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NRL FEATURES
The NRL crew after the successful flight of a 3-D printed fuel cell aboard the Ion Tiger UAV. Left to right: Dan Edwards,
Drew Rodgers, Ben Gould, Steve Carruthers, Mike Schuette, and Karen Swider-Lyons. Not shown: Chris Bovais.
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NRL FEATURES
plates, and develop the welding processes. So I thought this was a great
opportunity to try 3-D printing of metal
plates so we could quickly try out several designs without having to commit
to any tooling or welding.
First, the NRL team came up with
several flow field designs. To check
their viability, the team used the 3-D
printing tools in the LASR to build up
prototype plastic flow fields for flow
visualization. In parallel, physicist Dr.
Ravi Ramamurti carried out CFD predictions of the gas and coolant flows
and heat rejection. A successful plate
design was achieved through several
rounds of design, building, testing,
and model verification.
The challenge now was to make a
hollow metal bipolar plate with external channels for air and fuel and an
internal channel for coolant in a single
three-dimensional structure that was
also thin enough to meet the stringent
low-weight requirements for flight. The
team investigated different 3-D metal
printing processes and found that direct metal laser sintering, DMLS, had
the most potential for fabrication of
this kind of geometry. NRL successfully worked with the DMLS company
3T RPD Ltd. (UK) to make thin titanium bipolar plates from NRL designs.
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NRL FEATURES
Details of the hollow titanium bipolar plates made by the 3-D printing process of direct metal laser sintering (DMLS).
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NRL FEATURES
put together 41 bipolar plates for a
working stack. With help from the
University of Hawaii, quality assurance
processes were developed to confirm
the fuel cell performance.
Putting the plates together in a stack
exposed a critical problem with the
3-D metal printing process: warping. In DMLS, titanium particles are
sintered into place with a laser, and
then the whole body is sintered. Classic metallurgy teaches that residual
strains in the metal-to-metal contact
points lead to deformations as the
material undergoes strain relief. The
first set of metal bipolar plates had
dimensions of 4 centimeters (cm) by
8 cm and could be pressed together
effectively with other plates to make
good contact; however, an attempt to
make larger 8 cm by 12 cm plates was
unsuccessful, as they all came in from
the manufacturer warped by several
thousandths of an inch. NRL is still
investigating how to eliminate warps
so that the plates have an adequate
flatness tolerance. Developing accurate tolerancing is likely to be a key
aspect of future research in metal 3-D
printing.
WINTER 2014
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