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Full-Text Articles in Mechanical Engineering

Laser Powder Bed Fusion Of Nitihf High-Temperature Shape Memory Alloy: Effect Of Process Parameters On The Thermomechanical Behavior, Mohammadreza Nematollahi, Guher P. Toker, Keyvan Safaei, Alejandro Hinojos, S. Ehsan Saghaian, Othmane Benafan, Michael J. Mills, Haluk E. Karaca, Mohammad Elahinia Nov 2020

Laser Powder Bed Fusion Of Nitihf High-Temperature Shape Memory Alloy: Effect Of Process Parameters On The Thermomechanical Behavior, Mohammadreza Nematollahi, Guher P. Toker, Keyvan Safaei, Alejandro Hinojos, S. Ehsan Saghaian, Othmane Benafan, Michael J. Mills, Haluk E. Karaca, Mohammad Elahinia

Mechanical Engineering Faculty Publications

Laser powder bed fusion has been widely investigated for shape memory alloys, primarily NiTi alloys, with the goal of tailoring microstructures and producing complex geometries. However, processing high temperature shape memory alloys (HTSMAs) remains unknown. In our previous study, we showed that it is possible to manufacture NiTiHf HTSMA, as one of the most viable alloys in the aerospace industry, using SLM and investigated the effect of parameters on defect formation. The current study elucidates the effect of process parameters (PPs) on the functionality of this alloy. Shape memory properties and the microstructure of additively manufactured Ni-rich NiTiHf alloys were ...


Open Source High-Temperature Reprap For 3-D Printing Heat-Sterilizable Ppe And Other Applications, Noah G. Skrzypczak, Nagendra G. Tanikella, Joshua M. Pearce Oct 2020

Open Source High-Temperature Reprap For 3-D Printing Heat-Sterilizable Ppe And Other Applications, Noah G. Skrzypczak, Nagendra G. Tanikella, Joshua M. Pearce

Michigan Tech Publications

Thermal sterilization is generally avoided for 3-D printed components because of the relatively low deformation temperatures for common thermoplastics used for material extrusion-based additive manufacturing. 3-D printing materials required for high-temperature heat sterilizable components for COVID-19 and other applications demands 3-D printers with heated beds, hot ends that can reach higher temperatures than polytetrafluoroethylene (PTFE) hot ends and heated chambers to avoid part warping and delamination. There are several high temperature printers on the market, but their high costs make them inaccessible for full home-based distributed manufacturing required during pandemic lockdowns. To allow for all these requirements to be met ...


Additive Manufacturing Of Isotropic Ndfeb Pps Bonded Permanent Magnets, M. Parans Paranthaman, Volkan Yildirim, Tej Nath Lamichhane, Benjamin A. Begley, Brian K. Post, Ahmed A. Hassen, Brian C. Sales, Kinjal Gandha, Ikenna C. Nlebedim Jul 2020

Additive Manufacturing Of Isotropic Ndfeb Pps Bonded Permanent Magnets, M. Parans Paranthaman, Volkan Yildirim, Tej Nath Lamichhane, Benjamin A. Begley, Brian K. Post, Ahmed A. Hassen, Brian C. Sales, Kinjal Gandha, Ikenna C. Nlebedim

Ames Laboratory Accepted Manuscripts

Extrusion based additive manufacturing of polymer composite magnets can increase the solid loading volume fraction with greater mechanical force through the printing nozzle as compared to traditional injection molding process. About 63 vol% of isotropic NdFeB magnet powders were compounded with 37 vol% of polyphenylene sulfide and bonded permanent magnets were fabricated while using Big Area Additive Manufacturing without any degradation in magnetic properties. The polyphenylene sulfide bonded magnets have a tensile stress of 20 MPa, almost double than that of nylon bonded permanent magnets. Additively manufactured and surface-protective-resin coated bonded magnets meet the industrial stability criterion of up to ...


Effects Of Zirconia Doping On Additively Manufactured Alumina Ceramics By Laser Direct Deposition, John M. Pappas, Aditya R. Thakur, Xiangyang Dong Jul 2020

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 ...


