Mechanical Engineering Commons^™

Optimization Of Selective Laser Sintering Process For Fabrication Of Zirconium Diboride Parts, Ming-Chuan Leu, Shashwatashish Pattnaik, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective Laser Sintering (SLS) was investigated to fabricate Zirconium Diboride (ZrB₂) parts for ultra-high temperature applications. Experiments were conducted to determine values of SLS process parameters (laser power, scan speed, line spacing, and layer thickness) that can be used to build ZrB₂ parts with high integrity and sharp geometrical features. A sacrificial plate with a proper number of layers (determined from experimentation) separated from the main part was built in order to reduce thermal gradients when building the main part. The sacrificial plate was found to assist in eliminating cracks in the bottom of the main part. …

Effect Of Different Graphite Materials On Electrical Conductivity And Flexural Strength Of Bipolar Plates Fabricated By Selective Laser Sintering, Nannan Guo, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Graphite is an excellent material for bipolar plates used in Proton Exchange Membrane (PEM) fuel cell due to its great chemical resistance, but the brittle nature makes it difficult to manufacture. Selective Laser Sintering (SLS) based on layer-by-layer manufacturing technology can fabricate graphite bipolar plates with complex gas flow channels. To improve the performance of bipolar plates including electrical conductivity and flexural strength, different graphite materials (natural graphite, synthetic graphite, carbon black, and carbon fiber) were investigated to fabricate test samples. These samples then went through post processing including carbonization and infiltration. The results show that bipolar plates with electrical …

Laser Based Rapid Manufacturing Of Metallic Gas Diffusion Layers For Pem Fuel Cells, Gargi Tandra, Todd E. Sparks, Shyam Barua, Nikhil P. Kulkarni, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Gas Diffusion layers (GDL’s) are an essential component of Polymer Electrolyte Membrane Fuel cells (PEMFC’s) which aid in thermal & electrical conductivities, water management and act as backup layers for the membrane electrode assemblies. This paper summarizes the effort to prototype metallic GDL designs using a miniature laser deposition system developed at Missouri University of Science & Technology. The pore sizes are controlled by masking the diverging laser beam using stainless steel masks of varying sizes and shapes. The through pore feature and further treatment of the GDL’s for hydrophobicity reduces the water management issue and thereby increases the performance …

Mea Manufacturing Using An Additive Manufacturing Process To Deposit A Catalyst Pattern In An Mea And Its Impact On Cost Reduction, Nikhil P. Kulkarni, Todd E. Sparks, Gargi Tandra, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The manufacturing of a fuel cell Membrane Electrode Assembly (MEA) is a significant cost driver in polymer-electrolyte membrane (PEM) fuel cell technologies, primarily due to the inclusion of expensive materials in the catalyst layer. The selective deposition of a catalyst on the MEA of a fuel cell can drastically reduce the costs depending upon the catalyst, method used for deposition, and production volume. In this paper, testing and analysis of a novel catalyst iridium oxide is discussed. The performance of the catalyst will be compared with the conventional catalysts which will give us an estimate of its effectiveness however, in …

Selective Laser Sintering And Freeze Extrusion Fabrication Of Scaffolds For Bone Repair Using 13-93 Bioactive Glass: A Comparison, Krishna C. R. Kolan, Nikhil P. Doiphode, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

13-93 glass is a third-generation bioactive material which accelerates the bone’s natural ability to heal by itself through bonding with surrounding tissues. It is an important requirement for synthetic scaffolds to maintain their bioactivity and mechanical strength with a porous internal architecture comparable to that of a human bone. Additive manufacturing technologies provide a better control over design and fabrication of porous structures than conventional methods. In this paper, we discuss and compare some of the common aspects in the scaffold fabrication using two such processes, viz. selective laser sintering (SLS) and freeze extrusion fabrication (FEF). Scaffolds fabricated using each …

Multi-Axis Planning System (Maps) For Hybrid Laser Metal Deposition Processes, Frank W. Liou, Jianzhong Ruan, Todd E. Sparks

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper summarizes the research and development of a Multi-Axis Planning System (MAPS) for hybrid laser metal deposition processes. The project goal is to enable the current direct metal deposition systems to fully control and utilize multi-axis capability to make complex parts. MAPS allows fully automated process planning for multi-axis layered manufacturing to control direct metal deposition machines for automated fabrication. Such a capability will lead to dramatic reductions in lead time and manufacturing costs for high-value, low-volume components with high performance material. The overall approach, slicing algorithm, machine simulation for planning validation, and the planning results will be presented.

