Atomic layer deposition of oxide coatings on porous metal and polymer structures fabricated by additive manufacturing methods (laser-based powder bed fusion, material extrusion, material jetting)

Kaindl, Reinhard; Homola, Tomáš; Rastelli, Armando; Schwarz, Albin; Tarre, Aivar; Kopp, Dietmar; Coclite, Anna Maria; Görtler, Michael; Meier, Benjamin; Prettenthaler, Bernd; Belegratis, Maria; Lackner, J.M.; Waldhauser, W.

doi:10.1016/j.surfin.2022.102361

Cited by 8 publications

(4 citation statements)

References 42 publications

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“…250 °C, it is intriguing that the thinner films in TiO 2 -50-10 and TiO 2 -100-10 developed as amorphous coatings, while the thicker ones in TiO 2 -250-10 and TiO 2 -500-10 exhibited crystalline properties. Crystallization thus appears to be thickness-dependent; i.e., it starts with individual crystal grains (S6A) that form after a specific number of ALD cycles, and above a certain TiO 2 layer thickness, this crystallization process extends over the entire deposited film. , …”

Section: Resultsmentioning

confidence: 99%

Highly Porous Polymer Beads Coated with Nanometer-Thick Metal Oxide Films for Photocatalytic Oxidation of Bisphenol A

Ballai,

Kotnik,

Finšgar

et al. 2023

ACS Appl. Nano Mater.

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Highly porous metal oxide–polymer nanocomposites are attracting considerable interest due to their unique structural and functional features. A porous polymer matrix brings properties such as high porosity and permeability, while the metal oxide phase adds functionality. For the metal oxide phase to perform its function, it must be fully accessible, and this is possible only at the pore surface, but functioning surfaces require controlled engineering, which remains a challenge. Here, highly porous nanocomposite beads based on thin metal oxide nanocoatings and polymerized high internal phase emulsions (polyHIPEs) are demonstrated. By leveraging the unique properties of polyHIPEs, i.e., a three-dimensional (3D) interconnected network of macropores, and high-precision of the atomic-layer-deposition technique (ALD), we were able to homogeneously coat the entire surface of the pores in polyHIPE beads with TiO2-, ZnO-, and Al2O3-based nanocoatings. Parameters such as nanocoating thickness, growth per cycle (GPC), and metal oxide (MO) composition were systematically controlled by varying the number of deposition cycles and dosing time under specific process conditions. The combination of polyHIPE structure and ALD technique proved advantageous, as MO-nanocoatings with thicknesses between 11 ± 3 and 40 ± 9 nm for TiO2 or 31 ± 6 and 74 ± 28 nm for ZnO and Al2O3, respectively, were successfully fabricated. It has been shown that the number of ALD cycles affects both the thickness and crystallinity of the MO nanocoatings. Finally, the potential of ALD-derived TiO2-polyHIPE beads in photocatalytic oxidation of an aqueous bisphenol A (BPA) solution was demonstrated. The beads exhibited about five times higher activity than nanocomposite beads prepared by the conventional (Pickering) method. Such ALD-derived polyHIPE nanocomposites could find wide application in nanotechnology, sensor development, or catalysis.

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Section: Resultsmentioning

confidence: 99%

Highly Porous Polymer Beads Coated with Nanometer-Thick Metal Oxide Films for Photocatalytic Oxidation of Bisphenol A

Ballai,

Kotnik,

Finšgar

et al. 2023

ACS Appl. Nano Mater.

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“…A new frontier of research is emerging due to the unique geometry of AM components for targeted application areas. For example, electroless nickel coating processes [ 167 ] and atomic layer deposition (ALD) [ 168 ] can coat complex and three-dimensional structures uniformly, including hidden surfaces. The work on the coating area of surface-finished AM components is a new frontier of research and is vast in scope.…”

Section: Future Directionsmentioning

confidence: 99%

An Overview of the Latest Progress in Internal Surface Finishing of the Additively Manufactured Metallic Components

Davoodi,

Taghian,

Carbone

et al. 2023

Materials

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Fast progress in near-net-shape production of parts has attracted vast interest in internal surface finishing. Interest in designing a modern finishing machine to cover the different shapes of workpieces with different materials has risen recently, and the current state of technology cannot satisfy the high requirements for finishing internal channels in metal-additive-manufactured parts. Therefore, in this work, an effort has been made to close the current gaps. This literature review aims to trace the development of different non-traditional internal surface finishing methods. For this reason, attention is focused on the working principles, capabilities, and limitations of the most applicable processes, such as internal magnetic abrasive finishing, abrasive flow machining, fluidized bed machining, cavitation abrasive finishing, and electrochemical machining. Thereafter, a comparison is presented based on which models were surveyed in detail, with particular attention to their specifications and methods. The assessment is measured by seven key features, with two selected methods deciding their value for a proper hybrid machine.

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“…These techniques deposit droplets of liquid photopolymers from piezo/thermal printing heads which are cured using UV light lamps. In its simplest working, material (build) is injected over the build platform via printhead utilizing either piezoelectric or thermal means at pre-specified areas [109,110]. These deposited droplets get solidified and form the first layer.…”

Section: Am Processes Based On Materials Jettingmentioning

confidence: 99%

A review of various materials for additive manufacturing: Recent trends and processing issues

Srivastava

Rathee²,

Patel³

et al. 2022

Journal of Materials Research and Technology

116

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Atomic layer deposition of oxide coatings on porous metal and polymer structures fabricated by additive manufacturing methods (laser-based powder bed fusion, material extrusion, material jetting)

Cited by 8 publications

References 42 publications

Highly Porous Polymer Beads Coated with Nanometer-Thick Metal Oxide Films for Photocatalytic Oxidation of Bisphenol A

Highly Porous Polymer Beads Coated with Nanometer-Thick Metal Oxide Films for Photocatalytic Oxidation of Bisphenol A

An Overview of the Latest Progress in Internal Surface Finishing of the Additively Manufactured Metallic Components

A review of various materials for additive manufacturing: Recent trends and processing issues

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