Open-Source Digitally Replicable Lab-Grade Scales, Benjamin R. Hubbard, Joshua M. Pearce Jun 2020

Open-Source Digitally Replicable Lab-Grade Scales, Benjamin R. Hubbard, Joshua M. Pearce

Michigan Tech Publications

This study provides designs for a low-cost, easily replicable open-source lab-grade digital scale that can be used as a precision balance. The design is such that it can be manufactured for use in most labs throughout the world with open-source RepRap-class material extrusion-based 3-D printers for the mechanical components and readily available open-source electronics including the Arduino Nano. Several versions of the design were fabricated and tested for precision and accuracy for a range of load cells. The results showed the open-source scale was found to be repeatable within 0.05 g with multiple load cells, with even better precision ...


Conversion Of Self-Contained Breathing Apparatus Mask To Open Source Powered Air-Purifying Particulate Respirator For Fire Fighter Covid-19 Response, Benjamin R. Hubbard, Joshua M. Pearce Jun 2020

Conversion Of Self-Contained Breathing Apparatus Mask To Open Source Powered Air-Purifying Particulate Respirator For Fire Fighter Covid-19 Response, Benjamin R. Hubbard, Joshua M. Pearce

Michigan Tech Publications

To assist firefighters and other first responders to use their existing equipment for respiration during the COVID-19 pandemic without using single-use, low-supply, masks, this study outlines an open source kit to convert a 3M-manufactured Scott Safety self-contained breathing apparatus (SCBA) into a powered air-purifying particulate respirator (PAPR). The open source PAPR can be fabricated with a low-cost 3-D printer and widely available components for less than $150, replacing commercial conversion kits saving 85% or full-fledged proprietary PAPRs saving over 90%. The parametric designs allow for adaptation to other core components and can be custom fit specifically to fire-fighter equipment, including ...


Open Source High-Temperature Reprap For 3-D Printing Heat-Sterilizable Ppe And Other Applications, Noah G. Skrzypczak, Nagendra Gautam Tanikella, Joshua M. Pearce May 2020

Open Source High-Temperature Reprap For 3-D Printing Heat-Sterilizable Ppe And Other Applications, Noah G. Skrzypczak, Nagendra Gautam Tanikella, Joshua M. Pearce

Michigan Tech Publications

Thermal sterilization is generally avoided for 3-D printed components because of the relatively low deformation temperatures for common thermoplastics used for material extrusion-based additive manufacturing. 3-D printing materials required for high-temperature heat sterilizable components for COVID-19 and other applications demands 3-D printers with heated beds, hot ends that can reach higher temperatures than polytetrafluoroethylene (PTFE) hot ends and heated chambers to avoid part warping and delamination. There are several high temperature printers on the market, but their high costs make them inaccessible for full home-based distributed manufacturing required during pandemic lockdowns. To allow for all these requirements to be met ...


Design Of Versatile Feedback Control System Components For Selective Laser Sintering, Thomas Chessman May 2020

Design Of Versatile Feedback Control System Components For Selective Laser Sintering, Thomas Chessman

University Scholar Projects

Selective laser sintering (SLS) is an additive manufacturing technique that involves using a laser to fuse powdered material together, layer by layer, in order to create a 3-D product. Despite its numerous benefits over traditional methods of manufacturing, including higher efficiency, versatility, and the ability to process many materials, selective laser sintering suffers from its propensity to generate structural errors during operation.

Feedback control has been shown to improve fabrication quality in other laser-based additive manufacturing techniques when implemented properly. Widespread exploration of applying feedback control in SLS might lead to significant performance improvements in this form of manufacturing.

This ...


Parametric Nasopharyngeal Swab For Sampling Covid-19 And Other Respiratory Viruses: Open Source Design, Sla 3-D Printing And Uv Curing System, Nicole Gallup, Adam Pringle, Shane Oberloier, Nagendra Gautam Tanikella, Joshua M. Pearce May 2020

Parametric Nasopharyngeal Swab For Sampling Covid-19 And Other Respiratory Viruses: Open Source Design, Sla 3-D Printing And Uv Curing System, Nicole Gallup, Adam Pringle, Shane Oberloier, Nagendra Gautam Tanikella, Joshua M. Pearce

Michigan Tech Publications

Access to nasopharyngeal swabs for sampling remain a bottleneck in some regions for COVID19 testing. This study develops a distributed manufacturing solution using only an open source manufacturing tool chain consisting of two types of open source 3-D printing and batch UV curing, and provides a parametric fully free design of a nasopharyngeal swab. The swab was designed using parametric OpenSCAD in two components (a head with engineered break point and various handles), which has several advantages: i) minimizing print time on relatively slow SLA printers, ii) enabling the use of smaller print volume open source SLA printers, iii) reducing ...


