| 1. |
- Li, J., et al.
(author)
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Multifunctional metal matrix composites with embedded printed electrical materials fabricated by Ultrasonic Additive Manufacturing
- 2017
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In: Composites Part B. - Kidlington : Pergamon Press. - 1359-8368 .- 1879-1069. ; 113, s. 342-354
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Journal article (peer-reviewed)abstract
- This work proposes a new method for the fabrication of multifunctional Metal Matrix Composite (MMC) structures featuring embedded printed electrical materials through Ultrasonic Additive Manufacturing (UAM). Printed electrical circuitries combining conductive and insulating materials were directly embedded within the interlaminar region of UAM aluminium matrices to realise previously unachievable multifunctional composites. A specific surface flattening process was developed to eliminate the risk of short circuiting between the metal matrices and printed conductors, and simultaneously reduce the total thickness of the printed circuitry. This acted to improve the integrity of the UAM MMC's and their resultant mechanical strength. The functionality of embedded printed circuitries was examined via four-point probe measurement. DualBeam Scanning Electron Microscopy (SEM) and Focused Ion Beam (FIB) milling were used to investigate the microstructures of conductive materials to characterize the effect of UAM embedding energy whilst peel testing was used to quantify mechanical strength of MMC structures in combination with optical microscopy. Through this process, fully functioning MMC structures featuring embedded insulating and conductive materials were realised whilst still maintaining high peel resistances of ca. 70 N and linear weld densities of ca. 90%. © 2017 Elsevier Ltd
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| 2. |
- Monaghan, T., et al.
(author)
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Complementary catalysis and analysis within solid state additively manufactured metal micro flow reactors
- 2022
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In: Scientific Reports. - London : Nature Publishing Group. - 2045-2322. ; 12
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Journal article (peer-reviewed)abstract
- Additive Manufacturing is transforming how researchers and industrialists look to design and manufacture chemical devices to meet their specific needs. In this work, we report the first example of a flow reactor formed via the solid-state metal sheet lamination technique, Ultrasonic Additive Manufacturing (UAM), with directly integrated catalytic sections and sensing elements. The UAM technology not only overcomes many of the current limitations associated with the additive manufacturing of chemical reactionware but it also significantly increases the functionality of such devices. A range of biologically important 1, 4-disubstituted 1, 2, 3-triazole compounds were successfully synthesised and optimised in-flow through a Cu mediated Huisgen 1, 3-dipolar cycloaddition using the UAM chemical device. By exploiting the unique properties of UAM and continuous flow processing, the device was able to catalyse the proceeding reactions whilst also providing real-time feedback for reaction monitoring and optimisation. © 2022. The Author(s).
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| 3. |
- Monaghan, T., et al.
(author)
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Customisable 3D printed microfluidics for integrated analysis and optimisation
- 2016
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In: Lab on a Chip. - Cambridge : Royal Society of Chemistry. - 1473-0197 .- 1473-0189. ; 16:17, s. 3362-3373
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Journal article (peer-reviewed)abstract
- The formation of smart Lab-on-a-Chip (LOC) devices featuring integrated sensing optics is currently hindered by convoluted and expensive manufacturing procedures. In this work, a series of 3D-printed LOC devices were designed and manufactured via stereolithography (SL) in a matter of hours. The spectroscopic performance of a variety of optical fibre combinations were tested, and the optimum path length for performing Ultraviolet-visible (UV-vis) spectroscopy determined. The information gained in these trials was then used in a reaction optimisation for the formation of carvone semicarbazone. The production of high resolution surface channels (100–500 μm) means that these devices were capable of handling a wide range of concentrations (9 μM–38 mM), and are ideally suited to both analyte detection and process optimisation. This ability to tailor the chip design and its integrated features as a direct result of the reaction being assessed, at such a low time and cost penalty greatly increases the user's ability to optimise both their device and reaction. As a result of the information gained in this investigation, we are able to report the first instance of a 3D-printed LOC device with fully integrated, in-line monitoring capabilities via the use of embedded optical fibres capable of performing UV-vis spectroscopy directly inside micro channels. © The Royal Society of Chemistry 2016.
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| 4. |
- Li, J., et al.
