Guang Yang

Developing advanced nuclear fuel technologies is critical for high-performance applications such as nuclear thermal propulsion (NTP). This study explores the feasibility of direct ink writing (DIW) for fabricating ceramic pellets for potential nuclear applications. Zirconium carbide (ZrC) is used as a matrix material and vanadium carbide (VC) is used as a surrogate for uranium carbide (UC) in this study. A series of ink formulations were developed with varying concentrations of VC and nanocrystalline cellulose (NCC) to optimize the rheological properties for DIW processing. Post-sintering analysis revealed that conventionally sintered samples at 1750 °C exhibited high porosity (>60%), significantly reducing the compressive strength compared to dense ZrC ceramics. However, increasing VC content improved densification and mechanical properties, albeit at the cost of increased shrinkage and ink flow challenges. Spark plasma sintering (SPS) achieved near-theoretical density (~97%) but introduced geometric distortions and microcracking. Despite these challenges, this study demonstrates that DIW offers a viable route for fabricating ZrC-based ceramic structures, provided that sintering strategies and ink rheology are further optimized. These findings establish a baseline for DIW of ZrC-based materials and offer valuable insights into the porosity control, mechanical stability, and processing limitations of DIW for future nuclear fuel applications.

The 3D freeze printing (3DFP) of nanocellulose aerogels are demonstrated with large‐scale aligned pore orientations as a sustainable alternative to current acoustical materials. In contrast with the unidirectional pore network orientations obtained from current 3DFP techniques, a bidirectional orientation is achieved by using an inhomogeneous printing substrate to alter the thermal gradient within the print volume. The microstructural morphology shows that bidirectional printing results in a 2D pore orientation, with comparatively thinner pore walls and larger pore widths. Acoustic measurements reveal that altering the pore network characteristics significantly affects the acoustical behavior of the printed CNC aerogels; the wider pores allow the bidirectional CNC aerogels to provide higher sound absorption performance at lower frequencies than the unidirectional samples. Notably, both 3D Freeze printed CNC aerogels provide substantially higher sound transmission loss performance as compared to current acoustical materials. The unidirectional pore structure results in CNC aerogels with higher stiffness and improved energy absorption performance, with both 3D freeze printed CNC aerogels outperforming other CNC aerogel materials in their stiffness‐to‐density ratios. The ability to simultaneously control their pore orientation and macrostructural geometry paves the way for printing complex shaped CNC aerogel structures for multifunctional noise control applications.

The 3D freeze printing (3DFP) of nanocellulose aerogels are demonstrated with large‐scale aligned pore orientations as a sustainable alternative to current acoustical materials. In contrast with the unidirectional pore network orientations obtained from current 3DFP techniques, a bidirectional orientation is achieved by using an inhomogeneous printing substrate to alter the thermal gradient within the print volume. The microstructural morphology shows that bidirectional printing results in a 2D pore orientation, with comparatively thinner pore walls and larger pore widths. Acoustic measurements reveal that altering the pore network characteristics significantly affects the acoustical behavior of the printed CNC aerogels; the wider pores allow the bidirectional CNC aerogels to provide higher sound absorption performance at lower frequencies than the unidirectional samples. Notably, both 3D Freeze printed CNC aerogels provide substantially higher sound transmission loss performance as compared to current acoustical materials. The unidirectional pore structure results in CNC aerogels with higher stiffness and improved energy absorption performance, with both 3D freeze printed CNC aerogels outperforming other CNC aerogel materials in their stiffness‐to‐density ratios. The ability to simultaneously control their pore orientation and macrostructural geometry paves the way for printing complex shaped CNC aerogel structures for multifunctional noise control applications.

