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- All Subjects: Nanoporous metals
Description
The goal of our research was to develop and validate a method for predicting the mechanical behavior of Additively Manufactured multi-material honeycomb structures. Multiple approaches already exist in the field for modeling the behavior of cellular materials, including the bulk property assumption, homogenization and strut level characterization [1]. With the bulk property approach, the structure is assumed to behave according to what is known about the material in its bulk formulation, without regard to its geometry or scale. With the homogenization technique, the specimen that is being tested is treated as a solid material within the simulation environment even if the physical specimen is not. Then, reduced mechanical properties are assigned to the specimen to account for any voids that exist within the physical specimen. This approach to mechanical behavior prediction in cellular materials is shape dependent. In other words, the same model cannot be used from one specimen to the next if the cell shapes of those lattices differ in any way. When using the strut level characterization approach, a single strut (the connecting member between nodes constituting a cellular material) is isolated and tested. With this approach, there tends to be a significant deviation in the experimental data due to the small size of the isolated struts. Yet it has the advantage of not being shape sensitive, at least in principle. The method that we developed, and chose to test lies within the latter category, and is what we have coined as the Representative Lattice Element (RLE) Method. This method is modeled after the well-established Representative Volume Element (RVE) method [2]. We define the RLE as the smallest unit over which mechanical tests can be conducted that will provide results which are representative of the larger lattice structure. In other words, the theory is that a single member (or beam in this case) of a honeycomb structure can be taken, tests can be conducted on this member to determine the mechanical properties of the representative lattice element and the results will be representative of the mechanical behavior whole structure. To investigate this theory, we designed specimens, conducted various tensile and compression tests, analyzed the recorded data, conducted a micromechanics study, and performed structural simulation work using commercial Finite Element Analysis software.
ContributorsSalti, Ziyad Zuheir (Co-author) / Eppley, Trevor (Co-author) / Bhate, Dhruv (Thesis director) / Song, Kenan (Committee member) / Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
Nanoparticle (NP) assembly is critical where NPs are organized into complex superstructures through direct and indirect interactions. Long-range NP orders have nanoscale locational selectivity, orientational alignment, and scalable micropatterning, which are indispensable for enabling multiple functionalities and improving the performances of different systems. Though nanoparticles can self-assemble into organized nanostructures via simple drying thermodynamics, scalability has been a primary issue. Thus, this research focuses on more scalable manufacturing for directed NP assembly. First, 3D printing was used for template fabrications with varying topology features. Next, nanoparticle engineering with colloidal and surface studies leads to desirable NP packing on template surfaces. Finally, the processed devices will also demonstrate a few applications of surface micropatterning with nanoscale particle orders. Specifically, a few manufacturing procedures involve (i) stereolithography (SLA)/layer-by-layer dip coating, (ii) continuous liquid interface projection (CLIP)/ink writing, (iii) fused deposition melting (FDM)/direct ink writing, and (iv) multiphase direct ink writing (MDIW)/wet etching. To demonstrate the applicability of hybrid manufacturing, a broad range of nanoparticles, including carbon nanofibers (CNFs), MXene nanoflakes, and boron nitride nanoplatelets (BNNPs) were studied in this research. With well-managed template physics and NP dispersion control, nanoparticle orientational alignment and positional preferences are driven by short- and long-range intermolecular interactions (e.g., convective, van der Waals, capillarity, shear, and other secondary bonding). The printed devices displayed multifunctional properties, i.e., anisotropic conductivity, piezoresistive and chemical sensitivity, mechanical durability, and heat dissipation capabilities, for microelectronic applications. This fabrication technique shows enormous potential for rapid, scalable, and low-cost manufacturing of hierarchical structures, especially for micropatterning of nanoparticles not easily accessible through conventional processing methods.
ContributorsJambhulkar, Sayli (Author) / Song, Kenan (Thesis advisor) / Arizona State University (Publisher)
Created2023
Description
In recent years, the scientific community around the synthesis and processing of nanoporous metals is striving to integrate them into powder metallurgy processes such as additive manufacturing since it has a potential to fabricate 3D hierarchical high surface area electrodes for energy applications. Recent research in dealloying – a versatile method for synthesizing nanoporous metals – emphasized the need in understanding its process-structure relationships to independently control the relative density, ligament and pore sizes with good process reproducibly. In this dissertation, a new understanding of the dealloying process is presented for synthesizing (i) nanoporous gold thin-films and (ii) nanoporous Cu spherical powders with an emphasis on understanding variability in their process-structure relationships and process scalability. First, this work sheds the light on the nature of the dealloying front and its percolation along the grain boundaries in nanocrystalline gold-silver thin films by studying the early stages of ligament nucleation. Additionally, this work analyses its variability by investigating new process variables such as (i) equilibration time and (ii) precursor aging and their impacts in achieving process reproducibility. The correlation of relative density with ligament size is contextualized with state-of-the-art data mining research. Second, this work provides a new methodology for large scale production of nanoporous Cu powder and demonstrates its integration with powder casting to fabricate porous conductive electrode. By understanding the influence of etching solution concentration and titration methodology on the structure and composition of nanoporous Cu, it was possible to fabricate precipitate-free powders at high throughputs. Further, the nature of oxygen incorporation into porous Cu powder was studied as a function of surface-to-volume ratio of powder in atmospheric conditions. To consolidate powders into parts via open-die casting, this work harvests Ostwald Ripening phenomena associated with thermal coarsening in nanoporous metals to weld them at low temperatures (approximately one-third of its melting temperature). This work represents a major step towards the integration of nanoporous Cu feedstocks into additive manufacturing.
