Material extrusion is an additive manufacturing technique that enables the creation of reproducible and complex hardware by depositing a viscous, shear-thinning ink onto a substrate in a custom-pattern via extrusion through a syringe. The ability of an ink to be extruded onto a substrate in many layers, and maintain the desired shape is what defines the printability. Printability is often investigated by formulating, printing, and postmortem analysis of final parts in an iterative manner. Investigations of printability through rheological characterization have often been concerned with inks that straddle the line between printable and too thin, leaving out an entire class of inks that are highly-filled pastes, where extrudability is the limiting factor. Highly-filled pastes continue to pose issues for researchers as the effect of filler morphology, size, loading, and packing fraction on the ink rheology and corresponding printability is not understood. While traditional rheological characterizations may be useful for some inks, we show that protocols utilizing steady-shear, or large-amplitude oscillatory shear are difficult and unreliable for highly-filled pastes. Through transient rheology paired with real-time images we show that each traditional protocol produces inhomogeneous deformations that violate the assumptions that underly common rheological definitions. Instead, we demonstrate metrics measured with small-amplitude oscillatory shear that are correlated to the printability of various ink formulations ranging in loading. The rheological measures that accurately predict the printability of the inks are the axial stress measured at small amplitudes, and the critical stress amplitude above which rheological characterizations become impossible. In addition, we estimate the maximum packing fraction for each filler, based on the exponent common to hard sphere models, and show that the printability of each ink can be predicted by the ratio of the packing fraction to the theoretical maximum. We show how small-amplitude oscillatory shear allows users to develop printability criteria for any ink to enhance the workflow in the development of new inks, increase the performance of material extrusion printing, and improve the stability of printed parts, with less wasted time and materials.
The explosive BTF (benzotrifuroxan) is an interesting molecule for sub-millimeter studies of initiation and detonation. It has no hydrogen, thus no water in the detonation products and a subsequently high temperature in the reaction zone. The material has impact sensitivity that is comparable or less than that of PETN (pentaerythritol tetranitrate) and slightly greater than RDX, HMX, and CL-20. Physical vapor deposition (PVD) can be used to grow high-density films of pure explosives with precise control over geometry, and we apply this technique to BTF to study detonation and initiation behavior as a function of sample thickness. The geometrical effects on detonation and corner turning behavior are studied with the critical detonation thickness experiment and the micromushroom test, respectively. Initiation behavior is studied with the high-throughput initiation experiment. Vapor-deposited films of BTF show detonation failure, corner turning, and initiation consistent with a heterogeneous explosive. Scaling of failure thickness to failure diameter shows that BTF has a very small failure diameter.
The eXtended History Variable Reactive Burn (XHVRB) model is parameterized for hexanitrostilbene (HNS) and pentaerythritol tetranitrate (PETN) based on data collected from a series of high-throughput initiation (HTI) experiments. The HTI experiment has generated a wealth of thin-pulse, sub-millimeter shock initiation data for a variety of vapor deposited explosive films. This is because it provides access to growth-to-detonation information for explosives that exhibit a shock-to-detonation transition (SDT) with length and time scales that are too short to be resolved by conventional experiments. The XHVRB model was selected because previous work has shown that simpler, homogeneous reactive burn models (RBMs) were incapable of reproducing the particle velocity buildup observed in experiments with heterogeneous explosives. Therefore, calibrated XHVRB models are developed in an attempt to capture the heterogeneous behavior not captured previously and to assess the models’ ability to capture the SDT across multiple explosive film thicknesses.
Vapor-deposited PETN films undergo significant microstructure evolution when exposed to elevated temperatures, even for short periods of time. This accelerated aging impacts initiation behavior and can lead to chemical changes as well. In this study, as-deposited and aged PETN films are characterized using scanning electron microscopy and ultra-high performance liquid chromatography and compared with changes in initiation behavior measured via a high-throughput experimental platform that uses laser-driven flyers to sequentially impact an array of small explosive samples. Accelerated aging leads to rapid coarsening of the grain structure. At longer times, little additional coarsening is evident, but the distribution of porosity continues to evolve. These changes in microstructure correspond to shifts in the initiation threshold and onset of reactions to higher flyer impact velocities.
