Testing Data ◽  
The Relationship

AbstractThe small punch test (SPT) was developed for situations where source material is scarce, costly or otherwise difficult to acquire, and has been used for assessing components with variable, location-dependent material properties. Although lacking standardization, the SPT has been employed to assess material properties and verified using traditional testing. Several methods exist for equating SPT results with traditional stress–strain data. There are, however, areas of weakness, such as fracture and fatigue approaches. This document outlines the history and methodologies of SPT, reviewing the body of contemporary literature and presenting relevant findings and formulations for correlating SPT results with conventional tests. Analysis of literature is extended to evaluating the suitability of the SPT for use with additively manufactured (AM) materials. The suitability of this approach is shown through a parametric study using an approximation of the SPT via FEA, varying material properties as would be seen with varying AM process parameters. Equations describing the relationship between SPT results and conventional testing data are presented. Correlation constants dictating these relationships are determined using an accumulation of data from the literature reviewed here, along with novel experimental data. This includes AM materials to assess the fit of these and provide context for a wider view of the methodology and its interest to materials science and additive manufacturing. A case is made for the continued development of the small punch test, identifying strengths and knowledge gaps, showing need for standardization of this simple yet highly versatile method for expediting studies of material properties and optimization.

Design and Analysis of Hybrid Fused Filament Fabrication Apparatus for Fabrication of Composites

2021 ◽  
Vol 14 ◽  
Author(s):  
Aniket Yadav ◽  
Piyush Chohan ◽  
Ranvijay Kumar ◽  
Jasgurpreet Singh Chohan ◽  
Raman Kumar
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Design Process ◽  
Low Cost ◽  
Matrix Material ◽  
Fabrication Process ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Composite Manufacturing ◽  
Tool Paths

Background: Additive manufacturing is the most famous technology which requires materials or composites to be fabricated with layer by layer deposition strategy. Due to its lower cost, higher accuracy and less material wastage; this technology is used in almost every sector. But in many applications there is a need to alter the properties of a product in a certain direction with the help of some reinforcements. With the use of reinforcements, composite layers can be fabricated using additive manufacturing technique which will enhance the directional properties. A novel apparatus is designed to spray the reinforcement material into the printed structures in a very neat and precise manner. This spray nozzle is fully automated, which works according to tool-paths generated by slicing software. The alternate deposition of layers of reinforcement and build materials helped to fabricate customized composite products. Objective: The objective of present study is to design and analyze the working principle of novel technique which has been developed to fabricate composite materials using additive manufacturing. The apparatus is numerically controlled by computer according to CAD data which facilitates the deposition of alternate layers of reinforcement and matrix material. The major challenges during the design process and function of each component has been explored. Methods: The design process is initiated after comprehensive literature review performed to study previous composite manufacturing processes. The recent patents published by different patent offices of the world are studied in detail and analysis has been used to design a low cost composite fabrication apparatus. A liquid dispensing device comprises a storage tank attached with a pump and microprocessor. The microprocessor receives the signal from the computer as per tool paths generated by slicing software which decides the spray of reinforcements on polymer layers. The spraying apparatus moves in coordination with the primary nozzle of the Fused Filament Fabrication process. Results: The hybridization of Fused Filament Fabrication [process with metal spray process has been successfully performed. The apparatus facilitates the fabrication of low cost composite materials along with flexibility of complete customization of composite manufacturing process. The anisotropic behaviour of products can be easily controlled and managed during fabrication which can be used for different applications.

The Elastic Characterization of Composite Based on Ultrasonic Waves

2021 ◽  
Author(s):  
Y. H. Park ◽  
J. Dana
Keyword(s):  
Composite Materials ◽  
Fatigue Failure ◽  
Elastic Constants ◽  
Material Properties ◽  
Weight Ratio ◽  
Transversely Isotropic ◽  
Ultrasonic Waves ◽  
Material Strength ◽  
Isotropic Composite

Abstract Anisotropic composite materials have been extensively utilized in mechanical, automotive, aerospace and other engineering areas due to high strength-to-weight ratio, superb corrosion resistance, and exceptional thermal performance. As the use of composite materials increases, determination of material properties, mechanical analysis and failure of the structure become important for the design of composite structure. In particular, the fatigue failure is important to ensure that structures can survive in harsh environmental conditions. Despite technical advances, fatigue failure and the monitoring and prediction of component life remain major problems. In general, cyclic loadings cause the accumulation of micro-damage in the structure and material properties degrade as the number of loading cycles increases. Repeated subfailure loading cycles cause eventual fatigue failure as the material strength and stiffness fall below the applied stress level. Hence, the stiffness degradation measurement can be a good indication for damage evaluation. The elastic characterization of composite material using mechanical testing, however, is complex, destructive, and not all the elastic constants can be determined. In this work, an in-situ method to non-destructively determine the elastic constants will be studied based on the time of flight measurement of ultrasonic waves. This method will be validated on an isotropic metal sheet and a transversely isotropic composite plate.

A Review on Non-Asbestos Friction Materials: Material Composition and Manufacturing

2018 ◽  
Vol 1150 ◽  
pp. 22-42
Author(s):  
Dinesh Shinde ◽  
Kishore N. Mistry ◽  
Suyog Jhavar ◽  
Sunil Pathak
Keyword(s):  
Composite Materials ◽  
Material Properties ◽  
Single Phase ◽  
Friction Material ◽  
Material Surface ◽  
Surface Wear ◽  
Friction Modifier ◽  
Friction Materials ◽  
Morphological Studies ◽  
The Impact

The peculiar feature of friction materials to absorb the kinetic energy of rotating wheels of an automobile to control the speed makes them remarkable in automobile field. The regulation of speed cannot be achieved with the use of single phase material as a friction material. Consequently, the friction material should be comprised of composite materials which consist of several ingredients. Incidentally, the friction materials were formulated with friction modifier, binders, fillers and reinforcements. Due to its pleasant physical properties, asbestos was being used as a filler. Past few decades, it is found that asbestos causes dangerous cancer to its inhaler, which provides a scope its replacement. Several attempts have been made to find an alternative to the hazardous asbestos. The efforts made by different researchers for the impact of every composition of composite friction material in the field are reviewed and studied for their effect on the properties of friction material. Surface morphological studies of different friction material are compared to interpret the concept of surface wear and its correlation with material properties.

Sign in / Sign up

Export Citation Format

Share Document