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Title: Liquid direct reactive interface printing of structural aluminum alloys

Abstract

Direct reactive interface printing is a fused filament fabrication method that exploits specially designed alloys with reactive chemistries and, in this example, structurally significant mechanical properties. Spatial control and fully molten filament stability are driven by high surface energy interfaces resulting from high formation enthalpy. In this study, molten Al–Ce-based alloys are deposited directly onto a build surface where they rapidly solidify, retaining an intended shape, and successive layers bond to one another through highly reactive interfaces. Significant free space spanning, greater than 5 cm, is demonstrated. Electron microscopy and nanoindentation are used to examine the metallurgical bond. Furthermore, the use of efficient electromagnetic heating and low-cost feedstock, such as cast performs or wires rather than powders, can lower equipment costs and increase scalability and adaptation.

Authors:
ORCiD logo [1]; ORCiD logo [2]; ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [2];  [3];  [4];  [4];  [5]; ORCiD logo [2]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); The Univ. of Tennessee, Knoxville, TN (United States)
  3. Eck Industries, Inc., Manitowoc, WI (United States)
  4. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
  5. Florida Institute of Technology, Melbourne, FL (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1492920
Alternate Identifier(s):
OSTI ID: 1482457; OSTI ID: 1542725
Report Number(s):
LLNL-JRNL-740219
Journal ID: ISSN 2352-9407
Grant/Contract Number:  
AC05-00OR22725; AC52-07NA27344
Resource Type:
Journal Article: Published Article
Journal Name:
Applied Materials Today
Additional Journal Information:
Journal Volume: 13; Journal Issue: C; Journal ID: ISSN 2352-9407
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; Additive manufacturing; Direct-write; Al–Ce; Surface energy; Liquid metal; Materials science

Citation Formats

Kesler, Michael S., Neveau, Max L., Carter, William G., Henderson, Hunter B., Sims, Zachary C., Weiss, David, Li, Tian T., McCall, Scott K., Glicksman, Martin E., and Rios, Orlando. Liquid direct reactive interface printing of structural aluminum alloys. United States: N. p., 2018. Web. doi:10.1016/j.apmt.2018.10.005.
Kesler, Michael S., Neveau, Max L., Carter, William G., Henderson, Hunter B., Sims, Zachary C., Weiss, David, Li, Tian T., McCall, Scott K., Glicksman, Martin E., & Rios, Orlando. Liquid direct reactive interface printing of structural aluminum alloys. United States. doi:10.1016/j.apmt.2018.10.005.
Kesler, Michael S., Neveau, Max L., Carter, William G., Henderson, Hunter B., Sims, Zachary C., Weiss, David, Li, Tian T., McCall, Scott K., Glicksman, Martin E., and Rios, Orlando. Tue . "Liquid direct reactive interface printing of structural aluminum alloys". United States. doi:10.1016/j.apmt.2018.10.005.
@article{osti_1492920,
title = {Liquid direct reactive interface printing of structural aluminum alloys},
author = {Kesler, Michael S. and Neveau, Max L. and Carter, William G. and Henderson, Hunter B. and Sims, Zachary C. and Weiss, David and Li, Tian T. and McCall, Scott K. and Glicksman, Martin E. and Rios, Orlando},
abstractNote = {Direct reactive interface printing is a fused filament fabrication method that exploits specially designed alloys with reactive chemistries and, in this example, structurally significant mechanical properties. Spatial control and fully molten filament stability are driven by high surface energy interfaces resulting from high formation enthalpy. In this study, molten Al–Ce-based alloys are deposited directly onto a build surface where they rapidly solidify, retaining an intended shape, and successive layers bond to one another through highly reactive interfaces. Significant free space spanning, greater than 5 cm, is demonstrated. Electron microscopy and nanoindentation are used to examine the metallurgical bond. Furthermore, the use of efficient electromagnetic heating and low-cost feedstock, such as cast performs or wires rather than powders, can lower equipment costs and increase scalability and adaptation.},
doi = {10.1016/j.apmt.2018.10.005},
journal = {Applied Materials Today},
issn = {2352-9407},
number = C,
volume = 13,
place = {United States},
year = {2018},
month = {10}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record at 10.1016/j.apmt.2018.10.005

Citation Metrics:
Cited by: 1 work
Citation information provided by
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Figures / Tables:

Fig.1 Fig.1: Schematic of the (A) printing head and feed mechanism and (B) the printing

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Figures/Tables have been extracted from DOE-funded journal article accepted manuscripts.