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Full-Text Articles in Engineering
Heat Treatments For Minimization Of Residual Stresses And Maximization Of Tensile Strengths Of Scalmalloy® Processed Via Directed Energy Deposition, Rachel Boillat-Newport, Sriram Praneeth Isanaka, Jonathan Kelley, Frank Liou
Heat Treatments For Minimization Of Residual Stresses And Maximization Of Tensile Strengths Of Scalmalloy® Processed Via Directed Energy Deposition, Rachel Boillat-Newport, Sriram Praneeth Isanaka, Jonathan Kelley, Frank Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Scalmalloy® is an Al-Mg-Sc-Zr-Based Alloy Specifically Developed for Additive Manufacturing (AM). This Alloy is Designed for Use with a Direct Aging Treatment, as Recommended by the Manufacturer, Rather Than with a Multistep Treatment, as Often Seen in Conventional Manufacturing. Most Work with Scalmalloy® is Conducted using Powder Bed Rather Than Powder-Fed Processes. This Investigation Seeks to Fill This Knowledge Gap and Expand Beyond Single-Step Aging to Promote an overall Balanced AM-Fabricated Component. for This Study, Directed Energy Deposition (DED)-Fabricated Scalmalloy® Components Were Subjected to Low-Temperature Treatments to Minimize Residual Stresses Inherent in the Material Due to the Layer-By-Layer Build Process. …
Multifunctional Additive Manufacturing And Multiphysics Numerical Investigations Of Carbon Fiber Structural Battery Composite Using A Drop-On-Demand Method With In-Situ Consolidation, Xiangyang Dong, Yuekun Chen
Multifunctional Additive Manufacturing And Multiphysics Numerical Investigations Of Carbon Fiber Structural Battery Composite Using A Drop-On-Demand Method With In-Situ Consolidation, Xiangyang Dong, Yuekun Chen
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Lightweight Carbon Fiber Structural Battery Composite Has Great Potential in Increasing Structural Energy Storage Efficiency for Multifunctional Applications. However, It is Still Challenging to Design Carbon Fiber Multifunctional Composite Due to Lack of Proper Manufacturing Methods. in This Study, an Integrated Multifunctional Design and Fabrication Approach is Developed by Combining a Drop-On-Demand Additive Manufacturing Method with a Multiphysics Numerical Model to Guide the Development of the New Multifunctional Composite. through Deposition with In-Situ Consolidation, the Function and Thickness of Each Carbon Fiber Layer as Well as its Fiber Volume Fraction Are Accurately Controlled. Decreasing Layer Thickness Improves Flexural Properties. the …
Experimental And Numerical Studies Of Slurry-Based Coextrusion Deposition Of Continuous Carbon Fiber Micro-Batteries To Additively Manufacture 3d Structural Battery Composites, Aditya R. Thakur, Xiangyang Dong
Experimental And Numerical Studies Of Slurry-Based Coextrusion Deposition Of Continuous Carbon Fiber Micro-Batteries To Additively Manufacture 3d Structural Battery Composites, Aditya R. Thakur, Xiangyang Dong
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Carbon Fiber Structural Battery Composites Have Recently Attracted Growing Interests Due to their Potentials of Simultaneously Carrying Mechanical Loads and Storing Electrical Energy for Lightweight Application. in This Study, We Present a Slurry-Based Coextrusion Deposition Method to Additively Manufacture 3D Structural Battery Composites from Carbon Fiber Micro-Batteries. Cathode Slurry is Coextruded Together with Solid Polymer Electrolyte-Coated Carbon Fibers in a Single Deposition. a Network of Carbon Fiber Micro-Batteries is Achieved within the Fabricated Structural Battery Composites. Electrochemical Tests Show a Stable Charge-Discharge Performance Up to 100 Cycles. the Rheological Behavior of the Cathode Slurry is Found to Govern the Coextrusion …
Performance Evaluation Of Composite Sandwich Structures With Additively Manufactured Aluminum Honeycomb Cores With Increased Bonding Surface Area, M. Rangapuram, S. K. Dasari, Joseph William Newkirk, K. Chandrashekhara, H. Misak, P. R. Toivonen, D. Klenosky, T. Unruh, J. Sam
