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Novel Vector Assignment Approach For Inherent Strain Modeling Of Laser Powder Bed Fusion Manufacturing, Lucas M. Morand

All Dissertations

The expansion of the design space due to additive manufacturing (AM) has been a large motivator for the success of this family of processes. Despite the complexity of the physics in metal laser powder bed fusion AM causing significant stresses and strains in finished parts, the design advantages and subsequent performance improvements continue to drive the expansion of AM. Because the trial-and-error approach to AM part development is cost prohibitive, simulation of prints has become crucial. However, full thermo-mechanical simulation is susceptible to the same pitfall of time and computational cost in order to attain part-scale results. The development of …

Multi-Scale Modeling Of Selective Laser Sintering: From Manufacturing Process And Microstructure To Mechanical Performance In Semi-Crystalline Thermoplastics, Cameron Zadeh

All Dissertations

Selective laser sintering is an additive manufacturing process that opens many design possibilities but is limited in its reliability and reproducibility. Numerical simulations validated by experimental data yield insights into the process and resulting part properties, allowing users to make more informed decisions. In this dissertation, a model for the process and microstructure is developed and validated, followed by a coupling to mechanical models to predict part performance. Further developments include a new addition of a reaction kinetics model to the process model to describe the interplay between thermal degradation and melt pool properties, and an exploration of the parameter …

Integration Of Infrared Thermography And Deep Learning For Real-Time In-Situ Defect Detection And Rapid Elimination Of Defect Propagation In Material Extrusion, Asef Ishraq Sadaf

Electronic Theses and Dissertations

This study presents a novel approach to overcoming process reliability challenges in Material Extrusion (ME), a prominent additive manufacturing (AM) technique. Despite ME's advantages in cost, versatility, and rapid prototyping, it faces significant barriers to commercial-scale production, primarily due to quality issues such as overextrusion and underextrusion, which compromise final part performance. Traditional manual monitoring methods severely lack the capability to efficiently detect these defects and highlight the necessity for an efficient and real-time monitoring solution. Considering these challenges, an innovative and field-deployable infrared thermography-based in-situ real-time defect detection and feedback control system is proposed in this thesis. A novel …

Thermal Processing Of Al-Zn-Cu-Mg-Zr Laser Powder Bed Fusion Material For Increased Ductility, Jeffrey S. Gaddes

Dissertations

Although the use of wrought high strength aluminum alloys is prevalent throughout aerospace systems, they often have long lead times and become difficult to source throughout the long lifecycle of aviation systems. Laser Powder Bed Fusion (LPBF) Additive Manufacturing (AM) provides opportunity to directly manufacture wrought equivalent aluminum products without forging supply chain challenges. If these LBPF components are made with the same aluminum material system with similar strength and ductility, they can be a direct replacement for traditionally manufactured components. However, existing 7xxx aluminum alloys are prone to cracking during fusion welding and therefore are not readily produced through …

Characterization Of Size Effects In Additively Manufactured Grcop-42 And Their Influence On Mechanical Response, Gabriel Demeneghi

Dissertations

This study investigates size effects on microstructure, mechanical behavior, and fatigue performance of additively manufactured GRCop-42. Systematic analyses, encompassing changes on powder composition, wall thickness, and heat treatment, was conducted on specimens produced through laser powder bed fusion (L-PBF) and laser powder direct energy deposition (DED) techniques. L-PBF specimens exhibited a reduction in strength and elongation with decreasing thickness, attributed to increasing porosity as specimen’s thickness decreases. Conversely, in DED specimens, decreasing mechanical properties with thickness were associated to surface topography. Emphasizing the non-generalizability of size effects across AM methods. Size effects were also investigated on high cycle fatigue, as …

Microstructure Control Through The Use Of Gas Tungsten Arc Welding Based Additive Manufacturing, Benjamin M. Beeker

Dissertations

Additively manufactured (AM) parts are subjected to rapid and repeated localized melting, solidification, and reheating, which produces a heterogeneous microstructure. To homogenize the resulting heterogeneous microstructure that results from this non-equilibrium thermal cycling, ex-situ heat treatments can be used. However, this is intended to provide homogenous properties to the printed part, thereby not realizing one of the potential benefits of AM in providing site-specific properties such as fatigue resistance, wear resistance or high strength. This study explores the use of in-situ heat treatments to spatially control microstructure evolution, thereby controlling the location of specific mechanical properties. To guide the processing …

Evaluating The Effects Of L-Pbf Printing Parameters On The Microstructure And Mechanical Properties Of Grcop-42, Elaina Walker

