Engineering topics

Duty, Chad E

Publications and source records attributed to Duty, Chad E.

7 records

DOE OSTI2017

Infrared Preheating to Enhance Interlayer Strength of Components Printed on the Big Area Additive Manufacturing (BAAM) System

The Big Area Additive Manufacturing (BAAM) system has the capacity to print structures on the order of several meters at a rate exceeding 50 kg/h, thereby having the potential to significantly impact the production of components in automotive, aerospace and energy sectors. However, a primary issue that limits the functional use of such parts is mechanical anisotropy. The strength of printed parts across successive layers in the build direction (z-direction) is significantly lower than the corresponding in-plane strength (x-y directions). This is largely due to poor bonding between the printed layers as the lower layers cool below the glass transition temperature (Tg) before the next layer is deposited. This work explores the use of infrared heating to increase the surface temperature of the printed layer just prior to deposition of new material to improve the interlayer strength of the components. The material used in this study was acrylonitrile butadiene styrene (ABS) reinforced with 20% chopped carbon fiber by weight. Significant improvements in z-strength were observed for the parts whose surface temperature was increased from below Tg to close to or above Tg using infrared heating. Parameters such as print speed, nozzle diameter and extrusion temperature were also found to impact the heat input required to enhance interlayer adhesion without significantly degrading the polymer and compromising on surface finish.

Kishore, Vidya↗

DOE OSTI2015

Glass strengthening and patterning methods

High intensity plasma-arc heat sources, such as a plasma-arc lamp, are used to irradiate glass, glass ceramics and/or ceramic materials to strengthen the glass. The same high intensity plasma-arc heat source may also be used to form a permanent pattern on the glass surface--the pattern being raised above the glass surface and integral with the glass (formed of the same material) by use of, for example, a screen-printed ink composition having been irradiated by the heat source.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Sintering Kinetics of Inkjet Printed Conductive Silver Lines on Insulating Plastic Substrate

This paper focuses on sintering kinetics of inkjet printed lines containing silver nanoparticles deposited on a plastic substrate. Upon heat treatment, the change of resistance in the printed lines was measured as a function of time and sintering temperatures from 150 to 200 C. A critical temperature was observed for the sintering process, beyond which there was no further reduction in resistance. Analysis shows the critical temperature correlates to the boiling point of the solvent, which is attributed to a liquid-mediated sintering mechanism. It is demonstrated that the sintering process shuts down after the solvent has completely evaporated.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Breaking Barriers in Polymer Additive Manufacturing

Additive Manufacturing (AM) enables the creation of complex structures directly from a computer-aided design (CAD). There are limitations that prevent the technology from realizing its full potential. AM has been criticized for being slow and expensive with limited build size. Oak Ridge National Laboratory (ORNL) has developed a large scale AM system that improves upon each of these areas by more than an order of magnitude. The Big Area Additive Manufacturing (BAAM) system directly converts low cost pellets into a large, three-dimensional part at a rate exceeding 25 kg/h. By breaking these traditional barriers, it is possible for polymer AM to penetrate new manufacturing markets.

additive manufacturing↗

DOE OSTI2014

Scalable production of microbially-mediated ZnS nanoparticles and application to functional thin films

A series of semiconducting zinc sulfide (ZnS) nanoparticles were scalably, reproducibly, controllably, and economically synthesized with anaerobic metal-reducing Thermoanaerobacter species. They reduced partially oxidized sulfur sources to sulfides that extracellularly and thermodynamically incorporated with zinc ions to produce sparingly soluble ZnS nanoparticles with ~5 nm crystallites at yields of ~5 g l 1 month 1. A predominant sphalerite formation was facilitated by rapid precipitation kinetics, low cation/anion ratio, higher zinc concentration, water stabilization, or some combination of the four. The sphalerite ZnS nanoparticles exhibited narrow size distribution, high emission intensity, and few native defects. Scale-up and emission tunability using copper-doping were confirmed spectroscopically. Surface characterization was determined using Fourier transform infrared and X-ray photoelectron spectroscopies, which confirmed amine and carboxylic acid not only maintaining a nano-dimensional average crystallite size, but also increasing aggregation. Application of ZnS nanoparticle ink to a functional thin film was successfully tested for potential future applications.

Moon, Ji Won↗

DOE OSTI2014

The Importance of Carbon Fiber to Polymer Additive Manufacturing

Additive manufacturing holds tremendous promise in terms of revolutionizing manufacturing. However, fundamental hurdles limit mass adoption of the technology. First, production rates are extremely low. Second, the physical size of parts is generally small, less than a cubic foot. Third, while there is much excitement about metal additive manufacturing, the major growth area is in polymer additive manufacturing systems. Unfortunately, the mechanical properties of the polymer parts are poor, limiting the potential for direct part replacement. To address this issue, we describe three benefits of blending carbon fiber with polymer additive manufacturing. First, development of carbon fiber reinforced polymers for additive manufacturing achieves specific strengths approaching aerospace quality aluminum. Second, carbon fiber radically changes the behavior of the material during deposition, enabling large scale, out-of-the-oven, high deposition rate manufacturing. Finally, carbon fiber technology and additive manufacturing complement each other. Merging the two manufacturing processes enables the construction of complex components that would not be possible otherwise.

additive manufacturing↗

DOE OSTI2014

Effective Mechanical Properties of Lattice Material Fabricated by Material Extrusion Additive Manufacturing

In this paper, a two-step homogenization method is proposed and implemented for evaluating effective mechanical properties of lattice structured material fabricated by the material extrusion additive manufacturing process. In order to consider the characteristics of the additive manufacturing process in estimation procedures, the levels of scale for homogenization are divided into three stages the levels of layer deposition, structural element, and lattice structure. The method consists of two transformations among stages. In the first step, the transformation between layer deposition and structural element levels is proposed to find the geometrical and material effective properties of structural elements in the lattice structure. In the second step, the method to estimate effective mechanical properties of lattice material is presented, which uses a unit cell and is based on the discretized homogenization method for periodic structure. The method is implemented for cubic lattice structure and compared to experimental results for validation purposes.

Park, Sang-In↗