3D Printing for Energy Applications

Cover
Title Page
Copyright Page
Contents
Contributors
Introduction to 3D Printing Technologies
Part 1 3D printing of functional materials
	Chapter 1 Additive Manufacturing of Functional Metals
		1.1 Introduction
			1.1.1 Industrial Application of Metal AM in the Energy Sector
			1.1.2 Geometrical Gradients in AM
			1.1.3 Material Gradients in AM
		1.2 Powder Bed Fusion AM
			1.2.1 Geometric Gradients in PBF
			1.2.2 Material Gradients in PBF
		1.3 Direct Material Deposition
			1.3.1 Powder and Wire Feedstock for Near-Net-Shape AM
			1.3.2 Functional Material Gradients in DED
		1.4 Solid-State Additive Manufacturing
		1.5 Hybrid AM Through Green Body Sintering
			1.5.1 Common AM Technologies for Green Body Manufacturing
			1.5.2 CAD Design and Shrinkage Compensation
			1.5.3 Additive Manufacture
			1.5.4 Debinding and Sintering
			1.5.5 Functionally Graded Components in Sintered Components
		1.6 Conclusions
		Acknowledgment
		References
	Chapter 2 Additive Manufacturing of Functional Ceramics
		2.1 Introduction
			2.1.1 Why 3D Printing of Technical Ceramics?
			2.1.2 Materials and Applications
		2.2 Ceramics 3D Printing Technologies
			2.2.1 Lamination Object Modeling (LOM)
			2.2.2 Ceramics Extrusion
				2.2.2.1 Robocasting/Direct Ink Writing
				2.2.2.2 Fused Deposition of Ceramics
			2.2.3 Photopolymerization
			2.2.4 Laser-Based Technologies
			2.2.5 Jetting
		References
	Chapter 3 3D Printing of Functional Composites with Strain Sensing and Self-Heating Capabilities
		3.1 Introduction
		3.2 Carbon Nanotube Reinforced Functional Polymer Nanocomposites
			3.2.1 Strain Sensing of CNT Reinforced Polymer Nanocomposites
			3.2.2 Resistive Heating of CNT Reinforced Polymer Nanocomposites
		3.3 Printing Strategies
			3.3.1 Spray Deposition Modeling and Fused Deposition Modeling
			3.3.2 Printing of Highly Flexible Carbon Nanotube/Polydimethylsilicone Strain Sensor
			3.3.3 Printing of Carbon Nanotube/Shape Memory Polymer Nanocomposites
		3.4 Strain Sensing of Printed Nanocomposites
		3.5 Electric Heating Performance Analysis
		3.6 Electrical Actuation of the CNT/SMP Nanocomposites
		3.7 Conclusions
		References
Part B 3D printing challenges for production of complex objects
	Chapter 4 Computational Design of Complex 3D Printed Objects
		4.1 Introduction
		4.2 Dedicated Computational Design for 3D Printing
			4.2.1 Overhang Angle Control Approaches
				4.2.1.1 Local Angle Control
				4.2.1.2 Physics-Based Constraints
				4.2.1.3 Simplified Printing Process
			4.2.2 Design Scenarios
		4.3 Case Study: Computational Design of a 3D-Printed Flow Manifold
			4.3.1 Fluid Flow TO
			4.3.2 Front Propagation-Based 3D Printing Constraint
			4.3.3 Fluid TO with 3D Printing Constraint
		4.4 Current State and Future Challenges
		References
	Chapter 5 Multicomponent and Multimaterials Printing: A Case Study of Embedded Ceramic Sensors in Metallic Pipes
		5.1 Multicomponent Printing: A Short Review
		5.2 Multicomponent Printing: A Case Study on Piezoceramic Sensors in Smart Pipes
			5.2.1 Brief Introduction to AM of Embedded Sensors for Smart Metering
			5.2.2 Fabrication of the Embedded Piezoceramic Sensor in Metallic Pipes
				5.2.2.1 Smart Coupling Fabrication Process Using EPBF Technology
				5.2.2.2 Materials
				5.2.2.3 Sensor Housing
				5.2.2.4 Re-poling of PZT
				5.2.2.5 Impact in Sensing Properties Due to Heat-Treatment Induced By AM Process
				5.2.2.6 Smart Coupling Component
				5.2.2.7 Compressive Force Sensing
				5.2.2.8 Temperature Sensing
			5.2.3 Impact of the AM and Performance of the Multicomponent Printed Device
				5.2.3.1 Compressive Force Sensing
				5.2.3.2 Temperature Sensing
				5.2.3.3 Crystalline Structure Analysis
		5.3 Summary and Outlook
		Acknowledgments
		References
	Chapter 6 Tailoring of AM Component Properties via Laser Powder Bed Fusion
		6.1 Introduction
		6.2 Machines, Materials, and Sample Preparation
		6.3 Sample Preparation and Characterization Techniques
		6.4 Material Qualification and Process Development
		6.5 Tailoring Grain Size via Adaptive Processing Strategies
		6.6 Tailoring Material Properties By Using Powder Blends
		6.7 Tailoring Properties By Using Special Geometries Such As Lattice Structures
		Funding
		Conflicts of Interest
		References
	Chapter 7 3D Printing Challenges and New Concepts for Production of Complex Objects
		7.1 Introduction
		7.2 Geometrical Complexity
		7.3 Material Complexity
		7.4 Energy Requirements
		7.5 Promising Metal Deposition Approaches