Performance Evaluation Of Composite Sandwich Structures With Additively Manufactured Aluminum Honeycomb Cores With Increased Bonding Surface Area, M. Rangapuram, S. K. Dasari, Joseph William Newkirk, K. Chandrashekhara, H. Misak, P. R. Toivonen, D. Klenosky, T. Unruh, J. Sam
Materials Science and Engineering Faculty Research & Creative Works
Modern aerostructures, including wings and fuselages, increasingly feature sandwich structures due to their high-energy absorption, low weight, and high flexural stiffness. The face sheet of these sandwich structures are typically thin composite laminates with interior honeycombs made of Nomex or aluminum. Standard cores are structurally efficient, but their design cannot be varied throughout the structure. With additive manufacturing (AM) technology, these core geometries can be altered to meet the design requirements that are not met in standard honeycomb cores. This study used a modified aluminum honeycomb core, with increased surface area on the top and bottom, as the core material …
Experimental Approach For Development Of A Powder Spreading Metric In Additive Manufacturing, M. Hossein Sehhat, Austin T. Sutton, Zane Yates, Ming-Chuan Leu
Experimental Approach For Development Of A Powder Spreading Metric In Additive Manufacturing, M. Hossein Sehhat, Austin T. Sutton, Zane Yates, Ming-Chuan Leu
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The Powder Spreading is a Vital Step of Powder-Based Additive Manufacturing (AM) Processes. the Quality of Spread Powder Can Considerably Influence the Properties of Fabricated Parts. Poorly Packed Powder Beds with High Surface Roughness Result in Printed Part Layers with Large Porosity and Low Dimensional Accuracy, Leading to Poor Mechanical Properties. Therefore, the Powder Spread ability and its Dependence on Process Parameters and Powder Characteristics Should Be Quantified to Improve the Efficiency of Powder-Based AM Methods. This Study Proposes a Novel Dimensionless Powder Spread Ability Metric that Can Be Commonly Used in Different Powder-Based AM Processes. the Quality of Spread …
Additively Manufactured Carbon Fiber- Reinforced Thermoplastic Composite Mold Plates For Injection Molding Process, C. Bivens, A. Wood, D. Ruble, M. Rangapuram, S. K. Dasari, K. Chandrashekhara, J. Degrange
Additively Manufactured Carbon Fiber- Reinforced Thermoplastic Composite Mold Plates For Injection Molding Process, C. Bivens, A. Wood, D. Ruble, M. Rangapuram, S. K. Dasari, K. Chandrashekhara, J. Degrange
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Polymer injection molding processes have been used to create high-volume parts quickly and efficiently. Injection molding uses mold plates that are traditionally made of very hard tool steels, such as P20 steel, which is extremely heavy and has very long lead times to build new molds. In this study, composite-based additive manufacturing (CBAM) was used to create mold plates using long-fiber carbon fiber and polyether ether ketone (PEEK). These mold plates were installed in an injection molding machine, and rectangular flat plates were produced using Lustran 348 acrylonitrile butadiene styrene (ABS). Tensile and flexural testing was performed on these parts …
Additive Manufacturing Of Complexly Shaped Sic With High Density Via Extrusion-Based Technique – Effects Of Slurry Thixotropic Behavior And 3d Printing Parameters, Ruoyu Chen, Adam Bratten, Joshua Rittenhouse, Tian Huang, Wenbao Jia, Ming-Chuan Leu, Haiming Wen
Additive Manufacturing Of Complexly Shaped Sic With High Density Via Extrusion-Based Technique – Effects Of Slurry Thixotropic Behavior And 3d Printing Parameters, Ruoyu Chen, Adam Bratten, Joshua Rittenhouse, Tian Huang, Wenbao Jia, Ming-Chuan Leu, Haiming Wen
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Additive manufacturing of dense SiC parts was achieved via an extrusion-based process followed by electrical-field assisted pressure-less sintering. The aim of this research was to study the effect of the rheological behavior of SiC slurry on the printing process and quality, as well as the influence of 3D printing parameters on the dimensions of the extruded filament, which are directly related to the printing precision and quality. Different solid contents and dispersant- Darvan 821A concentrations were studied to optimize the viscosity, thixotropy and sedimentation rate of the slurry. The optimal slurry was composed of 77.5 wt% SiC, Y2O3 and Al2O3 …