Similarity Evaluation Of Topography Measurement Results By Different Optical Metrology Technologies For Additive Manufactured Parts, Yi Zheng, Xiao Zhang, Shaodong Wang, Qing Li, Hantang Qin, Beiwen Li Mar 2020

Similarity Evaluation Of Topography Measurement Results By Different Optical Metrology Technologies For Additive Manufactured Parts, Yi Zheng, Xiao Zhang, Shaodong Wang, Qing Li, Hantang Qin, Beiwen Li

Industrial and Manufacturing Systems Engineering Publications

The surface topographic measurements can be used by the additive manufacturing (AM) industry for in-situ quality inspection. However, disagreements may arise when we use different technologies to measure the topography of the same sample surface due to noise, sampling or optical properties of the sample surface, which may cause miscommunications or confusions between manufacturers. Thus, proposing methods for rating the similarities to match surface topographic data measured by various optical techniques is of crucial importance. This research investigates similarity evaluation methods for three-dimensional point-cloud topography data acquired by different technologies. Two different optical techniques (focus variation microscopy and structured light ...


Additive Manufacturing Of Magnesium Alloys, Rakeshkumar Karunakaran, Sam Ortgies, Ali Tamayol, Florin Bobaru, Michael P. Sealy Jan 2020

Additive Manufacturing Of Magnesium Alloys, Rakeshkumar Karunakaran, Sam Ortgies, Ali Tamayol, Florin Bobaru, Michael P. Sealy

Mechanical & Materials Engineering Faculty Publications

Magnesium alloys are a promising new class of degradable biomaterials that have a similar stiffness to bone, which minimizes the harmful effects of stress shielding. Use of biodegradable magnesium implants eliminates the need for a second surgery for repair or removal. There is a growing interest to capitalize on additive manufacturing's unique design capabilities to advance the frontiers of medicine. However, magnesium alloys are difficult to 3D print due to the high chemical reactivity that poses a combustion risk. Furthermore, the low vaporization temperature of magnesium and common biocompatible alloying elements further increases the difficulty to print fully dense ...


On Geometric Design Rules And In-Process Build Quality Monitoring Of Thin-Wall Features Made Using Laser Powder Bed Fusion Additive Manufacturing Process, Aniruddha Gaikwad Jan 2020

On Geometric Design Rules And In-Process Build Quality Monitoring Of Thin-Wall Features Made Using Laser Powder Bed Fusion Additive Manufacturing Process, Aniruddha Gaikwad

Mechanical (and Materials) Engineering -- Dissertations, Theses, and Student Research

The goal of this thesis is to quantify the link between the design features (geometry), in-process signatures, and build quality of parts made using the laser powder bed fusion (LPBF) additive manufacturing (AM) process. This knowledge is the foundational basis for proposing design rules in AM, as well as for detecting the impending build failures using in-process sensor data.

As a step towards this goal, the objectives of this work are two-fold:

1) Quantify the effect of the geometry and orientation on the build quality of thin-wall features. To explain further, the geometry related factor is the ratio of the ...


Processing Of Alnico Magnets By Additive Manufacturing, Emma White, Emily Rinko, Timothy Prost, Timothy Horn, Christopher Ledford, Christopher Rock, Iver E. Anderson Nov 2019

Processing Of Alnico Magnets By Additive Manufacturing, Emma White, Emily Rinko, Timothy Prost, Timothy Horn, Christopher Ledford, Christopher Rock, Iver E. Anderson

Ames Laboratory Accepted Manuscripts

Permanent magnets without rare earth (RE) elements, such as alnico, will improve supply stability and potentially decrease permanent magnet cost, especially for traction drive motors and other increased temperature applications. Commercial alnico magnets with the highest energy product are produced by directional solidification (DS) to achieve a <001> columnar grain orientation followed by significant final machining, adding to the high cost. Additive manufacturing (AM) is an effective method to process near net-shape parts with minimal final machining of complex geometries. AM also, has potential for texture/grain orientation control and compositionally graded structures. This report describes fabrication of alnico magnets by ...


