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Full-Text Articles in Mechanical Engineering
Effect Of Powder Particle Size On The Fabrication Of Ti-6al-4v Using Laser Metal Deposition From Elemental Powder Mixture, Xueyang Chen, Lei Yan, Wei Li, Frank W. Liou, Joseph William Newkirk
Effect Of Powder Particle Size On The Fabrication Of Ti-6al-4v Using Laser Metal Deposition From Elemental Powder Mixture, Xueyang Chen, Lei Yan, Wei Li, Frank W. Liou, Joseph William Newkirk
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Direct Laser Metal Deposition (LMD) was used to fabricate thin-wall Ti-6Al-4V using the powder mixture of Ti-6 wt.%Al-4 wt.%V. Scanning electron microscopy (SEM), optical microscopy (OM) and energy dispersive spectroscopy (EDS) were employed to examine the chemical composition and microstructure of the as-deposited sections. Vickers hardness tests were then applied to characterize the mechanical properties of the deposit samples which were fabricated using pre-mixed elemental powders. The EDS line scans indicated that the chemical composition of the samples was homogenous across the deposit. X-ray diffraction (XRD) was used for the phase identification. After significant analysis, some differences were observed among …
Proposed Hybrid Processes For Part Building Using Fusion Welding And Friction Stir Processing, Megan A. Gegesky, Frank W. Liou, Joseph William Newkirk
Proposed Hybrid Processes For Part Building Using Fusion Welding And Friction Stir Processing, Megan A. Gegesky, Frank W. Liou, Joseph William Newkirk
Mechanical and Aerospace Engineering Faculty Research & Creative Works
It has been shown that a hybrid laser additive manufacturing and friction stir processing can deposit components with forged-like structures. This paper reports a hybrid fusion welding and friction stir process to create parts with quality structures. Combining traditional fusion welding and friction stir processing techniques for non-weldable aluminum alloys could facilitate the joining of difficult geometries in manufactured parts. This research illustrates mechanical property changes for non-weldable and weldable aluminum alloys. The Vickers hardness, and microhardness in the case of AA5052-H32, tensile strength and corrosion resistance of four processing states: base material, fusion welded material, friction stir welded material, …
3d Printing Of A Polymer Bioactive Glass Composite For Bone Repair, Caroline Murphy, Krishna C. R. Kolan, M. Long, Ming-Chuan Leu, Julie A. Semon, D. E. Day
3d Printing Of A Polymer Bioactive Glass Composite For Bone Repair, Caroline Murphy, Krishna C. R. Kolan, M. Long, Ming-Chuan Leu, Julie A. Semon, D. E. Day
Mechanical and Aerospace Engineering Faculty Research & Creative Works
A major limitation of synthetic bone repair is insufficient vascularization of the interior region of the scaffold. In this study, we investigated the 3D printing of adipose derived mesenchymal stem cells (AD-MSCs) with polycaprolactone (PCL)/bioactive glass composite in a single process. This offered a three-dimensional environment for complex and dynamic interactions that govern the cell’s behavior in vivo. Borate based bioactive (13-93B3) glass of different concentrations (10 to 50 weight %) was added to a mixture of PCL and organic solvent to make an extrudable paste. AD-MSCs suspended in Matrigel was extruded as droplets using a second syringe. Scaffolds measuring …
Properties Of Partially Stabilized Zirconia Components Fabricated By The Ceramic On-Demand Extrusion Process, Wenbin Li, Amir Ghazanfari, Devin Mcmillen, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts
Properties Of Partially Stabilized Zirconia Components Fabricated By The Ceramic On-Demand Extrusion Process, Wenbin Li, Amir Ghazanfari, Devin Mcmillen, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The Ceramic On-Demand Extrusion (CODE) process is a novel additive manufacturing process for fabricating dense ceramic components from aqueous pastes of high solids loading. In this study, 3 mol% Y2O3 stabilized tetragonal zirconia polycrystal (3Y-TZP) parts were fabricated using the CODE process. The parts were then dried in a humidity controlled environmental chamber and sintered under atmospheric pressure. Mechanical properties of the sintered parts were examined using ASTM standard test techniques, including density, Young’s modulus, flexural strength, Weibull modulus, fracture toughness and Vickers hardness. The microstructure was analyzed, and grain size was measured using scanning electron microscopy. …