Uncertainty Analysis In Laser Deposition Finish Machining Operations, Jomy Francis, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The Laser Aided Manufacturing Process (LAMP) from Missouri S&T is a laser based metals rapid manufacturing process that uses machining to improve the final part's surface finish. When free-form machining, the absence of enough deposited material results in inconsistent scallop heights which result in poor surface finish or incorrect geometry in the final part. This paper investigates a probabilistic approach to various uncertainties involved in the deposition and subsequent machining of an arbitrary part. Furthermore, this paper analyses the machine errors which makes the response of Scallop Height to exceed the predefined maximum scallop height when traveling along the tool …

Freeze Extrusion Fabrication Of 13-93 Bioactive Glass Scaffolds For Bone Repair, Tieshu Huang, Nikhil D. Doiphode, M. N. Rahaman, Ming-Chuan Leu, B. Sonny Bal, D. E. Day

Materials Science and Engineering Faculty Research & Creative Works

There is an increasing demand for synthetic scaffolds with the requisite biocompatibility, internal architecture, and mechanical properties for the bone repair and regeneration. In this work, scaffolds of a silicate bioactive glass (13-93) were prepared by a freeze extrusion fabrication (FEF) method and evaluated in vitro for potential applications in bone repair and regeneration. The process parameters for FEF production of scaffolds with the requisite microstructural characteristics, as well as the mechanical and cell culture response of the scaffolds were evaluated. After binder burnout and sintering (60 min at 700°C), the scaffolds consisted of a dense glass network with interpenetrating …

Computer Aided Contour Profiling Of High Strength Deposits, Sriram Praneeth Isanaka, Amar Bala Sridhar, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive manufacturing processes suffer from the effect of ripples, edge rounding and surface variations. To reduce their effect, ideal process parameters for the laser deposition process were investigated. Also, a new method was identified to analyze deposits by accurately plotting their contours. This was achieved through point cloud data of the deposits generated using coordinate measurement and 3D scanning. Curve fitting was performed on the data in Matlab to generate the contours of the deposit. The intercept values, heights, and contact angle of the curves give an indication of the uniformity of deposits and aid in reducing defects.

Selective Laser Sintering Of 13-93 Bioactive Glass, Krishna C. R. Kolan, Ming-Chuan Leu, Greg Hilmas, Mariano Garcia Velez

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Bioactive glasses are more promising than biopolymers in fabricating scaffolds for bone tissue repair because they convert to hydroxyapatite, when implanted in vivo. Both direct and indirect selective laser sintering (SLS) methods of 13-93 bioactive glass were considered in this research to study the feasibility of fabricating scaffolds for bone repair applications. Stearic acid was used as the binder in the indirect method to fabricate the scaffolds. The green scaffolds underwent binder burnout and sintering at various soaking conditions between 675⁰C and 700⁰C, achieving a maximum compressive strength of 23.6 MPa, which is higher than that of the human cancellous …

Development Of A Low Cost Imaging System For A Laser Metal Deposition Process, Shyam Barua, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The size of the melt pool created by the laser is one of the most important quality characteristic in a laser metal deposition process. This paper discusses the development of a low-cost vision system to automatically determine the size of the melt pool for in-process control. To cope with the intense infrared signal from the laser and melt pool, external ultraviolet illumination is paired with narrow bandpass filters on a usb microscope to achieve a clear image of the melt pool. The sensitivity of the melt pool to changes in system parameters and various substrate materials are also evaluated.

