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At least 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Effect of surface treatment of microfiberlated cellulose fibers on biocomposite properties and additive manufacturing process

Polymer additive manufacturing (AM) is a rapidly growing technology and it is transitioning to become an advanced manufacturing technique with the introduction of fiberlar reinforcing materials such as carbon and glass fibers into polymer feedstock. As a result of increasing environmental and long-term sustainability concerns, there is an increasing interest in using bio-derived cellulose fibers to reinforce composites instead of carbon and glass fibers. Melt extrusion/fused filament fabrication method is the most commonly used polymer AM technique which enables direct digital manufacturing of parts with complex geometry with a controlled anisotropic distribution of reinforcing phase. However, there are multiple factors that affect the mechanical performance of the final part such as the dispersion and orientation of the reinforcing fibers, the adhesion between the fibers and the polymer matrix, and the porosity/defects present in the part. Chemical modification of the surface of the reinforcing fibers is an effective way of improving the fiber-polymer interaction. Furthermore, the improved adhesion between the fibers and the polymer can also enhance the fiber dispersion, improve the rheological behavior of the molten feedstock and minimize the formation of porosity during the printing process, which is one of the major issues in AM. In this study, we are investigating the effect of silane surface treatment of micro-cellulose fibers on the thermal, rheological and mechanical properties of cellulose-PLA biocomposites and on the 3D-printing process. X-ray photoelectron spectroscopy results confirmed the increase in amine and silane groups on the surface of modified fibers, indicating successful functionalization. Thermal and mechanical characterization of modified fiber-PLA composites showed significant increases in storage modulus, glass transition temperature, and complex viscosity compared to neat PLA.

Tekinalp, Halil↗
DOE OSTI2023

Grayscale Digital Light Processing Gradient Printing for Stress Concentration Reduction and Material Toughness Enhancement

Avoiding stress concentrations is essential to achieve robust parts since failure tends to originate at such concentrations. With recent advances in multimaterial additive manufacturing, it is possible to alter the stress (or strain) distribution by adjusting the material properties in selected locations. Here, we investigate the use of grayscale digital light processing (g-DLP) 3D printing to create modulus gradients around areas of high stress. These gradients prevent failure by redistributing high stresses (or strains) to the neighboring material. The improved material distributions are calculated using finite element analysis. The much-enhanced properties are demonstrated experimentally for thin plates with circular, triangular, and elliptical holes. In conclusion, this work suggests that multimaterial additive manufacturing techniques like g-DLP printing provide a unique opportunity to create tougher engineering materials and parts.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Low-Cost, Efficient and Durable High Temperature Wireless Sensors by Direct Write Additive Manufacturing for Application in Fossil Energy Systems

In-situ monitoring of physical parameters in fossil energy (FE) systems is challenging because of their high operating temperatures and oxidizing environments. This research aims utilize Aerosol Jet (AJ) nanoparticle printing, an advanced additive manufacturing method, to fabricate high temperature sensors for FE applications. Sensor films were fabricated by the AJ printing method with an excellent control over film microstructure and properties, in addition to creating less waste. Printing of six different materials, namely, silver (Ag), nickel (Ni), nickel-chromium (NiCr) alloy, copper (Cu), copper-nickel (CuNi), and carbon nanotubes (CNTs) was carried out for their evaluation of as sensor films. The films were then characterized using impedance spectroscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM), x-ray diffraction (XRD), and x-ray photoelectron spectroscopy (XPS). Film microstructure was correlated with the sensor electrical and mechanical behavior at different temperatures (24-500 °C) and frequencies (0.02 - 300 kHz). This knowledge was then used to fabricate, test, and characterize strain and temperature sensors for high temperature applications. The strain sensors were shown to have a very low thermal strain up to 500 °C and a 57% higher gauge factor compared to the commercially available counterparts. This enhance performance was attributed to the inherent porosity in the sensor films that allowed the films to exhibit a metamaterial-like behavior when deformed. The AJ printed temperature sensors were shown to have the highest Seebeck coefficient amongst all the film-based temperature sensors. In addition, fundamental aspects of crystal structure and phase transformations in Ba(Fe0.7Ta0.3)O3-δ (BFTO), a high temperature sensor material, was investigated along with 3D printed antennas that can transmit sensor signals at high temperatures. Two PhD students, one from first generation college-going underrepresented minority community (URM), two postdoctoral fellows, and several masters and undergraduate students were supported by this award. This work opens up the possibility of realizing low-cost high-performance sensor devices using advanced manufacturing techniques for high temperature FE applications.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