Designed Extrudate For Additive Manufacturing Of Zirconium Diboride By Ceramic On-Demand Extrusion, Devin Mcmillen, Wenbin Li, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts
Designed Extrudate For Additive Manufacturing Of Zirconium Diboride By Ceramic On-Demand Extrusion, Devin Mcmillen, Wenbin Li, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts
Mechanical and Aerospace Engineering Faculty Research & Creative Works
This work describes a process by which zirconium diboride (ZrB2) parts may be fabricated using the Ceramic On-Demand Extrusion (CODE) process. An oxide-carbide-nitride system consisting of ceramic powders and pre-ceramic organics, designed to yield ZrB2 after reaction sintering, has been developed to produce an aqueous-based extrudate for subsequent processing in the CODE system. Pressurelessly sintered test specimens containing 1 wt% PVA binder achieve high relative density ≥ 99%. The viscoelastic response of the extrudate was characterized via spindle rheometry with a small sample adapter. Batches with 1 wt% PVA and 0.5 wt% Methocel show strong shear thinning characteristic, under …
Novel Extrusion-Based Additive Manufacturing Process For Ceramic Parts, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Greg Hilmas
Novel Extrusion-Based Additive Manufacturing Process For Ceramic Parts, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Greg Hilmas
Mechanical and Aerospace Engineering Faculty Research & Creative Works
An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical density is introduced in this paper. In this process, an aqueous paste of ceramic particles with a very low binder content (< 1 vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Several sample parts for various applications were produced using this process and their properties were obtained. The results indicate that the proposed method enables fabrication of large, dense ceramic parts with complex geometries.
A Novel Extrusion-Based Additive Manufacturing Process For Ceramic Parts, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Greg Hilmas
A Novel Extrusion-Based Additive Manufacturing Process For Ceramic Parts, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Greg Hilmas
Mechanical and Aerospace Engineering Faculty Research & Creative Works
An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical density is introduced in this paper. In this process, an aqueous paste of ceramic particles with a very low binder content ( < 1 vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Several sample parts for various applications were produced using this process and their properties were obtained. The results indicate that the proposed method enables fabrication of large, dense ceramic parts with complex geometries.
Powders For Additive Manufacturing Processes: Characterization Techniques And Effects On Part Properties, Austin T. Sutton, Caitlin S. Kriewall, Ming-Chuan Leu, Joseph William Newkirk
Powders For Additive Manufacturing Processes: Characterization Techniques And Effects On Part Properties, Austin T. Sutton, Caitlin S. Kriewall, Ming-Chuan Leu, Joseph William Newkirk
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Powder-bed based Additive Manufacturing is a class of Additive Manufacturing (AM) processes that bond successive layers of powder by laser melting to facilitate the creation of parts with complex geometries. As AM technology transitions from the fabrication of prototypes to end-use parts, the understanding of the powder properties needed to reliably produce parts of acceptable quality becomes critical. Consequently, this has led to the use of powder characterization techniques such as scanning electron microscopy (SEM), laser light diffraction, x-ray photoelectron spectroscopy (XPS), and differential thermal analysis (DTA) to both qualitatively and quantitatively study the effect of powder characteristics on part …
Investigation Of Tensile Properties Of Bulk And Slm Fabricated 304l Stainless Steel Using Various Gage Length Specimens, Sreekar Karnati, I. Axelsen, Frank W. Liou, Joseph William Newkirk
Investigation Of Tensile Properties Of Bulk And Slm Fabricated 304l Stainless Steel Using Various Gage Length Specimens, Sreekar Karnati, I. Axelsen, Frank W. Liou, Joseph William Newkirk
