Large-scale additive manufacturing of highly exothermic reactive polymer systems

Stian K. Romberg; Christopher J. Hershey; John M. Lindahl; William Carter; Brett G. Compton; Vlastimil Kunc

doi:10.33599/nasampe/s.19.1616

Large-scale additive manufacturing of highly exothermic reactive polymer systems

Stian K. Romberg, Christopher J. Hershey, John M. Lindahl, William Carter, Brett G. Compton, Vlastimil Kunc

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

11 Scopus citations

Abstract

Additive manufacturing (AM) of reactive polymer systems involves the deposition of materials at room temperature that either cure during printing through a chemically initiated reaction or require thermal initiation after printing. This presentation focuses on large-scale AM of chemically initiated thermosetting resins to characterize the effects of heat generation, temperature-dependent viscoelasticity, and crosslinking on the printing process. Real-time tracking of both temperature and cure fronts during the build process were investigated using infrared (IR) and optical vision systems in combination with selected material dyes. Heat generation within the previously-deposited layers was observed to cause significant reduction in the storage modulus (G’) and viscosity of newly-deposited layers, resulting in bead instabilities and failure of the print. Quantitative experimental observations on thin-wall structures suggest strategies for mitigating this failure mode through selection of print parameters and tailoring of viscoelastic properties of the feedstock resin.

Original language	English
Title of host publication	SAMPE Conference and Exhibition
Editors	Kevin Ahlstrom, Jacob Preston Anderson, Scott Beckwith, Andrew Craig Becnel, Paul Joseph Biermann, Matt Buchholz, Elizabeth Cates, Brian Gardner, Jim Harris, Michael J. Knight, German Reyes-Villanueva, Stephen E. Scarborough, Phil Sears, James Thomas, Erik T. Thostenson
Publisher	Soc. for the Advancement of Material and Process Engineering
ISBN (Electronic)	9781934551301
DOIs	https://doi.org/10.33599/nasampe/s.19.1616
State	Published - 2019
Event	SAMPE 2019 Conference and Exhibition - Charlotte, United States Duration: May 20 2019 → May 23 2019

Publication series

Name	International SAMPE Technical Conference
Volume	2019-May

Conference

Conference	SAMPE 2019 Conference and Exhibition
Country/Territory	United States
City	Charlotte
Period	05/20/19 → 05/23/19

Funding

Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Industrial Technologies Program, under contract DE-AC05-00OR22725 with UT-Battelle, LLC. SAMPE Conference Proceedings. Charlotte, NC, May 20-23, 2019. Society for the Advancement of Material and Process Engineering This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

Access to Document

10.33599/nasampe/s.19.1616

Cite this

Romberg, S. K., Hershey, C. J., Lindahl, J. M., Carter, W., Compton, B. G., & Kunc, V. (2019). Large-scale additive manufacturing of highly exothermic reactive polymer systems. In K. Ahlstrom, J. P. Anderson, S. Beckwith, A. C. Becnel, P. J. Biermann, M. Buchholz, E. Cates, B. Gardner, J. Harris, M. J. Knight, G. Reyes-Villanueva, S. E. Scarborough, P. Sears, J. Thomas, & E. T. Thostenson (Eds.), SAMPE Conference and Exhibition (International SAMPE Technical Conference; Vol. 2019-May). Soc. for the Advancement of Material and Process Engineering. https://doi.org/10.33599/nasampe/s.19.1616

Romberg, Stian K. ; Hershey, Christopher J. ; Lindahl, John M. et al. / Large-scale additive manufacturing of highly exothermic reactive polymer systems. SAMPE Conference and Exhibition. editor / Kevin Ahlstrom ; Jacob Preston Anderson ; Scott Beckwith ; Andrew Craig Becnel ; Paul Joseph Biermann ; Matt Buchholz ; Elizabeth Cates ; Brian Gardner ; Jim Harris ; Michael J. Knight ; German Reyes-Villanueva ; Stephen E. Scarborough ; Phil Sears ; James Thomas ; Erik T. Thostenson. Soc. for the Advancement of Material and Process Engineering, 2019. (International SAMPE Technical Conference).

@inproceedings{334bd663071c4f8b94c18d9295d2c3f7,

title = "Large-scale additive manufacturing of highly exothermic reactive polymer systems",

abstract = "Additive manufacturing (AM) of reactive polymer systems involves the deposition of materials at room temperature that either cure during printing through a chemically initiated reaction or require thermal initiation after printing. This presentation focuses on large-scale AM of chemically initiated thermosetting resins to characterize the effects of heat generation, temperature-dependent viscoelasticity, and crosslinking on the printing process. Real-time tracking of both temperature and cure fronts during the build process were investigated using infrared (IR) and optical vision systems in combination with selected material dyes. Heat generation within the previously-deposited layers was observed to cause significant reduction in the storage modulus (G{\textquoteright}) and viscosity of newly-deposited layers, resulting in bead instabilities and failure of the print. Quantitative experimental observations on thin-wall structures suggest strategies for mitigating this failure mode through selection of print parameters and tailoring of viscoelastic properties of the feedstock resin.",

author = "Romberg, {Stian K.} and Hershey, {Christopher J.} and Lindahl, {John M.} and William Carter and Compton, {Brett G.} and Vlastimil Kunc",

