Dropwise Digital Printing of Metals

1:00pm - 2:00pm
Meeting ID: 983 1009 6894 Passcode: 249003


Metal additive manufacturing (AM) has the potential to impact an immense range of applications across industries, including the production of advanced structural, propulsion, and thermal management systems. However, current metal AM processes do not easily permit multi-material printing or local optimization of materials properties. By contrast, established processes that deposit metal directly have low resolution (e.g. directed energy deposition) or cannot achieve bulk metal properties (e.g. ink-based methods). In this talk, I will showcase two significant milestones that could potentially address these limitations. Firstly, I will present a new direct metal printing method involving on-demand deposition of discrete metal microparticles produced by electrohydrodynamic ejection from a water meniscus and followed by in-flight laser melting. We demonstrated the printing of solder and platinum particles ranging in size from 30-150 µm, and explored the process parameter space as limited by the ejection conditions and the kinetics of laser melting, droplet impingement, and solidification. The experiments demonstrate process compatibility with a wide range of power feedstock materials. Second, I will present a new route to enhance metal parts’ mechanical properties by in situ graphene growth. I developed a highly dynamic chemical vapor deposition (CVD) synthesis method to achieve high-quality graphene rapid growth (<1 min) on ultrathin metal films while overcoming solid-state dewetting instability, which usually occurs at high synthesis temperatures. As-grown graphene-metal interface enables efficient load transfer across the whole material and cracks bridging and energy dissipation during crack advancement. This new interface engineering approach can be potentially utilized in the metal particle printing process mentioned above, enabling high-performance nanocomposites manufacturing. My work opens the door for multi-material AM with tailored interfaces and functionalities and directly impacts the industries which have significant limitations in functionality integration and fine feature fabrication.

1:00pm - 2:00pm
Meeting ID: 983 1009 6894 Passcode: 249003
講者/ 表演者:
Dr. Kaihao Zhang
Department of Mechanical Engineering, Massachusetts Institute of Technology


Kaihao Zhang is currently a postdoctoral associate in the Mechanosynthesis Group at the Massachusetts Institute of Technology, working with John Hart. He earned his M.S. and Ph.D. both in Mechanical Engineering from the University of Illinois Urbana Champaign, where he was advised by Sameh Tawfick, and undergraduate degree in Energy and Environment System Engineering from Zhejiang University. His doctoral research focused on rapid graphene synthesis and graphene-metal interface engineering for high strength graphene-based nanocomposites. His current research involves new metal additive manufacturing techniques and advanced 2D materials synthesis. His work has been published in journals like Additive Manufacturing, Advanced Functional Materials, 2D Materials, Advanced Electronic Materials, etc.

Systems Hub, HKUST(GZ)