Predicting Defects In Laser Powder Bed Fusion Using In-Situ Thermal Imaging Data And Machine Learning, Sina Malakpour Estalaki, Cody S. Lough, Robert G. Landers, Edward C. Kinzel, Tengfei Luo
Predicting Defects In Laser Powder Bed Fusion Using In-Situ Thermal Imaging Data And Machine Learning, Sina Malakpour Estalaki, Cody S. Lough, Robert G. Landers, Edward C. Kinzel, Tengfei Luo
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Variation in the local thermal history during the Laser Powder Bed Fusion (LPBF) process in Additive Manufacturing (AM) can cause micropore defects, which add to the uncertainty of the mechanical properties (e.g., fatigue life, tensile strength) of the built materials. In-situ sensing has been proposed for monitoring the AM process to minimize defects, but successful minimization requires establishing a quantitative relationship between the sensing data and the porosity, which is particularly challenging with a large number of variables (e.g., laser speed, power, scan path, powder property). Physics-based modeling can simulate such an in-situ sensing-porosity relationship, but it is computationally costly. …
In-Situ Infrared Thermographic Inspection For Local Powder Layer Thickness Measurement In Laser Powder Bed Fusion, Tao Liu, Cody S. Lough, Hossein Sehhat, Yi Ming Ren, Panagiotis D. Christofides, Edward C. Kinzel, Ming-Chuan Leu
In-Situ Infrared Thermographic Inspection For Local Powder Layer Thickness Measurement In Laser Powder Bed Fusion, Tao Liu, Cody S. Lough, Hossein Sehhat, Yi Ming Ren, Panagiotis D. Christofides, Edward C. Kinzel, Ming-Chuan Leu
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The laser powder bed fusion (LPBF) process is strongly influenced by the characteristics of the powder layer, including its thickness and thermal transport properties. This paper investigates in-situ characterization of the powder layer using thermographic inspection. A thermal camera monitors the temperature history of the powder surface immediately after a layer of new powder is deposited by the recoating system. During this process, thermal energy diffuses from the underlying solid part, eventually raising the temperature of the above powder layer. Guided by 1D modeling of this heat-up process, experiments show how the parameterized thermal history can be correlated with powder …
Tini-Based Bi-Metallic Shape-Memory Alloy By Laser-Directed Energy Deposition, Yitao Chen, Cesar Ortiz Rios, Braden Mclain, Joseph William Newkirk, Frank W. Liou
Tini-Based Bi-Metallic Shape-Memory Alloy By Laser-Directed Energy Deposition, Yitao Chen, Cesar Ortiz Rios, Braden Mclain, Joseph William Newkirk, Frank W. Liou
Materials Science and Engineering Faculty Research & Creative Works
In this study, laser-directed energy deposition was applied to build a Ti-rich ternary Ti–Ni–Cu shape-memory alloy onto a TiNi shape-memory alloy substrate to realize the joining of the multifunctional bi-metallic shape-memory alloy structure. The cost-effective Ti, Ni, and Cu elemental powder blend was used for raw materials. Various material characterization approaches were applied to reveal different material properties in two sections. The as-fabricated Ti–Ni–Cu alloy microstructure has the TiNi phase as the matrix with Ti2Ni secondary precipitates. The hardness shows no high values indicating that the major phase is not hard intermetallic. A bonding strength of 569.1 MPa was obtained …
Data On The Validation To Determine The Material Thermal Properties Estimation Via A One-Dimensional Transient Convection Model, Lauren B. Tomanek, Daniel S. Stutts
Data On The Validation To Determine The Material Thermal Properties Estimation Via A One-Dimensional Transient Convection Model, Lauren B. Tomanek, Daniel S. Stutts
Mechanical and Aerospace Engineering Faculty Research & Creative Works
