CAREER: Additive Manufacture of Copper Cellular Materials

这个教师早期职业发展（Career）项目的主要研究目标是测试铜细胞材料可以通过氧化铜粉末的三维打印（3DP）实现，然后进行还原/烧结后处理，将其转化为金属铜。第二个研究目的是验证喷射的纳米悬浮粘结剂(i)会填充零件床的间隙空隙，从而增加零件密度；（ii）在烧结过程中会有效粘结邻近的粉末颗粒，提供连续的粘结强度，从而提高最终零件的性能。该计划的主要教育目标是为通过增材制造（AM）设计和制造复杂系统的新一代工程师做好准备。这将通过在广泛的教育范围内提供增材制造技术的学习经验来实现，包括(i)本科/研究生增材制造课程，（ii）为学生提供开放式增材制造的“3D打印自动售货机”，以及（iii）为K-12 STEM教师提供增材制造夏季讲习班。如果成功，这项研究将产生一种能够制造铜细胞材料的制造工艺，并了解纳米悬浮液粘合剂的3d打印如何影响该工艺及其最终部件。所提出的制造过程产生的组件可用于许多机械和电气产品的热管理。了解纳米悬浮粘结剂如何影响3d打印，将为解决这种和其他增材制造工艺的材料限制提供基础。该计划的集成制造和工程教育研究活动将导致以探究为基础的学习干预措施，旨在教育未来的工程师设计AM系统。定性和定量工程教育研究方法的结合将有助于理解所提出的干预措施如何影响教师/学生对制造业的看法。拟议中的暑期工作坊将为15名教师提供3D打印机以及AM教学模块，这些模块将在专门的Wiki网站上共享。教师和学生对工程和制造业的看法的变化将通过高中高中学生对数学、科学和工程的态度调查和德勤和制造业研究所的制造业态度调查来探讨。“3D打印自动售货机”的设计将公开分享给其他大学和公共场所（如博物馆、图书馆等）利用。以在线使用统计和调查、半结构化访谈和工程设计自我效能工具的形式进行的评估将为探索学生如何参与技术注入的非正式学习环境提供机会。

The primary research objective of this Faculty Early Career Development (CAREER) project is to test the hypothesis that copper cellular materials can be realized via three-dimensional printing (3DP) of copper oxide powders followed by a reduction/sintering post-process to convert it to metallic copper. The secondary research objective is to test the hypothesis that jetted nanosuspension binder (i) will fill interstitial voids in the part bed, thus increasing part density and (ii) will effectively bond neighboring powder particles during sintering to provide continuous bonding strength, thus enhancing final part properties. The primary educational goal of this program is to prepare a new generation of engineers for the design and fabrication of complex systems via additive manufacturing (AM). This will be achieved by providing learning experiences with AM technologies across a broad educational spectrum, including (i) an undergraduate/graduate AM course, (ii) a "3D Printing Vending Machine" that provides students open access to AM, and (iii) AM summer workshops for K-12 STEM teachers.If successful, this research will result in a manufacturing process capable of fabricating copper cellular materials and an understanding of how 3DP of nanosuspension binders affect the process and its resultant parts. Components resulting from the proposed manufacturing process could be useful for thermal management of many mechanical and electrical products. An understanding of how nanosuspension binder affects 3DP will provide a basis for addressing material constraints of this, and other, AM processes. This program's integrated manufacturing and engineering education research activities will result in inquiry-based learning interventions targeted at educating future engineers in designing systems with AM. A combination of qualitative and quantitative engineering education research methods will provide an understanding of how the proposed interventions affect teacher/student perceptions of manufacturing. The proposed summer workshop will provide 15 teachers with 3D printers as well as AM instructional modules for their classrooms, which will be shared on a dedicated Wiki website. Changes in teacher and student perceptions of engineering and manufacturing will be explored via the High School High School Students' Attitude to Mathematics, Science and Engineering Survey and the Deloitte and the Manufacturing Institute's Manufacturing Attitude Survey. The design of the "3D Printing Vending Machine" will be openly shared for other universities and public spaces (e.g., museums, libraries, etc.) to leverage. Assessment, in the form of in-line usage statistics and surveys, semi-structured interviews, and the Engineering Design Self Efficacy Instrument will provide opportunity to explore how students engage in technology-infused informal learning settings.