ContributorsNiauzorau, Stanislau (Author) / Azeredo, Bruno (Thesis advisor) / Sieradzki, Karl (Committee member) / Song, Kenan (Committee member) / Chawla, Nikhilesh (Committee member) / Arizona State University (Publisher)
Created2022
Description
This dissertation is focused on the rheology scaling of metal particle reinforced polymermatrix composite made of solid and nanoporous metal powders to enable their
continuous 3D printing at high (>60vol%) metal content. There remained a specific
knowledge gap on how to predict successful extrusion with densely packed metals by
utilizing their suspension melt rheological properties. In the first project, the scaling of
the dynamic viscosity of melt-extrudate filaments made of Polylactic acid (PLA) and
gas-atomized solid NiCu powders was studied as a function of the metal’s volumetric
packing and feedstock pre-mixing strategies and correlated to its extrudability
performance, which fitted well with the Krieger-Dougherty analytical model. 63.4
vol% Filaments were produced by employing solution-mixing strategy to reduce
sintered part porosity and shrinkage. After sintering, the linear shrinkage dropped by
76% compared to the physical mixing. By characterizing metal particle reinforced
polymer matrix composite feedstock via flow-sweep rheology, a distinct extension of
shear-thinning towards high shear rates (i.e. 100 s-1) was observed at high metal content
– a result that was attributed to the improved wall adhesion. In comparison, physically mixed filament failed to sustain more than 10s-1 shear rate proving that they were prone
to wall slippage at a higher shear rate, giving an insight into the onset of extrusion
jamming. In the second project, nanoporous copper made out of electroless chemical
dealloying was utilized as fillers, because of their unique physiochemical properties.
The role of capillary imbibition of polymers into metal nanopores was investigated to
understand their effect on density, zero-shear viscosity, and shear thinning. It was
observed that, although the polymeric fluid’s transient concentration regulates its
wettability, the polymer chain length ultimately dictates its melt rheology, which consequentially facilitates densification of pores during vacuum annealing. Finally, it
was demonstrated that higher imbibition into nanopores leads to extrusion failure due
to a combined effect of volumetric packing increase and nanoconfinement, providing a
deterministic materials design tool to enable continuous 3D printing. The outcome of
this study might be beneficial to integrate nanoporous metals into binder-based 3D
printing technology to fabricate interdigitated battery electrodes and multifunctional 3D
printed electronics.
ContributorsHasib, Amm (Author) / Azeredo, Bruno (Thesis advisor) / Song, Kenan (Thesis advisor) / Nian, Qiong (Committee member) / Kwon, Beomjin (Committee member) / Li, Xiangjia (Committee member) / Arizona State University (Publisher)
Created2022
Description
Photocatalytic activity of titanium dioxide (titania or TiO2) offers enormous potential in solving energy and environmental problems. Immobilization of titania nanoparticles on inert substrates is an effective way of utilizing its photocatalytic activity since nanoparticles enable high mass-transport, and immobilization avoids post-treatment separation. For competitive photocatalytic performance, the morphology of the substrate can be engineered to enhance mass-transport and light accessibility. In this work, two types of fiber architectures (i.e., dispersed polymer/titania phase or D-phase, and multi-phase polymer-core/composite-shell fibers or M-phase) were explored as effective substrate solutions for anchoring titania. These fibers were fabricated using a low-cost and scalable fiber spinning technique. Polymethyl methacrylate (PMMA) was selected as the substrate material due to its ultraviolet (UV) transparency and stability against oxidative radicals. The work systematically investigates the influence of the fiber porosity on mass-transport and UV light scattering. The properties of the fabricated fiber systems were characterized by scanning electron microscopy (SEM), Brunauer–Emmett–Teller (BET), UV-vis spectrophotometry (UV-vis), and mechanical analysis. The photocatalytic performance was characterized by monitoring the decomposition of methylene blue (MB) under UV (i.e., 365 nm) light. Fabrication of photocatalytic support structures was observed to be an optimization problem where porosity improved mass transport but reduced UV accessibility. The D-phase fibers demonstrated the highest MB degradation rate (i.e., 0.116 min-1) due to high porosity (i.e., 33.2 m2/g). The M-phase fibers reported a better degradation rate compared to a D-phase fibers due to higher UV accessibility efficiency.
ContributorsKanth, Namrata (Author) / Song, Kenan (Thesis advisor) / Tongay, Sefaattin (Thesis advisor) / Kannan, Arunachala Mada (Committee member) / Arizona State University (Publisher)
Created2020