Additive manufacturing and its societal impact: a literature review

Thirty years into its development, additive manufacturing has become a mainstream manufacturing process. Additive manufacturing build up parts by adding materials one layer at a time based on a computerized 3D solid model. It does not require the use of fixtures, cutting tools, coolants, and other auxiliary resources. It allows design optimization and the producing of customized parts on-demand. Its advantages over conventional manufacturing have captivated the imagination of the public, reflected in recent mainstream publications that call additive manufacturing “the third industrial revolution.” This paper reviews the societal impact of additive manufacturing from a technical perspective. Abundance of evidences were found to support the promises of additive manufacturing in the following areas: (1) customized healthcare products to improve population health and quality of life, (2) reduced environmental impact for manufacturing sustainability, and (3) simplified supply chain to increase efficiency and responsiveness in demand fulfillment. In the mean time, the review also identified the need for further research in the areas of life-cycle energy consumption evaluation and potential occupation hazard assessment for additive manufacturing.     

Aggregation of lead phthalocyanine in blends with polycarbonate

The blends of a nonlinear optical dye with polycarbonate are described and comparisons are made with solutions of the dye in chloroform. Absorption spectra of blends with up to 1 wt % lead tetracumylphenoxy phthalocyanine showed the dye to be primarily in the monomer form. The monomer absorption spectrum and the measured extinction coefficient replicated those in chloroform solution. As the dye concentration increased to 20 wt %, the monomer intensity decreased and new spectral features characteristic of the dimer appeared. The spectra were resolved into contributions of monomer and dimer, and the concentration effect was analyzed according to the monomer/dimer equilibrium. Much higher monomer concentrations were achieved in polycarbonate blends compared to chloroform solutions. It was concluded that when the blends were quenched from the melt, the equilibrium established at the melt temperature was preserved in the solid state glass. Quenching the blend from different melt temperatures confirmed this interpretation. Extrapolation of the temperature dependent equilibrium constant to 25°C yielded a value close to that reported for chloroform solution at 25°C. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 104: 464–469, 2007     

The variable property grain model applied to the zinc oxide-hydrogen sulfide reaction

The variable property grain model, including the effect of grain diffusion resistance, has been applied to experimental results from the reaction of hydrogen sulfide with zinc oxide. Grain radius is assumed to vary under the combined effects of sintering and extent of reaction. Property variations are correlated by the specific surface area, an easily measured quantity. All model parameters with the exception of the grain diffusion coefficient have been evaluated by literature correlations or independent experimental measurements. Significant improvement in the match with experimental data, as compared to the constant property grain model, has been achieved.     

Solar-fuel fired cogeneration plants—Sizing and costing model for molten salt storage systems

The large-scale utilization of solar energy will be facilitated by economical and efficient energy storage. The proposed energy storage systems have been critically reviewed, and capital cost estimates compared on a common basis. A model for sizing an energy storage system is proposed and used to determine the size range of practical interest. Based on selection criteria and relevant data two storage systems have been investigated: an all sodium system and a molten salt system. The design equations, cost estimates, and correlations indicate that, for the energy storage systems developed to date, in the capacity range of 700–2100 MWh, a molten salt, two-tank isolated-type system is the most cost effective and technically feasible for a solar, central receiver, hybrid cogeneration plant. At the extremes of the above range the unit capital cost for the molten salt storage system was found to be 22.8–26.7 $/kWh of stored energy, compared to 43.0–45.4 $/kWh for the sodium storage system.     

An approximate model for sizing and costing a solar thermal collector-central receiver system

An approximate generalized theoretical model is presented for the geometry and energy transfer of a solar thermal collector-central receiver system. Equations permit sizing the receiver, tower, and heliostat field. Cost functions correlate data from Department of Energy studies. Based on a set of assumed conditions, simplified, optimized sizing equations yield the minimum capital cost. The costs of the tower and central receiver will change with plant and equipment cost indices, while heliostat costs are expected to diminish as annual production increases. The heliostat cost is the major cost component even at lowest projected unit cost; therefore optimization tends toward minimum heliostat area. The model permits order-of-magnitude cost estimates to be made very quickly, compared to detailed simulation.     

