Engineering topics
Swain, Greg M.
Publications and source records attributed to Swain, Greg M..
The Electrochemical Behavior of As-Prepared Aluminum Alloy A360 Produced by Selective Laser Melting Fabrication with and without a Trivalent Chromium Process Conversion Coating
In this paper, we report on the electrochemical behavior and corrosion resistance of as-prepared aluminum alloy, A360 (AlSi10Mg), fabricated by additive manufacturing, with and without a trivalent chromium process conversion coating. Selective laser melting was the 3D printing process used for the alloy build. The corrosion suppression provided by the coating system was assessed through electrochemical measurements and accelerated degradation testing during a 14-day continuous neutral salt-spray exposure. The results indicate that the conversion coating can be formed by solution pretreating (degreasing and deoxidation) the alloy (X-Z plane perpendicular to the build plane) with its native surface roughness (as-prepared) followed by immersion for 10, 15 or 20 min in the coating bath. All three immersion times provide an equivalent level of corrosion protection to the alloy. The conversion coating suppresses both anodic and cathodic currents, increases the polarization resistance, and provides both anodic and cathodic corrosion protection to the as-prepared alloy. The conversion-coated specimens exhibit good stand-alone corrosion resistance during a 14-day neutral salt-spray exposure with corrosion intensity values (g/m 2 -year) ~10x lower than values for the uncoated, as-prepared alloy specimens.
High surface area, low weight composite nickel fiber electrodes
The energy density and power density of light weight aerospace batteries utilizing the nickel oxide electrode are often limited by the microstructures of both the collector and the resulting active deposit in/on the collector. Heretofore, these two microstructures were intimately linked to one another by the materials used to prepare the collector grid as well as the methods and conditions used to deposit the active material. Significant weight and performance advantages were demonstrated by Britton and Reid at NASA-LeRC using FIBREX nickel mats of ca. 28-32 microns diameter. Work in our laboratory investigated the potential performance advantages offered by nickel fiber composite electrodes containing a mixture of fibers as small as 2 microns diameter (Available from Memtec America Corporation). These electrode collectors possess in excess of an order of magnitude more surface area per gram of collector than FIBREX nickel. The increase in surface area of the collector roughly translates into an order of magnitude thinner layer of active material. Performance data and advantages of these thin layer structures are presented. Attributes and limitations of their electrode microstructure to independently control void volume, pore structure of the Ni(OH)2 deposition, and resulting electrical properties are discussed.
A new composite electrode architecture for energy storage devices
The research objective is to determine how the electrode microstructure (architecture) affect the performance of the nickel hydroxide electrochemical system. It was found that microstructure and additional surface area makes a difference. The best architectures are the FIBREX/nickel and nickel fiber composite electrodes. The conditioning time for full utilization was greatly reduced. The accelerated increase in capacity vs. cycling appears to be a good indicator of the condition of the electrode/active material microstructure and morphology. Conformal deposition of the active material may be indicated and important. Also higher utilizations were obtained; greater than 80 pct. after less than 5 cycles and greater than 300 pct. after more than 5 cycles using nickel fiber composite electrode assuming a 1 electron transfer per equivalent.