Building to last: challenges in additive manufacturing ...
Transcript of Building to last: challenges in additive manufacturing ...
![Page 1: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/1.jpg)
Building to last: challenges in additive manufacturing going from prototype to functional component
Angel Yanguas-Gil
![Page 2: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/2.jpg)
Characterization of materials throughout their lifecycle through two different perspectives
Advanced manufacturing perspective: beyond prototype and design
Characterization perspective: knowledge and cultural gaps
Suggestions
NIST Roadmapping workshop
2
![Page 3: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/3.jpg)
NIST Roadmapping workshop
3
Perspective #1: Advanced manufacturing
![Page 4: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/4.jpg)
Characterization of Materials Throughout Their Lifecycle
NIST Roadmapping workshop
4
Challenge #1: application dependence
![Page 5: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/5.jpg)
Example #1: additive manufacturing for nuclear chemical engineering
NIST Roadmapping workshop
5
For more information contact Kent Wardle ([email protected])
Liquid-liquid extraction equipment for advanced separations processes
Custom annular centrifugal contactor (ACC) designs
ACC with enhanced mixing and residence time [1]
Prototyping to functional ‘end-use’ equipment
Complete multi-stage extraction systems Multi-stage 2-cm ACC assembly for HCl-based process chemistry [2]
Scaled-down designs for waste minimization
1.25cm rotor contactor (enhanced residence time design)[3]
![Page 6: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/6.jpg)
Example #2: additive manufacturing for biochemical synthesis
NIST Roadmapping workshop
6
Integrated functional structures providing
1) high mass transfer between gas-liquid-solid interfaces
2) Desired metabolic activities in bioprocessing
Goals:
- Achieve higher survival rates of microbes through controlled bioaffinity
- Higher process efficiency
3D printed biocarrier
Example: syngas fermentation
For more information contact Meltem Urgun Dermirtas([email protected])
![Page 7: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/7.jpg)
Challenge #1: application dependence
NIST Roadmapping workshop
7
Performance metrics and degradation mechanisms of the materials are strongly application-dependent
For many of these applications we don’t even know what the lifecycle of the material would be.
Unknown material reliability can have a big impact in the techno-economic assessment of a technology: down time
Characterization over the life cycle of a material should be built into the projects
![Page 8: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/8.jpg)
Characterization of Materials Throughout Their Lifecycle
NIST Roadmapping workshop
8
Challenge #2: materials diversity
![Page 9: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/9.jpg)
Materials diversity
NIST Roadmapping workshop
9
composition
fabrication
![Page 10: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/10.jpg)
Materials diversity
NIST Roadmapping workshop
10
composition
fabrication
Surface modification
![Page 11: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/11.jpg)
Example #1: Plasma processing
NIST Roadmapping workshop
11
Plasma-based modification of polymers is a well-established field
Surface and subsurface modification, functionalization, and grafting
![Page 12: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/12.jpg)
Example #2: Chemical Vapor Processing for Additive Manufacturing
NIST Roadmapping workshop
12
For more information contact Jeffrey W. Elam ([email protected])
![Page 13: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/13.jpg)
CVPAM on ABS 3D Printed Parts
13
Dielectrics:– Al2O3, MgO
Semiconductors:– ZnO, TiO2
Metals:– W
Composites:– W-AlF3, W-Al2O3
W, 85 ºC ZnO, 85 ºC
Al2O3, 85 ºC
NIST Roadmapping workshop
![Page 14: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/14.jpg)
CVPAM for Wear Resistance and Lubrication
14
3D-Printed Bushings• Al2O3 for wear-resistance• MoS2 for lubrication
Thingverse.comNovusNotioEngineering.com
Tribology Laboratory (ES)• Ali Erdemir, Giovanni Ramirez• Nanoindentation (load-
displacement)• Pin on disc (friction, wear)
NIST Roadmapping workshop
![Page 15: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/15.jpg)
Tungsten-Aluminum Fluoride Coatings for Chemical Robustness
15
Annular Centrifugal Contactor (Kent Wardle, NE)• Compact mixer/centrifuge for
nuclear fuel• 3D printed parts, ABS polymer• Problem: embrittlement in
mineral acids and solvents
ALD W-AlF3• ALD composite material
Developed for Li battery cathode protection
• Insoluble in HF acid• Insoluble in organic solvents
3D printed components of annular centrifugal contactors coated with 10 nm ALD WAlFx coatings.
![Page 16: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/16.jpg)
Challenge #2: Materials diversity
NIST Roadmapping workshop
16
When the surface functionality becomes relevant, we are adding an extra degree of complexity
Information available on the impact of fabrication on the reliability of 3D printed materials is insufficient
![Page 17: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/17.jpg)
Characterization of Materials Throughout Their Lifecycle
NIST Roadmapping workshop
17
If you are trying to develop functional additive manufacturing materials, where do you look for information on long-term behavior?
![Page 18: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/18.jpg)
Looking at AM scientific literature
NIST Roadmapping workshop
18
![Page 19: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/19.jpg)
Looking at AM scientific literature
NIST Roadmapping workshop
19
![Page 20: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/20.jpg)
NIST Roadmapping workshop
20
Only 3% of the sampled papers emphasize reliability or failure
Only 5% of the sampled papers emphasize reliability or failure or degradation
Many of these papers target metal AM
![Page 21: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/21.jpg)
NIST Roadmapping workshop
21
The state of the art is clearly insufficient to help us understand the reliability of our materials and our parts, and consequently of our processes
![Page 22: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/22.jpg)
NIST Roadmapping workshop
22
Perspective #2: Characterization point of view
![Page 23: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/23.jpg)
We can combine experimental and simulation techniques to characterize properties and degradation
NIST Roadmapping workshop
23
ABS polymer
W-Al2O3 coating
Carbon
Tungsten AluminumPolymer infiltration
Electron multiplier structures
![Page 24: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/24.jpg)
We can even design in-situ experiments
24
In-situ GISAXS of chemical vapor processing in Block Copolymer Lamellae
NIST Roadmapping workshop
![Page 25: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/25.jpg)
But…
NIST Roadmapping workshop
25
![Page 26: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/26.jpg)
But…
NIST Roadmapping workshop
26
The challenge is that process development and detailed characterization are not highly compatible:
- Timescale- Funding- Different skillsets and communities
![Page 27: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/27.jpg)
Conclusions and suggestions
NIST Roadmapping workshop
27
Increased focus on reliability and performance
Consolidate existing published research
Improved metadata to ease data exchange and evaluation
Parts for info program to incentivize characterization of 3D printed materials
![Page 28: Building to last: challenges in additive manufacturing ...](https://reader033.fdocuments.us/reader033/viewer/2022050612/6273bc4ece0313004669f49f/html5/thumbnails/28.jpg)
Thanks!
NIST Roadmapping workshop
28