These data were acquired to estimate the parameters of a closed form solution of a one-dimensional transient convection heat diffusion PDE. The purpose was to demonstrate that the model could be used to determine the thermal conductivity. The system was tested for a wide range of thermal conductivity, 15-400 W/mK, in order to verify that the method was applicable for various materials. The data reported here refer to the study in the research articles, “Material Thermal Properties Estimation Via a One-Dimensional Transient Convection Model” and “Influence of porosity on the thermal, electrical, and mechanical performance of selective laser melted stainless …
Effects Of Particle Size Distribution With Efficient Packing On Powder Flowability And Selective Laser Melting Process, Zachary Young, Minglei Qu, Meelap Michael Coday, Qilin Guo, Seyed Mohammad H. Hojjatzadeh, Luis I. Escano, Kamel Fezzaa, Lianyi Chen
Effects Of Particle Size Distribution With Efficient Packing On Powder Flowability And Selective Laser Melting Process, Zachary Young, Minglei Qu, Meelap Michael Coday, Qilin Guo, Seyed Mohammad H. Hojjatzadeh, Luis I. Escano, Kamel Fezzaa, Lianyi Chen
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by …
Data On The Validation To Determine The Material Thermal Properties Estimation Via A One-Dimensional Transient Convection Model, Lauren B. Tomanek, Daniel S. Stutts
Data On The Validation To Determine The Material Thermal Properties Estimation Via A One-Dimensional Transient Convection Model, Lauren B. Tomanek, Daniel S. Stutts
Mechanical and Aerospace Engineering Faculty Research & Creative Works
These data were acquired to estimate the parameters of a closed form solution of a one-dimensional transient convection heat diffusion PDE. The purpose was to demonstrate that the model could be used to determine the thermal conductivity. The system was tested for a wide range of thermal conductivity, 15-400 W/mK, in order to verify that the method was applicable for various materials. The data reported here refer to the study in the research articles, "Material Thermal Properties Estimation Via a One-Dimensional Transient Convection Model" [1] and "Influence of porosity on the thermal, electrical, and mechanical performance of selective laser melted …
Effects Of Particle Size Distribution With Efficient Packing On Powder Flowability And Selective Laser Melting Process, Zachary Young, Minglei Qu, Meelap Michael Coday, Qilin Guo, Seyed Mohammad H. Hojjatzadeh, Luis I. Escano, Kamel Fezzaa, Lianyi Chen
Effects Of Particle Size Distribution With Efficient Packing On Powder Flowability And Selective Laser Melting Process, Zachary Young, Minglei Qu, Meelap Michael Coday, Qilin Guo, Seyed Mohammad H. Hojjatzadeh, Luis I. Escano, Kamel Fezzaa, Lianyi Chen
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by …
Additive Manufacturing Of Continuous Carbon Fiber-Reinforced Sic Ceramic Composite With Multiple Fiber Bundles By An Extrusion-Based Technique, Ruoyu Chen, Adam Bratten, Joshua Rittenhouse, Ming-Chuan Leu, Haiming Wen
Additive Manufacturing Of Continuous Carbon Fiber-Reinforced Sic Ceramic Composite With Multiple Fiber Bundles By An Extrusion-Based Technique, Ruoyu Chen, Adam Bratten, Joshua Rittenhouse, Ming-Chuan Leu, Haiming Wen
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Due to the high cost, complex preparation process and difficulty in structural design, the traditional methods for carbon fiber reinforced SiC ceramic composite preparation have great limitations. This paper presents a technique for the additive manufacturing multiple continuous carbon fiber bundle-reinforced SiC ceramic composite with core-shell structure using an extrusion-based technique. A conventional nozzle system was modified to print simultaneously a water based SiC paste with continuous carbon fibers. Different levels of binder contents were investigated to optimize the stickiness, viscosity, thixotropy and viscoelasticity of the paste. After sintering, SiC whiskers were generated on the surface of fiber, which is …
Experimental Investigation Of Additive Manufacturing Of Continuous Carbon Fiber Composites With Multifunctional Electro-Tensile Properties, Ritesh Ghimire, Frank W. Liou
