3D Printing for Energy Applications

ISBN-13: 9781119560753 / Angielski / Twarda / 2021 / 400 str.

Albert Taranc?n; Vincenzo Esposito

Spis treści

Contributor xivIntroduction to 3D Printing Technologies xviiiPart I 3D printing of functional materials 11 Additive Manufacturing of Functional Metals 3Venkata Karthik Nadimpalli and David Bue Pedersen1.1 Introduction 31.1.1 Industrial Application of Metal AM in the Energy Sector 51.1.2 Geometrical Gradients in AM 61.1.3 Material Gradients in AM 61.2 Powder Bed Fusion AM 71.2.1 Geometric Gradients in PBF 81.2.2 Material Gradients in PBF 91.3 Direct Material Deposition 121.3.1 Powder and Wire Feedstock for Near-Net-Shape AM 121.3.2 Functional Material Gradients in DED 131.4 Solid-State Additive Manufacturing 161.5 Hybrid AM Through Green Body Sintering 191.5.1 Common AM Technologies for Green Body Manufacturing 191.5.2 CAD Design and Shrinkage Compensation 201.5.3 Additive Manufacture 201.5.4 Debinding and Sintering 211.5.5 Functionally Graded Components in Sintered Components 221.6 Conclusions 22Acknowledgment 24References 242 Additive Manufacturing of Functional Ceramics 33José Fernando Valera-Jiménez, Juan Ramón Marín-Rueda, Juan Carlos Pérez-Flores, Miguel Castro-García, and Jesús Canales-Vázquez2.1 Introduction 332.1.1 Why 3D Printing of Technical Ceramics? 352.1.2 Materials and Applications 352.2 Ceramics 3D Printing Technologies 362.2.1 Lamination Object Modeling (LOM) 372.2.2 Ceramics Extrusion 382.2.2.1 Robocasting/Direct Ink Writing 392.2.2.2 Fused Deposition of Ceramics 422.2.3 Photopolymerization 442.2.4 Laser-Based Technologies 472.2.5 Jetting 49References 523 3D Printing of Functional Composites with Strain Sensing and Self-Heating Capabilities 69Xin Wang and Jihua Gou3.1 Introduction 693.2 Carbon Nanotube Reinforced Functional Polymer Nanocomposites 703.2.1 Strain Sensing of CNT Reinforced Polymer Nanocomposites 703.2.2 Resistive Heating of CNT Reinforced Polymer Nanocomposites 713.3 Printing Strategies 723.3.1 Spray Deposition Modeling and Fused Deposition Modeling 723.3.2 Printing of Highly Flexible Carbon Nanotube/Polydimethylsilicone Strain Sensor 733.3.3 Printing of Carbon Nanotube/Shape Memory Polymer Nanocomposites 733.4 Strain Sensing of Printed Nanocomposites 733.5 Electric Heating Performance Analysis 793.6 Electrical Actuation of the CNT/SMP Nanocomposites 823.7 Conclusions 85References 87Part II 3D printing challenges for production of complex objects 914 Computational Design of Complex 3D Printed Objects 93Emiel van de Ven, Can Ayas, and Matthijs Langelaar4.1 Introduction 934.2 Dedicated Computational Design for 3D Printing 954.2.1 Overhang Angle Control Approaches 964.2.1.1 Local Angle Control 964.2.1.2 Physics-Based Constraints 974.2.1.3 Simplified Printing Process 974.2.2 Design Scenarios 984.3 Case Study: Computational Design of a 3D-Printed Flow Manifold 994.3.1 Fluid Flow TO 1004.3.2 Front Propagation-Based 3D Printing Constraint 1024.3.3 Fluid TO with 3D Printing Constraint 1034.4 Current State and Future Challenges 104References 1055 Multicomponent and Multimaterials Printing: A Case Study of Embedded Ceramic Sensors in Metallic Pipes 109Cesar A. Terrazas, Mohammad S. Hossain, Yirong Lin, and Ryan B. Wicker5.1 Multicomponent Printing: A Short Review 1095.2 Multicomponent Printing: A Case Study on Piezoceramic Sensors in Smart Pipes 1115.2.1 Brief Introduction to AM of Embedded Sensors for Smart Metering 1115.2.2 Fabrication of the Embedded Piezoceramic Sensor in Metallic