BNNT-Al Composites via Cold Spray Additive Manufacturing

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Solution Overview

Problem

Current methods are limited in achieving large-scale production of high-strength boron nitride nanotubes (BNNT)/aluminum (Al) metal matrix composites, as BNNTs are challenging to disperse uniformly in Al alloy matrices due to their low mass, and existing 3D printing techniques often require melting, which compromises the mechanical properties of wrought Al alloys.

Innovation Solution

The use of a combination of ultrasonication and spray drying techniques to disperse BNNTs uniformly in Al alloy powders, followed by cold spray technology, which is a solid-state 3D printing process that retains the pristine properties of Al alloys without melting, allowing for the large-scale additive manufacturing of BNNT/Al metal matrix composites.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional 3D printing techniques are used to manufacture BNNT/Al composites, then large-scale production is enabled, but the mechanical properties of Al alloys are compromised due to melting

Engineering Contradiction:

Improvelarge-scale production capabilityVSAvoidmechanical properties of Al alloy

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The invention changes the temperature parameter of the 3D printing process from high-temperature melting to low-temperature cold spray deposition. By operating below the melting point of aluminum, the process preserves the mechanical properties of the Al alloy while still enabling large-scale additive manufacturing of BNNT/Al composites

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the thermal field (melting-based deposition) with a mechanical field (cold spray deposition). The cold spray process uses high-velocity particle impact and plastic deformation to bond layers, substituting the thermal melting mechanism with a mechanical bonding mechanism that preserves alloy properties

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If BNNTs are added to Al alloy matrices, then composite strength is improved, but uniform dispersion is difficult to achieve due to low mass of BNNTs

Engineering Contradiction:

Improvecomposite strengthVSAvoiduniformity of BNNT dispersion

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The invention performs preliminary dispersion of BNNTs in the Al alloy powder before the 3D printing process. By pre-mixing and pre-dispersing the nanotubes uniformly in the feedstock powder, the process ensures homogeneous distribution throughout the composite structure, preventing agglomeration and achieving uniform reinforcement

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses a binder or coating material as an intermediary between BNNTs and Al alloy particles. This intermediary facilitates uniform distribution of the low-mass BNNTs by providing a matrix that holds them in place during mixing and deposition, preventing segregation and ensuring homogeneous dispersion in the final composite

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method enables the production of high-strength BNNT/Al composites with uniform dispersion and retention of BNNTs, maintaining the mechanical properties of Al alloys while allowing for scalable, low-temperature manufacturing of complex shapes and sizes, suitable for industrial applications such as corrosion protection and radiation shielding.

Implementation Method 1

A combination of ultrasonication and spray drying techniques can produce good BNNT/Al alloy feedstock powders for the cold spray process

Methodology Applied

Scientific EffectUltrasonication: Ultrasound

Implementation Method 2

performing a sonication process (e.g., ultrasonication and/or tip sonication) on the first solution to give a first mixed solution

Methodology Applied

Scientific EffectAcoustic cavitation: Acoustic Cavitation

Implementation Method 3

performing a drying process on the intermediate mixture to give the BNNT-Al powder

Methodology Applied

Scientific EffectSpray drying: Spray

Implementation Method 4

drying the second mixed solution. The drying of the second mixed solution can comprise drying the second mixed solution in an oven and/or spray drying the second mixed solution

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 5

Cold spray technology, which is a solid-state three-dimensional (3D) printing process for metallic powders, can be used

Methodology Applied

Scientific EffectCold spray:

Data Source

PatentUS12103071B2Boron nitride nanotube aluminum composites and methods of manufacturing the same

Publication Date: 2024.10.01 FLORIDA INTERNATIONAL UNIVERSITY

AI summary

Methods for large-scale additive manufacturing of high-strength boron nitride nanotubes (BNNT)/aluminum (Al) (e.g., reinforced Al alloy) metal matrix composites (MMCs) (BNNT/Al MMCs), as well as the BNNT/Al MMCs produced by the large-scale additive manufacturing methods, are provided. A combination of ultrasonication and spray drying techniques can produce good BNNT/Al alloy feedstock powders, which can be used in a cold spraying process.