An increasing desire for higher application temperatures and complex geometries for metallic materials has spurred significant development in additive manufacturing (AM) of metal-ceramic composites; however, limited process-microstructure-properties relationships exist for these materials and processing strategies. Herein we investigate the processing window and high-temperature oxidation performance of an in situ reactive, oxidation-resistant titanium metal-matrix composite reinforced with boron nitride (BN) and boron carbide (B4C) via selective laser melting (SLM) to understand the effects of processing parameters on the in situ reactive characteristics and their effects on build reliability and high-temperature oxidation performance. SLM processing required a 50% decrease in overall energy density relative to titanium's optimal parameters to avoid processing failure due to the high in situ reactivity and exothermic reaction between feedstock materials. A precise balance was necessary to combine decreasing the input energy to avoid cracking due to in situ reactivity while simultaneously providing enough input energy to keep the bulk density as high as possible to limit porosity that contributes to processing inconsistencies at low input energy. Process optimization resulted in composites with as high as 98.3% relative density, comparable to some of the best composites reported in the literature, and high-temperature oxidation testing revealed a 39% decrease in oxidation mass gain compared to Ti6Al4V, owing directly to ceramic reinforcement. Our results indicate that control of SLM processing parameters can yield advanced composites with enhanced properties and characteristics compared to the base material, revealing an array of design possibilities for researchers and engineers in many fields.
more »
« less
This content will become publicly available on February 1, 2025
Heat radiation mitigation in rare-earth pyrosilicate composites: A first principles investigation of refractive index mismatch
Thermal radiation emission poses a challenge for using most existing ceramics for thermal environmental barrier coatings of gas-turbine engines operating at temperatures approaching 1500 °C and beyond. This study presents a strategy for photon transport mitigation in fully dense ceramic composites by increasing the refractive index mismatch between the matrix and particle oxides. We investigate this strategy by analyzing radiative properties in 118 different rare-earth pyrosilicate–pyrochlore ceramic composites. We use density functional theory to predict the optical properties of homogeneous oxides and Lorentz–Mie theory to model scattering at the interfaces of the composite. Our findings demonstrate that increasing the refractive mismatch between the matrix and oxide phases can significantly reduce radiative heat flux. Furthermore, we show that additional thermal radiation suppression can be achieved by increasing the particle size. Our theoretical investigation has the potential to aid in the discovery of new coating ceramic composites and guide their microstructural design.
more »
« less
- Award ID(s):
- 1954621
- NSF-PAR ID:
- 10491720
- Publisher / Repository:
- Elsevier
- Date Published:
- Journal Name:
- Ceramics International
- ISSN:
- 0272-8842
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Abstract. Scattering codes are used to study the optical properties of polar stratospheric clouds (PSCs). Particle backscattering and depolarization coefficients can be computed with available scattering codes once the particle size distribution (PSD) is known and a suitable refractive index is assumed. However, PSCs often appear as external mixtures of supercooled ternary solution (STS) droplets, solid nitric acid trihydrate (NAT) and possibly ice particles, making the assumption of a single refractive index and a single morphology to model the scatterers questionable.Here we consider a set of 15 coincident measurements of PSCs above McMurdo Station, Antarctica, using ground-based lidar, a balloon-borne optical particle counter (OPC) and in situ observations taken by a laser backscattersonde and OPC during four balloon stratospheric flights from Kiruna, Sweden. This unique dataset of microphysical and optical observations allows us to test the performances of optical scattering models when both spherical and aspherical scatterers of different composition and, possibly, shapes are present. We consider particles as STS if their radius is below a certain threshold value Rth and NAT or possibly ice if it is above it. The refractive indices are assumed known from the literature. Mie scattering is used for the STS, assumed spherical. Scattering from NAT particles, considered spheroids of different aspect ratio (AR), is treated with T-matrix results where applicable. The geometric-optics–integral-equation approach is used whenever the particle size parameter is too large to allow for a convergence of the T-matrix method.The parameters Rth and AR of our model have been varied between 0.1 and 2 µm and between 0.3 and 3, respectively, and the calculated backscattering coefficient and depolarization were compared with the observed ones. The best agreement was found for Rth between 0.5 and 0.8 µm and for AR less than 0.55 and greater than 1.5.To further constrain the variability of AR within the identified intervals, we have sought an agreement with the experimental data by varying AR on a case-by-case basis and further optimizing the agreement by a proper choice of AR smaller than 0.55 and greater than 1.5 and Rth within the interval 0.5 and 0.8 µm. The ARs identified in this way cluster around the values 0.5 and 2.5.The comparison of the calculations with the measurements is presented and discussed. The results of this work help to set limits to the variability of the dimensions and asphericity of PSC solid particles, within the limits of applicability of our model based on the T-matrix theory of scattering and on assumptions on a common particle shape in a PSD and a common threshold radius for all the PSDs.more » « less
-
more » « less
Abstract Windows play significant roles in commercial and residential buildings and automobiles, which direct and control light illumination, thermal insulation, natural ventilation, and aesthetics. Various approaches are attempted to make windows “smart” by tailoring their transparency and thermal insulation in response to environmental changes. Hence, there has been much effort to develop smart windows that can dynamically modulate the transmission and reflectance of the visible light and solar radiance into buildings according to weather conditions or personal preferences. Development of smart window materials is also beneficial to applications including wearable sensors, energy harvesting and storage, and medical devices. By carefully matching the refractive indices of nanoparticle (NPs) and polymer matrix, surface chemistry, and their mechanical properties, particle‐embedded polymer composites can exhibit synergistic effects with improved chemical and mechanical stability, enhanced dispersion of NPs, and optimized and stimuli‐responsive optical properties. Here, an overview of recent progresses in the development of smart windows based on electro‐, thermo‐, and mechanoactuations is provided. Additional functionalities, e.g., flexibility, stretchability, and mechanical/chemical stability, can also be achieved by careful choices of NPs and polymers.
