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Full-Text Articles in Engineering
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
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 …
Damage Detection With An Integrated Smart Composite Using A Magnetostriction-Based Nondestructive Evaluation Method: Integrating Machine Learning For Prediction, Christopher Nelon
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 …
Mechanical Characterization Of Automated Fiber Placement And Additive Manufacturing Hybrid Composites, Lucan Haviland
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 …
Effects Of Varied Oxygen Levels, Laser Powers, And Scanning Speeds On Manufactured Components By Laser-Based Powder Bed Fusion, Amelia Mcnamee
Effects Of Varied Oxygen Levels, Laser Powers, And Scanning Speeds On Manufactured Components By Laser-Based Powder Bed Fusion, Amelia Mcnamee
Honors College Theses
This project addresses the effects of oxygen concentration, laser power, and scanning speed on the melt pool geometry of laser-based powder bed fusion (L-PBF) additively manufactured components. A parametric analysis using the substrate alone was conducted to determine a range of desirable laser powers and scanning speeds. The parameter with the more significant effect will be decided upon based on the depth-to-width ratios (D/W) of the resultant laser weld bead. A range of oxygen levels and scan speeds was selected for the next phase. These samples were then be analyzed for depth-to-width ratios. It was expected that higher oxygen concentrations …
Optimization Of 3d Printed Mold Performance For Injection Molding Via Hollow Infill Patterns, Alan Fong
Optimization Of 3d Printed Mold Performance For Injection Molding Via Hollow Infill Patterns, Alan Fong
University Honors Theses
The applicability of hollow infill patterns has been explored for its applications in making 3D printed polymer-based injection molds in the additive manufacturing industry. Hollow infill patterns offer a significant reduction in material costs as well as the opportunity for reducing the cooling times via pumping a coolant fluid through the hollow cavity in a similar fashion to traditional conformal cooling channels. A 3D Jacks Support Hollow mold model was determined to be the best performing design. FEA analysis was conducted to determine the maximum reduction in internal volume (percentage of material saved) that could be achieved without exceeding the …
Design For Additive Manufacturing, Michael Charonnat, Leonardo Franco-Muñoz, Sam Noble, J.P. Purdom
Design For Additive Manufacturing, Michael Charonnat, Leonardo Franco-Muñoz, Sam Noble, J.P. Purdom
Mechanical Engineering
This document outlines the critical design details and timeline for the Design for Additive Manufacturing Senior Project sponsored by Solar Turbines, Inc. The scope of this project encompasses the redesign of two of Solar Turbine’s cast parts for metal additive manufacturing in order to minimize lead time, cost, and weight. With the overall objective of performing in-depth analysis exploring affordability & feasibility, this redesign process will aid Solar Turbines in expanding their knowledge of Design for Additive Manufacturing principles and enable them to further incorporate the use of additive manufacturing into their production processes. The first part that the team …
Modeling And Validations Of Control Parameters For Material Extrusion-Based Additive Manufacturing Of Thixotropic Aluminum Alloys., Lars Herhold
Electronic Theses and Dissertations
Additive Manufacturing (AM) with metals has been accomplished mainly through powder bed fusion processes. Initial experiments and simulations using Material Extrusion Additive Manufacturing (MEAM) have been performed by various researchers especially using low melting alloys. Recently Stratasys Inc. submitted a patent application for the use of their Material Extrusion technology also called Fused Deposition Modeling (FDM) where they describe the process using thixotropic semi-solid alloys. Currently this process using semi-solid, engineering type alloys such as A356 or THIXALLOY 540 aluminum have not been researched to evaluate the control parameters. This research combines the in-depth knowledge of applying thixotropic semi-solid aluminum …
Additive Manufacturing Powder Removal, Madison A. Lignell, Tyler W. Laird, Kurt K. Reed
Additive Manufacturing Powder Removal, Madison A. Lignell, Tyler W. Laird, Kurt K. Reed
Mechanical Engineering
Metal powder-bed fusion is an additive manufacturing process which enables the creation of unique shapes in metal parts that would otherwise be difficult, expensive, or impossible to machine. Metallic powder is melted and fused together by either a laser or electron beam to produce parts quickly. The excess powder covers newly printed parts and can be difficult to remove from small internal features. The scope of this project is to design a device that effectively removes the powder from newly printed parts safely, while reclaiming as much powder as possible for reuse. The solution for this project must be able …
Fabrication Of 3d Conjugated Polymer Structures Via Vat Polymerization Additive Manufacturing, Andrew T. Cullen
Fabrication Of 3d Conjugated Polymer Structures Via Vat Polymerization Additive Manufacturing, Andrew T. Cullen
Electronic Thesis and Dissertation Repository
Conjugated polymers are a class of electromechanically active materials that can produce motion in response to an electric potential. This motion can be harnessed to perform mechanical work, and therefore these materials are particularly well suited for use as sensors and actuators in microelectromechanical systems. Conventional methods to fabricate conjugated polymer actuators result in planar morphologies that limit fabricated devices to simplistic linear or bending actuation modes. To overcome this limitation, this work develops a conjugated polymer formulation and associated additive manufacturing method capable of realizing three-dimensional conductive polymer structures. A light-based additive manufacturing technique known as vat polymerization is …