Diego Giovanni Manfredi

From Powders to Dense Metal Parts: Characterization of a Commercial AlSiMg Alloy Processed through Direct Metal Laser Sintering

In this paper, a characterization of an AlSiMg alloy processed by direct metal laser sintering (DMLS) is presented, from the analysis of the starting powders, in terms of size, morphology and chemical composition, through to the evaluation of mechanical and microstructural properties of specimens built along different orientations parallel and perpendicular to the powder deposition plane. With respect to a similar aluminum alloy as-fabricated, a higher yield strength of about 40% due to the very fine microstructure, closely related to the mechanisms involved in this additive process is observed.

Additive Manufacturing of Al Alloys and Aluminium Matrix Composites (AMCs)

In this chapter a large description of additive manufacturing techniques for obtaining Al alloys and Al matrix composites is given. Results on mechanical properties, roughness and microstructure achievable with such fabrication route on Al alloys are reported

3D Printing of Conductive Complex Structures with in Situ Generation of Silver Nanoparticles

Coupling the photoreduction of a metal precursor with 3D-printing technology is shown to allow the fabrication of conductive 3D hybrid structures consisting of metal nanoparticles and organic polymers shaped in complex multilayered architectures. 3D conductive structures are fabricated incorporating silver nitrate into a photocurable oligomer in the presence of suitable photoinitiators and exposing them to a digital light system.

Overview on Additive Manufacturing Technologies

This paper provides an overview on the main additive manufacturing/3D printing technologies suitable for many satellite applications and, in particular, radio-frequency components. In fact, nowadays they have become capable of producing complex net-shaped or nearly net-shaped parts in materials that can be directly used as functional parts, including polymers, metals, ceramics, and composites. These technologies represent the solution for low-volume, high-value, and highly complex parts and products.

Tribological Behavior of Aluminum Alloy AlSi10Mg-TiB2 Composites Produced by Direct Metal Laser Sintering (DMLS)

Direct metal laser sintering (DMLS) is an additive manufacturing technique for the production of parts with complex geometry and it is especially appropriate for structural applications in aircraft and automotive industries. Aluminum-based metal matrix composites (MMCs) are promising materials for these applications because they are lightweight, ductile, and have a good strength-to-weight ratio This paper presents an investigation of microstructure, hardness, and tribological properties of AlSi10Mg alloy and AlSi10Mg alloy/TiB2 composites prepared by DMLS. MMCs were realized with two different compositions: 10% wt. of microsize TiB2, 1% wt. of nanosize TiB2. Wear tests were performed using a pin-on-disk apparatus on the prepared samples. Performances of AlSi10Mg samples manufactured by DMLS were also compared with the results obtained on AlSi10Mg alloy samples made by casting. It was found that the composites displayed a lower coefficient of friction (COF), but in the case of microsize TiB2 reinforcement the wear rate was higher than with nanosize reinforcements and aluminum alloy without reinforcement. AlSi10Mg obtained by DMLS showed a higher COF than AlSi10Mg obtained by casting, but the wear rate was higher in the latter case.

3D Printed PEG-Based Hybrid Nanocomposites Obtained by Sol–Gel Technique

In this work, three-dimensional (3D) structured hybrid materials were fabricated combining 3D printing technology with in situ generation of inorganic nanoparticles by sol-gel technique. Those materials, consisting of silica nanodomains covalently interconnected with organic polymers, were 3D printed in complex multilayered architectures, incorporating liquid silica precursors into a photocurable oligomer in the presence of suitable photoinitiators and exposing them to a digital light system. A post sol-gel treatment in acidic vapors allowed the in situ generation of the inorganic phase in a dedicated step. This method allows to build hybrid structures operating with a full liquid formulation without meeting the drawbacks of incorporating inorganic powders into 3D printable formulations. The influence of the generated silica nanoparticle on the printed objects was deeply investigated at macro- and nanoscale; the resulting light hybrid structures show improved mechanical properties and, thus, have a huge potential for applications in a variety of advanced technologies.

On the effect of process parameters on properties of AlSi10Mg parts produced by DMLS

Purpose – The aim of this research is to reach a deep understanding on the effect of the process parameters of Direct Metal Laser Sintering process (DMLS) on macroscopic properties (hardness and density) of AlSi10Mg parts and resulting microstructure. Design/methodology/approach – A full factorial design of experiment (DOE) was applied to determine the most significant process parameter influencing macroscopic properties of AlSi10Mg parts manufactured by DMLS process. The analysis aims to define the optimum process parameters and deduce the process window that provides better macroscopic properties of AlSi10Mg parts. Optical microscopy observations are carried out to link the microstructure to macroscopic properties. Findings – Macroscopic properties of DMLS parts are influenced by the change in process parameters. There is a close correlation between the geometry of scan tracks and macroscopic properties of AlSi10Mg parts manufactured by DMLS process. Originality/value – The knowledge of utilizing optimi...

Effect of the fabrication method on the functional properties of BaTiO3: PVDF nanocomposites

This paper deals with the preparation and characterization of nanocomposite (NC) materials, comparing different technologies for sample fabrication, in view of their possible application as piezoelectric sensors. Those NCs consist on BaTiO3 nanoparticles embedded into a polyvinylidene fluoride matrix, where both the ceramic and the polymeric phases could exhibit ferroelectricity. In particular, we compare the properties of samples prepared through three different methods, i.e., solvent casting, enabling a fast realization, spin-coating, which allows to realize thin flexible films particularly interesting for large area sensors, and hot embossing, which is exploited to modify the residual porosity in the thick films. The influence of the fabrication techniques on the physical and chemical properties is investigated. Different electrode materials have been tested and compared, ranging from sputtered Pt to an engineered thermally evaporated Ti/Au bilayer. Leakage current, polarization, displacement curves, and piezoelectric coefficient d33 are evaluated by small signal indirect measurements, comparing the properties of different materials and understanding how processing technologies influence the sensor performances by acting on the functional materials.

Enhanced Topology of

A new E-plane filtering structure suitable for very high-power telecom satellite applications is presented. The conceived configuration exploits the design flexibility provided by cascading highly integrated step/stub resonators with pseudoelliptic frequency responses. Several design examples of filters and diplexers in Ku-, K-, and Q-band are reported and supported by experimental tests campaigns. The components have been designed with a full-wave 2-D spectral element method. Prototypes have been realized in aluminum clam-shell technology. Excellent agreement between the models and the experimental results has been achieved. An alternative manufacturing of the proposed architecture based on the selective laser melting technology is also reported. The attractiveness of the structure in view of this emerging additive manufacturing solution is demonstrated. The main advantages of the proposed filter configuration suitable for components operated in heavily loaded multi-carrier environment are: compact design, very low losses, high rejection, and high power-handling capability.

E

In contemporary society we observe an everlasting permeation of electron devices, smartphones, portable computing tools. The tiniest living organisms on Earth could become the key to address this challenge: energy generation by bacterial processes from renewable stocks/waste through devices such as microbial fuel cells (MFCs). However, the application of this solution was limited by a moderately low efficiency. We explored the limits, if any, of additive manufacturing (AM) technology to fabricate a fully AM-based powering device, exploiting low density, open porosities able to host the microbes, systems easy to fuel continuously and to run safely. We obtained an optimal energy recovery close to 3 kWh m−3 per day that can power sensors and low-power appliances, allowing data processing and transmission from remote/harsh environments.