Fabrication of complex aluminum alloy structures based on sacrificial salt templates

Abstract

Hierarchical and porous complex metal structures have important prospects in biomedical medicine, aerospace, and other important industries. Current processing methods, including conventional and additive manufacturing, still face many challenges in fabricating 3\mathrm{D} metal structures with complex internal structures, especially aluminum alloy ones. Metal molten infiltration on the basis of sacrificial salt templates provides a feasible solution for manufacturing complex internal structures of aluminum alloy, and the development of paste for direct ink writing is pivotal for the successful fabrication of salt templates. This study introduces a novel salt-based paste for printing sacrificial templates by direct ink writing. A print analysis model is formulated based on direct ink writing. Model and experimental results show a remarkable link between strut size and printing pressure and moving speed, but no such link exists between strut size and nozzle height. The paste can be printed into various complex structures by direct ink writing devices. Complex structures of aluminum alloys can be fabricated by metal infiltration and leaching of salt templates. This work provides a new reference technology for fabricating aluminum alloys with complex structures in the future.

Graphical abstract

Keywords

sacrificial template / complex structure / aluminum alloy / salt-based paste / direct ink writing

References

[1] Wang X X , Li X W , Li Z D , Wang Z G , Zhai W . A ribbed strategy disrupts conventional metamaterial deformation mechanisms for superior energy absorption. Virtual and Physical Prototyping, 2024, 19(1): e2337310

[2] Karacan K , Celik S , Toros S , Alkan M , Aydin U . Investigation of formability of metallic bipolar plates via stamping for light-weight PEM fuel cells. International Journal of Hydrogen Energy, 2020, 45(60): 35149–35161

[3] Hung J C , Lin C C . Fabrication of micro-flow channels for metallic bipolar plates by a high-pressure hydroforming apparatus. Journal of Power Sources, 2012, 206: 179–184

[4] Abeyrathna B , Zhang P , Pereira M P , Wilkosz D , Weiss M . Micro-roll forming of stainless steel bipolar plates for fuel cells. International Journal of Hydrogen Energy, 2019, 44(7): 3861–3875

[5] Liu Y X , Hua L . Fabrication of metallic bipolar plate for proton exchange membrane fuel cells by rubber pad forming. Journal of Power Sources, 2010, 195(11): 3529–3535

[6] Li J G , An X L , Liang J J , Zhou Y Z , Sun X F . Recent advances in the stereolithographic three-dimensional printing of ceramic cores: Challenges and prospects. Journal of Materials Science and Technology, 2022, 117: 79–98

[7] Chen L Y , Liang S X , Liu Y J , Zhang L C . Additive manufacturing of metallic lattice structures: Unconstrained design, accurate fabrication, fascinated performances, and challenges. Materials Science and Engineering R: Reports, 2021, 146: 100648

[8] Li X W , Chua J W , Yu X , Li Z D , Zhao M , Wang Z G , Zhai W . 3D-printed lattice structures for sound absorption: current progress, mechanisms and models, structural-property relationships, and future outlook. Advanced Science, 2024, 11(4): 2305232

[9] Zhang J , Huang P Y , Ding H H , Xin D Q , Sun S F . Investigation of the three-dimensional flow field for proton exchange membrane fuel cell with additive manufactured stainless steel bipolar plates: Numerical simulation and experiments. Energy, 2023, 269: 126709

[10] Li Q L , An X L , Liang J J , Liu Y S , Hu K H , Lu Z G , Yue X Y , Li J G , Zhou Y Z , Sun X F . Balancing flexural strength and porosity in DLP-3D printing Al₂O₃ cores for hollow turbine blades. Journal of Materials Science and Technology, 2022, 104: 19–32

[11] Sefene E M . State-of-the-art of selective laser melting process: A comprehensive review. Journal of Manufacturing Systems, 2022, 63: 250–274

[12] Ishfaq K , Abdullah M , Mahmood M A . A state-of-the-art direct metal laser sintering of Ti6Al4V and AlSi10Mg alloys: Surface roughness, tensile strength, fatigue strength and microstructure. Optics & Laser Technology, 2021, 143: 107366

[13] Nurhudan A I , Supriadi S , Whulanza Y , Saragih A S . Additive manufacturing of metallic based on extrusion process: A review. Journal of Manufacturing Processes, 2021, 66: 228–237

[14] Wang K , Xie G Q , Xiang J Y , Li T , Peng Y , Wang J , Zhang H H . Materials selection of 3D printed polyamide-based composites at different strain rates: A case study of automobile front bumpers. Journal of Manufacturing Processes, 2022, 84: 1449–1462

[15] Tamir T S , Xiong G , Shen Z , Leng J W , Fang Q H , Yang Y , Jiang J C , Lodhi E , Wang F Y . 3D printing in materials manufacturing industry: A realm of Industry 4.0. Heliyon, 2023, 9(9): e19689

[16] Boretti A . A techno-economic perspective on 3D printing for aerospace propulsion. Journal of Manufacturing Processes, 2024, 109: 607–614

[17] Ngo T D , Kashani A , Imbalzano G , Nguyen K T Q , Hui D . Additive manufacturing (3D printing): A review of materials, methods, applications and challenges. Composites Part B: Engineering, 2018, 143: 172–196

[18] Meza L R , Das S , Greer J R . Strong, lightweight, and recoverable three-dimensional ceramic nanolattices. Science, 2014, 345(6202): 1322–1326