Experimental Investigation Of Additive Manufacturing Of Continuous Carbon Fiber Composites With Multifunctional Electro-Tensile Properties, Ritesh Ghimire, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Manufacturing processes for monofunctional and multifunctional materials vary depending on the design optimization. Multifunctional continuous carbon fiber composites provide great potential in achieving coupled structural and electrical properties for their applications in aircraft, unmanned aircraft systems, and spacecraft. Proper optimization of tensile and electrical properties offers benefits early in the design and continuous operational safety phases to obtain coupled multifunctional properties. In this paper, fused filament fabrication additive manufacturing (AM) technique was used to fabricate continuous carbon fiber solid laminated composites test coupons. The proposed new method characterizes the electrical conductivity's coupled effects on the tensile properties, including the failure …
Additive Manufacturing Of Stainless Steel -- Copper Functionally Graded Materials Via Inconel 718 Interlayer, Xinchang Zhang, Lan Li, Frank W. Liou
Additive Manufacturing Of Stainless Steel -- Copper Functionally Graded Materials Via Inconel 718 Interlayer, Xinchang Zhang, Lan Li, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The joining of dissimilar materials is becoming increasingly prevalent to integrate different material properties to enhance design flexibility and overall performance. This study introduced an innovative approach to additively manufacture copper on 316L stainless steel (SS316L) via Inconel 718 interlayers using directed energy deposition (DED). The novel multi-material structure was studied both experimentally and theoretically. The microstructure, tensile properties, microhardness, and thermal performance of the structure were characterized. Residual stress distribution over the structure was revealed by experimental-validated numerical modeling. The result exhibits that defect-free structures with excellent interfacial bonding can be achieved by introducing Inconel 718 interlayers. The bonding …
A Novel Laser-Aided Machining And Polishing Process For Additive Manufacturing Materials With Multiple Endmill Emulating Scan Patterns, Mohammad Masud Parvez, Sahil Patel, Sriram Praneeth Isanaka, Frank W. Liou
A Novel Laser-Aided Machining And Polishing Process For Additive Manufacturing Materials With Multiple Endmill Emulating Scan Patterns, Mohammad Masud Parvez, Sahil Patel, Sriram Praneeth Isanaka, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
In additive manufacturing (AM), the surface roughness of the deposited parts remains significantly higher than the admissible range for most applications. Additionally, the surface topography of AM parts exhibits waviness profiles between tracks and layers. Therefore, post-processing is indispensable to improve surface quality. Laser-aided machining and polishing can be effective surface improvement processes that can be used due to their availability as the primary energy sources in many metal AM processes. While the initial roughness and waviness of the surface of most AM parts are very high, to achieve dimensional accuracy and minimize roughness, a high input energy density is …
The Effect Of Nanostructures In Aluminum Alloys Processed Using Additive Manufacturing On Microstructural Evolution And Mechanical Performance Behavior, Rachel Boillat, Sriram Praneeth Isanaka, Frank W. Liou
The Effect Of Nanostructures In Aluminum Alloys Processed Using Additive Manufacturing On Microstructural Evolution And Mechanical Performance Behavior, Rachel Boillat, Sriram Praneeth Isanaka, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
This paper reviews the status of nanoparticle technology as it relates to the additive manufacturing (AM) of aluminum-based alloys. A broad overview of common AM processes is given. Additive manufacturing is a promising field for the advancement of manufacturing due to its ability to yield near-net-shaped components that require minimal post-processing prior to end-use. AM also allows for the fabrication of prototypes as well as economical small batch production. Aluminum alloys processed via AM would be very beneficial to the manufacturing industry due to their high strength to weight ratio; however, many of the conventional alloy compositions have been shown …