Open Source Waste Plastic Granulator, Arvind Ravindran, Sean Scsavnicki, Walker Nelson, Peter Gorecki, Jacob Franz, Shane Oberloier, Theresa K. Meyer, Andrew Barnard, Joshua M. Pearce Oct 2019

Open Source Waste Plastic Granulator, Arvind Ravindran, Sean Scsavnicki, Walker Nelson, Peter Gorecki, Jacob Franz, Shane Oberloier, Theresa K. Meyer, Andrew Barnard, Joshua M. Pearce

Michigan Tech Publications

In order to accelerate deployment of distributed recycling by providing low-cost feed stocks of granulated post-consumer waste plastic, this study analyzes an open source waste plastic granulator system. It is designed, built, and tested for its ability to convert post-consumer waste, 3D printed products and waste into polymer feedstock for recyclebots of fused particle/granule printers. The technical specifications of the device are quantified in terms of power consumption (380 to 404 W for PET and PLA, respectively) and particle size distribution. The open source device can be fabricated for less than $2000 USD in materials. The experimentally measured power ...


Smart Additive Manufacturing: In-Process Sensing And Data Analytics For Online Defect Detection In Metal Additive Manufacturing Processes, Mohammad Montazeri Oct 2019

Smart Additive Manufacturing: In-Process Sensing And Data Analytics For Online Defect Detection In Metal Additive Manufacturing Processes, Mohammad Montazeri

Mechanical (and Materials) Engineering -- Dissertations, Theses, and Student Research

The goal of this dissertation is to detect the incipient flaws in metal parts made using additive manufacturing processes (3D printing). The key idea is to embed sensors inside a 3D printing machine and conclude whether there are defects in the part as it is being built by analyzing the sensor data using artificial intelligence (machine learning). This is an important area of research, because, despite their revolutionary potential, additive manufacturing processes are yet to find wider acceptance in safety-critical industries, such as aerospace and biomedical, given their propensity to form defects. The presence of defects, such as porosity, can ...


Mechanical And Corrosion Properties Of Additively Manufactured Cocrfemnni High Entropy Alloy, Michael A. Melia, Jay D. Carroll, Shaun R. Whetten, Saba N. Esmaeely, Jenifer Locke (Warner), Emma White, Iver E. Anderson, Michael Chandross, Joseph R. Michael, Nicolas Argibay, Eric J. Schindelholz, Andrew B. Kustas Oct 2019

Mechanical And Corrosion Properties Of Additively Manufactured Cocrfemnni High Entropy Alloy, Michael A. Melia, Jay D. Carroll, Shaun R. Whetten, Saba N. Esmaeely, Jenifer Locke (Warner), Emma White, Iver E. Anderson, Michael Chandross, Joseph R. Michael, Nicolas Argibay, Eric J. Schindelholz, Andrew B. Kustas

Ames Laboratory Accepted Manuscripts

This study investigates the mechanical and corrosion properties of as-built and annealed equiatomic CoCrFeMnNi alloy produced by laser-based directed energy deposition (DED) Additive Manufacturing (AM). The high cooling rates of DED produced a single-phase, cellular microstructure with cells on the order of 4 μm in diameter and inter-cellular regions that were enriched in Mn and Ni. Annealing created a chemically homogeneous recrystallized microstructure with a high density of annealing twins. The average yield strength of the as-built condition was 424 MPa and exceeded the annealed condition (232 MPa), however; the strain hardening rate was lower for the as-built material stemming ...


Laser‐Induced Keyhole Defect Dynamics During Metal Additive Manufacturing, Andrew M. Kiss, Anthony Y. Fong, Nicholas P. Calta, Vivek Thampy, Aiden A. Martin, Philip J. Depond, Jenny Wang, Manyalibo J. Matthews, Ryan T. Ott, Christopher J. Tassone, Kevin H. Stone, Matthew J. Kramer, Anthony Van Buuren, Michael F. Toney, Johanna Nelson Weker Oct 2019

Laser‐Induced Keyhole Defect Dynamics During Metal Additive Manufacturing, Andrew M. Kiss, Anthony Y. Fong, Nicholas P. Calta, Vivek Thampy, Aiden A. Martin, Philip J. Depond, Jenny Wang, Manyalibo J. Matthews, Ryan T. Ott, Christopher J. Tassone, Kevin H. Stone, Matthew J. Kramer, Anthony Van Buuren, Michael F. Toney, Johanna Nelson Weker

