Aluminum Alloys for Additive Manufacturing A Metallurgical Perspective of the Modern Economy Joseph R Croteau, MS Materials Engineer NanoAl LLC nanoal.com 8025 Lamon Ave, Suite 446 Skokie, IL 60077 jcroteau@nanoal.com
The Fourth Industrial Revolution 18 th - 19 th Centuries Mechanization Water/Steam Power Textiles, Iron, Steam Engine 1870 1914 Mass Production Electric Power Steel, Oil, Internal Combustion 1980s Now? Digitization Automation The PC, Internet, Telecommunication The Present Smart Factories Super Computing, Big Data, The Internet of Things Industry 4.0 Computerization of manufacturing Enabled by breakthroughs in artificial intelligence, robotics, internet, autonomy, 3D printing, nanotechnology Allows for extreme customization and personalization The Sharing Economy The Maker Movement 2017 Conference for Midwest Nanotechnician Programs 2
What is Additive Manufacturing Subtractive Manufacturing Additive Manufacturing Material is cut from a larger piece until the final shape is achieved Lathe, mill, drill, etc. Components are assembled into a final part (weld, braze, bolt, glue, etc.) VS Successive layers of material are built up until the final shape is achieved 2017 Conference for Midwest Nanotechnician Programs 3
Additive Manufacturing Technologies Materials: plastics, rubbers, ceramics, metals, composites, biomaterials, construction materials, nuclear fuels, electronic circuits, in-situ composites, reactive materials.. 2017 Conference for Midwest Nanotechnician Programs 4
Powder Bed Fusion 2017 Conference for Midwest Nanotechnician Programs 5
Advantages to Additive Manufacturing Left: LEAP Fuel nozzle, 18 parts reduced to 1, improved fluid dynamics Right: Turboprop engine, 800+ parts reduced to 30, reduced weight, eliminated parasitic loss, improved efficiency. Both manufactured by GE Additive 2017 Conference for Midwest Nanotechnician Programs 6
NanoAl Introduction Dr. Nhon Vo CEO/CTO, Co-Founder Dr. David Dunand CSO and Co-Founder Dr. David Seidman CSO and Co-Founder Dr. Davaadorj Bayansn Metallurgical Engineer Francisco Flores Materials Engineer Evander Ramos Materials Technician NanoAl s history of innovation includes: High strength, high conductivity, and creep resistant wire and cable High strength, weldable sheet products High strength casting alloys Custom alloy design and novel solutions 2017 Conference for Midwest Nanotechnician Programs 7
Aluminum Applications F1 Cylinder Head 60% weight reduction 10X more surface area for cooling Improved vibration management Manufactured by FIT West 2017 Conference for Midwest Nanotechnician Programs 8
Aluminum Applications Aerospace Heat Exchanger Complex geometry is impossible by any other method Improved cooling efficiency Weight reduction 2017 Conference for Midwest Nanotechnician Programs 9
Designing a Strong Alloy Solid-Solution Strengthening Single atoms Precipitates 5 100 nm Dispersion Strengthening Dispersoids 100 300 nm Secondary Phases 100 s nm 10 s μm Grain Boundary Strengthening 10 s nm 100 s μm Montero Sistiaga, et al. Jounral of Materials Processing Technology 238 (2016) 437-445 Hierarchy of Scale C. Booth Morrison, D. Dunand, D. Seidman. Acta Materialia 60 (2012) 3643-3654 Picometers Nanometers Micrometers Millimeters 2017 Conference for Midwest Nanotechnician Programs 10
Characterization of Nanoscale Features Atom Probe Tomography (APT) Resolution: single atoms Atomic Force Microscopy (AFM) Resolution: < 1 nm Scanning Electron Microscopy (SEM) Resolution: < 10 nm Transmission Electron Microscopy (TEM) Resolution: 50 pm Hierarchy of Scale X-Ray Diffraction (XRD) Resolution: atomic spacing Picometers Nanometers Micrometers Millimeters 2017 Conference for Midwest Nanotechnician Programs 11
Atom Probe Tomography (APT) Surface of material is vaporized one layer at a time Instrument detects the element and its position in the material Software reconstructs a 3D model First instrument which allowed us to see an atom C. Booth Morrison, D. Dunand, D. Seidman. Acta Materialia 59 (2011) 7029-7042 2017 Conference for Midwest Nanotechnician Programs 12
Transmission Electron Microscopy (TEM) Specimen is thinned so that it becomes electron transparent About 100 nm Electron beam is generated in the column, passes through the specimen, and is recorded by a CCD camera below the specimen Reveals crystal structure and chemistry with subnanometer resolution E. A. Marquis, D. Dunand, D. Seidman. Acta Materialia 51 (2003) 4751-4760 2017 Conference for Midwest Nanotechnician Programs 13
Atomic Force Microscopy (AFM) AFM probe taps along the material surface measures topography and surface chemistry Recently developed scanning Kelvin probe force microscopy (SKPFM) is used to identify micro-galvanic couples between metal and strengthening phases Micro-galvanic couples influence overall corrosion SKPFM measures corrosion potential between phases analogous to electric potential of a battery R. L. Liu, M. F. Hurley, A. Kvryan, G. Williams, J. R. Scully, N. Birbilis. Scientific Reports 6, 28747 (2016) 2017 Conference for Midwest Nanotechnician Programs 14
X-Ray Diffraction (XRD) Identifies the crystal structure of all phases present in the sample Determines relative quantity of all phases present Can measure grain size, lattice strain, and atomic spacing 2017 Conference for Midwest Nanotechnician Programs 15
Scanning Electron Microscopy (SEM) Electrons are generated in the column above the specimen, and are reflected off the specimen towards the detector Advantages of SEM include large field of view, large depth of field, and large depth of focus Gives topographic, chemical, and crystallographic information 2017 Conference for Midwest Nanotechnician Programs 16
Companies Investing in Additive 2017 Conference for Midwest Nanotechnician Programs 17
Economic Opportunities in Additive Additive manufacturing was a $5.1B industry in 2015 NIST projects it to be a $50B industry by 2030, and a $100B industry by 2040 GE Additive Believes there to be a $76B opportunity in additive Started on September 27, 2016 As of this week they have 1,000 employees They will have 20,000 employees involved in additive by the end of 2017 Plan to sell 10,000 3D printers in next 10 years Investing $10M in schools in next 5 years 2017 Conference for Midwest Nanotechnician Programs 18
NSF 2014 Educational Workshop on AM Ensure that AM curricula provide students with an understanding of AM and traditional manufacturing processes to enable them to effectively select the appropriate process for product realization; the relationships between AM processes and material properties; Design for AM, including computational tools for AM design as well as frameworks for process selection, costing, and solution generation that take advantage of AM capabilities. Establishment of a national network for AM education that, by leveraging existing distributed educational models and NSF Programs, provides open source resources as well as packaged activities, courses, and curricula for all educational levels (K-Gray). Promote K-12 educational programs in STEAM and across all formal and informal learning environments in order to leverage the unique capabilities of AM in engaging students in hands-on, tactile, and visual learning activities. Provide support for collaborative and community-oriented maker spaces that promote awareness of AM among the public and provide AM training programs for incumbent workers and students seeking alternative pathways to gain AM knowledge and experience. https://community.asme.org/additive_manufacturing/m/default.aspx 2017 Conference for Midwest Nanotechnician Programs 19
Thank You! Joseph R Croteau, MS Materials Engineer NanoAl LLC nanoal.com 8025 Lamon Ave, Suite 446 Skokie, IL 60077 jcroteau@nanoal.com 20