Additive manufacturing of metallic components – Process, structure and properties

Solar-powered water evaporation — the extraction of vapour from liquid water using solar energy — provides the basis for the development of eco-friendly and cost-effective freshwater production. Liquid water consumes and carries energy, and, thus, plays an essential role in this process. As such, extensive experimental and theoretical studies have been focused on water management to achieve efficient solar vapour generation. Many innovative materials have been proposed to enable highly controllable and efficient solar-to-thermal energy conversion to address the challenges in the energy–water nexus from the microscale to the molecular level. In this Review, we summarize the fundamental principles of materials design for efficient solar-to-thermal energy conversion and vapour generation. We discuss how to integrate photothermal materials, nanostructures/microstructures and water–material interactions to improve the performance of the evaporation system via in situ utilization of solar energy. Focusing on materials science and engineering, we overview the key challenges and opportunities for nanostructured and microstructured materials in both fundamental research and practical water-purification applications. Materials engineering enables the control of water–material interactions in solar vapour generators, which aim to efficiently utilize solar energy for the cost-effective production of clean water. This Review discusses material-design principles for solar evaporators, spanning from macrostructures to molecular configurations.

Materials for solar-powered water evaporation

Energy and water are of fundamental importance for our modern society, and advanced technologies on sustainable energy storage and conversion as well as water resource management are in the focus of intensive research worldwide. Beyond their traditional biological applications, hydrogels are emerging as an appealing materials platform for energy- and water-related applications owing to their attractive and tailorable physiochemical properties. In this review, we highlight the highly tunable synthesis of various hydrogels, involving key synthetic elements such as monomer/polymer building blocks, cross-linkers, and functional additives, and discuss how hydrogels can be employed as precursors and templates for architecting three-dimensional frameworks of electrochemically active materials. We then present an in-depth discussion of the structure-property relationships of hydrogel materials based on fundamental gelation chemistry, ultimately targeting properties such as enhanced ionic/electronic conductivities, mechanical strength, flexibility, stimuli-responsiveness, and desirable swelling behavior. The unique interconnected porous structures of hydrogels enable fast charge/mass transport while offering large surface areas, and the polymer-water interactions can be regulated to achieve desirable water retention, absorption, and evaporation within hydrogels. Such structure-derived properties are also intimately coordinated to realize multifunctionality and stability for different target devices. The plethora of stimulating examples is expounded with a focus on batteries, supercapacitors, electrocatalysts, solar water purification, and atmospheric water harvesting, which showcase the unprecedented technological potential enabled by hydrogels and hydrogel-derived materials. Finally, we study the challenges and potential ways of tackling them to reveal the underlying mechanisms and transform the current development of hydrogel materials into sustainable energy and water technologies.

Hydrogels and Hydrogel-Derived Materials for Energy and Water Sustainability.

Solar vapor generation has presented great potential for wastewater treatment and seawater desalination with high energy conversion and utilization efficiency. However, technology gaps still exist for achieving a fast evaporation rate and high quality of water combined with low-cost deployment to provide a sustainable solar-driven water purification system. In this study, a naturally abundant biomass, konjac glucomannan, together with simple-to-fabricate iron-based metal-organic framework-derived photothermal nanoparticles is introduced into the polyvinyl alcohol networks, building hybrid hydrogel evaporators in a cost-effective fashion ($14.9 m-2 of total materials cost). With advantageous features of adequate water transport, effective water activation, and anti-salt-fouling function, the hybrid hydrogel evaporators achieve a high evaporation rate under one sun (1 kW m-2 ) at 3.2 kg m-2 h-1 out of wastewater with wide degrees of acidity and alkalinity (pH 2-14) and high-salinity seawater (up to 330 g kg-1 ). More notably, heavy metal ions are removed effectively by forming hydrogen and chelating bonds with excess hydroxyl groups in the hydrogel. It is anticipated that this study offers new possibilities for a deployable, cost-effective solar water purification system with assured water quality, especially for economically stressed communities.

Biomass‐Derived Hybrid Hydrogel Evaporators for Cost‐Effective Solar Water Purification

Nanotube films and articles and methods of making the same are disclosed. A conductive article includes an aggregate of nanotube segments in which the nanotube segments contact other nanotube segments to define a plurality of conductive pathways along the article. The nanotube segments may be single walled carbon nanotubes, or multi-walled carbon nanotubes. The various segments may have different lengths and may include segments having a length shorter than the length of the article. The articles so formed may be disposed on substrates, and may form an electrical network of nanotubes within the article itself. Conductive articles may be made on a substrate by forming a nanotube fabric on the substrate, and defining a pattern within the fabric in which the pattern corresponds to the conductive article. The nanotube fabric may be formed by growing the nanotube fabric on the substrate using a catalyst, for example, in which the catalyst is a gas phase catalyst, or in which the catalyst is a metallic gas phase catalyst. The nanotube fabric may be formed by depositing a solution of suspended nanotubes on the substrate. The deposited solution may be spun to create a spin-coating of the solution. The solution may be deposited by dipping the substrate into the solution. The nanotube fabric is formed by spraying an aerosol having nanotubes onto a surface of the substrate.