(author)
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Exploring the mechanical performance and material structures of integrated electrical circuits within solid state metal additive manufacturing matrices
- 2014
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In: Proceedings of the Twenty-Fifth Annual International Solid Freeform Fabrication (SFF) Symposium – An Additive Manufacturing Conference. ; , s. 857-864
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Conference paper (peer-reviewed)abstract
- Ultrasonic Additive Manufacturing (UAM) enables the integration of a wide variety of components into solid metal matrices due to a high degree of metal plastic flow at low matrix bulk temperatures. This phenomenon allows the fabrication of previously unobtainable novel engineered metal matrix components. The aim of this paper was to investigate the compatibility of electronic materials with UAM, thus exploring an entirely new realm of multifunctional components by integration of electrical structures within dense metal components processed in the solid-state. Three different dielectric materials were successfully embedded into UAM fabricated metal-matrices with, research derived, optimal processing parameters. The effect of dielectric material hardness on the final metal matrix mechanical strength after UAM processing was investigated systematically via mechanical peel testing and microscopy. The research resulted in a quantification of the role of material hardness on final UAM sample mechanical performance, which is of great interest for future industrial applications.
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| 5. |
- Li, J., et al.
(author)
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Exploring the mechanical strength of additively manufactured metal structures with embedded electrical materials
- 2015
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In: Journal of Materials Science and Engineering. - New York, NY : David Publishing Company. - 2161-6213 .- 0921-5093. ; 639, s. 474-481
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Journal article (peer-reviewed)abstract
- Ultrasonic Additive Manufacturing (UAM) enables the integration of a wide variety of components into solid metal matrices due to the process induced high degree of metal matrix plastic flow at low bulk temperatures. Exploitation of this phenomenon allows the fabrication of previously unobtainable novel engineered metal matrix components.The feasibility of directly embedding electrical materials within UAM metal matrices was investigated in this work. Three different dielectric materials were embedded into UAM fabricated aluminium metal-matrices with, research derived, optimal processing parameters. The effect of the dielectric material hardness on the final metal matrix mechanical strength after UAM processing was investigated systematically via mechanical peel testing and microscopy. It was found that when the Knoop hardness of the dielectric film was increased from 12.1 HK/0.01 kg to 27.3 HK/0.01 kg, the mechanical peel testing and linear weld density of the bond interface were enhanced by 15% and 16%, respectively, at UAM parameters of 1600 N weld force, 25 µm sonotrode amplitude, and 20 mm/s welding speed. This work uniquely identified that the mechanical strength of dielectric containing UAM metal matrices improved with increasing dielectric material hardness. It was therefore concluded that any UAM metal matrix mechanical strength degradation due to dielectric embedding could be restricted by employing a dielectric material with a suitable hardness (larger than 20 HK/0.01 kg). This result is of great interest and a vital step for realising electronic containing multifunctional smart metal composites for future industrial applications. © 2015 The Authors.
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| 6. |
- Masurtschak, S., et al.
(author)
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Fiber laser induced surface modification/manipulation of an ultrasonically consolidated metal matrix
- 2013
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In: Journal of Materials Processing Technology. - Amsterdam : Elsevier. - 0924-0136 .- 1873-4774. ; 213:10, s. 1792-1800
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Journal article (peer-reviewed)abstract
- Ultrasonic Consolidation (UC) is a manufacturing technique based on the ultrasonic joining of a sequence of metal foils. It has been shown to be a suitable method for fiber embedment into metal matrices. However, integration of high volume fractions of fibers requires a method for accurate positioning and secure placement to maintain fiber layouts within the matrices. This paper investigates the use of a fiber laser for microchannel creation in UC samples to allow such fiber layout patterns. A secondary goal, to possibly reduce plastic flow requirements in future embedding processes, is addressed by manipulating the melt generated by the laser to form a shoulder on either side of the channel. The authors studied the influence of laser power, traverse speed and assist gas pressure on the channel formation in aluminium alloy UC samples. It was found that multiple laser passes allowed accurate melt distribution and channel geometry in the micrometre range. An assist gas aided the manipulation of the melted material. © 2013 Elsevier B.V. All rights reserved.
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| 7. |
- Masurtschak, S., et al.
(author)
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Laser-Machined Microchannel Effect on Microstructure and Oxide Formation of an Ultrasonically Processed Aluminum Alloy
- 2015
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In: Journal of engineering materials and technology. - New York, NY : ASME Press. - 0094-4289 .- 1528-8889. ; 137:1
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Journal article (peer-reviewed)abstract
- Ultrasonic consolidation (UC) has been proven to be a suitable method for fiber embedment into metal matrices. To aid successful embedment of high fiber volumes and to ensure their accurate positioning, research on producing microchannels in combination with adjacent shoulders formed by distribution of the melt onto unique UC sample surfaces with a fiber laser was carried out. This paper investigated the effect of the laser on the microstructure surrounding the channel within an Al 3003-H18 sample. The heat input and the extent of the heat-affected zone (HAZ) from one and multiple passes was examined. The paper explored the influence of air, as an assist gas, on the shoulders and possible oxide formation with regards to future bonding requirements during UC. The authors found that one laser pass resulted in a keyhole-shaped channel filled with a mixture of aluminum and oxides and a symmetrical HAZ surrounding the channel. Multiple passes resulted in the desired channel shape and a wide HAZ which appeared to be an eutectic microstructure. The distribution of molten material showed oxide formation all along the channel outline and especially within the shoulder. © 2015 by ASME.
