We report a method to fabricate Nd-Fe-B (NdFeB) bonded magnets of complex shape via extrusion-based additive manufacturing (AM), also known as 3D-printing. We have successfully formulated a 3D-printable epoxy-based ink for direct-write AM with anisotropic MQA NdFeB magnet particles that can be deposited at room temperature. The new feedstocks contain up to 40 vol.% MQA anisotropic NdFeB magnet particles, and they are shown to remain uniformly dispersed in the thermoset matrix throughout the deposition process. Ring, bar, and horseshoe-type 3D magnet structures were printed and cured in air at 100°C without degrading the magnetic properties. This study provides a new pathway for fabricating NdFeB bonded magnets with complex geometry at low temperature, and presents new opportunities for fabricating multifunctional hybrid structures and devices.
In this study we investigate the use of hexagonal boron nitride (hBN) as a rheology modifier in polysilazane resin to enable direct‐ink writing (DIW) of polysilazane‐derived boron nitride‐reinforced ceramic composites. hBN is shown to effectively modify the flow properties of the resin by imparting strong shear thinning and yield stress behavior, and to reduce the mass loss and shrinkage associated with the polymer‐to‐ceramic conversion process, when compared with unfilled polysilazane resin. DIW inks are formulated with 40 vol.% hBN and used print flexural specimens and complex structures with high resolution. Mechanical properties of the resulting polymer‐derived ceramic composites were evaluated by 3‐pt. flexure and Vickers microhardness. The printed composites exhibit flexural strength of 56.4 MPa and microhardness of 111.4 HV2.
Compact military-grade jet engines offer many potential applications, including use in remotely piloted vehicles, but can be expensive to use for research and development purposes. A study aimed at increasing the power and thrust output of an inexpensive commercial compact engine found a material limitation issue in the turbomachinery. To gain the additional power, hotter turbine inlet temperatures were required. This temperature increase exceeded the limit of current uncooled metal turbine rotors but could be achieved through turbine rotors made from ceramics, such as silicon nitride, which would allow an increase in the thrust and power output by a factor of 1.44. Current ceramic turbine manufacturing methods are costly and time consuming for rapid prototyping, but recent breakthroughs in ceramic additive manufacturing have allowed for cheaper methods and faster production which are beneficial for use in research and development when designs are being rapidly changed and tested. This research demonstrated, through finite element analysis, that a silicon nitride turbine rotor could meet the increased turbine inlet temperature conditions to provide the desired thrust and power increase. Further, as a proof of concept, an additively manufactured drop-in replacement alumina turbine rotor was produced for the JetCat P400 small-scale engine in a manner that was cost-effective, timely, and potentially scalable for production. This compact engine was used to demonstrate that a cost-effective ceramic turbine could be manufactured. At the time of publication, the desired ceramic material, silicon nitride, was not available for additive manufacturing.
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