Browsing by Author "Vieira, Maria Teresa"
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- In search of the optimal conditions to process shape memory alloys (NiTi) using fused filament fabrication (FFF)Publication . Carreira, Pedro; Cerejo, Fábio; Alves, Nuno; Vieira, Maria TeresaThis research was performed so as to investigate the additive manufacturing of NiTi shape memory alloys, which is associated with direct processes, such as selective laser melting. In addition to its expensive production costs, NiTi readily undergoes chemical and phase modifications, mainly as a result of Ni loss during processing as a result of high temperatures. This research explores the potential usefulness of NiTi as well as its limitations using indirect additive processes, such as fused filament fabrication (FFF). The first step was to evaluate the NiTi critical powder volume content (CPVC) needed to process high-quality filaments (via extrusion). A typical 3D printer can build a selected part/system/device layer-by-layer from the filaments, followed by debinding and sintering (SDS), in order to generate a near-net-shape object. The mixing, extruding (filament), printing (shaping), debinding, and sintering steps were extensively studied in order to optimize their parameters. Moreover, for the sintering step, two main targets should be met, namely: the reduction of contamination during the process in order to avoid the formation of secondary phases, and the decrease in sintering temperature, which also contributes to reducing the production costs. This study aims to demonstrate the possibility of using FFF as an additive manufacturing technology for processing NiTi.
- Influence of Metallic Powder Characteristics on Extruded Feedstock Performance for Indirect Additive ManufacturingPublication . Santos, Cyril; Gatões, Daniel; Cerejo, Fábio; Vieira, Maria TeresaMaterial extrusion (MEX) of metallic powder-based filaments has shown great potential as an additive manufacturing (AM) technology. MEX provides an easy solution as an alternative to direct additive manufacturing technologies (e.g., Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition) for problematic metallic powders such as copper, essential due to its reflectivity and thermal conductivity. MEX, an indirect AM technology, consists of five steps—optimisation of mixing of metal powder, binder, and additives (feedstock); filament production; shaping from strands; debinding; sintering. The great challenge in MEX is, undoubtedly, filament manufacturing for optimal green density, and consequently the best sintered properties. The filament, to be extrudable, must accomplish at optimal powder volume concentration (CPVC) with good rheological performance, flexibility, and stiffness. In this study, a feedstock composition (similar binder, additives, and CPVC; 61 vol. %) of copper powder with three different particle powder characteristics was selected in order to highlight their role in the final product. The quality of the filaments, strands, and 3D objects was analysed by micro-CT, highlighting the influence of the different powder characteristics on the homogeneity and defects of the greens; sintered quality was also analysed regarding microstructure and hardness. The filament based on particles powder with D50 close to 11 µm, and straight distribution of particles size showed the best homogeneity and the lowest defects.
- Searching new solutions for NiTi sensors through indirect additive manufacturingPublication . Carreira, Pedro; Gatões, Daniel; Alves, Nuno; Ramos, Ana Sofia; Vieira, Maria TeresaShape Memory Alloys (SMAs) can play an essential role in developing novel active sensors for self-healing, including aeronautical systems. However, the NiTi SMAs available in the market are almost limited to wires, small sheets, and coatings. This restriction is mainly due to the difficulty in processing NiTi through conventional processes. Thus, the objective of this study is to evaluate the potential of one of the most promising routes for NiTi additive manufacturing—material extrusion (MEX). Optimizing the different steps during processing is mandatory to avoid brittle secondary phases formation, such as Ni3Ti. The prime NiTi powder is prealloyed, but it also contains NiTi2 and Ni as secondary phases. The present study highlights the role of Ni and NiTi2, with the later having a melting temperature (Tm = 984 ºC) lower than the NiTi sintering temperature, thus allowing a welcome liquid phase sintering (LPS). Nevertheless, the reaction of the liquid phase with the Ni phase could contribute to the formation of brittle intermetallic compounds, particularly around NiTi and NiTi2 phases, affecting the final structural properties of the 3D object. The addition of TiH2 to the virgin prealloyed NiTi powder was also studied and revealed the non-formation of Ni3Ti for a specific composition. The balancing addition of extra Ni revealed priority in the Ni3Ti appearance, emphasizing the role of Ni. Feedstocks extruded (filaments) and green strands (layers), before and after debinding & sintering, were used as homothetic of 3D objects for evaluation of defects (microtomography), microstructures, and mechanical properties. The composition of prealloyed powder with 5 wt.% TiH2 addition after sintering showed a homogeneous matrix with the NiTi2 second phase uniformly dispersed.
- The study of new NiTi actuators to reinforce the wing movement of aircraft systemsPublication . Braga, Rafael; Rodrigues, Patrícia Freitas; Cordeiro, Hélder; Carreira, Pedro; Vieira, Maria TeresaActuators using Shape Memory Alloy (SMA) springs could operate in different mechanical systems requiring geometric flexibility and high performance. The aim of the present study is to highlight the potential of these actuators, using their dimensional variations resulting from the phase transformations of NiTi springs (SMA) to make the movements of the system’s mobile components reversible. This reversibility is due to thermal-induced martensitic transformation of NiTi springs. The transformation promotes the extended and retracted of the springs as the phase changing (martensite–austenite) creates movement in part of the system. Therefore, the phase transition temperatures of NiTi, evaluated by differential scanning calorimetry (DSC), are required to control the dimensional variation of the spring. The influence of the number of springs in the system, as well as how impacts on the reaction time were evaluated. The different numbers of springs (two, four, and six) and the interspaces between them made it possible to control the time and the final angle attained in the mobile part of the system. Mechanical resistance, maximum angle, and the system’s reaction time using different NiTi springs highlight the role of the actuators. Fused Deposition Modelling (FDM)/Material Extrusion (MEX) or Selective Laser Sintering (SLS) was selected for shaping the composite matrix system. A new prototype was designed and developed to conduct tests that established the relationship between the recoverable deformation of the matrix suitable for the application as well as the number and distribution of the actuators.