Joseph R Croteau, MS – Materials Engineer jcroteau@nanoal.com

NanoAl LLC – nanoal.com

8025 Lamon Ave, Suite 446 – Skokie, IL 60077

Aluminum Alloys for Additive ManufacturingA Metallurgical Perspective of the Modern Economy

The Fourth Industrial Revolution

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18th - 19th Centuries Mechanization

Water/Steam Power

Textiles, Iron, Steam

Engine

1870 – 1914 Mass Production

Electric Power

Steel, Oil, Internal

Combustion

1980s – Now? Digitization

Automation

The PC, Internet,

Telecommunication

The Present Smart Factories

Super Computing,

Big Data, The

Internet of Things

“Industry 4.0” Computerization of

manufacturing

Enabled by breakthroughs in artificial intelligence, robotics, internet, autonomy, 3D printing, nanotechnology

Allows for extreme customization and personalization

The Sharing Economy

The Maker Movement

What is Additive Manufacturing

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Material is cut from a larger piece until the final shape is achieved

Lathe, mill, drill, etc.

Components are assembled into a final part (weld, braze, bolt, glue, etc.)

Subtractive Manufacturing Additive Manufacturing

Successive layers of material are built up until the final shape is achieved

VS

Additive Manufacturing Technologies

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Materials: plastics, rubbers, ceramics, metals, composites, biomaterials, construction materials, nuclear fuels, electronic circuits, “in-situ composites”, reactive materials…..

Powder Bed Fusion

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Advantages to Additive Manufacturing

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Left: LEAP Fuel nozzle, 18 parts reduced to 1, improved fluid dynamics

Right: Turboprop engine, 800+ parts reduced to 30, reduced weight, eliminated parasitic loss, improved efficiency. Both manufactured by GE Additive

NanoAl Introduction

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Dr. Nhon VoCEO/CTO, Co-Founder

Dr. Davaadorj BayansnMetallurgical Engineer

Dr. David DunandCSO and Co-Founder

Dr. David SeidmanCSO and Co-Founder

Francisco FloresMaterials Engineer

Evander RamosMaterials Technician

NanoAl’s history of innovation includes:

High strength, high conductivity, and creep resistant wire and cable

High strength, weldable sheet products

High strength casting alloys

Custom alloy design and novel solutions

Aluminum Applications

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F1 Cylinder Head

60% weight reduction

10X more surface area for cooling

Improved vibration management

Manufactured by FIT West

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Aluminum Applications

Aerospace Heat Exchanger

Complex geometry is impossible by any other method

Improved cooling efficiency

Weight reduction

Designing a Strong Alloy

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Hierarchy of Scale

Picometers Nanometers Micrometers Millimeters

Solid-Solution StrengtheningSingle atoms

Precipitates5 – 100 nm

Dispersoids100 – 300 nm

Secondary Phases100’s nm – 10’s μm

Dispersion Strengthening Grain Boundary Strengthening10’s nm – 100’s μm

C. Booth Morrison, D. Dunand, D. Seidman.

Acta Materialia 60 (2012) 3643-3654

Montero Sistiaga, et al. Jounral of Materials Processing Technology 238 (2016) 437-445

Characterization of Nanoscale Features

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Transmission Electron

Microscopy (TEM)Resolution: 50 pm

Atomic Force Microscopy

(AFM)Resolution: < 1 nm

Atom Probe Tomography

(APT)Resolution: single atoms

X-Ray Diffraction (XRD)

Resolution: atomic spacing

Scanning Electron

Microscopy (SEM)Resolution: < 10 nm

Hierarchy of Scale

Picometers Nanometers Micrometers Millimeters

Atom Probe Tomography (APT)

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C. Booth Morrison, D. Dunand, D. Seidman. Acta Materialia 59 (2011) 7029-7042

Surface of material is vaporized one layer at a time

Instrument detects the element and its position in the material

Software reconstructs a 3D model

First instrument which allowed us to “see” an atom

Transmission Electron Microscopy (TEM)

Specimen is thinned so that it becomes “electron transparent” – About 100 nm

Electron beam is generated in the column, passes through the specimen, and is recorded by a CCD camera below the specimen

Reveals crystal structure and chemistry with sub-nanometer resolution

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E. A. Marquis, D. Dunand, D. Seidman.

Acta Materialia 51 (2003) 4751-4760

Atomic Force Microscopy (AFM)

AFM probe “taps” along the material surface –measures topography and surface chemistry

Recently developed scanning Kelvin probe force microscopy (SKPFM) is used to identify micro-galvanic couples between metal and strengthening phases

Micro-galvanic couples influence overall corrosion

SKPFM measures corrosion potential between phases –analogous to electric potential of a battery

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R. L. Liu, M. F. Hurley, A. Kvryan, G. Williams, J. R. Scully, N. Birbilis. Scientific Reports 6, 28747 (2016)

X-Ray Diffraction (XRD)

Identifies the crystal structure of all phases present in the sample

Determines relative quantity of all phases present

Can measure grain size, lattice strain, and atomic spacing

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Scanning Electron Microscopy (SEM)

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Electrons are generated in the column above the specimen, and are reflected off the specimen towards the detector

Advantages of SEM include large field of view, large depth of field, and large depth of focus

Gives topographic, chemical, and crystallographic information

Companies Investing in Additive

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Economic Opportunities in Additive

Additive manufacturing was a $5.1B industry in 2015

NIST projects it to be a $50B industry by 2030, and a $100B industry by 2040

GE Additive

Believes there to be a $76B opportunity in additive

Started on September 27, 2016

As of this week they have 1,000 employees

They will have 20,000 employees involved in additive by the end of 2017

Plan to sell 10,000 3D printers in next 10 years

Investing $10M in schools in next 5 years

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NSF 2014 Educational Workshop on AM

Ensure that AM curricula provide students with an understanding of AM and traditional manufacturing processes to enable them to effectively select the appropriate

process for product realization; the relationships between AM processes and material properties; “Design for AM”, including computational tools for AM design as well as frameworks for process

selection, costing, and solution generation that take advantage of AM capabilities.

Establishment of a national network for AM education that, by leveraging existing “distributed” educational models and NSF Programs, provides open source resources as well as packaged activities, courses, and curricula for all educational levels (K-Gray).

Promote K-12 educational programs in STEAM and across all formal and informal learning environments in order to leverage the unique capabilities of AM in engaging students in hands-on, tactile, and visual learning activities.

Provide support for collaborative and community-oriented maker spaces that promote awareness of AM among the public and provide AM training programs for incumbent workers and students seeking alternative pathways to gain AM knowledge and experience.

https://community.asme.org/additive_manufacturing/m/default.aspx

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Joseph R Croteau, MS – Materials Engineer jcroteau@nanoal.com

NanoAl LLC – nanoal.com

8025 Lamon Ave, Suite 446 – Skokie, IL 60077

Thank You!

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