PFI-RP: Novel 3D Nanomaterial Printer for Additive Manufacturing of Multiscale Materials

创新研究伙伴关系（PFI-RP）项目的更广泛的影响/商业潜力是开发新的不锈钢（SS）合金。这些材料对于需要在高温和/或辐射损伤等极端条件下工作的结构部件非常重要，但其中一些合金的加工成本高，焊接困难。该项目通过独特的混合平台解决了这些挑战，可以在不锈钢增材制造过程中选择性地生产特殊SS合金，预计到2023年将占金属增材制造市场的22%。最后，我们将通过培训参与该项目的研究生来激励和教育下一代科学家和创新者。该项目具有高度创新性，旨在将微反应器辅助纳米材料3D打印头（MAN3D）集成到激光定向能沉积（DED）打印机中。前者将在建造点部署目标体积的纳米材料，能源需求更低，从而消除了储存和运输潜在危险材料的需要。所提出的新工艺是独特的，将推进当前技术和知识的发展，因为它不需要气溶胶，它通过激活处理步骤在现场产生反应性化学通量，而且它是无溶剂的。该项目解决了知识空白，如与激光DED打印机集成的MAN3D打印头的设计优化，反应参数的控制以产生可控的反应通量，防止通道污染的策略，纳米结构打印的工艺优化，以及具有目标性能的氧化物分散增强（ODS）合金的控制制造。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of Partnerships for Innovation – Research Partnerships (PFI-RP) project is to develop new stainless steel (SS) alloys. These materials are important for structural components that need to operate under extreme conditions such as high temperature and/or radiation damage, but some of these alloys suffer from high processing cost and difficulties in welding. This project addresses these challenges with a unique hybrid platform to selectively produce special SS alloys during the additive manufacturing of stainless steel, expected to be 22% of the metal additive manufacturing market by 2023. Finally, we will inspire and educate the next generation of scientists and innovators by training the graduate students participating in the project.The proposed project is highly innovative and aims to integrate a microreactor-assisted nanomaterial 3D printhead (MAN3D) into a laser directed energy deposition (DED) printer. The former will deploy targeted volumes of nanomaterials at the point-of-build, with lower energy requirements, thus eliminating the need to store and transport potentially hazardous materials. The proposed novel process is distinctive and will advance the state of the art and current knowledge because it does not require an aerosol, it generates reactive chemical fluxes in-situ via an activation processing step, and it is solvent-free. This project addresses knowledge gaps such as the design optimization of a MAN3D printhead for integration with a laser DED printer, the controlling of reaction parameters to generate controlled reactive fluxes, strategies to prevent channel fouling, process optimization for nanostructure printing, and the controlled fabrication of oxide-dispersion-strengthened (ODS) alloys with targeted properties.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.