Theses

GRCop-42 is a dispersion strengthened copper alloy of interest due to its high thermal conductivity. Since it is fabricated as a powder, it is adaptable to powder based, metal additive manufacturing (AM) processing. The chromium-niobium additives phase separate from the copper matrix and form strengthening dispersoids during the gas atomization process used to produce the powder. This study looks at the effect of the powder based, laser powder bed fusion (L-PBF) AM processing parameters on the resulting microstructure and mechanical properties. Builds were obtained from five different vendors, deposited using their best practice, for metallurgical and mechanical property evaluation. By …

Quasi-Static And Dynamic Tension Testing Of As-Built And Heat-Treated Additively Manufactured 316l Stainless Steel, Terrell Elias Marler

Theses

Additive manufacturing (AM) has several advantages over conventional subtractive manufacturing techniques, including the ability to create parts of highly complex geometries in one process thus reducing time and cost for each part. However, AM parts show different mechanical behavior compared to wrought parts due to the differences in the manufacturing processes. In particular, lack-of-fusion defects, voids, and keyhole defects can act as crack initiation sites leading to the possibility of more brittle behavior. This may be exacerbated by high rate loads, which tends to induce more brittle behavior, higher flow stress, and higher yield stress in materials. Therefore, it is …

Characterization Of 3d Printed Lattice Structures Used In The Design Of Modified Compression Release Stabilized Transhumeral Prosthetic Sockets, Jade Myers

Theses

Abstract A prosthetic socket is the critical interface between a person and their prosthetic device. Pressure, shear, and friction experienced by the residual limb from wearing a socket can damage soft tissue. While Compression Release Stabilized (CRS) style sockets are beneficial for enhancing prosthesis stability, range of motion, and control, the abrupt differences in compression throughout the socket present risks for tissue damage to the residual limb. A socket design that enables clinicians to control a progressive decrease in firmness in the transition areas between compression and release could mitigate such undesirable effects. Density-graded lattice structures designed and produced with …

An Investigation Into Applications Of Canonical Polyadic Decomposition & Ensemble Learning In Forecasting Thermal Data Streams In Direct Laser Deposition Processes, Jonathan Storey

Theses and Dissertations

Additive manufacturing (AM) is a process of creating objects from 3D model data by adding layers of material. AM technologies present several advantages compared to traditional manufacturing technologies, such as producing less material waste and being capable of producing parts with greater geometric complexity. However, deficiencies in the printing process due to high process uncertainty can affect the microstructural properties of a fabricated part leading to defects. In metal AM, previous studies have linked defects in parts with melt pool temperature fluctuations, with the size of the melt pool and the scan pattern being key factors associated with part defects. …

Ultrasonic Non-Destructive Evaluation Of Additively Manufactured Polymer-Ceramic Composites, Christian Alexander Ruiz

Open Access Theses & Dissertations

Digital light processing (DLP) is an attractive additive manufacturing technique due to its ability to create ceramic parts with complex geometries. DLP uses ultraviolet light to polymerize a slurry comprised of ceramic powder and photosensitive resin in layers to create solid parts. Printing parameters such as light intensity and exposure time are critical when producing these parts. Improper parameters can lead to over or under-curing, adversely impacting print quality and strength. Samples were printed at varying layer exposure times and then tested using ultrasonics to determine the degree of conversion. Additionally, ultrasonics were used as a non-destructive technique to obtain …

Additive Manufacturing Of Composites For Sensing And Harsh Environments Application, Md Sahid Hassan

Open Access Theses & Dissertations

Composite materials are made by combining two or more materials, such as fibers and resins to create a material system that has improved mechanical and physical properties compared to its individual components. The use of 3D printing technology in composite manufacturing allows for the creation of complex and custom shapes with precise control over the placement of the materials. This makes it possible to create composite parts with enhanced performance characteristics and reduced weight. The work presented in this dissertation lies in the design and development of highly flexible impact propagation sensor through material extrusion 3D printing technique. By using …

Development Of A Potassium Permanganate Catalyst-Infused Fuel Grain For Hydrogen Peroxide Hybrid Thruster Ignition Enhancement, Ryan J. Thibaudeau