The explosive BTF (benzotrifuroxan) is an interesting molecule for sub-millimeter studies of initiation and detonation. It has no hydrogen, thus no water in the detonation products and a subsequently high temperature in the reaction zone. The material has impact sensitivity that is comparable or less than that of PETN (pentaerythritol tetranitrate) and slightly greater than RDX, HMX, and CL-20. Physical vapor deposition (PVD) can be used to grow high-density films of pure explosives with precise control over geometry, and we apply this technique to BTF to study detonation and initiation behavior as a function of sample thickness. The geometrical effects on detonation and corner turning behavior are studied with the critical detonation thickness experiment and the micromushroom test, respectively. Initiation behavior is studied with the high-throughput initiation experiment. Vapor-deposited films of BTF show detonation failure, corner turning, and initiation consistent with a heterogeneous explosive. Scaling of failure thickness to failure diameter shows that BTF has a very small failure diameter.
Vapor-deposited PETN films undergo significant microstructure evolution when exposed to elevated temperatures, even for short periods of time. This accelerated aging impacts initiation behavior and can lead to chemical changes as well. In this study, as-deposited and aged PETN films are characterized using scanning electron microscopy and ultra-high performance liquid chromatography and compared with changes in initiation behavior measured via a high-throughput experimental platform that uses laser-driven flyers to sequentially impact an array of small explosive samples. Accelerated aging leads to rapid coarsening of the grain structure. At longer times, little additional coarsening is evident, but the distribution of porosity continues to evolve. These changes in microstructure correspond to shifts in the initiation threshold and onset of reactions to higher flyer impact velocities.
As additive manufacturing (AM) has become a reliable method for creating complex and unique hardware rapidly, the quality assurance of printed parts remains a priority. In situ process monitoring offers an approach for performing quality control while simultaneously minimizing post-production inspection. For extrusion printing processes, direct linkages between extrusion pressure fluctuations and print defects can be established by integrating pressure sensors onto the print head. In this work, the sensitivity of process monitoring is tested using engineered spherical defects. Pressure and force sensors located near an ink reservoir and just before the nozzle are shown to assist in identification of air bubbles, changes in height between the print head and build surface, clogs, and particle aggregates with a detection threshold of 60–70% of the nozzle diameter. Visual evidence of printed bead distortion is quantified using optical image analysis and correlated to pressure measurements. Importantly, this methodology provides an ability to monitor the quality of AM parts produced by extrusion printing methods and can be accomplished using commonly available pressure-sensing equipment.
The notion of plane shock waves is a macroscopic, very fruitful idealization of near discontinuous disturbance propagating at supersonic speed. Such a picture is comparable to the picture of shorelines seen from a very high altitude. When viewed at the grain scale where the structure of solids is inherently heterogeneous and stochastic, features of shock waves are non-laminar and field variables, such as particle velocity and pressure, fluctuate. This paper reviews select aspects of such fluctuating nonequilibrium features of plane shock waves in solids with focus on grain scale phenomena and raises the need for a paradigm change to achieve a deeper understanding of plane shock waves in solids.
A first-of-its-kind model calibration was performed using Sandia National Laboratories' high-throughput initiation (HTI) experiment for two types of vapor-deposited explosive films consisting of hexanitrostilbene (HNS) or pentaerythritol tetranitrate (PETN). These films exhibit prompt initiation, and they reach steady detonation at sub-millimeter length scales. Following prior work on HNS, we test the hypothesis of approximating these explosive films as fine-grained homogeneous solids with simple Arrhenius kinetics burn models. The model calibration process is described herein using a single-step as well as a two-step Arrhenius rate law, and it consists of systematic parameter sampling leading to a reduction in the model degrees of freedom. Multiple local minima are observed; results are given for seven different optimized parameter sets. Each model set is further evaluated in a two-dimensional simulation of the critical failure thickness for a sustained detonation. Overall, the two-step Arrhenius kinetics model captures the observed behavior for HNS; however, neither model produces a good fit to the PETN data. We hypothesize that the HTI results for PETN correspond to a heterogeneous response, owing to the smaller reaction zone of PETN compared to HNS (i.e., it does not homogenize the fine-grained hot spots as well). Future work should consider using the ignition and growth model for PETN, as well as other reactive burn models such as xHVRB, AWSD, PiSURF, and CREST.
