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    Item type:Publication, Access status: with files ,
    Material extrusion of metals: Enabling multi-material alloys in additive manufacturing
    (Elsevier, 2024-03)
    Asami, Mohammad Karim
    ;
    Crego Lozares, Jose Manuel
    ;
    Ullah, Abid
    ;
    Bossen, Bastian
    ;
    Clague, Leighton Shane
    This article discusses the use of Material Extrusion of Metals (MEX/M - defined in ISO/ASTM 52900) technology for producing multi-material components, which offers a cost-effective and efficient method without requiring major adaptations to existing equipment. The article presents the successful manufacture of 316L/17–4PH multi-alloy steel cubes for four different sintering temperatures using commercially available equipment and feedstock. The feasibility study of the multi-material samples was supported by analyzing the shrinkage, optical density, and microstructure as output parameters. Unlike other works, the multi-material produced parts showed regular shrinkage behaviour and no major deformation, indicating the possibility of creating functional parts without the need for post-processing. Interestingly, relevant findings were made on the different shrinkage values obtained for the constellations considered. Further in-depth investigation of each parameter involved in all the stages of the chain value (extrusion, debinding, and sintering) will be key to support the present results. Additional research into the mechanical and magnetic properties of the samples produced could lead this combination of materials to applications in various industries including automotive and aerospace.
    Publicationtype: Journal Article
      53  159
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    Item type:Publication, Access status: with files ,
    Design and numerical assessment of an additively manufactured Schwarz diamond triply periodic minimal surface fluid-fluid heat exchanger
    (American Institute of Physics (AIP), 2023-11)
    Röver, Tim
    ;
    Kuehne, Maxim
    ;
    Bischop, Floyd
    ;
    Clague, Leighton
    ;
    Bossen, Bastian
    In aerospace, thermal applications demand compact, lightweight, and efficient heat exchangers. Additive manufacturing processes offer the potential to create highly complex structures that are not achievable through traditional manufacturing methods. This work presents the development of an additively manufactured fluid-fluid heat exchanger that shows the potential to enhance the performance, reduce weight, and increase compactness compared to a conventional plate heat exchanger. A numerical model of the conventional plate heat exchanger was created, and fluid dynamics simulations with heat transfer were performed. Validation of the simulations was done by experiments. Then, a novel heat exchanger was designed using a bottom-up approach and investigated at different levels of complexity using computational fluid dynamics. The internal structure of the final heat exchanger consists of a repeating triply periodic Schwarz diamond minimum surface elongated in the direction of flow. The heat exchanger was manufactured with laser powder bed fusion process using AlSi10Mg. It had a 108% higher compactness and 54% lower weight compared to the plate heat exchanger. Numerical analysis yielded the pressure loss in pascal was reduced by 50%-59% while heat transfer in watts was improved by 3%-5%. Future researches should experimentally investigate the thermal and fluid mechanical characteristics of the novel additively manufactured heat exchanger and increase compactness and heat transfer further by analyzing the minimum partition wall thickness and the impact of wall roughness and deposit formation.
    Publicationtype: Journal Article
      82  162