Performance of personal access communications system-unlicensed B

The FCC has allocated the band between 1920 MHz and 1930 MHz for unlicensed personal communications services (UPCS) using isochronous or circuit operation. The UPCS spectrum is between the licensed PCS spectrum bands of 1850-1910 MHz and 1930-1990 MHz. Terminal interoperability in both the UPCS spectrum on private indoor wireless systems and the licensed spectrum on public PCS systems is desirable and encouraged by the FCC. This paper presents a port channel assignment process for the personal access communications system-unlicensed B (PACS-UB) which abides by the FCC etiquette for UPCS and discusses the corresponding uplink and downlink performance. Uplink power control is employed to improve the uplink performance. PACS-UB has a high degree of commonality with licensed PACS to permit economical licensed/unlicensed terminals and common network services. The results of our simulation show that, at 1% to 2% blocking probability, 99% of downlink local-mean signal-to-noise plus interference ratio (SINR) values are above 17 dB for a 10 to 20 m port separation. For a three-dimensional office environment, the uplink limits the SINR performance, however, with uplink power control, a 5.5 to 7 dB improvement in the uplink SINR can be achieved even for high traffic load     

Dual-metal gate CMOS technology with ultrathin silicon nitride gatedielectric

We report the first demonstration of a dual-metal gate complementary metal oxide semiconductor (CMOS) technology using titanium (Ti) and molybdenum (Mo) as the gate electrodes for the N-metal oxide semiconductor field effect transistors (N-MOSFETs) and P-metal oxide semiconductor field effect transistors (P-MOSFETs), respectively. The gate dielectric stack consists of a silicon oxy-nitride interfacial layer and a silicon nitride (Si₃N₄) dielectric layer formed by a rapid-thermal chemical vapor deposition (RTCVD) process. C-V characteristics show negligible gate depletion. Carrier mobilities comparable to that predicted by the universal mobility model for silicon dioxide (SiO₂) are observed     

Effect of Interphase Structure on the Debonding of Polycarbonate from S-2 Glass Fibers

The effect of interphase structure on the debonding of polycarbonate from S-2 glass fibers has been studied. The shear strength, fracture toughness and hydrolyic stability of the interphases were measured in a single fiber composite of a continuous S-2 glass fiber embedded in a polycarbonate matrix. Polycarbonate oligomers were chemically grafted onto the glass fiber surfaces through use of a silicon tetrachloride intermediary and the properties of the resulting interphases were compared with those of two commercial sizings and ozone-cleaned surfaces. Evaluation was accomplished by measuring the stress transmission across the interphase, τ, by carrying the embedded single fiber fragmentation test to saturation and by using computer simulations and a finite element analysis to calculate the strain energy release rate, G, of the observed fiber-matrix debonding accompanying the first fiber fracture. The oligomer-grafted interphase exhibited improved stress transmissibility and toughness, after 24 hours in boiling water. The tenacity of the tightly bound oligomers was confirmed via DRIFT, TGA and GC/MS experiments on Soxhlet-extracted fibers.

The grafting reaction was modeled on a high surface area silica and studied using solid state NMR to determine reasons for the greater stability of the oligomer-treated surfaces. Measurements of chemical shifts and spin-lattice relaxation times indicate that the oligomers are chemically attached to the surfaces, providing for a well bonded, water resistant interphase. Parallel experiments on a monomeric Bisphenol A-primed silica surface provided evidence that chemical bonding was primarily responsible for the greater hydrolytic stability.     

CFD predictions of flow near impeller blades in baffled stirred vessels: Assessment of computational snapshot approach

The present article summarizes simulations of turbulent flow generated by a Rushton turbine (six blades with disc) and a downflow pitched blade turbine (four blades, 45° inclined) using a computational snapshot approach. The computational snapshot approach proposed by Ranade and Dommeti was extended and generalized to suit impellers of any shape. The approach was implemented using a commercial CFD code, FLUENT (Fluent Inc., USA). Mean flow and turbulence characteristics were computed by solving the Reynolds averaged Navier-Stokes equations combined with the standard k - l turbulence model. The QUICK discretization scheme (with SUPERBEE limiter function) was used to discretize all the governing equations. Preliminary numerical experiments were carried out to identify adequate grid resolution. The predicted results were compared with the comprehensive data set available in the literature. Simulated results show a pair of trailing vortex behind the blades of a turbine. The results were also compared quantitatively in the near-impeller region with the published experimental data and published simulated results using other approaches. The simulations have captured most of the key features of near-impeller flows with sufficient accuracy. The results and conclusions drawn from this study will have important implications for extending the applicability of CFD models to simulate complex stirred reactors.