Additive manufacturing,quasi-static and dynamic compressive behaviours of ceramic lattice structures

Ceramic lattice structures (CLSs) are used for construction in common and extreme environments because of the extraordinary properties of ceramics. In this study, we designed and additively manufactured CLSs with distinct structural parameters to explore their quasi-static and dynamic compressive behaviours in detail. It was demonstrated that both the relative density (?ρ) and inclination angle (ω) had a significant impact on the quasi-static and dynamic mechanical properties of the CLSs. Furthermore, the mathematical relationships between the quasi-static compressive properties, including quasi-static compressive strength (QS), quasi-static Young’s modulus (QY), and quasi-static energy absorption (QE), versus ?ρ and ω obeyed the Gibson–Ashby and Deshpande and Fleck models, respectively. It was revealed by experiment and simulation that as the stiffness increased, the quasi-static failure mode of the CLSs changed from a parallel-vertical-inclined mixed mode to a parallel-vertical mode. In addition, the relationship between the dynamic mechanical properties of the CLSs versus ?ρ and ω also followed the Gibson–Ashby and Deshpande and Fleck models. The exceptional dynamic increase factor indicated that CLSs are highly suitable for extreme environments. These findings will aid in the research and development of customised additively manufactured CLSs.     

The effect of particle size distribution on the microstructure and properties of Al2O3 ceramics formed by stereolithography

Stereolithography (SL) shows advantages for preparing alumina-based ceramics with complex structures. The effects of the particle size distribution, which strongly influence the sintering properties in ceramic SL, have not been systematically explored until now. Herein, the influence of the particle size distribution on SL-manufactured alumina ceramics was investigated, including bending strength at room temperature, post-sintering shrinkage, porosity, and microstructural morphology. Seven particle size distributions of alumina ceramics were studied (in μm/μm: 30/5, 20/3, 10/2, 5/2, 5/0.8, 3/0.5, and 2/0.3); a coarse:fine particle ratio of 6:4 was maintained. At the same sintering temperature, the degree of sintering was greater for finer particle sizes. The particle size distribution had a larger influence on flexural strength, porosity and shrinkage than sintering temperature when the particle size distribution difference reached 10-fold but was weaker for 10 μm/2 μm, 5 μm/2 μm and 5 μm/0.8 μm. The sintering shrinkage characteristics of cuboid samples with different particle sizes were studied. The use of coarse particles influenced the accuracy of small-scale samples. When the particle size was comparable to the sample width, such as 30 μm/5 μm and 5 mm, the width shrinkage was consistent with the height shrinkage. When the particle size was much smaller than the sample width, such as 2 μm/0.3 μm and 5 mm, the width shrinkage was consistent with the length shrinkage. The results of this study provide meaningful guidance for future research on applications of SL and precise control of alumina ceramics through particle gradation.     

Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions

One of the main challenges in the laser powder bed fusion (LPBF) process is making dense and defect-free components. These porosity defects are dependent upon the melt pool geometry and the processing conditions. Power-velocity (PV) processing maps can aid in visualizing the effects of LPBF processing variables and mapping different defect regimes such as lack-of-fusion, under-melting, balling, and keyholing. This work presents an assessment of existing analytical equations and models that provide an estimate of the melt pool geometry as a function of material properties. The melt pool equations are then combined with defect criteria to provide a quick approximation of the PV processing maps for a variety of materials. Finally, the predictions of these processing maps are compared with experimental data from the literature. The predictive processing maps can be computed quickly and can be coupled with dimensionless numbers and high-throughput (HT) experiments for validation. The present work provides a boundary framework for designing the optimal processing parameters for new metals and alloys based on existing analytical solutions.     

Authenticity green coffee bean species and geographical origin using near-infrared spectroscopy combined with chemometrics

To prevent the adulteration of agricultural resources and provide a solution to enhance the green coffee bean supply chain, authentication using the near-infrared spectroscopy (NIRS) technique was investigated. Partial least square with discrimination analysis (PLS-DA) models combined with various preprocessing methods were built from NIR spectra of 153 Vietnamese green coffee samples. The model combined with the standard normal variate and the first order of derivative yielded excellent performance in predicting coffee species with the error cross-validation of 0.0261. PLS-DA model of mean centre and first-order derivative spectra also yielded good performance in verifying geographical indication of green coffee with the error of 0.0656. By contrast, the predicting abilities of post-harvest methods were poor. The overall results showed a high potential of the NIRS in online authentication practices.     

Green Measurements for Software Product Based on Sustainability Dimensions

Software is a central component in the modern world and vastly affects the environment’s sustainability. The demand for energy and resource requirements is rising when producing hardware and software units. Literature study reveals that many studies focused on green hardware; however, limited efforts were made in the greenness of software products. Green software products are necessary to solve the issues and problems related to the long-term use of software, especially from a sustainability perspective. Without a proper mechanism for measuring the greenness of a particular software product executed in a specific environment, the mentioned benefits will not be attained. Currently, there are not enough works to address this problem, and the green status of software products is uncertain and unsure. This paper aims to identify the green measurements based on sustainable dimensions in a software product. The second objective is to reveal the relationships between the elements and measurements through empirical study. The study is conducted in two phases. The first phase is the theoretical phase, where the main components, measurements and practices that influence the sustainability of a software product are identified. The second phase is the empirical study that involved 103 respondents in Malaysia investigating current practices of green software in the industrial environment and further identifying the main sustainability dimensions and measurements and their impact on achieving green software products. This study has revealed seven green measurements of software product: Productivity, Usability, Cost Reduction, Employee Support, Energy Efficiency, Resource Efficiency and Tool Support. The relationships are statistically significant, with a significance level of less than 0.01 (p = 0.000). Thus, the hypothesised relationships were all accepted. The contributions of this study revolve around the research perspectives of the measurements to attain a green software product.     