Ames Laboratory Accepted Manuscripts

Laser powder bed fusion (LPBF) metal additive manufacturing provides distinct advantages for aerospace and biomedical applications. However, widespread industrial adoption is limited by a lack of confidence in part properties driven by an incomplete understanding of how unique process parameters relate to defect formation and ultimately mechanical properties. To address that gap, high‐speed X‐ray imaging is used to probe subsurface melt pool dynamics and void‐formation mechanisms inaccessible to other monitoring approaches. This technique directly observes the depth and dynamic behavior of the vapor depression, also known as the keyhole depression, which is formed by recoil pressure from ...


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 Aug 2019

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 ...


Modeling Thermal And Mechanical Cancellation Of Residual Stress From Hybrid Additive Manufacturing By Laser Peening, Guru Madireddy, Chao Li, Jingfu Liu, Michael P. Sealy Jul 2019

Modeling Thermal And Mechanical Cancellation Of Residual Stress From Hybrid Additive Manufacturing By Laser Peening, Guru Madireddy, Chao Li, Jingfu Liu, Michael P. Sealy

Mechanical & Materials Engineering Faculty Publications

Additive manufacturing (AM) of metals often results in parts with unfavorable mechanical properties. Laser peening (LP) is a high strain rate mechanical surface treatment that hammers a workpiece and induces favorable mechanical properties. Peening strain hardens a surface and imparts compressive residual stresses improving the mechanical properties of a material. This work investigates the role of LP on layer-by-layer processing of 3D printed metals using finite element analysis. The objective is to understand temporal and spatial residual stress development after thermal and mechanical cancellation caused by cyclically coupling printing and peening. Results indicate layer peening frequency is a critical process ...


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 Jun 2019

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 ...


Mechanical Properties And Applications Of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing, Matthew J. Reich, Aubrey Woern, Nagendra Gautam Tanikella, Joshua M. Pearce May 2019

Mechanical Properties And Applications Of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing, Matthew J. Reich, Aubrey Woern, Nagendra Gautam Tanikella, Joshua M. Pearce

Michigan Tech Publications

Past work has shown that particle material extrusion (fused particle fabrication (FPF)/fused granular fabrication (FGF)) has the potential for increasing the use of recycled polymers in 3D printing. This study extends this potential to high-performance (high-mechanical-strength and heat-resistant) polymers using polycarbonate (PC). Recycled PC regrind of approximately 25 mm2 was 3D printed with an open-source Gigabot X and analyzed. A temperature and nozzle velocity matrix was used to find useful printing parameters, and a print test was used to maximize the output for a two-temperature stage extruder for PC. ASTM type 4 tensile test geometries as well as ...


Open Source Completely 3-D Printable Centrifuge, Salil S. Sule, Aliaksei Petsiuk, Joshua M. Pearce May 2019

Open Source Completely 3-D Printable Centrifuge, Salil S. Sule, Aliaksei Petsiuk, Joshua M. Pearce

Michigan Tech Publications

Centrifuges are commonly required devices in medical diagnostics facilities as well as scientific laboratories. Although there are commercial and open source centrifuges, the costs of the former and the required electricity to operate the latter limit accessibility in resource-constrained settings. There is a need for low-cost, human-powered, verified, and reliable lab-scale centrifuges. This study provides the designs for a low-cost 100% 3-D printed centrifuge, which can be fabricated on any low-cost RepRap-class (self-replicating rapid prototyper) fused filament fabrication (FFF)- or fused particle fabrication (FPF)-based 3-D printer. In addition, validation procedures are provided using a web camera and free and ...


Nde In-Process For Metal Parts Fabricated Using Powder Based Additive Manufacturing, Leonard J. Bond, Lucas W. Koester, Hossein Taheri Mar 2019

Nde In-Process For Metal Parts Fabricated Using Powder Based Additive Manufacturing, Leonard J. Bond, Lucas W. Koester, Hossein Taheri

Aerospace Engineering Publications

Ensuring adequate quality for additive manufactured (AM) materials presents unique metrology challenges to the on-line process measurement and nondestructive evaluation (NDE) communities. AM parts now have complex forms that are not possible using subtractive manufacturing and there are moves for their use in safety criticality components. This paper briefly reviews the status, challenges and metrology opportunities throughout the AM process from powder to finished parts. The primary focus is on new acoustic signatures that have been demonstrated to correlate process parameters with on-line measurement for monitoring and characterization during the build. In-process, quantitative characterization and monitoring of material state is ...