Pipes 1145.2.2.1 Smart Coupling Fabrication Process Using EPBF Technology 1145.2.2.2 Materials 1165.2.2.3 Sensor Housing 1175.2.2.4 Re-poling of PZT 1185.2.2.5 Impact in Sensing Properties Due to Heat-Treatment Induced By AM Process 1195.2.2.6 Smart Coupling Component 1195.2.2.7 Compressive Force Sensing 1195.2.2.8 Temperature Sensing 1205.2.3 Impact of the AM and Performance of the Multicomponent Printed Device 1225.2.3.1 Compressive Force Sensing 1225.2.3.2 Temperature Sensing 1245.2.3.3 Crystalline Structure Analysis 1265.3 Summary and Outlook 128Acknowledgments 129References 1306 Tailoring of AM Component Properties via Laser Powder Bed Fusion 135Simon Ewald, Maximilian Voshage, Steffen Hermsen, Max Schaukellis,Patrick Köhnen, Christian Haase, and Johannes Henrich Schleifenbaum6.1 Introduction 1356.2 Machines, Materials, and Sample Preparation 1386.3 Sample Preparation and Characterization Techniques 1396.4 Material Qualification and Process Development 1406.5 Tailoring Grain Size via Adaptive Processing Strategies 1436.6 Tailoring Material Properties By Using Powder Blends 1466.7 Tailoring Properties By Using Special Geometries Such As Lattice Structures 148Funding 150Conflicts of Interest 150References 1507 3D Printing Challenges and New Concepts for Production of Complex Objects 153Hayden Taylor, Hossein Heidari, Chi Chung Li, Joseph Toombs, and Sui Man Luk7.1 Introduction 1537.2 Geometrical Complexity 1547.3 Material Complexity 1557.4 Energy Requirements 1567.5 Promising Metal Deposition Approaches 1577.6 Multimaterial and Multi-property SLA 1597.7 Temporal Multiplexing 1597.8 Resin Formulations with Multiple End-States 1607.9 Associated Processing Considerations 1607.10 Bioprinting of Realistic and Vascularized Tissue 1627.11 Emerging Volumetric Additive Processes 1637.12 Computation for CAL 1667.13 Material-Process Interactions in CAL 1677.14 Current Challenges in CAL 1697.15 Expanding the Capabilities of CAL 1707.16 Concluding Remarks and Outlook 171Acknowledgments 172References 172Part III 3D printing of energy devices 1818 Current State of 3D Printing Technologies and Materials 183Poul Norby8.1 3D Printing of Energy Devices 1838.1.1 Batteries 1838.1.1.1 3D Printing Structured Electrodes 1868.1.1.2 3D Printing Solid Electrolytes 1958.1.1.3 3D Printed Full Batteries 1978.1.1.4 Conclusion and Outlook 200References 2009 Capacitors 205Lukas Fieber and Patrick S. Grant9.1 Introduction 2059.2 Capacitors and Their Current Manufacture 2069.2.1 Capacitor Classifications, Operating Principles, Applications, and Current Manufacture 2069.2.1.1 Electrostatic Capacitors 2069.2.1.2 Electrolytic Capacitors 2099.2.1.3 Electrochemical Capacitors 2109.2.2 Capacitor Components: Function and Requirements 2119.2.3 Performance 2139.2.4 The Challenge of Manufacturing Capacitors 2149.3 The Promise of Additive Manufacturing 2159.4 Additive Manufacturing Technologies: Considerations for Capacitor Fabrication 2179.4.1 AM Process Categories 2179.4.1.1 Material Extrusion - Fused Filament Fabrication 2179.4.1.2 Material Extrusion - Direct Ink Writing 2219.4.1.3 Vat Polymerization 2239.4.1.4 Powder Bed Fusion 2259.4.1.5 Material Jetting 2279.4.1.6 Binder Jetting 2289.4.2 Multi-technology or Hybrid Printing 2299.4.3 Complete Capacitor Devices Fabricated by Additive Manufacturing 2309.5 Summary and Outlook 232Acronyms 233References 23510 3D-Printing for Solar Cells 249Marcel Di Vece, Lourens van Dijk, and Ruud E.I. Schropp10.1 Introduction 24910.2 Examples of 3D-Printing for