Fused filament fabrication of novel phase-change material functional composites

Freeman, Thomas B.; Messenger, Melissa A.; Troxler, Casey J.; Nawaz, Kashif; Rodriguez, Rafael M.; Boetcher, Sandra K. S.

doi:10.1016/j.addma.2021.101839

Title: Fused filament fabrication of novel phase-change material functional composites

Journal Article · Wed Jan 13 00:00:00 EST 2021 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2021.101839· OSTI ID:1817443

Freeman, Thomas B. ^[1]; Messenger, Melissa A. ^[1]; Troxler, Casey J. ^[1];

^[2]; Rodriguez, Rafael M. ^[1]; Boetcher, Sandra K. S. ^[1]

Embry-Riddle Aeronautical Univ., Daytona Beach, FL (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Additively manufactured polymer heat exchangers are of recent interest in the thermal sciences due to their lightweight and intricate heat-transfer-enhancing geometrical features. The goal of the present research is to directly encapsulate phase-change material (PCM) into polymer filament for the purpose of 3D printing polymer heat exchangers capable of latent heat thermal energy storage and management. PCMs have the ability to absorb large amounts of latent heat while undergoing a solid-to-liquid phase change at a nearly constant temperature. Encapsulation or containment of PCMs is necessary to prevent leaking since the material continuously cycles between a liquid and a solid state. An organic-based PCM and high-density polyethylene (HDPE) were combined and extruded into a functional composite filament. For the first time, with the aid of a heated enclosure and HDPE build plates, it was demonstrated that these functional composite materials can be printed using fused filament fabrication (FFF). Printing HDPE is known to be difficult; however, based on what was observed in the current study, the PCM and HDPE composite was easier to print than pure HDPE. Thermal properties, such as latent heat of fusion, phase-change temperature, and thermal conductivity, of the composite filament and 3D printed samples were investigated and compared with compression-molded bulk material. Finally, the microstructures of the composite filament and 3D printed samples were visualized, and the basic structures of the HDPE and PCM within both the filament and 3D printed parts were clearly delineated.

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Research Organization:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); National Science Foundation (NSF)

Grant/Contract Number:: AC05-00OR22725; DGE-2041850; MRI-1337742

OSTI ID:: 1817443

Journal Information:: Additive Manufacturing, Vol. 39, Issue 39; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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