LLNL-PRES-771518This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under contract DE-AC52-07NA27344. Lawrence Livermore National Security, LLCL

Overview of Emerging Capabilities

Anantha Krishnan, Sc.D.Associate Director for Engineering April 9, 2019

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Advanced Manufacturing Laboratory – Livermore Valley Open Campus

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Advanced approaches are enabling new components and materials for next generation solutions

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By integrating optimization, design and modeling, tailored synthesis, and additive manufacturing methods, we can enable high performance materials and components

Modelingand Design Synthesis Additive

ManufacturingQualification/Certification

HPC, multi-scale, multi-physics,

topology optimization, analytical design

Tunable nanomaterials,

nanoparticles, crystal growth, polymers,

aerogels, feedstocks

Commercial AM tools, custom AM

processes

Process modeling, in-situ

characterization

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Control of microstructural architecture offers the potential for designed material properties and new functionalities

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Order-of-magnitude performance improvement and decoupling of material properties is possible

Designed microarchitectureStretch-dominated lattices can provide these properties

Designed microarchitectureStretch-dominated lattices can provide these

properties

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The Octet Truss microlattice has been fabricated with PmSL and compared to bend dominated architectures

5X. Zheng, et al., Science, 2014

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The expected structure-property relationshiphas been demonstrated

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This mechanical metamaterial has orders of magnitude higher stiffnessthan other porous materials in this

low density regime.

X. Zheng, et al., Science, 2014

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Analytical methods can rapidly produce designs with unique properties

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Nanoparticle suspensions and coatings have been used to broaden the material palette and achieve ultra-light weight lattices

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Solid polymer

r ~ 80 kg/m3(11% rel. density)

Hollow tube Ni-P

r ~ 40 kg/m3(0.5% rel. density)

Hollow tube Al2O3 (ALD)

r ~ 0.9 kg/m3(0.025% rel. density)

Solid (sintered) Al2O3

r ~ 320 kg/m3(8% rel. density)

X. Zheng, et al., Science, 2014

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Metallic hierarchical lattice created with LAPmSL and nanoscale coatings spans seven orders of magnitude in length-scale

9X. Zheng, et al., Nature Materials, 2016

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Large Area Projection Microstereolithography (LAPmSL) in action

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Hierarchical Materials Enable Novel Performance

X. Zheng, et al., Nature Materials, 2016

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DIW 3D printing of graphene aerogel – properties

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3D printed graphene aerogel microlattice

▪ Large surface areas (700-1000 m2/g)

▪ Lightweight (as low as 15 mg/cm3)

▪ Electrically conductive (up to 300 S/m)

▪ Ultra-compressible (up to 90% strain)

C. Zhu, et al., Nature Communications, 2015

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Printed graphene aerogel can be made into supercapacitor electrodes

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3D printed graphene aerogel show excellent rate performance

– 90% capacity @ 0.5-10A/g

C. Zhu, et al., Nature Communications, 2015

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50 μm

20 μm

50 μm

FemtoProWrite: Novel Two Photon Lithography Process Wins 2018 Federal Lab Consortium Award for Outstanding Technology Development

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Two-photon lithography

10x actual speed

Actual Speed

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ALE 3D provides a detailed look at the process physics at the powder particle level

S. Khairallah et al., Acta. Mat, 2016 16

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Combining in-situ diagnosis with modeling and simulation produces a powerful combination for qualification

In-situ probes validate models, and we can begin to predict defects

Simulated vapor flux map

840 μm

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We are using feedback control in simulations to develop strategies for intelligent feed forward (IFF)

Pore forming at turn-around at constant

power and speed

ALE3D optimizes laser power to achieve user pre-

assigned depth and scan speed

ALE3D intelligent feed forward strategy tightens control over build process quality

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New ProcessesDiode Additive Manufacturing (DiAM): Shaping high-power laser diode

light using a dynamic mask

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DiAM system is now operational

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DiAM system is operational and melt trials have started for tinand 316 stainless steel to determine operating conditions and properties

M. Matthews et al., Optics Express, 2017

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In collaboration with multiple university partners:

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DisclaimerThis document was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor Lawrence Livermore National Security, LLC, nor any of their employees makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or Lawrence Livermore National Security, LLC. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or Lawrence Livermore National Security, LLC, and shall not be used for advertising or product endorsement purposes.