Methods of nanotube films and articles

Water purification by solar distillation is a promising technology to produce fresh water. However, solar vapor generation, is energy intensive, leading to a low water yield under natural sunlight. Therefore, developing new materials that can reduce the energy requirement of water vaporization and speed up solar water purification is highly desirable. Here, we introduce a highly hydratable light-absorbing hydrogel (h-LAH) consisting of polyvinyl alcohol and chitosan as the hydratable skeleton and polypyrrole as the light absorber, which can use less energy ( −2  hour −1 under 1 sun. The h-LAH-based solar still also exhibits long-term durability and antifouling functionality toward complex ionic contaminants.

Architecting highly hydratable polymer networks to tune the water state for solar water purification

Precisely controlled distribution of energy in solar-to-thermal energy conversion systems could allow for enhanced energy utilization. Light-absorbing hydrogels provide a means for evaporating water by using solar energy, yet targeted delivery of solar thermal energy to power the water evaporation process remains challenging. Here, we report a light-absorbing sponge-like hydrogel (LASH) that is created by in situ gelation of a light-absorbing nanoparticle-modified polymer, leading to synergistic energy nanoconfinement and water activation. By experimental demonstration and theoretical simulation, the LASH presents record high vapor generation rates up to ∼3.6 kg m-2 h-1 and stable long-term performance under 1 sun (1 kW m-2) irradiation. We investigate the energy confinement at the polymer-nanoparticle interphases and the water activation enabled by polymer-water interaction to reveal the significance of such effects for high-rate solar vapor generation. The water vaporization enabled by LASHs can remove over 99.9% of salt ions in seawater through solar water desalination. The fundamental design principle, scalable fabrication route, and superior performance offer possibilities for portable solar water purification, industrial solar-powered water treatment, and other advanced solar thermal applications.

Synergistic Energy Nanoconfinement and Water Activation in Hydrogels for Efficient Solar Water Desalination.

The present invention provides fabrics that have unique chemical, electrical, and thermal properties. The fabrics comprise layers of yarns woven together wherein the yarns further comprise carbon nanotube fibers. These carbon nanotube fibers may be either single-walled or multi-walled carbon nanotubes. The use of carbon nanotube fibers allows the fabrics to insulate, semi-conduct or super-conduct electrical charges. Additionally, the thermal properties of carbon nanotubes allow thermal energy to flow efficiently between the fabric and a heat sink or source. Additional yarns of materials other than carbon nanotubes can be integrated or woven into the fabric to provide other unique properties for the fabric. These fabrics can be layered to form unique garments or structures.

Carbon nanotube fabrics

The present invention provides fabrics that have unique mechanical, chemical, electrical, and thermal properties. The fabrics comprise layers of woven, knit or felted fibers, yarns or tow. Interstitially synthesized nanotubes, such as single-walled or multi-walled carbon nanotubes, enhance the fabric's antiballistic properties. These nanotubes may also insulate, semi-conduct or super-conduct electrical charges, or provide enhanced thermal properties of these fabrics which can be layered to form unique garments or structures.

Ballistic fabrics with improved antiballistic properties

Warhead structures and features are fabricated using direct manufacturing technologies, a method for fabricating bulk warhead structures by sequential and additive deposition of melted feedstock layers. Suitable energy sources for melting the feedstock can be various high energy density technologies including laser, electron beam, plasma arc deposition, and the like. The high energy density in combination with high cooling rates results in structures with homogeneous microstructures. The feedstock can be in the form of wire or powder and is applied to a substrate by introduction to a molten pool on the substrate, accumulating to additively combine with the substrate. The approach provides for warhead structures with singular and combined unique features to include: integral constructions, tailored fragmentation patterns, use of dissimilar materials for special effects, and variable material property constructions for enhanced performance.

Brian T. Rosenberger

Papers

Architecting highly hydratable polymer networks to tune the water state for solar water purification

Synergistic Energy Nanoconfinement and Water Activation in Hydrogels for Efficient Solar Water Desalination.

Carbon nanotube fabrics

Ballistic fabrics with improved antiballistic properties

Warhead with integral, direct-manufactured features