Feasibility of manufacturing of Al2O3–Mo HTCC by hybrid additive process

Additive manufacturing processes make it possible to produce increasingly complex 3D parts. In addition, these numerical processes can be usefully used to manufacture ceramic/metal parts of high dimensional resolution with thermal, electrical and electronic properties of interest for applications in the field of power electronics.In this context, a hybrid additive machine was developed to manufacture ceramic/metal parts. This machine consists in the combination of two additive manufacturing processes: stereolithography and robocasting.Using this hybrid process, the feasibility of HTCC components has been demonstrated by building dielectric alumina by stereolithography and molybdenum conductive network by robocasting. Molybdenum-based metallic formulation adapted to the process and allowing to obtain a high conductive metallic network has been developed. The co-debinding and co-sintering cycles have been optimized to minimize the content of residual carbon and to prevent the oxidation of molybdenum. The alumina/molybdenum interface has also been observed to conclude about a possible delamination between these two materials with different thermal expansion coefficients (CTE). Sintered HTCC parts have been characterized in the domain of hyperfrequency. The frequency responses deviate from the simulation due to a lack of dimensional accuracy of the metallic network.     

Direct writing of textured ceramics using anisotropic nozzles

Direct writing is a unique means to align anisotropic particles for the fabrication of textured ceramics by templated grain growth (TGG). We show that alignment of tabular barium titanate (BT) template particles (20–40 μm width and 0.5–2 μm thickness) in a PIN-PMN-PT matrix powder (d₅₀ = 280 nm) is significantly improved during direct writing using anisotropic nozzles at high printing rates. The particle orientation distribution in as-printed filaments, and the texture orientation distribution in sintered ceramic filaments are shown to directly correlate with COMSOL Multiphysics-predicted torque distributions for direct writing with aspect ratio 2, 3 and 5 oval nozzles. Electromechanical strain properties of the textured piezoelectric ceramics significantly improved relative to random ceramics when printed with anisotropic nozzles. Simulations of aspect ratio 20 nozzles and nozzles with interior baffles demonstrate significantly increased torque and near elimination of constant shear stress cores (i.e. plug flow).     

Additive manufacturing of bipolar plates for hydrogen production in proton exchange membrane water electrolysis cells

Water electrolysis is a process that can produce hydrogen in a clean way when renewable energy sources are used. This allows managing large renewable surpluses and transferring this energy to other sectors, such as industry or transport. Among the electrolytic technologies to produce hydrogen, proton exchange membrane (PEM) electrolysis is a promising alternative. One of the main components of PEM electrolysis cells are the bipolar plates, which are machined with a series of flow distribution channels, largely responsible for their performance and durability. In this work, AISI 316L stainless steel bipolar plates have been built by additive manufacturing (AM), using laser powder bed fusion (PBF-L) technology. These bipolar plates were subjected to ex-situ corrosion tests and assembled in an electrolysis cell to evaluate the polarization curve. Furthermore, the obtained results were compared with bipolar plates manufactured by conventional machining processes (MEC). The obtained experimental results are very similar for both manufacturing methods. This demonstrates the viability of the PBF-L technology to produce metal bipolar plates for PEM electrolyzers and opens the possibilities to design new and more complex flow distribution channels and to test these designs in initial phases before scaling them to larger surfaces.     

Mechanical properties of Al2O3 and Al2O3/Al with Gyroid structure obtained by stereolithographic additive manufacturing and melt infiltration

To obtain both plasticity and toughness of the material at the same time, various manufacturing techniques of ceramic-metal composites and structures have been studied. In this work, a bio-inspired Al₂O₃ ceramic scaffold with Gyroid structure was designed and prepared by stereolithographic (SL) additive manufacturing, then the Al₂O₃/Al ceramic-metal hybrid structure was prepared by infiltrating molten Al into the Al₂O₃ ceramic structure. The performances of the Al₂O₃ ceramic scaffold and the Al₂O₃/Al ceramic-metal hybrid structure were compared and analyzed by a quasi-static compression experiment. The quasi-static compressive strength of the pristine Al₂O₃ scaffold was 14.36 MPa, while that of the Al₂O₃/Al ceramic-metal hybrid structure was up to 89.06 MPa. Moreover, the plasticity of the Al₂O₃/Al ceramic-metal hybrid structure was much higher than that of the Al₂O₃ scaffold. During compression, the Al₂O₃/Al ceramic-metal hybrid structure had excellent energy absorption, reaching up to 2569.16 KJ/m³, 15 times that of the Al₂O₃ scaffold. Therefore, this method can obtain materials with excellent ductility and toughness.