[19] Shin J H , Heo J H , Jeon S , Park J H , Kim S , Kang H W . Bio-inspired hollow PDMS sponge for enhanced oil-water separation. Journal of Hazardous Materials, 2019, 365: 494–501

[20] Gallien F , Gass V , Mortensen A . Investment casting of periodic aluminum cellular structures using slurry-cast table salt moulds. Materials & Design, 2022, 215: 110488

[21] Mamatha S , Biswas P , Das D , Johnson R . Fabrication of complex shaped ceramic articles from 3D printed polylactic acid templates by replication process. Ceramics International, 2019, 45(15): 19577–19580

[22] Gergely R C R , Pety S J , Krull B P , Patrick J F , Doan T Q , Coppola A M , Thakre P R , Sottos N R , Moore J S , White S R . Multidimensional vascularized polymers using degradable sacrificial templates. Advanced Functional Materials, 2015, 25(7): 1043–1052

[23] Esser-Kahn A P , Thakre P R , Dong H F , Patrick J F , Vlasko-Vlasov V K , Sottos N R , Moore J S , White S R . Three-dimensional microvascular fiber-reinforced composites. Advanced Materials, 2011, 23(32): 3654–3658

[24] Goodall R , Marmottant A , Salvo L , Mortensen A . Spherical pore replicated microcellular aluminium: Processing and influence on properties. Materials Science and Engineering: A, 2007, 465(1–2): 124–135

[25] Fu K , Wang Y B , Yan C Y , Yao Y G , Chen Y , Dai J Q , Lacey S , Wang Y B , Wan J Y , Li T , Wang Z Y , Xu Y , Hu L B . Graphene oxide-based electrode inks for 3D-printed lithium-ion batteries. Advanced Materials, 2016, 28(13): 2587–2594

[26] Shahzad A , Lazoglu I . Direct ink writing (DIW) of structural and functional ceramics: Recent achievements and future challenges. Composites Part B: Engineering, 2021, 225: 109249

[27] Li G J , Marican M H M , Gan S W , Li T , Zhang L J , Liu J S , Li T , Yen C C , Chua B W , Zhai W . Replicating Mg scaffold via 3D printing sacrificial template. Journal of Manufacturing Processes, 2024, 124: 1349–1356

[28] Kleger N , Cihova M , Masania K , Studart A R , Löffler J F . 3D printing of salt as a template for magnesium with structured porosity. Advanced Materials, 2019, 31(37): 1903783

[29] Kleger N , Fehlmann S , Lee S S , Dénéréaz C , Cihova M , Paunović N , Bao Y Y , Leroux J C , Ferguson S J , Masania K , Studart A R . Light-based printing of leachable salt molds for facile shaping of complex structures. Advanced Materials, 2022, 34(32): 2203878

[30] Saadi M A S R , Maguire A , Pottackal N T , Thakur M S H , Ikram M M , Hart A J , Ajayan P M , Rahman M M . Direct ink writing: a 3D printing technology for diverse materials. Advanced Materials, 2022, 34(28): 2108855

[31] Nguyen T L , Staiger M P , Dias G J , Woodfield T B F . A novel manufacturing route for fabrication of topologically‐ordered porous magnesium scaffolds. Advanced Engineering Materials, 2011, 13(9): 872–881

[32] Caggioni M , Trappe V , Spicer P T . Variations of the Herschel–Bulkley exponent reflecting contributions of the viscous continuous phase to the shear rate-dependent stress of soft glassy materials. Journal of Rheology, 2020, 64(2): 413–422

[33] Atkinson H V . Modelling the semisolid processing of metallic alloys. Progress in Materials Science, 2005, 50(3): 341–412

[34] Turner B N , Strong R , Gold S A . A review of melt extrusion additive manufacturing processes: I. Process design and modeling. Rapid Prototyping Journal, 2014, 20(3): 192–204

[35] Zeng Q Y , An H J , Ohl C D . Wall shear stress from jetting cavitation bubbles: influence of the stand-off distance and liquid viscosity. Journal of Fluid Mechanics, 2022, 932: A14

[36] Pashazadeh S , Ghanbari R , Bek M , Aulova A , Moberg T , Brolin A , Kádár R . Mapping surface defects in highly-filled wood fiber polymer composite extrusion from inline spectral analysis. Composites Science and Technology, 2023, 242: 110133

[37] Jabbari A , Abrinia K . Developing thixo-extrusion process for additive manufacturing of metals in semi-solid state. Journal of Manufacturing Processes, 2018, 35: 664–671

[38] Lewandowski K , Piszczek K , Skórczewska K , Mirowski J , Zajchowski S , Wilczewski S . Rheological properties of wood polymer composites at high shear rates – Evaluation of additional pressure losses as a result of inlet effects. Composites Part A: Applied Science and Manufacturing, 2022, 154: 106804

[39] Jabbari A , Abrinia K . A metal additive manufacturing method: semi-solid metal extrusion and deposition. The International Journal of Advanced Manufacturing Technology, 2018, 94(9): 3819–3828

[40] Jebli I , Belouadha F Z , Kabbaj M I , Tilioua A . Prediction of solar energy guided by pearson correlation using machine learning. Energy, 2021, 224: 120109

RIGHTS & PERMISSIONS

Higher Education Press