This research investigates the design of structurally performant, lightweight architectural elements produced through concrete 3D printing (C3DP). Traditionally, concrete requires dense and sturdy formwork, whose production adds significantly to the total cost and results in massive and heavy parts after demolding. C3DP offers the unique opportunity to both eliminate the need for formwork and to create lighter parts by introducing internal voids and cavities. The advent of additive manufacturing in a broad range of scales, materials, industries, and applications, led to increased interest and intense research into different types of porous structures, their geometry, and structural performance under various boundary conditions. Precise control over the sparse distribution of material allows not only for parts with similar strength at reduced mass but even for modifications of mechanical properties, like turning brittle materials into elastic or shock-absorbent ones. While with powder-based additive manufacturing processes like metal 3D printing, truss-based lattices have become very popular for the light-weighting of parts or to provide tissue growth scaffolds for medical implants, their geometry – a sparse space frame resulting in numerous individual contour islands and accentuated overhangs – cannot as easily be produced by C3DP, which is based on a continuous material extrusion. Alternative types of micro-structures, so-called triply periodic minimal surfaces (TPMS), are better suited for this process as they are, as their name suggests, consisting of one continuous surface dividing space into two separate but interwoven subspaces. TPMS are therefore very popular for the efficient design of heat exchangers. We develop and present a continuous and integrated workflow, in which the architectural elements and their structural requirements are designed through transitioning back and forth between the force and the form diagram using 3D graphic statics [1]. The members and their topology from the abstract graph of the conceptual form diagram are seamlessly connected to the volumetric modeling (VM) framework, responsible for the definition of the part geometry [2]. VM represents form assigned distance functions (SDF) and can easily handle complex topologies and flawless Boolean operations of not only the outer shell geometry but also the internal micro-structural infill patterns (Fig. 1, a). In an iterative feedback loop, the infill can be further optimized to leave the material only along certain internal stress trajectories (force flows). This functional grading controlling the relative density is done based on the FE analysis results. The stress distribution is thereby defined as a three-dimensional field (Fig. 1, b). Its values can factor into the SDF equation and be used to modify the wavelength (periodicity) of the TPMS, the local thickness of the surface shell, the solid to void fraction by shifting the threshold iso-value or even the alignment and orientation of the unit cells (Fig. 1, c). They can be arranged in an orthogonal, polar- or even spherical coordinate system to optimally adapt to structural necessities. The TPMS pattern can also gradually transition from one type into another type along the gradient of a spatial function.
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Novel fabrication tools for dynamic compression targets with engineered voids using photolithography methods
Mesoscale imperfections, such as pores and voids, can strongly modify the properties and the mechanical response of materials under extreme conditions. Tracking the material response and microstructure evolution during void collapse is crucial for understanding its performance. In particular, imperfections in the ablator materials, such as voids, can limit the efficiency of the fusion reaction and ultimately hinder ignition. To characterize how voids influence the response of materials during dynamic loading and seed hydrodynamic instabilities, we have developed a tailored fabrication procedure for designer targets with voids at specific locations. Our procedure uses SU-8 as a proxy for the ablator materials and hollow silica microspheres as a proxy for voids and pores. By using photolithography to design the targets’ geometry, we demonstrate precise and highly reproducible placement of a single void within the sample, which is key for a detailed understanding of its behavior under shock compression. This fabrication technique will benefit high-repetition rate experiments at x-ray and laser facilities. Insight from shock compression experiments will provide benchmarks for the next generation of microphysics modeling.
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- Award ID(s):
- 2020249
- NSF-PAR ID:
- 10422019
- Author(s) / Creator(s):
- ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; more »
- Date Published:
- Journal Name:
- Review of Scientific Instruments
- Volume:
- 93
- Issue:
- 10
- ISSN:
- 0034-6748
- Page Range / eLocation ID:
- 103502
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Abstract Radiative cooling is an emerging cooling technology that can passively release heat to the environment. To obtain a subambient cooling effect during the daytime, chemically engineered structural materials are widely explored to simultaneously reject sunlight and preserve strong thermal emission. However, many previously reported fabrication processes involve hazardous chemicals, which can hinder a material's ability to be mass produced. In order to eliminate the hazardous chemicals used in the fabrication of previous works, this article reports a white polydimethylsiloxane (PDMS) sponge fabricated by a sustainable process using microsugar templates. By substituting the chemicals for sugar, the manufacturing procedure produces zero toxic waste and can also be endlessly recycled via methods widely used in the sugar industry. The obtained porous PDMS exhibits strong visible scattering and thermal emission, resulting in an efficient temperature reduction of 4.6 °C and cooling power of 43 W m−2under direct solar irradiation. In addition, due to the air‐filled voids within the PDMS sponge, its thermal conductivity remains low at 0.06 W (m K)−1. This unique combination of radiative cooling and thermal insulation properties can efficiently suppress the heat exchange with the solar‐heated rooftop or the environment, representing a promising future for new energy‐efficient building envelope material.
