Multifunctional Reactive Nanocomposites via Direct Ink Writing

Abstract

3D printing of reactive materials has, to date, primarily focused on controlling reaction velocities and energy release rates by printing novel architectures, which during reaction typically form gaseous and oxide powder products. The utility of printed reactive materials can be increased by designing the material such that its reaction produces both a controlled energy release and a functional product phase without gaseous products. Here, we report the direct ink writing of reactive materials composed of ternary nanocomposite powders that exhibit gasless, exceptionally low velocity reactions. The printed features can be patterned in arbitrary form factors and are brittle and electrically insulating as‐printed. Using a self‐propagating synthesis reaction, these features can be transformed into a mechanically robust, electrically conductive cermet that is capable of handling high currents. This study provides a new paradigm for printing multifunctional reactive materials in which both the energy release of the reaction, as well as the reaction products themselves, are useful for potential applications ranging from printed electronic devices to controlled, directed energy release.

Low-Carbon Manufacturing of Ti–Si–C Ceramics Using Geopolymer-Binder-Integrated Reactive Feedstocks

“…Consequently, these effects could collectively be responsible for the observed deterioration in mechanical properties compared to systems based on preceramic polymers. Nevertheless, the reported low-carbon ceramic composite manufacturing has the potential to offer enhanced mechanical performance when compared to 3D printing and self-sustaining reactively formed cermets, which currently have a yield strength of 13 MPa . Furthermore, to explore the variation in mechanical strength over time, we performed a compressive test of the same batch of ceramic composite.…”

“…Increasing the MK to activator ratio results in decreasing final porosity, as shown in Figure 6a. The lowest porosity achievable is 22% when the MK to activator ratio is 1:3, indicating ∼3 times decrease compared to self-sustaining reaction-assisted 3D-printed cermet structure 19 as illustrated in Table 1, an increase in the MK to activator ratio results in a higher Si/Al ratio, which in turn leaves more water within the geopolymer structure after the curing process. This observation aligns with findings from prior research.…”

“…Efforts have been made to apply self-sustaining reactions in the direct writing of thermosets, , continuous fiber composites, short fiber composites, multiscale composites, , and metals . The two-step printing approach has been employed to fabricate cermet structures, initially, volatile gel integrated ink was used to print the preform, and subsequently, a self-sustaining reaction was initiated to convert the preform into cermet structure. , However, the resulting inorganic structures are highly porous (66.4% void) and lack mechanical robustness, limiting their broader range of applications. Rapid energy-efficient additive-manufacturing process (REAP) was introduced by Liu et al where geometrically complex ceramic structure can be produced by self-sustaining ceramization of in situ cured preceramic polymer-binding ceramic preform.…”

Review of the Problems of Additive Manufacturing of Nanostructured High-Energy Materials

“…Reactive material products from the additive manufacturing process have been proposed for a wide variety of applications. Different applications may require very different, sometimes oppositional, properties of reactive materials: Providing a high reaction rate (for example, a multichannel igniter [ 72 ]); Providing a low controlled reaction rate and the absence of gas formation [ 73 ]; Releasing heat during the reaction (for example, destruction of microcircuits [ 74 ]); Generating gases (for example, micromotors and actuators [ 75 ]). …”

Predicting dimensional accuracy in 3D printed polydimethylsiloxane‐carbon nanotubes composites via machine learning

“…1,2 Within the realm of 3D Printing, there exists a specific process termed "Direct Ink Writing (DIW)," which involves the precise layer-by-layer extrusion of ink through a fine micron-sized nozzle. In this process, gels, 3 composite pastes, 4 colloids, 5 and polymers 6 can be easily printed at low cost and with high flexibility. Primarily, the DIW approach can operate at ambient temperatures, so it is possible to manufacture materials that are not directly melted or sintered.…”