All Graduate Theses and Dissertations, Fall 2023 to Present

This thesis describes and addresses the need for reliable ignition in small satellite hybrid propulsion systems using hydrogen peroxide. It describes process of creating custom 3D printed ABS plastic fuel grains with small amounts of catalysts. These catalysts lead to a more reliable and energy-efficient ignition of a hybrid rocked propulsion system using catalyst-infused ABS and high-test hydrogen peroxide (HTP). Hydrogen peroxide is a high-density oxidizer and therefore more volumetrically efficient for a small satellite using hybrid rocket technology when compared to gaseous oxygen (GOX). The traditional ignition methods of hybrid rocket propulsion systems using HTP are compared to and …

Woven Natural Fiber-Reinforced Pla Polymer 3d Printed Through A Laminated Object Manufacturing (Lom) Process, Sazidur Rahman Shahriar

All Theses

This investigation explored an innovative additive manufacturing method that employed laminated object manufacturing (LOM) technology in combination with woven natural fiber-reinforced biopolymer. Conventional synthetic composites are made from crude oil that are nonrenewable and have few options for disposal or recycling, rendering them ecologically unfavorable. Integration of continuous woven natural fiber with polylactic acid (PLA) markedly enhances the mechanical strength to ensure complete biodegradability. Woven natural fiber-reinforced biocomposites are considered a promising alternative to synthetic composites. The potential applications of these fiber-reinforced PLA polymers include vehicle panels, construction materials, athletics equipment, and musical apparatuses.

The author has developed and constructed …

Damage Detection With An Integrated Smart Composite Using A Magnetostriction-Based Nondestructive Evaluation Method: Integrating Machine Learning For Prediction, Christopher Nelon

All Dissertations

The development of composite materials for structural components necessitates methods for evaluating and characterizing their damage states after encountering loading conditions. Laminates fabricated from carbon fiber reinforced polymers (CFRPs) are lightweight alternatives to metallic plates; thus, their usage has increased in performance industries such as aerospace and automotive. Additive manufacturing (AM) has experienced a similar growth as composite material inclusion because of its advantages over traditional manufacturing methods. Fabrication with composite laminates and additive manufacturing, specifically fused filament fabrication (fused deposition modeling), requires material to be placed layer-by-layer. If adjacent plies/layers lose adhesion during fabrication or operational usage, the strength …

Upcyclying Of Polyethylene Terephtalate By Addition Of Thermoplastic Elastomer, Diego Francisco Bermudez

Open Access Theses & Dissertations

Continual overconsumption of single-use plastics has generated challenges of solid waste management across the United States. Common plastic waste management solutions, such as landfill, have caused the migration of contaminants into the environment consequently affecting not only the health of wildlife, but also that of human beings. Alternative strategies for the handling of single-use plastic such as polyethylene terephthalate (PET), used in the food packaging industry, can ultimately help mitigate the noxious consequences of single-use plastics affecting entire ecosystems. This study demonstrates a potential avenue of materials upcycling by studying the effects of coupling PET with the thermoplastic elastomer styrene-ethylene-butylene-styrene …

Design, Fabrication, And Integration Of Robotic Skin Sensors For Human Robot Interaction., Olalekan Olakitan Olowo

Electronic Theses and Dissertations

Enhancing physical human-robot interaction in modern robotics relies on refining the tactile perception of robot skin sensors. This research focuses on crucial aspects of the development process, including fabrication techniques, miniaturization, and integration for a more efficient collaborative human-robot interface. The fabrication process of robot skin sensors, designed to mimic human skin, is explored both within and outside cleanroom environments. An enhanced technique is presented to increase fabrication yield and create more miniaturized sensor designs with feature sizes in the tens of microns. These sensors function as piezoresistive arrays using organic polymers like PEDOT: PSS as the pressure-sensing medium. Various …

Advancing Additive Manufacturing For Biomedical Applications: Antimicrobial And X-Ray Absorptive Composite Filaments For Fused Filament Fabrication, John M. Arnold Jr

University of New Orleans Theses and Dissertations

The objective of this research was to investigate the use of nano- and microparticle amendments for the creation of Poly-lactic Acid composite materials for use in biomedical applications using the Fused Filament Fabrication process of Additive Manufacturing. Composites were created with the goal of imparting the useful properties of antimicrobial activity and x-ray absorption to the material. In addition to testing the efficacy of the particle amendments in achieving the desired properties, the thermal and mechanical properties of the composite materials were tested to ensure that the composites would be compatible with the Fused Filament Fabrication process and would produce …

Investigating The Effect Of Bead Geometry On Fiber Orientation And Thermomechanical Properties For Large-Format Extrusion-Based Additive Manufacturing, Joanna F. Keaton