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| 8. |
- Monaghan, Thomas, et al.
(author)
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In-situ time resolved spectrographic measurement using an additively manufactured metallic micro-fluidic analysis platform
- 2019
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In: PLOS ONE. - San Francisco, CA : Public Library of Science. - 1932-6203. ; 14:11
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Journal article (peer-reviewed)abstract
- IntroductionMicrofluidic reactionware allows small volumes of reagents to be utilized for highly controlled flow chemistry applications. By integrating these microreactors with onboard analytical systems, the devices change from passive ones to active ones, increasing their functionality and usefulness. A pressing application for these active microreactors is the monitoring of reaction progress and intermediaries with respect to time, shedding light on important information about these real-time synthetic processes.ObjectiveIn this multi-disciplinary study the objective was to utilise advanced digital fabrication to research metallic, active microreactors with integrated fibre optics for reaction progress monitoring of solvent based liquids, incompatible with previously researched polymer devices, in combination with on-board Ultraviolet-visible spectroscopy for real-time reaction monitoring.MethodA solid-state, metal-based additive manufactured system (Ultrasonic Additive Manufacturing) combined with focussed ion beam milling, that permitted the accurate embedment of delicate sensory elements directly at the point of need within aluminium layers, was researched as a method to create active, metallic, flow reactors with on-board sensing. This outcome was then used to characterise and correctly identify concentrations of UV-active water-soluble B-vitamin nicotinamide and fluorescein. A dilution series was formed from 0.01–1.75 mM; which was pumped through the research device and monitored using UV-vis spectroscopy.ResultsThe results uniquely showed the in-situ ion milling of ultrasonically embedded optical fibres resulted in a metallic microfluidic reaction and monitoring device capable of measuring solvent solutions from 18 μM to 18 mM of nicotinamide and fluorescein, in real time. This level of accuracy highlights that the researched device and methods are capable of real-time spectrographic analysis of a range of chemical reactions outside of those possible with polymer devices.
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| 9. |
- Monaghan, T., et al.
(author)
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Solid-state additive manufacturing for metallized optical fiber integration
- 2015
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In: Composites. Part A, Applied science and manufacturing. - Kidlington : Pergamon Press. - 1359-835X .- 1878-5840. ; 76, s. 181-193
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Journal article (peer-reviewed)abstract
- The formation of smart, Metal Matrix Composite (MMC) structures through the use of solid-state Ultrasonic Additive Manufacturing (UAM) is currently hindered by the fragility of uncoated optical fibers under the required processing conditions. In this work, optical fibers equipped with metallic coatings were fully integrated into solid Aluminum matrices using processing parameter levels not previously possible. The mechanical performance of the resulting manufactured composite structure, as well as the functionality of the integrated fibers, was tested. Optical microscopy, Scanning Electron Microscopy (SEM) and Focused Ion Beam (FIB) analysis were used to characterize the interlaminar and fiber/matrix interfaces whilst mechanical peel testing was used to quantify bond strength. Via the integration of metallized optical fibers it was possible to increase the bond density by 20–22%, increase the composite mechanical strength by 12–29% and create a solid state bond between the metal matrix and fiber coating; whilst maintaining full fiber functionality. © 2015 The Authors. Published by Elsevier Ltd.
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| 10. |
- Bournias-Varotsis, A., et al.
(author)
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Selectively anodised aluminium foils as an insulating layer for embedding electronic circuitry in a metal matrix via ultrasonic additive manufacturing
- 2016
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In: Solid Freeform Fabrication 2016. - : Laboratory for Freeform Fabrication. ; , s. 2260-2270
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Conference paper (peer-reviewed)abstract
- Ultrasonic Additive Manufacturing (UAM) is a hybrid Additive Manufacturing (AM) process that involves layer-by-layer ultrasonic welding of metal foils and periodic machining to achieve the desired shape. Prior investigative research has demonstrated the potential of UAM for the embedding of electronic circuits inside a metal matrix. In this paper, a new approach for the fabrication of an insulating layer between an aluminium (Al) matrix and embedded electronic interconnections is presented. First, an Anodic Aluminium Oxide (AAO) layer is selectively grown onto the surface of Al foils prior to bonding. The pre-treated foils are then welded onto a UAM fabricated aluminium substrate. The bonding step can be repeated for the full encapsulation of the electronic interconnections or components. This ceramic AAO insulating layer provides several advantages over the alternative organic materials used in previous works.
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