The Gas Carburization of Linear Cellular Alloys as a Novel Alloy Development Tool

Dial, Laura; Sanders, T. H.; Cochran, Jack

doi:10.1007/s11661-011-0973-8

Cited by 5 publications

(3 citation statements)

References 13 publications

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“…The upper range is nearly twice the reported upper values for the plastic strain energies of a variety of steel foams (≈19–68 MJ m −3 ) of similar relative densities . Optimization of the chemical reduction and thermal sintering parameters (e.g., times, temperatures, and particle size), changes in the cellular architecture, and alloying of the pure iron and nickel cellular materials (e.g., by using prealloyed powders, adding elemental powders directly to the inks, pack cementation, or carburization) could further improve the mechanical properties and expand the range of applications for these cellular materials.…”

Section: Resultsmentioning

confidence: 78%

Iron and Nickel Cellular Structures by Sintering of 3D‐Printed Oxide or Metallic Particle Inks

et al. 2016

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Inks comprised of metallic Fe or Ni powders, an elastomeric binder, and graded volatility solvents are 3D-printed via syringe extrusion and sintered to form metallic cellular structures. Similar structures are created from Fe 2 O 3 and NiO particle-based inks, with an additional hydrogen reduction step before sintering. All sintered structures exhibit 92-98% relative density within their struts, with neither cracking nor visible warping despite extensive volumetric shrinkage (%70-80%) associated with reduction (for oxide powders) and sintering (for both metal and oxide powders). The cellular architectures, with overall relative densities of 32-49%, exhibit low stiffness (1-6 GPa, due to the particular architecture used), high strength (4-31 MPa), and high ductility, leading to excellent elastic and plastic energy absorption, when subjected to uniaxial compression. IntroductionCellular materials exhibit numerous advantages over dense materials due to their high specific stiffness, strength, damping, energy absorption, and surface areas. [1][2][3][4] Both iron and nickel, pure or alloyed, have potential uses in cellular architectures for energy storage, [2,[5][6][7] emissions control, [2] catalyst supports, [1,8] and structural applications. [1,3,4,[8][9][10] The micro-architectures of ordered, periodic cellular materials such as scaffolds, honeycombs, lattices, and trusses can be optimized to provide additional improvement on these properties over randomly oriented cellular architectures. [8,[11][12][13] However, the widespread commercial and industrial adoption of cellular metal structures has been hindered by the fact that they are difficult and/or costly to manufacture at sufficient scales and rates relative to traditional metallic structures fabricated using long-established manufacturing methods such as casting. This is especially true for high-melting metals such as Fe and Ni which, unlike Al, are difficult to foam in the liquid state.We recently introduced a versatile and simple process for the additive manufacturing of cellular, metallic architectures, where a liquid ink, consisting of a suspension of metal oxide or metal particles, is first 3D-printed into a structure, and this structure is then subjected to sintering, with an intermediate thermochemical reduction step if oxides are used. [14] A similar direct ink writing approach has been used to produce reticulated sheets of TiH 2 that were then rolled or folded into scrolls or origami shapes [15,16] and Ti-6Al-4V scaffolds for bone implants. [17][18][19] Unlike established metal additive manufacturing methods (e.g., selective laser sintering or electron-beam sintering or melting [20] ), our extrusion-based method can be utilized to 3D-print complex architectures comprised of many layers from an extensive range of materials (e.g., ceramics, metals, biologics) with no required drying time and with a single 3D-printer at room temperature. [14,21] In our previous work, we 3D-printed, reduced,[*] Prof.

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Section: Resultsmentioning

confidence: 78%

Iron and Nickel Cellular Structures by Sintering of 3D‐Printed Oxide or Metallic Particle Inks

et al. 2016

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“…Among the many established approaches for using metallic powders to create metallic architectures directly, there have been several previous examples that utilize the general approach of creating metal oxide powder objects and transforming them into disordered metallic foams and linear cellular architectures . In these instances, powder‐based, metal‐oxide green bodies are created and subsequently thermochemically reduced and sintered at elevated temperatures in reducing atmosphere (e.g., H 2 gas) to produce metallic structures with water vapor as a byproduct.…”

Section: Introductionmentioning

confidence: 99%

Metallic Architectures from 3D‐Printed Powder‐Based Liquid Inks

Jakus

Taylor

Geisendorfer

et al. 2015

Adv Funct Materials

183

109

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A new method for complex metallic architecture fabrication is presented, through synthesis and 3D‐printing of a new class of 3D‐inks into green‐body structures followed by thermochemical transformation into sintered metallic counterparts. Small and large volumes of metal‐oxide, metal, and metal compound 3D‐printable inks are synthesized through simple mixing of solvent, powder, and the biomedical elastomer, polylactic‐co‐glycolic acid (PLGA). These inks can be 3D‐printed under ambient conditions via simple extrusion at speeds upwards of 150 mm s–1 into millimeter‐ and centimeter‐scale thin, thick, high aspect ratio, hollow and enclosed, and multi‐material architectures. The resulting 3D‐printed green‐bodies can be handled immediately, are remarkably robust, and may be further manipulated prior to metallic transformation. Green‐bodies are transformed into metallic counterparts without warping or cracking through reduction and sintering in a H2 atmosphere at elevated temperatures. It is shown that primary metal and binary alloy structures can be created from inks comprised of single and mixed oxide powders, and the versatility of the process is illustrated through its extension to more than two dozen additional metal‐based materials. A potential application of this new system is briefly demonstrated through cyclic reduction and oxidation of 3D‐printed iron oxide constructs, which remain intact through numerous redox cycles.

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“…Some of these applications include transportation, aerospace, environment protect, new power, mechanical chemistry, electronics and construction. The research, development and application of metal honeycombs have lead to a advanced technology, especially in lager scale manufacturing metal supports of exhaust gas catalyst [1][2][3][4][5].…”

Section: Introductionmentioning

confidence: 99%

Preparation, Structure and Properties of FeCrAl Honeycombs

Zhou

2013

AMR

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FeCrAl alloy powder is used to mix with an additive to prepare a powder mixed paste. FeCrAl alloy honeycombs are fabricated by extruding the powder mixed paste, then dried and sintered. While sintering at 1200°C, with sintering time increase, the volume of sintered honeycombs increase and density decrease. The structure parameters and properties of sintered honeycombs were obtained by measuring and calculating. Results show that wall thickness 0.18~0.23mm, cell number (1/in2) 316~339, clear cross section (%) 69~74, specific surface Sv (sq m/cu dm)2.35~2.52; specific heat capacity Cp(J/g.K) 0.60~0.70, heat conductivity κ (W/m.K) 6.52~6.78. SEM/XRD analysis shows that a large number of oxides formed on the surface of sintered honeycombs during sintering, such as Fe2Cr204, Fe2Si04, Al2O3.These oxides connect together to form film on surface of sintered honeycombs. By impregnating and baking test, the surface of sintered honeycomb can firmly adhere γ-Al2O3catalytic washcoat. The oxide film formed on the surface sintered honeycombs is benefit for adhering and supporting the catalytic active components.

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The Gas Carburization of Linear Cellular Alloys as a Novel Alloy Development Tool

Cited by 5 publications

References 13 publications

Iron and Nickel Cellular Structures by Sintering of 3D‐Printed Oxide or Metallic Particle Inks

Iron and Nickel Cellular Structures by Sintering of 3D‐Printed Oxide or Metallic Particle Inks

Metallic Architectures from 3D‐Printed Powder‐Based Liquid Inks

Preparation, Structure and Properties of FeCrAl Honeycombs

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