Liquid direct reactive interface printing of structural aluminum alloys

Michael S. Kesler, Max L. Neveau, William G. Carter, Hunter B. Henderson, Zachary C. Sims, David Weiss, Tian T. Li, Scott K. McCall, Martin E. Glicksman, Orlando Rios

Research output: Contribution to journalArticlepeer-review

13 Scopus citations

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. 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.

Original languageEnglish
Pages (from-to)339-343
Number of pages5
JournalApplied Materials Today
Volume13
DOIs
StatePublished - Dec 2018

Funding

This research was sponsored by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy (DOE) , Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory, and Eck Industries. This work was performed under the auspices of the U.S. DOE with ORNL under contract DE-AC05-00OR22725 and with LLNL under Contract DE-AC52-07NA27344 . We extend a special thank you to Andrew Pascal, from LLNL, for performing rheological testing from which we commented in the paper, and to Adam Morrison, from Ajax TOCCO, for the assistance with the power supply and coil enabling on-demand melting. Author M.E. Glicksman gratefully acknowledges his support as research professor from the Allen S. Henry Chair, Florida Institute of Technology, Melbourne, FL. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE 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 ).

FundersFunder number
Critical Materials Institute
Eck Industries
U.S. Department of Energy
Advanced Manufacturing Office
Office of Energy Efficiency and Renewable Energy
Lawrence Livermore National LaboratoryDE-AC52-07NA27344
Oak Ridge National LaboratoryDE-AC05-00OR22725

    Keywords

    • Additive manufacturing
    • Al–Ce
    • Direct-write
    • Liquid metal
    • Surface energy

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