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Title: Direct metal writing: Controlling the rheology through microstructure

Abstract

Most metal additive manufacturing approaches are based on powder-bed melting techniques such as laser selective melting or electron beam melting, which often yield uncontrolled microstructures with defects (e.g., pores or microcracks) and residual stresses. Here, we introduce a proof-of-concept prototype of a 3D metal freeform fabrication process by direct writing of metallic alloys in the semi-solid regime. This process is achieved through controlling the particular microstructure and the rheological behavior of semi-solid alloy slurries, which demonstrate a well suited viscosity and a shear thinning property to retain the shape upon printing. Furthermore, the ability to control the microstructure through this method yields a flexible manufacturing route to fabricating 3D metal parts with full density and complex geometries.

Authors:
 [1];  [1];  [1]; ORCiD logo [1];  [1];  [1];  [1]; ORCiD logo [1];  [2];  [2];  [1];  [1];  [1]
  1. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
  2. Worcester Polytechnic Institute, Worcester, MA (United States)
Publication Date:
Research Org.:
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1353155
Alternate Identifier(s):
OSTI ID: 1349372
Report Number(s):
LLNL-JRNL-716017
Journal ID: ISSN 0003-6951
Grant/Contract Number:  
AC52-07NA27344; Laboratory Directed Research and Development 14-SI-004
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Applied Physics Letters
Additional Journal Information:
Journal Volume: 110; Journal Issue: 9; Journal ID: ISSN 0003-6951
Publisher:
American Institute of Physics (AIP)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 42 ENGINEERING

Citation Formats

Chen, Wen, Thornley, Luke, Coe, Hannah G., Tonneslan, Samuel J., Vericella, John J., Zhu, Cheng, Duoss, Eric B., Hunt, Ryan M., Wight, Michael J., Apelian, Diran, Pascall, Andrew J., Kuntz, Joshua D., and Spadaccini, Christopher M. Direct metal writing: Controlling the rheology through microstructure. United States: N. p., 2017. Web. doi:10.1063/1.4977555.
Chen, Wen, Thornley, Luke, Coe, Hannah G., Tonneslan, Samuel J., Vericella, John J., Zhu, Cheng, Duoss, Eric B., Hunt, Ryan M., Wight, Michael J., Apelian, Diran, Pascall, Andrew J., Kuntz, Joshua D., & Spadaccini, Christopher M. Direct metal writing: Controlling the rheology through microstructure. United States. doi:10.1063/1.4977555.
Chen, Wen, Thornley, Luke, Coe, Hannah G., Tonneslan, Samuel J., Vericella, John J., Zhu, Cheng, Duoss, Eric B., Hunt, Ryan M., Wight, Michael J., Apelian, Diran, Pascall, Andrew J., Kuntz, Joshua D., and Spadaccini, Christopher M. Mon . "Direct metal writing: Controlling the rheology through microstructure". United States. doi:10.1063/1.4977555. https://www.osti.gov/servlets/purl/1353155.
@article{osti_1353155,
title = {Direct metal writing: Controlling the rheology through microstructure},
author = {Chen, Wen and Thornley, Luke and Coe, Hannah G. and Tonneslan, Samuel J. and Vericella, John J. and Zhu, Cheng and Duoss, Eric B. and Hunt, Ryan M. and Wight, Michael J. and Apelian, Diran and Pascall, Andrew J. and Kuntz, Joshua D. and Spadaccini, Christopher M.},
abstractNote = {Most metal additive manufacturing approaches are based on powder-bed melting techniques such as laser selective melting or electron beam melting, which often yield uncontrolled microstructures with defects (e.g., pores or microcracks) and residual stresses. Here, we introduce a proof-of-concept prototype of a 3D metal freeform fabrication process by direct writing of metallic alloys in the semi-solid regime. This process is achieved through controlling the particular microstructure and the rheological behavior of semi-solid alloy slurries, which demonstrate a well suited viscosity and a shear thinning property to retain the shape upon printing. Furthermore, the ability to control the microstructure through this method yields a flexible manufacturing route to fabricating 3D metal parts with full density and complex geometries.},
doi = {10.1063/1.4977555},
journal = {Applied Physics Letters},
number = 9,
volume = 110,
place = {United States},
year = {Mon Feb 27 00:00:00 EST 2017},
month = {Mon Feb 27 00:00:00 EST 2017}
}

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Works referenced in this record:

Supercapacitors Based on Three-Dimensional Hierarchical Graphene Aerogels with Periodic Macropores
journal, January 2016