THE IMPACT OF A STATIC-MIXING NOZZLE ON UNIFORMITY IN MATERIAL EXTRUSION LARGE-SCALE ADDITIVE MANUFACTURING

James C. Brackett; Elijah P. Charles; Tyler C. Smith; Ahmed A. Hassen; Vlastimil Kunc; Chad E. Duty

THE IMPACT OF A STATIC-MIXING NOZZLE ON UNIFORMITY IN MATERIAL EXTRUSION LARGE-SCALE ADDITIVE MANUFACTURING

James C. Brackett, Elijah P. Charles, Tyler C. Smith, Ahmed A. Hassen, Vlastimil Kunc, Chad E. Duty

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

Abstract

There are many methods of incorporating more than one material in Additive Manufacturing (AM) processes. Oak Ridge National Laboratory has developed a unique solution that enables in-situ material switching by developing a dual-hopper feed system for Cincinnati’s Big Area Additive Manufacturing (BAAM) system. Continuous extrusion during a step-change in material feedstock results in a unique blended material transition region that exhibits a heterogeneous internal morphology. To improve mixing of materials during extrusion, a customized static-mixing nozzle was created for use with the BAAM. Single-bead transitions from Material A to B and B to A were printed with the mixing nozzle at a specified screw speed. Compositional analysis tracked the progression of the material transition as a function of extrudate volume. The resulting transition curves were compared against a standard nozzle configuration. Optical microscopy of cross-sections also demonstrated that the static-mixing nozzle promoted a more uniform bead geometry as well as a more homogeneous internal structure throughout the material transition.

Original language	English
Title of host publication	SAMPE 2022 Conference and Exhibition
Publisher	Soc. for the Advancement of Material and Process Engineering
ISBN (Electronic)	9781934551417
State	Published - 2022
Event	SAMPE 2022 Conference and Exhibition - Charlotte, United States Duration: May 23 2022 → May 26 2022

Publication series

Name	International SAMPE Technical Conference
Volume	2022-May

Conference

Conference	SAMPE 2022 Conference and Exhibition
Country/Territory	United States
City	Charlotte
Period	05/23/22 → 05/26/22

Funding

The authors would also like to acknowledge funding from the State of Tennessee and Tennessee Higher Education Commission (THEC) through their support of the Center for Materials Processing. Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC.

Funders	Funder number
State of Tennessee and Tennessee Higher Education Commission
U.S. Department of Energy
Advanced Manufacturing Office	DE-AC05-00OR22725
Office of Energy Efficiency and Renewable Energy
Tennessee Higher Education Commission

Keywords

Additive Manufacturing
Multiple Materials
Polymer Extrusion

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Cite this

@inproceedings{8c79f802fe094f37b7ee05f4be2af29b,

title = "THE IMPACT OF A STATIC-MIXING NOZZLE ON UNIFORMITY IN MATERIAL EXTRUSION LARGE-SCALE ADDITIVE MANUFACTURING",

abstract = "There are many methods of incorporating more than one material in Additive Manufacturing (AM) processes. Oak Ridge National Laboratory has developed a unique solution that enables in-situ material switching by developing a dual-hopper feed system for Cincinnati{\textquoteright}s Big Area Additive Manufacturing (BAAM) system. Continuous extrusion during a step-change in material feedstock results in a unique blended material transition region that exhibits a heterogeneous internal morphology. To improve mixing of materials during extrusion, a customized static-mixing nozzle was created for use with the BAAM. Single-bead transitions from Material A to B and B to A were printed with the mixing nozzle at a specified screw speed. Compositional analysis tracked the progression of the material transition as a function of extrudate volume. The resulting transition curves were compared against a standard nozzle configuration. Optical microscopy of cross-sections also demonstrated that the static-mixing nozzle promoted a more uniform bead geometry as well as a more homogeneous internal structure throughout the material transition.",

keywords = "Additive Manufacturing, Multiple Materials, Polymer Extrusion",

author = "Brackett, {James C.} and Charles, {Elijah P.} and Smith, {Tyler C.} and Hassen, {Ahmed A.} and Vlastimil Kunc and Duty, {Chad E.}",