Electronic Theses and Dissertations

In large-format extrusion-based additive manufacturing of polymer composites, the relationship between material properties and processing parameters requires further investigation. This thesis focuses on the relationship between fiber orientation and thermomechanical properties for short fiber-filled thermoplastic polymer systems manufactured by extrusion-based additive manufacturing. Fiber orientation is particularly important in determining the thermomechanical properties of the composite material as properties in the direction of deposition are expected to be higher for highly aligned fibers than randomly aligned fibers. Fiber orientation distribution, which is related to processing parameters and deposition conditions, can be efficiently represented by the orientation tensor. The orientation tensor can …

Mechanical Characterization Of Automated Fiber Placement And Additive Manufacturing Hybrid Composites, Lucan Haviland

Electronic Theses and Dissertations

This thesis presents the optimization of processing parameters based on the mechanical properties of Continuous Fiber-Reinforced Thermoplastic (CFRTP) Unidirectional (UD) consolidated tapes. The UD tapes were consolidated using an AFP head and a thermoforming press for comparison. The adhesive strength of hybrid parts consisting of CFRTP UD tape bonded to a 3D-printed substrate with the same matrix system were investigated. Large Area Additive Manufacturing (LAAM) was utilized for the 3D-printed parts. Different types of thermoplastic composite materials were explored, including Glass Fiber reinforced Polyethylene Terephthalate Glycol (GF/PETG), Carbon Fiber reinforced Polyethylene Terephthalate Glycol (CF/PETG), Carbon Fiber reinforced Polycarbonate (CF/PC), and …

Additive Manufacturing Of High-Performance Nanolamellar Eutectic High-Entropy Alloys, Jie Ren

Doctoral Dissertations

Additive manufacturing, also called three-dimensional (3D) printing, is an emerging technology for printing net-shaped components layer by layer for applications in automotive, aerospace, biomedical and other industries. In addition to the vast design freedom offered by this approach, metal 3D printing via laser powder-bed fusion (L-PBF) involves large temperature gradients and rapid cooling and provides exciting opportunities for producing microstructures and mechanical properties beyond those achievable by conventional processing routes. Although these extreme printing conditions enable microstructural refinement to the nanoscale for achieving high strength. However, high-strength nanostructured alloys by laser additive manufacturing often suffer from limited ductility. Eutectic high-entropy …

Fatigue And Fracture Of Electron Beam Melting Ti-6al-4v, William A. Grell

Electronic Theses and Dissertations

For applications in the aerospace field, selection of materials for a given design requires an understanding of critical properties, like fatigue and fracture, in addition to static mechanical and physical properties. With the ongoing advancements in metallic additive manufacturing techniques and the interest in applying the process to aerospace applications, there is a clear need to fully characterize properties. Arguably, the most attractive alloy for applications in aerospace is the Ti-6Al-4V alloy. The current dissertation examines the mechanical properties of the alloy, made by the Electron Beam Melting (EBM) Powder Bed Fusion (PBF) method. As illustrated in this work, the …

Towards Sustainable Additive Manufacturing: Assessment Of Cost, Greenhouse Gas Emission, And Recyclability, Lei Di

Industrial, Manufacturing, and Systems Engineering Dissertations

Additive Manufacturing technologies fabricate 3D objects layer by layer following a predesigned CAD model. Owing to the unique layer-wise production method, additive manufacturing offers competitive advantages in comparison with traditional subtractive manufacturing, such as shortened production time, increased design freedom, improved manufacturing capability and complexity, and reduced manufacturing waste. Numerous research studies have been conducted to design, understand, and improve additive manufacturing technologies in order to facilitate the implementation in the supply chain. On the other hand, with the rapid growth of additive manufacturing, sustainability issues that exist on both process level and supply chain level have started to receive …

Design Of Machine Tool Cross Beam Using Metal Big Area Additive Manufacturing, Tyler Poon

Masters Theses

The modern world would not be what it is now without machine tools. Advances in materials and processes, such as carbon fiber and additive manufacturing (AM), enable the design space for machine tool components to expand. However, machine tool components require accurate geometry, which is not available from parts produced by metal Big Area Additive Manufacturing (mBAAM). This project outlines the process in which a traditionally manufactured machine tool component, a welded box structure on an existing machine tool, was redesigned to be made using mBAAM. The goal was to design a structure that was printable using the MedUSA system …

Creep Resistance And Microstructure In Binary Aluminum Cerium Alloy Produced By Laser Powder Bed Fusion, Jillian Ann Stinehart

Master's Theses (2009 -)

