David Dunand Research Group

Northwestern University

How can 3D printing and sintering produce load-bearing porous metal scaffolds with controlled microstructure and mechanical properties? The group develops 3D ink-extrusion and ink casting methods to fabricate metallic scaffolds and micro-lattices for high-temperature and biomedical applications. Researchers investigate hydrogen reduction of black mass from spent lithium-ion batteries to form Ni-Co-Mn master alloys that can be combined with Fe and Cr to produce stainless steel. The group uses neutron and synchrotron X-ray radiation to measure in situ strains, phase composition and perform tomography during processing and testing. Projects probe sintering resistance and microstructural evolution of porous iron and Fe–W systems under cyclic steam oxidation and hydrogen reduction to understand durability.