Title: The Impact of a Static-Mixing Nozzle on Uniformity in Material Extrusion Large-Scale Additive Manufacturing

Authors: James C. Brackett, Elijah P. Charles, Tyler C. Smith, Ahmed A. Hassen, Vlastimil Kunc, Chad E. Duty

DOI: 10.33599/nasampe/s.22.0798

Abstract: There are many methods of incorporating more than one material in Additive Manufacturing (AM) processes. Oak Ridge National Laboratory has developed a unique solution that enables in-situ material switching by developing a dual-hopper feed system for Cincinnati’s Big Area Additive Manufacturing (BAAM) system. Continuous extrusion during a step-change in material feedstock results in a unique blended material transition region that exhibits a heterogeneous internal morphology. To improve mixing of materials during extrusion, a customized static-mixing nozzle was created for use with the BAAM. Single-bead transitions from Material A to B and B to A were printed with the mixing nozzle at a specified screw speed. Compositional analysis tracked the progression of the material transition as a function of extrudate volume. The resulting transition curves were compared against a standard nozzle configuration. Optical microscopy of cross-sections also demonstrated that the static-mixing nozzle promoted a more uniform bead geometry as well as a more homogeneous internal structure throughout the material transition.

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Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000798

Pages: 15

Price: $30.00