SiC Receiver/Reactor by Additive Manufacturing for Concentrated Solar Thermocatalysis with Thermal Energy Storage (Final Technical Report - Public)

The direct use of solar thermal energy provides opportunities for low-cost heating sources for a variety of applications. Ultra-high temperatures around 1000°C are high value and highly useful for energy-demanding industries. Many materials cannot withstand these conditions. In the area of Sustainable Chemicals, further limitations on material stability exist. Combining state-of-the-art materials with new designs provides a promising pathway for harvesting solar thermal energy and performing high temperature chemical processes. However, conventional manufacturing limits the potential for design flexibility. In this project, Additive Manufacturing was combined with advanced materials and new chemical reactor designs. In addition, 24/7 energy is necessary for chemical processing, and designs for ultra-high temperature thermal storage were devised. Specifically, preliminary design of a novel solar thermal receiver was developed in this project and designed to work with thermocatalytic reactors for producing sustainable chemicals and fuels. An ultra-high temperature particle storage system and heat exchangers were proposed to transport ultra-hot air as thermal fluid for the system. On a broader scale, this system could be used to tap solar thermal energy for a centralized facility with capability of transferring that heat to various segments at a full range of temperatures to 1000°C. The project pushed the temperature boundaries past those in current use, and Additive Manufacturing was envisaged for fabricating the receiver to meet requirements of extreme environments. An extensive analysis of silicon carbide additive manufacturing was performed to compare the thermal and mechanical properties of complex geometries compared to conventional material and those manufactured via other methods. The Additive Manufacturing via Binder-Jet printing was optimized and characterized to provide high quality and reproducible components capable of withstanding the proposed extreme environments. The designs for the concentrating solar thermal cavity with ultra-hot air thermal fluid showed high performance in simulations, attributable to the complex optimized geometries of the 3D printed systems. The bright future of Additive Manufacturing with advanced materials developments should provide more options and even higher quality as the technology further develops. Current costs for Additive Manufacturing of advanced ceramics is relatively low, however post-processing of the materials for extreme environments is currently high. There is little industrial-scale infrastructure for these, but it is growing as niche applications become more mainstream. The results of the project can be translated into similar extreme environments for concentrating solar thermal energy as well as its integration with ultra-hot air thermal fluids. A number of industries that require ultra-high temperatures need to electrify or otherwise decarbonize for climate goals, and this project showed that theoretically there is a pathway to do so with direct concentrated solar thermal power.

10 SYNTHETIC FUELS↗
DOE OSTI2024

AOI [1] Advanced Manufacturing of Ceramic Anchors with Embedded Sensors for Process and Health Monitoring of Coal Boilers

