3D woven NiCr metallic lattice materials deliver tunable, structural damping in environments where conventional polymer-based solutions fail, enabling more reliable, longer‑life high‑temperature machinery and structures with a scalable, architected-metal manufacturing route.
Problem addressed
Rotating machinery and high‑speed systems (e.g., turbines) suffer wear, fatigue, and premature failure from vibrations. Conventional solutions to minimize the vibrations (dampen) rely on polymeric viscoelastic layers that lose performance or degrade at elevated temperatures and can be difficult to integrate into metallic structures. Metal foams provide some damping but have random pore structures, limiting repeatability, design control, and property optimization.
Solution
JHU researchers have developed a family of micro-architected, three‑dimensional (3D) woven metallic wire lattices (demonstrated in NiCr) whose pore architecture is deliberately designed and, when desired, bonded to form stiff, load‑bearing micro‑lattices with intrinsic vibration damping.
Architectures include “standard” and “modified” weaves created by selectively leaving positions unfilled to tailor topology and performance.
This novel material’s controlled 3D weaving creates periodic, designer pore structures with tunable density, stiffness, and contact topology—enabling targeted damping without sacrificing structural function. Metallic composition (NiCr) provides high maximum service temperature and oxidation resistance, allowing damping in environments inaccessible to polymers. The architecture can be co‑designed for multiple functions (e.g., stiffness, damping, and permeability), and wires can be bonded to tune stiffness vs. energy dissipation.
Lower vibration translates to extended component life, fewer unscheduled maintenance events, and potential weight or cost savings by reducing the need for secondary damping treatments.
Value proposition
- Performance at temperature
- Tunable, multifunctional design
- Durability and reliability
- Integration readiness
- System‑level impact
Target applications
- Gas turbines, compressors, and turbo‑machinery (rotors, casings, shrouds, and supports) requiring elevated temperature damping.
- Aerospace structures and engine nacelle components exposed to thermal cycling and vibration.
- Automotive and industrial exhaust/energy systems where heat and vibration co‑exist.
- Sandwich panels and mounts requiring both stiffness and damping.
Test Outcomes and Validation
- Measured mechanical loss factors across 1–200 Hz demonstrate meaningful intrinsic damping in 3D woven lattices while retaining structural integrity in bending.
- A property map correlating loss factor versus maximum service temperature shows these woven NiCr lattices uniquely combine significant damping with high temperature capability—occupying a space where polymeric dampers cannot operate.
-Prior work on 3D woven lattices establishes scalable manufacturing, architectural tunability (including topology optimization), and the ability to create stiff, bonded micro‑lattices.
- Experimental damping characterization (loss factor via DMA) conducted over 1–200 Hz; simulations support interpretation and design.
- Demonstrated architectures (“standard” and “modified”) indicate a design space for further optimization of damping vs. stiffness.
- Technology readiness: early-stage materials demonstration suitable for pilot integration in non‑critical subcomponents and for co‑development with OEMs.
Publications:
Scripta Materialia. 106. 1–4.
International Journal of Heat and Mass Transfer. 96. 296-311.
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