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TECHNOLOGY/BUSINESS OPPORTUNITY Hierarchical porous metals with deterministic 3D morphology and shape via 3D printed alloys - Figure 1

General Information

Document Type:SNOTE
Posted Date:Dec 04, 2017
Category: Research and Development
Set Aside:N/A

Contracting Office Address

Department of Energy, Lawrence Livermore National Laboratory (DOE Contractor), Industrial Partnerships & Commercialization, 7000 East Avenue, L-795, Livermore, California, 94550


DIW Approach Opportunity : Lawrence Livermore National Laboratory (LLNL), operated by the Lawrence Livermore National Security (LLNS), LLC under contract no. DE-AC52-07NA27344 (Contract 44) with the U.S. Department of Energy (DOE), is offering the opportunity to enter into a collaboration partnership to further develop and commercialize LLNLs method for fabricating metal foams with engineered hierarchical architectures. Background : Bulk nanoporous metals have generated much interest as electrode materials for catalysis and batteries as they combine both high surface area and high electrical conductivity. However, slow diffusion driven mass transport often limits their performance in these applications. One way to overcome mass transport limitations is by introducing a hierarchical pore architecture where macropores act as mass transport "highways" while nanopores provide the high surface area for high reactivity. Conventionally, nanoporous metals with uniform single level porosity have been fabricated by dealloying methods from an alloy precursor. The performance of these materials in many applications often suffers from mass transport limitations which is specifically true for monolithic macroscopic nanomaterials. In the extreme case, mass transport limitations limit reactions to the geometrical surface of the macroscopic monolithic material thus leaving the majority of the internal surface within the nanoporous bulk material unused. LLNL researchers have overcome this limitation by developing a new method for making hierarchical nanoporous metals by combining 3D printing with dealloying, a chemical corrosion process. Description : By combining 3D printing and dealloying., researchers at LLNL have developed a method for fabricating metal foams with engineered hierarchical architectures consisting of pores at least 3 distinct length scales. LLNLs method uses direct ink writing (DIW), a 3D printing technique for additive manufacturing to fabricate hierarchical nanoporous metal foams with deterministically controlled 3D multiscale porosities. Arbitrary shapes can be printed according to the application requirements. Moreover, the structure of three levels of porosity can be tuned independently which enables application specific multiscale architectures. In this method, DIW is used to extrude a gelbased metals mixture from a small nozzle into 3D periodic porous structures. The "ink" materials used for DIW are prepared by mixing two metal powders and an organic binder with varying concentrations to achieve the desired material composition and mechanical properties for 3D printing. After printing, the part is dried, and heat treated to remove residual organics while simultaneously forming a metal alloy. The resultant alloy part can be further processed to introduce the desired nanoporosity for high surface area via dealloying. Advantages : Additively manufactured multiscale porous materials decouple volume and surface area and thus have the potential to change the scaling laws that determine the design of chemical plants so that much smaller and more efficient units can be built. LLNLs method can be used to independently and deterministically tune all (at least three) levels of porosity within monoliths, films, or free forms to achieve spatially varying material properties, including: absorptivity, electrical conductivity, thermal expansion, chemical reactivity, density/porosity, and directed mass transport. Potential Applications : Deterministic control of the 3D hierarchical structure of metal foams opens the door to new applications in catalysis (fuel cells, industrial catalysts), energy storage (lithium ion battery, supercapacitors), or environmental areas (electrochemical transformations like CO2 reduction). Development Status LLNL has filed a patent application for this invention. LLNL is seeking industry partners with a demonstrated ability to bring such inventions to the market. Moving critical technology beyond the Laboratory to the commercial world helps our licensees gain a competitive edge in the marketplace. All licensing activities are conducted under policies relating to the strict nondisclosure of company proprietary information. Please visit the IPO website at https://ipo.llnl.gov/resources for more information on working with LLNL and the industrial partnering and technology transfer process. Note: THIS IS NOT A PROCUREMENT. Companies interested in commercializing LLNLs method for fabricating metal foams with engineered hierarchical architectures should provide a written statement of interest, which includes the following: 1. Company Name and address. 2. The name, address, and telephone number of a point of contact. 3. A description of corporate expertise and facilities relevant to commercializing this technology. Written responses should be directed to: Lawrence Livermore National Laboratory Innovation and Partnerships Office P.O. Box 808, L-795 Livermore, CA 94551-0808 Attention: FBO 361-18 Please provide your written statement within thirty (30) days from the date this announcement is published to ensure consideration of your interest in LLNLs method for fabricating metal foams with engineered hierarchical architectures.

Original Point of Contact

POC Connie L Pitcock, Phone: 925-422-1072

Place of Performance

Link: FBO.gov Permalink
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