-
more » « less
Abstract Additive manufacturing, no longer reserved exclusively for prototyping components, can create parts with complex geometries and locally tailored properties. For example, multiple homogenous material sources can be used in different regions of a print or be mixed during printing to define properties locally. Additionally, heterogeneous composites provide an opportunity for another level of tuning properties through processing. For example, within particulate-filled polymer matrix composites before curing, the presence of an applied electric and/or magnetic fields can reorient filler particles and form hierarchical structures depending on the fields applied. Control of particle organization is important because effective material properties are highly dependent on the distribution of filler material within composites once cured. While previous work in homogenization and effective medium theories have determined properties based upon ideal analytic distributions of particle orientations and spatial location, this work expands upon these methods generating discrete distributions from quasi-Monte Carlo simulations of the electromagnetic processing event. Results of simulations provide predicted microarchitectures from which effective properties are determined via computational homogenization.
These particle dynamics simulations account for dielectric and magnetic forces and torques in addition to hydrodynamic forces and hard particle separation. As such, the distributions generated are processing field dependent. The effective properties for a composite represented by this distribution are determined via computational homogenization using finite element analysis (FEA). This provides a path from constituents, through processing parameters to effective material properties. In this work, we use these simulations in conjunction with a multi-objective optimization scheme to resolve the relationships between processing conditions and effective properties, to inform field-assisted additive manufacturing processes.
The constituent set providing the largest range of properties can be found using optimization techniques applied to the aforementioned simulation framework. This key information provides a recipe for tailoring properties for additive manufacturing design and production. For example, our simulation results show that stiffness for a 10% filler volume fraction can increase by 34% when aligned by an electric field as compared to a randomly distributed composite. The stiffness of this aligned sample is also 29% higher in the direction of the alignment than perpendicular to it, which only differs by 5% from the random case [1]. Understanding this behavior and accurately predicting composite properties is key to producing field processed composites and prints. Material property predictions compare favorably to effective medium theory and experimentation with trends in elastic and magnetic effective properties demonstrating the same anisotropic behavior as a result of applied field processing. This work will address the high computational expense of physics simulation based objective functions by using efficient algorithms and data structures. We will present an optimization framework using nested gradient searches for micro barium hexaferrite particles in a PDMS matrix, optimizing on composite magnetization to determine the volume fraction of filler that will provide the largest range of properties by varying the applied electric and magnetic fields.
-
Abstract Boron nitride nanotubes (BNNTs) are the perfect candidate for nanofillers in high-temperature multifunctional ceramics due to their high thermal stability, oxidation resistance, good mechanical properties, high thermal conductivity, and radiation shielding. In this paper, 3D printed ceramic nanocomposite with 0.1 wt% of BNNT was prepared by fusing it at high temperatures. Samples were built with three different print directions to study the effect of print layers on mechanical performance along with BNNT addition. Dynamic mechanical analysis is performed to study the length effect of nanoscale reinforcements on the mechanical properties of the printed ceramic composites reporting significant improvements up to 55% in bending strength and 72% in bending modulus with just 0.1 wt% BNNT addition. A 63% thermal diffusivity improvement of ceramic by adding BNNTs is observed using laser flash analysis. The bridging and pull-out effect of nanotubes with a longer aspect ratio was observed with high-resolution microscopy. Such composites’ modeling and simulation approaches are crucial for virtual testing and industrial applications. Understanding the effect of nanoscale synthetic fillers for 3D printed high-temperature ceramics can revolutionize future extreme environment structures.more » « less