Experimental And Numerical Investigation In Directed Energy Deposition For Component Repair, Lan Li, Xinchang Zhang, Frank W. Liou
Experimental And Numerical Investigation In Directed Energy Deposition For Component Repair, Lan Li, Xinchang Zhang, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Directed energy deposition (DED) has been widely used for component repair. In the repair process, the surface defects are machined to a groove or slot and then refilled. The sidewall inclination angle of the groove geometry has been recognized to have a considerable impact on the mechanical properties of repaired parts. The objective of this work was to investigate the feasibility of repairing various V-shaped defects with both experiments and modeling. At first, the repair volume was defined by scanning the defective zone. Then, the repair volume was sliced to generate the repair toolpath. After that, the DED process was …
Direct 3d Printing Of Silica Doped Transparent Magnesium Aluminate Spinel Ceramics, John M. Pappas, Xiangyang Dong
Direct 3d Printing Of Silica Doped Transparent Magnesium Aluminate Spinel Ceramics, John M. Pappas, Xiangyang Dong
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Transparent magnesium aluminate spinel ceramics were additively manufactured via a laser direct deposition method in this study. With a minimum porosity of 0.3% achieved, highly transparent spinel samples with the highest total optical transmittance of 82% at a wavelength of 632.8 nm, were obtained by a 3D printing approach. However, cracking was found to be a major issue affecting printed spinel samples. To control prevalent cracking, the effect of silica dopants was investigated. Increased silica dopants reduced average total crack length by up to 79% and average crack density by up to 71%. However, a high dopant level limited optical …
Laser Metal Deposition Of An Alcocrfeniti₀.₅ High-Entropy Alloy Coating On A Ti6al4v Substrate: Microstructure And Oxidation Behavior, Wenyuan Cui, Wei Li, Wei Ting Chen, Frank W. Liou
Laser Metal Deposition Of An Alcocrfeniti₀.₅ High-Entropy Alloy Coating On A Ti6al4v Substrate: Microstructure And Oxidation Behavior, Wenyuan Cui, Wei Li, Wei Ting Chen, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Ti6Al4V has been recognized as an attractive material, due to its combination of low density and favorable mechanical properties. However, its insufficient oxidation resistance has limited the high-temperature application. In this work, an AlCoCrFeNiTi0.5 high-entropy alloy (HEA) coating was fabricated on a Ti6Al4V substrate using laser metal deposition (LMD). The microstructure and isothermal oxidation behaviors were investigated. The microstructure of as-deposited HEA exhibited a Fe, Cr-rich A2 phase and an Al, Ni, Ti-enriched B2 phase. Its hardness was approximately 2.1 times higher than that of the substrate. The oxidation testing at 700⁰C and 800⁰C suggested that the HEA coating …
Effects Of Zirconia Doping On Additively Manufactured Alumina Ceramics By Laser Direct Deposition, John M. Pappas, Aditya R. Thakur, Xiangyang Dong
Effects Of Zirconia Doping On Additively Manufactured Alumina Ceramics By Laser Direct Deposition, John M. Pappas, Aditya R. Thakur, Xiangyang Dong
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The ability to additively manufacture functional alumina ceramics has the potential to lower manufacturing costs and development time for complex components. In this study, the doping effects of zirconia on laser direct deposited alumina ceramics were investigated. The microstructure of the printed samples was analyzed in terms of grain size and composition distribution. The addition of zirconia was found to accumulate along alumina grain boundaries and resulted in significant grain refinement. The zirconia doping largely reduced crack formation during processing compared to that of pure alumina samples. In the case of 10 wt% zirconia, cracking during deposition was nearly completely …