PV 25010.3 Geometric Light Management 25510.3.1 Background 25510.3.2 Optical Model for External Light Trapping 25710.3.3 Design and 3D-Printing of the External Light Trap 26010.3.4 Characterization 26110.4 Conclusions 266References 26711 3D Printing of Fuel Cells and Electrolyzers 273A. Hornés, A. Pesce, L. Hernández-Afonso, A. Morata, M. Torrell, and Albert Tarancón11.1 Introduction 27311.2 3D Printing of Solid Oxide Cells Technology 27411.2.1 Solid Oxide Fuel Cells 27511.2.1.1 SOFC Electrolyte 27611.2.1.2 SOFC Electrodes 27811.2.2 Solid Oxide Electrolysis Cells 28311.2.3 SOC Stacks and Components 28411.3 3D Printing of Polymer Exchange Membranes Cells Technology 28611.3.1 Polymeric Exchange Membrane Fuel Cells 28711.3.1.1 PEMFC Electrolyte 28811.3.1.2 PEMFC Catalysts Layer 28811.3.1.3 PEMFC Gas Diffusion Layer 28911.3.1.4 PEMFC Bipolar Plates and Flow Fields 29011.3.2 Polymer Exchange Membrane Electrolysis Cells 29311.3.2.1 PEMEC Liquid Gas Diffusion Layer 29311.3.2.2 PEMEC Bipolar Plates and Flow Fields 29311.3.2.3 Fully Printed PEMEC 29411.4 3D Printing of Bio-Fuel Cells Technology 29411.5 Conclusions and Outlook 297References 29712 DED for Repair and Manufacture of Turbomachinery Components 307S. Linnenbrink, M. Alkhayat, N. Pirch, A. Gasser, and H. Schleifenbaum12.1 Introduction 30712.2 DED Based Repair of Turbomachinery Components 30912.2.1 DED Process 31012.2.2 Work Environment 31012.2.3 Process Chain for the Repair of Turbine Blades 31012.2.3.1 Step 1: "Machining & Preparation" 31012.2.3.2 Step 2: "Reverse Engineering" 31112.2.3.3 Step 3: "Generation of Tool Paths" 31312.2.3.4 Step 4: "DED Process" 31312.2.3.5 Step 5: "Adaptive Machining" 31412.3 DED Based Hybrid Manufacturing of New Components 31412.3.1 Hybrid Additive Manufacturing 31512.3.2 Turbocharger Nozzle Ring 31712.3.3 Hybrid Production Cell 31912.3.4 Process Chain for Hybrid Additive Manufacturing of Nozzle Rings 32012.3.4.1 Step 1: "Choice of DED Strategy" 32012.3.4.2 Step 2: "DED Process" 32112.3.4.3 Step 3: "Optical Metrology" 32212.3.4.4 Step 4: "Adaptive Milling" 32212.3.4.5 Step 5: "Joining of Top Ring" 32212.4 Summary 323Acknowledgments 324References 32413 Thermoelectrics 327Fredrick Kim, Seungjun Choo, and Jae Sung Son13.1 Introduction 32713.2 Additive Manufacturing Techniques of Thermoelectric Materials 32813.2.1 Extrusion-Based Additive Manufacturing Process 32813.2.2 Fused Deposition Modeling (FDM) Technique 33613.2.3 Stereolithography Apparatus (SLA) Process 33713.2.4 Selective Laser Sintering (SLS) Process 33913.2.5 Summary and Outlook 345Acknowledgements 345References 34514 Carbon Capture, Usage, and Storage 351Jason E. Bara14.1 Introduction 35114.2 Can 3D Printing Be Used to Fabricate a CO2 Capture Process at Scale? 35414.3 A Brief Note on 3D Printing and CO2 at Smaller Scales & Research Efforts 35614.4 Conclusions 358References 358Index 361

O autorze

Albert Tarancón is ICREA Research Professor and Head of the Nanoionics and Fuel Cells Group at the Catalonia Institute for Energy Research. He has authored over 100 peer-reviewed articles, 5 book chapters, and given over 200 oral presentations. He is Editor of the Journal of Physics Energy and the Journal of the European Ceramic Society.Vincenzo Esposito is Professor and Technology Coordinator in Ceramic Science and Engineering at the Department of Energy Conversion and Storage, Technical University of Denmark. His research focus is at the intersection of nanoionics, solid state chemistry and advanced materials processing.