Researchers at West Virginia University (WVU) developed methods to fabricate and test ceramic anchors with an embedded sensor technology for monitoring the health and processing conditions within pulverized coal (PC) and fluidized-bed combustion (FBC) boiler systems. The technology included the development of advanced manufacturing processes for 2D/3D printing electroceramic (conductive ceramic) sensor designs within the ceramic anchor microstructure during the manufacturing process. This advanced manufacturing process would allow for the precise control of local microstructure and composition in order to engineer layer-by-layer any protective and electrically active materials within the refractory anchor. This 3D printing technology would permit the rapid and controlled design of the refractory microstructure and embedded sensor design throughout the volume of the ceramic anchor. The work also included a method to interconnect the sensors to boiler shell through the anchor clamp, where the sensor signals will be processed by low-power electronics and transmitted wirelessly to a central processing hub. The end-goal of the program was to produce a ceramic anchor sensor system which would be ready for implementation within a coal boiler, and/or other similar refractory liner systems (such as that in the glass and metal manufacturing areas). The project objectives were to: 1) Define the chemical and microstructural stability, in addition to the electrical properties, of oxide and non-oxide ceramic composites to be embedded within the ceramic anchor compositions that may operate up to 1400ºC; 2) Develop and implement the 2D/3D printing technology to pattern and control the microstructure of the ceramic anchor and embedded sensor circuits; 3) Develop an interconnect technology which will permit easy installation of the ceramic anchors and signal collection at the boiler shell; 4) Develop low power analog electronics and wireless communication hardware to efficiently collect the sensor signal at each processing unit and transmit data to a central hub for data analysis; 5) Demonstrate the smart ceramic anchor system for temperature and liner fracture within a high-temperature processing unit, such as a boiler furnace or glass melting furnace floor/wall liner.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

In-situ magnetic alignment model for additive manufacturing of anisotropic bonded magnets

In this work, we report a mathematical framework which predicts the degree of alignment (DoA) in an in-situ aligned additively manufactured 3D printed bonded magnets. A multiphysics model is developed which couples the harmonious interactions of magnetic particles in a viscous flowing polymer under the presence of an external magnetic field. The hydrodynamic fluid-particle interaction is paired with the magnetophoretic force to predict the particle trajectory and distribution during extrusion through a 3D printer nozzle. Succeeding the force balance, a magnetohydrodynamic torque equilibrium analysis is performed to predict the net-orientation of the magnetic particles as a function of the applied field strength, viscous forces, and particle-to-particle interactions (P2P). Experimental validation of the DoA predictions is performed using 65 vol% Nd-Fe-B+Sm-Fe-N in Nylon12 (DoA exp = 0.620 and DoA theory = 0.686) and 15 vol% Sm-Co in PLA (DoA exp = 0.830 and DoA theory = 0.863). A parametric analysis is performed to analyze the effect of operating and design parameters like alignment field strength, magnetic loading fraction, extrusion load, and particle size. The model predicts a competing behavior between particle-fluid and particle-particle interactions under the presence of an applied field. Lastly, the model provides a framework to efficiently predict the DoA in tandem with a functionalized-magnetic 3D printer and allows the user to adjust the operating parameters according to the desired DoA.

36 MATERIALS SCIENCE↗
DOE OSTI2026

N -Terminal Octylated Peptoid Hydrogels as 3D-Printable Cell Scaffolds and Proteolytically Robust Cargo Depots

Supramolecular hydrogels that mimic the extracellular matrix (ECM) represent promising materials for tissue engineering and drug delivery. However, conventional hydrogels formed via the self-assembly of natural or synthetic building blocks often face a trade-off between biological functionality and biochemical stability, limiting their utility in long-term or protease-rich environments. Peptoids, a class of peptide-inspired, sequence-defined polymers, offer a compelling alternative due to their exceptional proteolytic resistance and bioactivity. Despite this potential, the development of supramolecular peptoid hydrogels has been hindered by the absence of backbone hydrogen bond donors, which limits long-range ordering necessary for efficient hydrogel formation. This work describes a short peptoid functionalized at the N-terminus with an octyl chain that readily self-assembles into hydrogels. Hydrophobic interactions among pendant octyl groups promote directional peptoid packing into highly ordered nanosheets, which interconnect to form a porous hydrogel network. These hydrogels exhibit tunable viscoelasticity, shear-thinning, and self-healing properties, enabling their use as inks for extrusion-based 3D printing. They support NIH-3T3 fibroblast adhesion, spreading, and proliferation, maintaining greater than 95% cell viability over 4 days. Moreover, the hydrogels retain their macroscopic integrity under protease-rich conditions, enabling sustained cargo release and uniform cellular uptake. Together, this study demonstrates a class of supramolecular peptoid hydrogelators that integrate biocompatibility, 3D printability, and proteolytic stability, providing a versatile platform for ECMmimetic scaffolds in regenerative medicine and long-term therapeutic delivery.