Functionally Graded Materials By Laser Metal Deposition (Preprint), Syamala R. Pulugurtha, Joseph William Newkirk, Frank W. Liou, Hsin-Nan Chou

Materials Science and Engineering Faculty Research & Creative Works

Fabrication of functionally graded materials (FGMs) by laser metal deposition (LMD) has the potential to offer solutions to key engineering problems over the traditional metalworking techniques. But the issues that need to be addressed while building FGMs are intermixing in the layers and cracking due to the residual stresses. This paper is to present the study of the effect of process parameters (laser power and travel speed) on the degree of dilution between the substrate (or, previous layer) and powder material for few metallurgical systems.

Freeze Extrusion Fabrication Of 13-93 Bioactive Glass Scaffolds For Bone Repair, Nikhil D. Doiphode

Masters Theses

"We have investigated Freeze Extrusion Fabrication (FEF) of 13-93 bioactive glass to fabricate three dimensional scaffolds for bone tissue engineering. Bioactive glass paste was prepared for consistent extrusion through micro-nozzle and controlled porosity scaffolds were fabricated using additive manufacturing FEF. CAD models were prepared for different scaffold designs and computer controlled layer-by-layer deposition of pseudoplastic paste was carried out to in accordance. Liquid nitrogen assisted freezing of pastes was used for the consolidation of deposited layers. Post processing binder burnout and sintering schedules were designed for evaporation of organic binder and densification of glass. Sintering shrinkage was measured, and X-ray …

Design And Development Of Microwire Feeder For Laser Applications, Amogh J. Shenoy

Masters Theses

"This thesis focuses on the design and development of a microwire feeder for laser applications. The use of wire-feeders in laser welding and electrical discharge machining applications has been prominent which can handle wire of 0.25 mm and it can go up to 10.0 mm in other applications. Development of microwire handling devices is complicated and difficult due to its low buckling strength; the need for high accuracy for its use; and the harsh environment it is exposed to, in laser applications. This paper presents a systematic methodology for the design and development of a high-precision microwire handling device. This …

Quantification Of Product Color Preference In A Utility Function, Hannah L. Turner

Masters Theses

"Currently, many marketing and engineering tools exist to help a designer optimize quantitative attributes of a product, such as height, weight, volume, or cost. However, these methods cannot effectively take into consideration aesthetic attributes of a product, or any other attributes for which there is no understood functional relationship between the attribute's potential values and the consumer's preference. This research has begun the work of developing this necessary functional relationship for the aesthetic attribute of color and has created a methodology for further research. To do this, colors were represented by their red, green, and blue light components, and preference …

Mechanical Properties And Microstructure Study For Direct Metal Deposition Of 316l Stainless Steel, Tian Fu

Masters Theses

"Direct metal deposition or laser cladding is a process capable of producing fully dense and net shape metal products and this process could be used on coating metal components in various engineering applications. This process has fast heating and cooling rates which can improve the surface hardness and provide excellent adhesion through metallurgical bond between coating material and substrate. This paper evaluated the laser deposited 316L stainless steel coating on 4340 steel, which is widely used for aircraft landing gear applications. The microstructure, micro-hardness and quantitative EDS were explored to verify the coating properties. The desired homogeneous microstructure and high …

Maskless Additive Manufacturing Of Micro Structures By Laser Sintering Of Nanoparticles, Vivekram Ramanathan

Masters Theses

"The focus of this study was to investigate an alternate microfabrication process of sintering nanoparticles using a patterned laser light to generate two dimensional (2D) and three dimensional (3D) geometries. With trends of producing electronic and medical devices using cheaper and faster technologies, a new procedure was developed to deposit and bond miniature patterns of silver nanoparticles onto silicon substrates.

The process consists of spraying silver nanoparticles onto the substrate while a patterned or modulated laser beam is focused onto the sprayed nanoparticles. These nanoparticles exposed under the modulated laser light undergo partial melting or sintering and adhere to the …