Currently, the only commercially available aluminum alloy for additive manufacturing (AM) is AlSi10Mg, which is not suitable for high temperature applications. Al-Ce based alloys have been shown to be highly printable, cost-efficient alloys. Compared to cast Al-Ce alloys, the eutectic features are refined (<1μm), which give AM Al-10Ce favorable strength and ductility at room temperature. The low diffusivity and solubility of cerium in aluminum improve the retention of mechanical properties at high temperatures. In order to quantify the effect of cerium on the thermal stability of AM aluminum and show its suitability for high-temperature applications, Al-10Ce was creep tested between 60-77% of its absolute melting temperature. The creep performance of AM Al-10Ce was favorable compared to that of cast binary Al-Ce and AM AlSi10Mg and was comparable to that of cast ternary Al-Ce alloys. The stress exponent, n, was approximately 1 in the low stress regime and 5-7 in the high stress regime. The activation energy was 231kJ/mol. In comparison, both cast binary Al-Ce and AM AlSi10Mg have higher stress exponents and lower activation energies, showing AM Al-10Ce to be more creep resistant. After creep testing, slight grain coarsening was observed, while grain orientation remained unchanged. The melt pool boundaries (MPBs) faded in appearance after creep testing, and the number of columnar grains decreased.

Image Segmentation With Human-In-The-Loop In Automated De-Caking Process For Powder Bed Additive Manufacturing, Vincent Opare Addo Asare-Manu

Theses and Dissertations

Additive manufacturing (AM) becomes a critical technology that increases the speed and flexibility of production and reduces the lead time for high-mix, low-volume manufacturing. One of the major bottlenecks in further increasing its productivity lies around its post-processing procedures. This work focuses on tackling a critical and inevitable step in powder-bed additive manufacturing processes, i.e., powder cleaning or de-caking. Pressing concerns can be raised with human involvement when performing this task manually. Therefore, a robot-driven automatic powder cleaning system could be an alternative to reducing time consumption and increasing safety for AM operators. However, since the color and surface texture …

How 3d Printing Can Revolutionize Developing Economies, Paul Zuber-Fantulin

Global Honors Theses

3D printing technology has the potential to completely revolutionize development in emerging markets. While 3D printing can make a wide variety of objects, and create the capacity for local manufacturing, it can also change the nature of the economy and how things are made. When looking at the potential for development, we must realize that much development is attained by the unequal exchange between nations. For this reason, capitalism often fails the developing world while benefiting the developed one. However, thanks to this technology, there might be a path toward breaking this cycle. Examining how 3D printing is opening up …

Vibration Powder Dispensing And Gravity-Fed Powder Delivery For Directed Energy Deposition Additive Manufacturing Systems, Andrew Greeley

Theses

Directed energy deposition is a class of additive manufacturing processes where focused thermal energy melts and fuses material being deposited on a part. This type of process is useful for making high performance parts, remanufacturing and repair, and for making multi-material parts. However, in systems where powder feedstock is used, only a fraction of the powder ends up in the part and the rest is usually wasted. Increasing the amount of powder captured in powder-fed directed energy deposition systems is the focus of this work. The proposed solution is to combine vibration powder dispensing and gravity-fed powder delivery systems to …

Monitoring Additive Manufacturing Machine Health, Jeremy Hale

Doctoral Dissertations

Additive manufacturing (AM) allows the production of parts and goods with many benefits over more conventional manufacturing methods. AM permits more geometrically complex designs, custom and low-volume production runs, and the flexibility to produce a wide variety of parts on a single machine with reduced pre-production cost and time requirements. However, it can be difficult to determine the condition, or health, of an AM machine since complex designs can increase the variability of part quality. With fewer parts produced, destructive testing is less desirable and statistical methods of tracking part quality may be less informative. Combined with the relatively more …

Correlating Large-Format Additive Manufacturing Processing Parameters To Fiber Length And The Mechanical Performance Of Reinforced Polymer Composites, Andrew Phillip Rhodes

Masters Theses

The Big Area Additive Manufacturing (BAAM) system at Oak Ridge National Laboratory has been used to produce carbon fiber reinforced structures for several years, including vehicles, building constituents, composite tooling, etc. While the development of a large-format polymer additive manufacturing (AM) system has moved quickly, the impact of the BAAM’s extruder on the length of carbon fiber feedstock has not been systematically studied. Numerous studies in processing fiber reinforced thermoplastics in plasticizing and injection molding systems have shown that fibers are subjected to significant shear as they are processed, which can cause a drastic reduction in fiber length which negatively …