Aluminum Parts Fabricated By Laser-Foil-Printing Additive Manufacturing: Processing, Microstructure, And Mechanical Properties, Chia Hung Hung, Yingqi Li, Austin Sutton, Wei Ting Chen, Xiangtao Gong, Heng Pan, Hai Lung Tsai, Ming-Chuan Leu
Aluminum Parts Fabricated By Laser-Foil-Printing Additive Manufacturing: Processing, Microstructure, And Mechanical Properties, Chia Hung Hung, Yingqi Li, Austin Sutton, Wei Ting Chen, Xiangtao Gong, Heng Pan, Hai Lung Tsai, Ming-Chuan Leu
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Fabrication of dense aluminum (Al-1100) parts (>99.3% of relative density) by our recently developed laser-foil-printing (LFP) additive manufacturing method was investigated as described in this paper. This was achieved by using a laser energy density of 7.0 MW/cm2 to stabilize the melt pool formation and create sufficient penetration depth with 300 μm thickness foil. The highest yield strength (YS) and ultimate tensile strength (UTS) in the LFP-fabricated samples reached 111 ± 8 MPa and 128 ± 3 MPa, respectively, along the laser scanning direction. These samples exhibited greater tensile strength but less ductility compared to annealed Al-1100 samples. Fractographic …
Fabrication And Characterization Of Alₓcrcufeni₂ High-Entropy Alloys Coatings By Laser Metal Deposition, Wenyuan Cui, Xinchang Zhang, Lan Li, Yitao Chen, Tan Pan, Frank W. Liou
Fabrication And Characterization Of Alₓcrcufeni₂ High-Entropy Alloys Coatings By Laser Metal Deposition, Wenyuan Cui, Xinchang Zhang, Lan Li, Yitao Chen, Tan Pan, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
High-entropy alloys (HEAs) are becoming new hot spots in the metallic materials community, which are defined to contain equiatomic or close-to-equiatomic compositions. HEAs can possess many interesting mechanical properties, and in particular, they have the great potential to be used as coating materials requiring high hardness and wear resistance. In this study, the feasibility of fabrication AlₓCrCuFeNi₂ (x=0,0.75) HEAs was investigated via laser metal deposition from elemental powders. The microstructure, phase structure, and hardness were studied by an optical microscope, scanning electron microscopy with energy dispersive spectroscopy (SEM/EDS), electron backscatter diffraction (EBSD) and Vickers hardness tester. The bonding between the …
A Hybrid Process Integrating Reverse Engineering, Pre-Repair Processing, Additive Manufacturing, And Material Testing For Component Remanufacturing, Xinchang Zhang, Wenyuan Cui, Wei Li, Frank W. Liou
A Hybrid Process Integrating Reverse Engineering, Pre-Repair Processing, Additive Manufacturing, And Material Testing For Component Remanufacturing, Xinchang Zhang, Wenyuan Cui, Wei Li, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Metallic components can gain defects such as dents, cracks, wear, heat checks, deformation, etc., that need to be repaired before reinserting into service for extending the lifespan of these parts. In this study, a hybrid process was developed to integrate reverse engineering, pre-repair processing, additive manufacturing, and material testing for the purpose of part remanufacturing. Worn components with varied defects were scanned using a 3D scanner to recreate the three-dimensional models. Pre-repair processing methods which include pre-repair machining and heat-treatment were introduced. Strategies for pre-repair machining of defects including surface impact damage, surface superficial damage and cracking were presented. Pre-repair …
Ultrafast X-Ray Imaging Of Laser-Metal Additive Manufacturing Processes, Niranjan D. Parab, Cang Zhao, Ross Cunningham, Luis I. Escano, Kamel Fezzaa, Wes Everhart, Anthony D. Rollett, Lianyi Chen, Tao Sun
Ultrafast X-Ray Imaging Of Laser-Metal Additive Manufacturing Processes, Niranjan D. Parab, Cang Zhao, Ross Cunningham, Luis I. Escano, Kamel Fezzaa, Wes Everhart, Anthony D. Rollett, Lianyi Chen, Tao Sun