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null (Ed.)Because of its far-reaching applications in geophysics and materials science, quartz has been one of the most extensively examined materials under dynamic compression. Despite 50 years of active research, questions remain concerning the structure and transformation of SiO 2 under shock compression. Continuum gas-gun studies have established that under shock loading quartz transforms through an assumed mixed-phase region to a dense high-pressure phase. While it has often been assumed that this high-pressure phase corresponds to the stishovite structure observed in static experiments, there have been no crystal structure data confirming this. In this study, we use gas-gun shock compression coupled with in situ synchrotron x-ray diffraction to interrogate the crystal structure of shock-compressed α-quartz up to 65 GPa. Our results reveal that α-quartz undergoes a phase transformation to a disordered metastable phase as opposed to crystalline stishovite or an amorphous structure, challenging long-standing assumptions about the dynamic response of this fundamental material.more » « less
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Abstract The response of forsterite, Mg2SiO4, under dynamic compression is of fundamental importance for understanding its phase transformations and high‐pressure behavior. Here, we have carried out an in situ X‐ray diffraction study of laser‐shocked polycrystalline and single‐crystal forsterite (
a ‐,b ‐, andc ‐orientations) from 19 to 122 GPa using the Matter in Extreme Conditions end‐station of the Linac Coherent Light Source. Under laser‐based shock loading, forsterite does not transform to the high‐pressure equilibrium assemblage of MgSiO3bridgmanite and MgO periclase, as has been suggested previously. Instead, we observe forsterite and forsterite III, a metastable polymorph of Mg2SiO4, coexisting in a mixed‐phase region from 33 to 75 GPa for both polycrystalline and single‐crystal samples. Densities inferred from X‐ray diffraction data are consistent with earlier gas‐gun shock data. At higher stress, the response is sample‐dependent. Polycrystalline samples undergo amorphization above 79 GPa. For [010]‐ and [001]‐oriented crystals, a mixture of crystalline and amorphous material is observed to 108 GPa, whereas the [100]‐oriented forsterite adopts an unknown phase at 122 GPa. The first two sharp diffraction peaks of amorphous Mg2SiO4show a similar trend with compression as those observed for MgSiO3in both recent static‐ and laser‐driven shock experiments. Upon release to ambient pressure, all samples retain or revert to forsterite with evidence for amorphous material also present in some cases. This study demonstrates the utility of femtosecond free‐electron laser X‐ray sources for probing the temporal evolution of high‐pressure silicate structures through the nanosecond‐scale events of shock compression and release. -
Abstract Sub-surface voids and material heterogeneities resulting from the friction stir welding (FSW) process often necessitate post-weld inspection to ensure the quality of weld obtained from this solid-state welding process. In this context, in-process void detection techniques can potentially help in optimizing the process conditions and thereby reduce expensive and time-consuming post-process inspection of welds. Current in-process void detection techniques rely on approaches that try to directly correlate the part-scale welding quality to void formation, without a fundamental understanding of the underlying mechanics and materials physics that modulate void evolution. In this work, we demonstrate an effective in-process numerical technique that uses process force signals to detect volumetric void formation and connect the variations in the force signals to interactions between the tool probe and the underlying material voids. Our approach relies on a high-fidelity finite element analysis simulation of the FSW process and on correlation of numerically obtained process force signals with the corresponding void structures. This correlation is obtained in the phase-space relating in-plane reaction forces on the tool to the tool rotation angle. We focus on the interactions of the tool geometry and tool motion with the surrounding material undergoing plastic deformation and deduce novel insights into various correlations of tool motion and void formation. Through this approach, we can identify tool-related process conditions that can be optimized to minimize void formation and demonstrate a potential in situ force-based void monitoring method that links to the underlying plastic flow and void structures during the FSW process.more » « less
- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1063/5.0107542
