This $155,000 Project Grant from the National Science Foundation (NSF) Office of Integrative Activities (CFDA 47.083) supports fundamental research at Iowa State University to understand how nanoparticle self-assembly can be integrated into laser/powder-based additive manufacturing (AM) of multimodal metallic materials. The overall goal is to gain a deeper understanding of the mechanisms governing nanoparticle self-assembly behavior, microstructure evolution, and property enhancements in AM of...
This $300,000 federal Project Grant award from the National Science Foundation's (NSF) Integrative Activities program (CFDA 47.083) supports research at Clemson University to advance metal additive manufacturing (AM) technologies for developing radiation-tolerant solid-solution alloys. The key objectives are to: (i) synthesize single-phase concentrated solid-solution alloys (SP-CSAS) with varying compositions and defect structures using laser-directed energy deposition AM; (ii) investigate the...
This $300,000 Project Grant award from the National Science Foundation's (NSF) Integrative Activities (CFDA 47.083) program supports fundamental research at Iowa State University to develop new material-process-structure-property relationships for additively manufactured electronics that can function in extreme environments. The key objectives are to: 1) understand printing process fundamentals for air-sensitive metals and alloys, 2) investigate material sintering techniques, and 3) characterize...
This National Science Foundation (NSF) Project Grant award, under the NSF Engineering program (CFDA 47.041), provides $475,399 to Auburn University to conduct fundamental research on laser nanoparticle powder-bed fusion, an additive nanomanufacturing process. The research aims to develop layer-by-layer fabrication of micro- and nano-scale functional structures and devices with tunable chemical compositions, interface interactions, and physical architectures. This work has potential...
This Project Grant award from the National Science Foundation (NSF) Engineering program (CFDA 47.041) provides $538,225 to Dartmouth College to conduct research on fabricating columnar-grained microstructures and single crystals of nickel-based superalloys through directional recrystallization of additively manufactured materials. The goal is to develop a cost-effective method for producing nickel alloy turbine blades, a critical component in jet engines. The research will investigate the...
The federal Project Grant award, titled "DREAM-TEAM: DEVELOPING A ROBUST ECOSYSTEM FOR ADDITIVE MANUFACTURING OF TUNGSTEN FOR EXTREME APPLICATIONS AND MANAGEMENT," was granted by the Department of Energy's Office of Science Financial Assistance Program (CFDA 81.049) to Iowa State University of Science and Technology. The $999,998.31 award, with a performance period from September 1, 2024 to August 31, 2025, supports fundamental scientific research focused on advancing additive...
This National Science Foundation (NSF) Engineering program (CFDA 47.041) Project Grant award of $262,929 will support research to develop an in-situ processing data-driven framework that can link manufacturing processes to environmentally-related performance for laser powder bed fusion (L-PBF) metal additive manufacturing. The key objectives are to: Establish a physics-constrained artificial intelligence (PCAI)-based surrogate model to predict part-scale residual stress and microstructures using...
This Project Grant award from the National Science Foundation's Engineering program (CFDA 47.041) supports research to develop a novel additive manufacturing process called Vacancy-Assisted Jet Fusion (VJF) for fabricating complex parts from transition-metal-carbide (TMC) ceramics. The $300,000 award to the University of Iowa aims to (1) quantify the effects of layerwise triggered electron flow on the diffusion of locally induced crystal vacancies, (2) uncover the underlying mechanisms governing...
This five-year, $641,328 National Science Foundation Project Grant supports research at the Colorado School of Mines to advance additive manufacturing of nickel-based superalloys for clean energy applications. Funded through NSF's Engineering program (CFDA 47.041), the award will develop a mechanistic understanding of how wire arc additive manufacturing processing conditions influence the microstructure and high-temperature mechanical properties of Haynes 282 superalloy. The research combines...
This Project Grant award from the National Science Foundation's (NSF) Engineering program (CFDA 47.041) supports research at The Ohio State University investigating the reuse and recycling of feedstock in the laser directed energy deposition metal additive manufacturing process. The $659,153 award, spanning May 2025 to April 2030, aims to reveal how characteristics of reused and recycled feedstock influence melting and solidification in this process, with the goal of creating a framework for...
This Project Grant award from the National Science Foundation Office of Integrative Activities (CFDA 47.083) will support research at Iowa State University on the development, characterization, and performance evaluation of surface engineered additively manufactured parts for nuclear reactor applications.
Specifically, the university will utilize a laser-based directed energy deposition process to fabricate metallic parts from Nitronic 60 stainless steel, a material used in nuclear reactor components due to its high-temperature wear and corrosion resistance. The top layers of the fabricated parts will be further engineered using ultrasonic impact peening treatment to enhance wear resistance. The team will analyze the microstructure, residual stress, and phase fractions of the additively manufactured samples at different build heights using neutron diffraction, and correlate these properties with tribological performance through reciprocating sliding and fretting wear testing. The total funding amount for this 2-year project is $248,376.