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The complex solidification dynamics and thermal cycling during Selective Laser Melting process is expected to result in non-equilibrium material characteristics. There is an essential need for characterization techniques which are critical towards the estimation of anisotropies. The current investigation is targeted towards establishing tensile testing methodologies and their relation to differing gage lengths. Dog-bone shaped specimen designs with gage lengths of 1”, 0.3” and 0.12” were employed in this research. The characterization was performed on hot rolled-annealed 304 stainless and SLM fabricated 304L stainless. It was theorized that smaller gage length specimens would be instrumental in mapping material property anisotropy …
Investigation Of Heat-Affected 304l Ss Powder And Its Effect On Built Parts In Selective Laser Melting, Caitlin S. Kriewall, Austin T. Sutton, Ming-Chuan Leu, Joseph William Newkirk, Ben Brown
Investigation Of Heat-Affected 304l Ss Powder And Its Effect On Built Parts In Selective Laser Melting, Caitlin S. Kriewall, Austin T. Sutton, Ming-Chuan Leu, Joseph William Newkirk, Ben Brown
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Selective laser melting (SLM) is a powder bed based additive manufacturing process in which a layer of powder is laid over the surface of a substrate and a laser with sufficient energy is employed to selectively melt particles to build a part layer by layer. During the SLM process, dark smoke was observed coming off of the powder bed surface where the laser was interacting with powder. This phenomenon resulted from heat-affected powder that was visibly different than the base powder. Since the concentration of the heat-affected powder differs throughout the build chamber as a result of the recirculating argon …
Modeling And Experimental Investigation Of Pre-Mixed Multi-Powder Flow In Fabricating Functional Gradient Material By Laser Metal Deposition Process, Wei Li, Jingwei Zhang, Sreekar Karnati, Yunlu Zhang, Frank W. Liou, Joseph William Newkirk, Karen M. Brown Taminger, W. L. Seufzer
Modeling And Experimental Investigation Of Pre-Mixed Multi-Powder Flow In Fabricating Functional Gradient Material By Laser Metal Deposition Process, Wei Li, Jingwei Zhang, Sreekar Karnati, Yunlu Zhang, Frank W. Liou, Joseph William Newkirk, Karen M. Brown Taminger, W. L. Seufzer
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Laser Metal Deposition (LMD) is an effective process to fabricate Functionally Graded Material (FGM) from pre-mixed powders. Since the supplied multi-powder directly affects the deposited FGM’s composition, investigation on Pre-Mixed Multi-Powder (PMMP) flow during LMD is greatly needed. This paper presents a comprehensive numerical PMMP flow model. By solving discrete particle force balance equations coupled with continuity equations and momentum equations for carrier gas, the dynamic behavior of PMMP flow through powder feeder tube and out of nozzle was calculated. With this model, the particle sizes of multi-powder were optimized to obtain considered FGM composition. To verify the modeling results, …
Effect Of Powder Particle Size On The Fabrication Of Ti-6al-4v Using Laser Metal Deposition From Elemental Powder Mixture, Xueyang Chen, Lei Yan, Wei Li, Frank W. Liou, Joseph William Newkirk
Effect Of Powder Particle Size On The Fabrication Of Ti-6al-4v Using Laser Metal Deposition From Elemental Powder Mixture, Xueyang Chen, Lei Yan, Wei Li, Frank W. Liou, Joseph William Newkirk
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Direct LMD (laser metal deposition) was used to fabricate thin-wall Ti-6Al-4V using the powder mixture of Ti-6 wt.%Al-4 wt.%V. SEM (scanning electron microscopy), OM (optical microscopy) and EDS (energy dispersive spectroscopy) were employed to examine the chemical composition and microstructure of the as-deposited sections. Vickers hardness tests were then applied to characterize the mechanical properties of the deposit samples which were fabricated using pre-mixed elemental powders. The EDS line scans indicated that the chemical composition of the samples was homogenous across the deposit. After significant analysis, some differences were observed among two sets of deposit samples which varied in the …