note = "Publisher Copyright: {\textcopyright} 2019 Soc. for the Advancement of Material and Process Engineering. All rights reserved.; SAMPE 2019 Conference and Exhibition ; Conference date: 20-05-2019 Through 23-05-2019",

year = "2019",

doi = "10.33599/nasampe/s.19.1616",

language = "English",

series = "International SAMPE Technical Conference",

publisher = "Soc. for the Advancement of Material and Process Engineering",

editor = "Kevin Ahlstrom and Anderson, {Jacob Preston} and Scott Beckwith and Becnel, {Andrew Craig} and Biermann, {Paul Joseph} and Matt Buchholz and Elizabeth Cates and Brian Gardner and Jim Harris and Knight, {Michael J.} and German Reyes-Villanueva and Scarborough, {Stephen E.} and Phil Sears and James Thomas and Thostenson, {Erik T.}",

booktitle = "SAMPE Conference and Exhibition",

}

Romberg, SK, Hershey, CJ , Lindahl, JM , Carter, W, Compton, BG & Kunc, V 2019, Large-scale additive manufacturing of highly exothermic reactive polymer systems. in K Ahlstrom, JP Anderson, S Beckwith, AC Becnel, PJ Biermann, M Buchholz, E Cates, B Gardner, J Harris, MJ Knight, G Reyes-Villanueva, SE Scarborough, P Sears, J Thomas & ET Thostenson (eds), SAMPE Conference and Exhibition. International SAMPE Technical Conference, vol. 2019-May, Soc. for the Advancement of Material and Process Engineering, SAMPE 2019 Conference and Exhibition, Charlotte, United States, 05/20/19. https://doi.org/10.33599/nasampe/s.19.1616

Large-scale additive manufacturing of highly exothermic reactive polymer systems. / Romberg, Stian K.; Hershey, Christopher J.; Lindahl, John M. et al.
SAMPE Conference and Exhibition. ed. / Kevin Ahlstrom; Jacob Preston Anderson; Scott Beckwith; Andrew Craig Becnel; Paul Joseph Biermann; Matt Buchholz; Elizabeth Cates; Brian Gardner; Jim Harris; Michael J. Knight; German Reyes-Villanueva; Stephen E. Scarborough; Phil Sears; James Thomas; Erik T. Thostenson. Soc. for the Advancement of Material and Process Engineering, 2019. (International SAMPE Technical Conference; Vol. 2019-May).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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T1 - Large-scale additive manufacturing of highly exothermic reactive polymer systems

AU - Romberg, Stian K.

AU - Hershey, Christopher J.

AU - Lindahl, John M.

AU - Carter, William

AU - Compton, Brett G.

AU - Kunc, Vlastimil

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N2 - Additive manufacturing (AM) of reactive polymer systems involves the deposition of materials at room temperature that either cure during printing through a chemically initiated reaction or require thermal initiation after printing. This presentation focuses on large-scale AM of chemically initiated thermosetting resins to characterize the effects of heat generation, temperature-dependent viscoelasticity, and crosslinking on the printing process. Real-time tracking of both temperature and cure fronts during the build process were investigated using infrared (IR) and optical vision systems in combination with selected material dyes. Heat generation within the previously-deposited layers was observed to cause significant reduction in the storage modulus (G’) and viscosity of newly-deposited layers, resulting in bead instabilities and failure of the print. Quantitative experimental observations on thin-wall structures suggest strategies for mitigating this failure mode through selection of print parameters and tailoring of viscoelastic properties of the feedstock resin.

AB - Additive manufacturing (AM) of reactive polymer systems involves the deposition of materials at room temperature that either cure during printing through a chemically initiated reaction or require thermal initiation after printing. This presentation focuses on large-scale AM of chemically initiated thermosetting resins to characterize the effects of heat generation, temperature-dependent viscoelasticity, and crosslinking on the printing process. Real-time tracking of both temperature and cure fronts during the build process were investigated using infrared (IR) and optical vision systems in combination with selected material dyes. Heat generation within the previously-deposited layers was observed to cause significant reduction in the storage modulus (G’) and viscosity of newly-deposited layers, resulting in bead instabilities and failure of the print. Quantitative experimental observations on thin-wall structures suggest strategies for mitigating this failure mode through selection of print parameters and tailoring of viscoelastic properties of the feedstock resin.

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BT - SAMPE Conference and Exhibition

A2 - Ahlstrom, Kevin

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A2 - Beckwith, Scott

A2 - Becnel, Andrew Craig

A2 - Biermann, Paul Joseph

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A2 - Cates, Elizabeth

A2 - Gardner, Brian

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T2 - SAMPE 2019 Conference and Exhibition

Y2 - 20 May 2019 through 23 May 2019

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Romberg SK, Hershey CJ , Lindahl JM , Carter W, Compton BG, Kunc V. Large-scale additive manufacturing of highly exothermic reactive polymer systems. In Ahlstrom K, Anderson JP, Beckwith S, Becnel AC, Biermann PJ, Buchholz M, Cates E, Gardner B, Harris J, Knight MJ, Reyes-Villanueva G, Scarborough SE, Sears P, Thomas J, Thostenson ET, editors, SAMPE Conference and Exhibition. Soc. for the Advancement of Material and Process Engineering. 2019. (International SAMPE Technical Conference). doi: 10.33599/nasampe/s.19.1616

Large-scale additive manufacturing of highly exothermic reactive polymer systems

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