		7.6 Multimaterial and Multi-property SLA
		7.7 Temporal Multiplexing
		7.8 Resin Formulations with Multiple End-States
		7.9 Associated Processing Considerations
		7.10 Bioprinting of Realistic and Vascularized Tissue
		7.11 Emerging Volumetric Additive Processes
		7.12 Computation for CAL
		7.13 Material–Process Interactions in CAL
		7.14 Current Challenges in CAL
		7.15 Expanding the Capabilities of CAL
		7.16 Concluding Remarks and Outlook
		Acknowledgments
		References
Part C 3D printing of energy devices
	Chapter 8 Current State of 3D Printing Technologies and Materials
		8.1 3D Printing of Energy Devices
			8.1.1 Batteries
				8.1.1.1 3D Printing Structured Electrodes
				8.1.1.2 3D Printing Solid Electrolytes
				8.1.1.3 3D Printed Full Batteries
				8.1.1.4 Conclusion and Outlook
		References
	Chapter 9 Capacitors
		9.1 Introduction
		9.2 Capacitors and Their Current Manufacture
			9.2.1 Capacitor Classifications, Operating Principles, Applications, and Current Manufacture
				9.2.1.1 Electrostatic Capacitors
				9.2.1.2 Electrolytic Capacitors
				9.2.1.3 Electrochemical Capacitors
			9.2.2 Capacitor Components: Function and Requirements
			9.2.3 Performance
			9.2.4 The Challenge of Manufacturing Capacitors
		9.3 The Promise of Additive Manufacturing
		9.4 Additive Manufacturing Technologies: Considerations for Capacitor Fabrication
			9.4.1 AM Process Categories
				9.4.1.1 Material Extrusion – Fused Filament Fabrication
				9.4.1.2 Material Extrusion – Direct Ink Writing
				9.4.1.3 Vat Polymerization
				9.4.1.4 Powder Bed Fusion
				9.4.1.5 Material Jetting
				9.4.1.6 Binder Jetting
			9.4.2 Multi-technology or Hybrid Printing
			9.4.3 Complete Capacitor Devices Fabricatedby Additive Manufacturing
		9.5 Summary and Outlook
		References
	Chapter 10 3D-Printing for Solar Cells
		10.1 Introduction
		10.2 Examples of 3D-Printing for PV
		10.3 Geometric Light Management
			10.3.1 Background
			10.3.2 Optical Model for External Light Trapping
			10.3.3 Design and 3D-Printing of the External Light Trap
			10.3.4 Characterization
		10.4 Conclusions
		References
	Chapter 11 3D Printing of Fuel Cells and Electrolyzers
		11.1 Introduction
		11.2 3D Printing of Solid Oxide Cells Technology
			11.2.1 Solid Oxide Fuel Cells
				11.2.1.1 SOFC Electrolyte
				11.2.1.2 SOFC Electrodes
			11.2.2 Solid Oxide Electrolysis Cells
			11.2.3 SOC Stacks and Components
		11.3 3D Printing of Polymer Exchange Membranes Cells Technology
			11.3.1 Polymeric Exchange Membrane Fuel Cells
				11.3.1.1 PEMFC Electrolyte
				11.3.1.2 PEMFC Catalysts Layer
				11.3.1.3 PEMFC Gas Diffusion Layer
				11.3.1.4 PEMFC Bipolar Plates and Flow Fields
			11.3.2 Polymer Exchange Membrane Electrolysis Cells
				11.3.2.1 PEMEC Liquid Gas Diffusion Layer
				11.3.2.2 PEMEC Bipolar Plates and Flow Fields
				11.3.2.3 Fully Printed PEMEC
		11.4 3D Printing of Bio-Fuel Cells Technology
		11.5 Conclusions and Outlook
		References
	Chapter 12 DED for Repair and Manufacture of Turbomachinery Components
		12.1 Introduction
		12.2 DED Based Repair of Turbomachinery Components
			12.2.1 DED Process
			12.2.2 Work Environment
			12.2.3 Process Chain for the Repair of Turbine Blades
				12.2.3.1 Step 1: “Machining & Preparation”
				12.2.3.2 Step 2: “Reverse Engineering”
				12.2.3.3 Step 3: “Generation of Tool Paths”
				12.2.3.4 Step 4: “DED Process”
				12.2.3.5 Step 5: “Adaptive Machining”
		12.3 DED Based Hybrid Manufacturing of New Components
			12.3.1 Hybrid Additive Manufacturing
			12.3.2 Turbocharger Nozzle Ring
			12.3.3 Hybrid Production Cell
			12.3.4 Process Chain for Hybrid Additive Manufacturing of Nozzle Rings
				12.3.4.1 Step 1: “Choice of DED Strategy”
				12.3.4.2 Step 2: “DED Process”
				12.3.4.3 Step 3: “Optical Metrology”
				12.3.4.4 Step 4: “Adaptive Milling”
				12.3.4.5 Step 5: “Joining of Top Ring”
		12.4 Summary
		Acknowledgments
		References
	Chapter 13 Thermoelectrics
		13.1 Introduction
		13.2 Additive Manufacturing Techniques of Thermoelectric Materials
			13.2.1 Extrusion-Based Additive Manufacturing Process
			13.2.2 Fused Deposition Modeling (FDM) Technique
			13.2.3 Stereolithography Apparatus (SLA) Process
			13.2.4 Selective Laser Sintering (SLS) Process
			13.2.5 Summary and Outlook
		Acknowledgements
		References
	Chapter 14 Carbon Capture, Usage, and Storage
		14.1 Introduction
		14.2 Can 3D Printing Be Used to Fabricate a CO2 Capture Process at Scale?
		14.3 A Brief Note on 3D Printing and CO2 at Smaller Scales & Research Efforts
		14.4 Conclusions
		References
Index
EULA