Dr. Saniya LeBlanc Profile

Dr. Saniya LeBlanc

at George Washington Univ

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Proceedings Article | 23 April 2020 Presentation + Paper

Meso-, micro-, and nano-structures induced in bismuth telluride thermoelectric materials by laser additive manufacturing

Ryan Welch, Dean Hobbis, George Nolas, Saniya LeBlanc

Proceedings Volume 11387, 1138710 (2020) https://doi.org/10.1117/12.2558676

KEYWORDS: Bismuth, Thermoelectric materials, Laser processing, Additive manufacturing, Manufacturing, Laser manufacturing

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Thermoelectric devices are solid-state energy conversion devices that are used in thermal management and waste heat recovery applications. Current thermoelectric devices are limited in their geometries, and the manufacturing process is labor-intensive. The traditional manufacturing methods limit the widespread use of thermoelectric modules in potential application areas. To address this issue and expand the use of thermoelectric devices, we investigated laser powder bed fusion, an additive manufacturing technique that is also known as selective laser melting. We performed selective laser melting on bismuth telluride, a common thermoelectric material. This work explored Bi₂Se_0.3 Te_2.7, an n-type thermoelectric material. After laser processing, the meso-, micro-, and nanostructure of selectively laser melted samples were analyzed to identify the relationship between the laser parameters and processed materials. The meso- and micro-structure was investigated with optical and scanning electron microscopy to identify the grain structure and morphology. The nanostructure was analyzed using transmission electron microscopy to explore the location and density of dislocations and point defects. The results reveal the impact of selective laser melting process parameters on n-type bismuth telluride and guide future work in determining the process-structure relationship for laser additive manufacturing of thermoelectric devices.

Proceedings Article | 15 May 2018 Presentation + Paper

Selective laser melting of half-Heusler thermoelectric materials

Haidong Zhang, Shanyu Wang, Patrick Taylor, Jihui Yang, Saniya LeBlanc

Proceedings Volume 10663, 106630B (2018) https://doi.org/10.1117/12.2306099

KEYWORDS: Laser processing, Thermoelectric materials, Additive manufacturing

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Traditional thermoelectric device manufacturing uses machining, assembly, and integration steps which lead to material waste and performance limitations. The approach offers little flexibility in designing thermoelectric module geometry. Additive manufacturing can overcome these challenges, but it has not been demonstrated for inorganic thermoelectric materials, particularly those geared toward mid-/high-temperature applications. This work describes selective laser melting, an additive manufacturing process which locally melts successive layers of material powder to construct three-dimensional objects. The work shows the firstever demonstrations of selective laser melting applied to half-Heusler thermoelectric materials: ZrNiSn, and Hf_0.3Zr_0.7CoSn_0.3Sb_0.7/nano-Zr_O2. Laser processing parameters critically affects the formation and appearance of ingots, and we found laser energy density is useful but cannot be the single consideration for the SLM process. The fabricated ingots are generally porous with rough surfaces. They are characterized through powder XRD and TGA. The results consistently show that produced parts preserved most of the original chemical structures with small chemical changes due to decomposition and oxidation during the selective laser melting process. The work demonstrates selective laser melting is feasible for half-Heusler thermoelectric materials.

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