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The high-speed synchrotron X-ray imaging technique was synchronized with a custom-built laser-melting setup to capture the dynamics of laser powder-bed fusion processes in situ. Various significant phenomena, including vapor-depression and melt-pool dynamics and powder-spatter ejection, were captured with high spatial and temporal resolution. Imaging frame rates of up to 10 MHz were used to capture the rapid changes in these highly dynamic phenomena. At the same time, relatively slow frame rates were employed to capture large-scale changes during the process. This experimental platform will be vital in the further understanding of laser additive manufacturing processes and will be particularly …
Mechanical Properties Of Zr-Based Bulk Metallic Glass Parts Fabricated By Laser-Foil-Printing Additive Manufacturing, Yingqi Li, Ming-Chuan Leu, Hai-Lung Tsai
Mechanical Properties Of Zr-Based Bulk Metallic Glass Parts Fabricated By Laser-Foil-Printing Additive Manufacturing, Yingqi Li, Ming-Chuan Leu, Hai-Lung Tsai
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The application of bulk metallic glasses (BMGs) has been traditionally limited to parts with small dimensions and simple geometries, due to the requirement of fast cooling during the conventional process of casting. This research exemplifies a promising additive manufacturing method, i.e., laser-foil-printing (LFP), to fabricate high-quality BMG parts with large dimensions and complex geometries. In this study, Zr52.5Ti5Al10Ni14.6Cu17.9 BMG parts were fabricated by LFP technology in which MG foils are laser welded layer-by- layer upon a substrate. The mechanical properties of the fabricated BMG parts were measured using micro-indentation, tensile test …
Development Of Pre-Repair Machining Strategies For Laser-Aided Metallic Component Remanufacturing, Xinchang Zhang, Wenyuan Cui, Leon Hill, Wei Li, Frank W. Liou
Development Of Pre-Repair Machining Strategies For Laser-Aided Metallic Component Remanufacturing, Xinchang Zhang, Wenyuan Cui, Leon Hill, Wei Li, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Remanufacturing worn metallic components can prolong the service life of parts that need frequent replacement but are extremely costly to manufacture, such as aircraft titanium components, casting dies. Additive manufacturing (AM) technology enables the repair of such valuable components by depositing filler materials at the worn area layer by layer to regenerate the missing geometry. In general, damaged parts would be inspected and pre-machined prior to material deposition to remove oil, residue, oxidized layers or defects located in inaccessible regions. Therefore, the motivation of this paper is to introduce pre-repair machining strategies for removing contaminated materials from damaged components and …
Fast Prediction Of Thermal Distortion In Metal Powder Bed Fusion Additive Manufacturing: Part 2, A Quasi-Static Thermo-Mechanical Model, Hao Peng, Morteza Ghasri-Khouzani, Shan Gong, Ross Attardo, Pierre Ostiguy, Ronald B. Rogge, Bernice Aboud Gatrell, Joseph Budzinski, Charles Tomonto, Joel Neidig, M. Ravi Shankar, Richard Billo, David B. Go, David Hoelzle
Fast Prediction Of Thermal Distortion In Metal Powder Bed Fusion Additive Manufacturing: Part 2, A Quasi-Static Thermo-Mechanical Model, Hao Peng, Morteza Ghasri-Khouzani, Shan Gong, Ross Attardo, Pierre Ostiguy, Ronald B. Rogge, Bernice Aboud Gatrell, Joseph Budzinski, Charles Tomonto, Joel Neidig, M. Ravi Shankar, Richard Billo, David B. Go, David Hoelzle
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The additive manufacturing (AM) process metal powder bed fusion (PBF) can quickly produce complex parts with mechanical properties comparable to that of wrought materials. However, thermal stress accumulated during Metal PBF may induce part distortion and even cause failure of the entire process. This manuscript is the second part of two companion manuscripts that collectively present a part-scale simulation method for fast prediction of thermal distortion in Metal PBF. The first part provides a fast prediction of the temperature history in the part via a thermal circuit network (TCN) model. This second part uses the temperature history from the TCN …