cargo delivery↗
DOE OSTI2024

Accurate additive manufacturing of lightweight and elastic carbons using plastic precursors

Despite groundbreaking advances in the additive manufacturing of polymers, metals, and ceramics, scaled and accurate production of structured carbons remains largely underdeveloped. This work reports a simple method to produce complex carbon materials with very low dimensional shrinkage from printed to carbonized state (less than 4%), using commercially available polypropylene precursors and a fused filament fabrication-based process. The control of macrostructural retention is enabled by the inclusion of fiber fillers regardless of the crosslinking degree of the polypropylene matrix, providing a significant advantage to directly control the density, porosity, and mechanical properties of 3D printed carbons. Using the same printed plastic precursors, different mechanical responses of derived carbons can be obtained, notably from stiff to highly compressible. This report harnesses the power of additive manufacturing for producing carbons with accurately controlled structure and properties, while enabling great opportunities for various applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

3-D Printed Electro-Magnetic Objects for THz Communications

Advanced materials and manufacturing techniques will pave the path towards high quality electro-magnetic circuits that operate up through THz and into optics regime. Digital additive manufacturing (AM) techniques offer game-changing potential for large scale manufacturing of Radio-frequency (RF) circuits and system in custom 2D/3D geometries. The technical collaboration will explore the design flexibility and product customization capabilities of additive manufacturing techniques to process magnetic materials in custom 3D geometries with tailored dielectric properties and frequency response characteristics. Transformation of an RF circuit design idea into a 3D printed system using additive manufacturing techniques will bring together the elements of advanced materials, additive integration, and low-cost manufacturing for future advanced wireless communication systems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

PDMS ‐silica composite gas separation membranes by direct ink writing

Abstract Polydimethylsiloxane (PDMS)‐based membranes containing amine‐functionalized and unfunctionalized silica particles were fabricated via direct ink writing for CO 2 /N 2 gas separation. The printability of the inks was evaluated by rheological measurements, while spectroscopy, microscopy, thermal measurements, and mechanical testing were employed to characterize the printed membranes. The surface morphology of the membranes revealed the absence of voids, demonstrating their suitability for gas separation. The printed membranes also exhibited desirable thermal and mechanical properties (i.e., thermal degradation temperature of 518 °C and tensile strength as high as 1.178 MPa with 529% elongation). The PDMS‐based membranes generally displayed high permeability for CO 2 but slightly low selectivity for the CO 2 /N 2 gas pair. The best‐combined permeability‐selectivity performance of 8794 barrer and selectivity of 11.64 was demonstrated by the printed PDMS membrane containing no SiO 2 fillers. The inclusion of unfunctionalized SiO 2 particles generally increased the membrane's gas permeability but compromised the selectivity. In contrast, membranes with amine‐functionalized silica showed improved selectivity compared to membranes containing unfunctionalized silica. Overall, the performance and characteristics offered by the PDMS/silica composite membranes demonstrated the potential of 3D printing as an economical and sustainable fabrication approach to developing materials for carbon capture applications.

Gutierrez, Dianne B.↗
DOE OSTI2020

MADE3D™ (Manufacturing and Additive Design of Electric Machines Enabled by Three-Dimensional Printing) [SWR-20-70]

The MADE3D™ software uses advanced neural networks for realizing novel high torque density electric machine designs with desired functional specifications not limited to but including torque, magnetic loading, and mass. This software allows for a reduction in cost of design by using next-generation computational resources including the cloud while still maintaining high accuracy. The design of the neural networks allows for exploration of large design space and possibilities to find more optimal designs and accommodate new manufacturing technologies like 3D printing.