note = "Publisher Copyright: Copyright C: This paper is declared a work of the U.S. Government and is not subject to copyright protection in the United States. Copyright 2022. Used by the Society of the Advancement of Material and Process Engineering with permission.; SAMPE 2022 Conference and Exhibition ; Conference date: 23-05-2022 Through 26-05-2022",

year = "2022",

language = "English",

series = "International SAMPE Technical Conference",

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

booktitle = "SAMPE 2022 Conference and Exhibition",

}

Brackett, JC, Charles, EP, Smith, TC, Hassen, AA , Kunc, V & Duty, CE 2022, THE IMPACT OF A STATIC-MIXING NOZZLE ON UNIFORMITY IN MATERIAL EXTRUSION LARGE-SCALE ADDITIVE MANUFACTURING. in SAMPE 2022 Conference and Exhibition. International SAMPE Technical Conference, vol. 2022-May, Soc. for the Advancement of Material and Process Engineering, SAMPE 2022 Conference and Exhibition, Charlotte, United States, 05/23/22.

THE IMPACT OF A STATIC-MIXING NOZZLE ON UNIFORMITY IN MATERIAL EXTRUSION LARGE-SCALE ADDITIVE MANUFACTURING. / Brackett, James C.; Charles, Elijah P.; Smith, Tyler C. et al.
SAMPE 2022 Conference and Exhibition. Soc. for the Advancement of Material and Process Engineering, 2022. (International SAMPE Technical Conference; Vol. 2022-May).

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

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AU - Hassen, Ahmed A.

AU - Kunc, Vlastimil

AU - Duty, Chad E.

N1 - Publisher Copyright: Copyright C: This paper is declared a work of the U.S. Government and is not subject to copyright protection in the United States. Copyright 2022. Used by the Society of the Advancement of Material and Process Engineering with permission.

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N2 - There are many methods of incorporating more than one material in Additive Manufacturing (AM) processes. Oak Ridge National Laboratory has developed a unique solution that enables in-situ material switching by developing a dual-hopper feed system for Cincinnati’s Big Area Additive Manufacturing (BAAM) system. Continuous extrusion during a step-change in material feedstock results in a unique blended material transition region that exhibits a heterogeneous internal morphology. To improve mixing of materials during extrusion, a customized static-mixing nozzle was created for use with the BAAM. Single-bead transitions from Material A to B and B to A were printed with the mixing nozzle at a specified screw speed. Compositional analysis tracked the progression of the material transition as a function of extrudate volume. The resulting transition curves were compared against a standard nozzle configuration. Optical microscopy of cross-sections also demonstrated that the static-mixing nozzle promoted a more uniform bead geometry as well as a more homogeneous internal structure throughout the material transition.

AB - There are many methods of incorporating more than one material in Additive Manufacturing (AM) processes. Oak Ridge National Laboratory has developed a unique solution that enables in-situ material switching by developing a dual-hopper feed system for Cincinnati’s Big Area Additive Manufacturing (BAAM) system. Continuous extrusion during a step-change in material feedstock results in a unique blended material transition region that exhibits a heterogeneous internal morphology. To improve mixing of materials during extrusion, a customized static-mixing nozzle was created for use with the BAAM. Single-bead transitions from Material A to B and B to A were printed with the mixing nozzle at a specified screw speed. Compositional analysis tracked the progression of the material transition as a function of extrudate volume. The resulting transition curves were compared against a standard nozzle configuration. Optical microscopy of cross-sections also demonstrated that the static-mixing nozzle promoted a more uniform bead geometry as well as a more homogeneous internal structure throughout the material transition.

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KW - Polymer Extrusion

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Y2 - 23 May 2022 through 26 May 2022

ER -

THE IMPACT OF A STATIC-MIXING NOZZLE ON UNIFORMITY IN MATERIAL EXTRUSION LARGE-SCALE ADDITIVE MANUFACTURING

Abstract

Publication series

Conference

Funding

Keywords

UN SDGs

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