Assembling 2D materials such as MXenes into functional 3D aerogels using 3D printing technologies gains attention due to simplicity of fabrication, customized geometry and physical properties, and improved performance. Also, the establishment of straightforward electrode fabrication methods with the aim to hinder the restack and/or aggregation of electrode materials, which limits the performance of the electrode, is of great significant. In this study, unidirectional freeze casting and inkjet‐based 3D printing are combined to fabricate macroscopic porous aerogels with vertically aligned Ti₃C₂T_x sheets. The fabrication method is developed to easily control the aerogel microstructure and alignment of the MXene sheets. The aerogels show excellent electromechanical performance so that they can withstand almost 50% compression before recovering to the original shape and maintain their electrical conductivities during continuous compression cycles. To enhance the electrochemical performance, an inkjet‐printed MXene current collector layer is added with horizontally aligned MXene sheets. This combines the superior electrical conductivity of the current collector layer with the improved ionic diffusion provided by the porous electrode. The cells fabricated with horizontal MXene sheets alignment as current collector with subsequent vertical MXene sheets alignment layers show the best electrochemical performance with thickness‐independent capacitive behavior.

Three dimensional freeze printing (3DFP) combines the advantages of freeze casting and additive manufacturing to fabricate multifunctional aerogels. Freeze casting is a cost-effective, efficient, and versatile method capable of fabricating micro-scale porous structures inside the aerogels for many different applications. The 3DFP provided the capability of fabricating highly customized geometries with controlled microporous structures as well. However, there are still many unexplained phenomena and features because of the complexity of post-processes and indirect observation methods. This study demonstrates the design and construction of the in situ imaging systems, which use the x-ray synchrotron radiography to observe freeze casting and 3DFP processes. With the advantages provided by the in situ x-ray imaging techniques, the ice crystal growth with its unique lamellar structures can be observed during the freeze casting process. The movement of freeze front, material deposition, and growth of ice crystals can also be visualized during the inkjet-based 3DFP process.

Three dimensional freeze printing (3DFP) combines the advantages of freeze casting and additive manufacturing to fabricate multifunctional aerogels. Freeze casting is a cost-effective, efficient, and versatile method capable of fabricating micro-scale porous structures inside the aerogels for many different applications. The 3DFP provided the capability of fabricating highly customized geometries with controlled microporous structures as well. However, there are still many unexplained phenomena and features because of the complexity of post-processes and indirect observation methods. This study demonstrates the design and construction of the in situ imaging systems, which use the x-ray synchrotron radiography to observe freeze casting and 3DFP processes. With the advantages provided by the in situ x-ray imaging techniques, the ice crystal growth with its unique lamellar structures can be observed during the freeze casting process. The movement of freeze front, material deposition, and growth of ice crystals can also be visualized during the inkjet-based 3DFP process.

In this study, we overviewed the magnetic aerogel for the first time in terms of their major types and important applications, and have paved the way for the further research on this futuristic advanced material.

Demands for producing high quality glass components have been increasing due to their superior mechanical and optical properties. However, due to their high hardness and brittleness, they present great challenges to researchers when developing new machining processes. In this work, the discrete element method (DEM) is used to simulate orthogonal machining of synthetic soda-lime glass workpieces that are created using a bonded particle model and installed with four different types of seed cracks. The effects of these seed cracks on machining performance are studied and predicted through the DEM simulation. It is found that cutting force, random cracks, and surface roughness are reduced by up to 90%, 74%, and 47%, respectively, for the workpieces with seed cracks compared to the regular ones. The results show that high performance machining through DEM simulation can be achieved with optimal seed cracks.

Transparent, brittle materials, like glass, are used in various applications due to their advantages of mechanical and optical properties. However, their hard and brittle nature causes significant challenges to researchers when they design and test a new machining process. In order to optimize this time-consuming process, discrete element method (DEM) is applied to simulate the cutting process of soda-lime glass in this study. The first step is to create a synthetic material that behaves like soda-lime glass. Then, the macroproperties are calibrated by adjusting the microparameters of the DEM model to match the mechanical properties of the real soda-lime glass. Finally, orthogonal machining simulations are conducted and model validation are conducted by comparing the predicted cutting forces with those from the orthogonal cutting experiments.