Sethuraman, Latha↗
DOE OSTI2024

Additive manufacturing of multiscale NiFeMn multi-principal element alloys with tailored composition

Nanostructured multi-principal element alloys (MPEAs) have been explored as next-generation engineering materials due to unique mechanical and functional properties which have significant advantages over traditional dilute alloys. However, the practical applications of nanostructured MPEAs are still limited due to the lack of scalable processing approaches to prepare a large quantity of nanostructured MPEAs, as well as lack of an efficient pathway for high-throughput discovery of better functional nanostructured MPEAs within their vast compositional space. Here we tackle these challenges by presenting an integrated approach by combining direct-ink-writing-based additive manufacturing, solid-state sintering, and chemical dealloying to manufacture hierarchically porous MPEAs. The hierarchical structure is comprised of macro- and micro-scale pores introduced via extrusion printing and polymer decomposition during sintering, as well as nanoscale pores formed via chemical dealloying. The macro- and micro-scale pores allow efficient dealloying of a large mass of material as the diffusion length that the corroding medium must penetrate remains at the scale of the ligaments formed after sintering (∼10 μm), despite the large volume of the 3D-printed samples. In addition, this integrated approach enables versatile control of the alloy composition via precisely tuning the ratio of elemental powders in the starting ink, thus offering a pathway for high-throughput discovery of novel functional MPEAs. As a case study, multiscale macro/micro/nanoporous NiFeMn MPEAs with three different compositions were investigated as catalysts to reduce the overpotential of oxygen evolution reaction (OER), where NiFeMn-based electrocatalysts display composition-dependent performance such that the overpotential measured at a current of 0.5 A g −1 for OER increases in the order of Ni 58 Fe 29 Mn 13 ⩽ Ni 64 Fe 26 Mn 10 < Ni 76 Fe 18 Mn 6 . This introduced manufacturing process offers new opportunities for scalable fabrication and rapid screening of nanostructured multi-component complex alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Markforged Continuous Fiber Composite Material Testing

Continuous fiber composite 3D printing promises to greatly expand the design space of polymer additive manufacturing (AM). A series of mechanical tests were performed to attempt to fully characterize the composite materials built from feedstock provided by the Markforged company. These tests included tensile, compression, Charpy impact, three point bending, coefficient of thermal expansion, and calorimetry tests. Specimens were prepared on the Mark Two 3D printer at LANL during the spring and summer of 2019. These samples were then shipped to New Mexico Institute of Mining and Technology’s Thermo-Mechanical Lab for testing during the summer and fall of 2019. Test data are reported and analyzed for each of the tests.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Full-Strength Additive Manufacturing of Pure Aluminum Alloy 7075 Using Liquid Metal Jet Printing

Additive manufacturing (AM) of high-strength aluminum alloys can produce high-performance aerospace and biomedical parts with unique geometries and functions. However, many high-performance alloy systems such as AA 7075 pose challenges during AM due to thermal cycles that cause hot cracking, limiting AM to casting-friendly alloys. Stock AA 7075 alloy poses additional challenges due to the excessive growth of insoluble precipitates during casting and needs to be thermomechanically processed to obtain acceptable mechanical properties. Here, this work uses liquid metal jet printing to produce high-resolution pure AA 7075 parts at high strength (593 MPa) and ductility (10 pct), surpassing the specific strength of any type of steel. The parts are printed by depositing fine droplets on a high-temperature substrate that reduces cooling rates, preventing hot cracking. The results show that fully dense, crack-free parts can only be printed at substrate temperatures of 500 °C with a cooling rate threshold of < 2000 K/s to prevent cracking and < 500 K/s to eliminate porosity. The tensile strength, microhardness, and ductility of the parts matched or were beyond the wrought alloy specifications after heat treatment, possibly due to high solidification rates that produce finer insoluble precipitates. Our results indicate that many challenging high-performance alloy systems can now be 3D printed based on the critical thresholds for cooling rates using any AM method that can satisfy these conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Polymer Nanocomposite Sensors with Improved Piezoelectric Properties through Additive Manufacturing

