Session: 12-18-01: Functional Origami and Kirigami-inspired Structures and Metamaterials

Paper Number: 95531

95531 - Utilizing Bilayer Shrinkage to Assemble Complex Ceramic Shapes 

Though millennia of ceramics manufacturing have allowed for the production of an unimaginable assortment of stunning structures and intricate objects, there are still limitations on what can be made via commercial and artisanal techniques. For example, structures with internal elements such as shells with internal grids or interlocked structures like chains cannot be produced without bonding separate ceramic pieces yielding mechanically inferior final products. This work introduces a new manufacturing technique borrowing insights from the world of origami and solid oxide fuel cells (SOFCs). SOFCs are multilayer ceramic composites often manufactured by applying thin films to a thick substrate which provides physical support. Hard, dense ceramics are then formed by sintering the assembly at temperatures exceeding 1000 ^oC. The substrate and the applied film have different thermal expansion coefficients (TECs), so as the composite cools down from the peak sintering temperature, deformation occurs. In the context of SOFCs, this behavior is a major problem. Proper sealing of the cell becomes difficult, causing mixing of fuel and oxidant gas streams. This behavior is difficult to eliminate, requiring physical constraint during sintering, or modified sintering procedures to promote plastic deformation which can relieve residual stresses caused by the mismatch in TECs. Instead of minimizing this deformation, we propose accentuating it. By varying film thickness and deposition pattern, the composite can be designed to deform only in certain areas, allowing for well-controlled folding of the sheet producing the “mountain” and “valley” folds found in origami. The research presented here introduces the methodology for ceramic origami as well as key behaviors observed when using bilayer shrinkage with ceramic materials. Specifically, when a uniform film is applied to a substrate, the behaviors are shown to be similar to what is observed in soft matter systems undergoing the “bilayer shrinkage” problem. Bifurcation between spherical deformation and cylindrical deformation is observed as well as sheet geometry controlled bending direction preference. Behaviors unique to the ceramic medium including macroscale cracking of the substrate and microscale cracking of the film are identified and discussed. Finally, initial attempts to utilize this method of self-assembly are presented with several simple demonstration patterns including a wave sheet, a sunflower sheet, and a self-rolled tube. As a rigorous framework connecting soft matter physics and highly deformable hard matter is established, the catalogue of structures that can be assembled can continue to expand and allow for ceramics to be utilized in a variety of previously unsuitable systems.

Presenting Author: Alexander Hartwell Syracuse University

Presenting Author Biography: Alexander Hartwell is a PhD student at Syracuse University and a member of the combustion and energy research lab (COMER) at the Syracuse Center of Excellence. In 2018 he graduated from the College of Nanoscale Science and Engineering with dual bachelor’s degrees in nanoscale engineering and applied mathematics, and in 2020 he completed his Master of Science degree in mechanical and aerospace engineering at Syracuse University. For over seven years he has been working in university level academic research on topics including solid oxide fuel cells, ceramics manufacturing, microscale/nanoscale biomaterial and bio-compatible systems, and microscale/nanoscale manufacturing techniques. He is also chief technical officer of FirePower, a startup out of the COMER lab working on developing a resilient combined heat and power system using a fully integrated fuel cell generator.

Authors:

Alexander Hartwell Syracuse University
Nathaniel Slabaugh Syracuse University
Jeongmin Ahn Syracuse University