Additive manufacturing (AM) technology has recently seen increased utilization due to its versatility in using functional materials, offering a new pathway for next-generation conformal electronics in the smart sensor field. However, the limited availability of polymer-based ultraviolet (UV)-curable materials with enhanced piezoelectric properties necessitates the development of a tailorable process suitable for 3D printing. This paper investigates the structural, thermal, rheological, mechanical, and piezoelectric properties of a newly developed sensor resin material. The polymer resin is based on polyvinylidene fluoride (PVDF) as a matrix, mixed with constituents enabling UV curability, and boron nitride nanotubes (BNNTs) are added to form a nanocomposite resin. The results demonstrate the successful micro-scale printability of the developed polymer and nanocomposite resins using a liquid crystal display (LCD)-based 3D printer. Additionally, incorporating BNNTs into the polymer matrix enhanced the piezoelectric properties, with an increase in the voltage response by up to 50.13%. This work provides new insights for the development of 3D printable flexible sensor devices and energy harvesting systems.

42 ENGINEERING↗
DOE OSTI2020

Periodic Porous 3D Electrodes Mitigate Gas Bubble Traffic during Alkaline Water Electrolysis at High Current Densities

We report alkaline water electrolysis at high current densities is plagued by gas bubble generation and trapping in stochastic porous electrodes (e.g., Ni foams), which causes a significant reduction in the number of electrolyte accessible catalyst active sites. Here, 3D printed Ni (3DPNi) electrodes with highly controlled, periodic structures are reported that suppress gas bubble coalescence, jamming, and trapping and, hence, result in rapid bubble release. The 3DPNi electrodes decorated with carbon-doped NiO achieve a high current density of 1000 mA cm -2 in 1.0 m KOH electrolyte at hydrogen evolution reaction and oxygen evolution reaction overpotentials of 245 and 425 mV, respectively. This work demonstrates a new approach to the deterministic design of 3D electrodes to facilitate rapid bubble transport and release to enhance the total electrode catalytic activity at commercially relevant current densities.

08 HYDROGEN↗
DOE OSTI2025

Fractional Skyrmion Tubes in Chiral‐Interfaced 3D Magnetic Nanowires

Magnetic skyrmions are chiral spin textures with rich physics and great potential for unconventional computing. Typically, skyrmions form in bulk crystals with reduced symmetry or ultrathin film multilayers involving heavy metals. Here, the formation of fractional Bloch skyrmion tubes at room temperature is demonstrated by 3D printing ferromagnetic double‐helix nanowires with two regions of opposite chirality. Using X‐ray microscopy and micromagnetic simulations, it is shown that the coexistence of vortex and anti‐parallel spin states induces the formation of fractional skyrmion tubes at zero magnetic fields, minimizing the energy cost of breaking the coupling between geometric and magnetic chirality. Control over zero‐field states is also demonstrated, including pure vortex, or mixed skyrmion‐vortex states, highlighting the magnetic reconfigurability of these 3D nanowires. This work shows how interfacing chiral geometries at the nanoscale can enable advanced forms of topological spintronics.

X-ray microscopy↗
DOE OSTI2019

Colloidal nanoparticle inks for printing functional devices: emerging trends and future prospects

Colloidal nanoparticles have been widely studied and proven to have unique and superior properties compared to their bulk form and are attractive building blocks for diverse technologies, including energy conversion and storage, sensing, electronics, etc. However, transforming colloidal nanoparticles into functional devices while translating their unique properties from the nanoscale to the macroscale remains a major challenge. The development of advanced manufacturing methodologies that can convert functional nanomaterials into high-performance devices in a scalable, controllable and affordable manner presents great research opportunities and challenges for the next several decades. One promising approach to fabricate functional devices from nanoscale building blocks is additive manufacturing, such as 2D and 3D printing, owing to their capability of fast prototyping and versatile fabrication. Here, we review recent progress and methodologies for printing functional devices using colloidal nanoparticle inks with an emphasis on 2D nanomaterial-based inks. This review provides a comprehensive overview on four important and interconnected topics, including nanoparticle synthesis, ink formulation, printing methods, and device applications. New research opportunities as well as future directions are also discussed.

36 MATERIALS SCIENCE↗