An Energy Profile Model For Fused Deposition Modeling 3d Printing Process, Calvin Hawkins Jan 2019

An Energy Profile Model For Fused Deposition Modeling 3d Printing Process, Calvin Hawkins

ROEU 2018-19

This project develops a strategy to monitor and estimate the energy consumption of fused deposition modeling (FDM) additive manufacturing, which will benefit manufacturers and designers seeking to design and manufacture products with minimal energy consumption.


Glocal Integrity In 420 Stainless Steel By Asynchronous Laser Processing, Michael P. Sealy, Haitham Hadidi, Cody Kanger, X. L. Yan, Bai Cui, J. A. Mcgeough Jan 2019

Glocal Integrity In 420 Stainless Steel By Asynchronous Laser Processing, Michael P. Sealy, Haitham Hadidi, Cody Kanger, X. L. Yan, Bai Cui, J. A. Mcgeough

Mechanical & Materials Engineering Faculty Publications

Cold working individual layers during additive manufacturing (AM) by mechanical surface treatments, such as peening, effectively “prints” an aggregate surface integrity that is referred to as a glocal (i.e., local with global implications) integrity. Printing a complex, pre-designed glocal integrity throughout the build volume is a feasible approach to improve functional performance while mitigating distortion. However, coupling peening with AM introduces new manufacturing challenges, namely thermal cancellation, whereby heat relaxes favorable residual stresses and work hardening when printing on a peened layer. Thus, this work investigates glocal integrity formation from cyclically coupling LENS® with laser peening on 420 stainless ...


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 Sep 2018

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 helpful ...


Finding Balance In Generative Product Design, Alex Lobos Aug 2018

Finding Balance In Generative Product Design, Alex Lobos

Presentations and other scholarship

Generative design develops complex forms and structures similar to those found in nature, taking advantage of automated tasks and high-scale computing power. This approach benefits designers in the creation systems that are efficient, resilient and visually engaging. These systems follow specific rules for form generation and meet clear design goals in terms of shape, strength, mass, and other physical attributes.

There is a large number of methods for creating generative systems, based on establishing desired outcomes and behaviors for how components relate to each other. Examples of methods include L-Systems, Shape Grammars, Swarm Intelligence, Form Optimization, Lattice Design, and many ...


Modeling Residual Stress Development In Hybrid Processing By Additive Manufacturing And Laser Shock Peening, Guru Charan Reddy Madireddy Apr 2018

Modeling Residual Stress Development In Hybrid Processing By Additive Manufacturing And Laser Shock Peening, Guru Charan Reddy Madireddy

Mechanical (and Materials) Engineering -- Dissertations, Theses, and Student Research

The term “hybrid” has been widely applied to many areas of manufacturing. Naturally, that term has found a home in additive manufacturing as well. Hybrid additive manufacturing or hybrid-AM has been used to describe multi-material printing, combined machines (e.g., deposition printing and milling machine center), and combined processes (e.g., printing and interlayer laser re-melting). The capabilities afforded by hybrid-AM are rewriting the design rules for materials and adding a new dimension in the design for additive manufacturing paradigm. This work focuses on hybrid-AM processes, which are defined as the use of additive manufacturing (AM) with one or more ...


Additive Manufacturing Of Transparent Fused Quartz, Junjie Luo, John M. Hostetler, Luke Gilbert, Jonathan T. Goldstein, Augustine M. Urbas, Douglas A. Bristow, Robert G. Landers, Edward C. Kinzel Apr 2018

Additive Manufacturing Of Transparent Fused Quartz, Junjie Luo, John M. Hostetler, Luke Gilbert, Jonathan T. Goldstein, Augustine M. Urbas, Douglas A. Bristow, Robert G. Landers, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper investigates a filament-fed process for additive manufacturing (AM) of fused quartz. Glasses such as fused quartz have significant scientific and engineering applications, which include optics, communications, electronics, and hermetic seals. AM has several attractive benefits such as increased design freedom, faster prototyping, and lower processing costs for small production volumes. However, current research into glass AM has focused primarily on nonoptical applications. Fused quartz is studied here because of its desirability for use in high-quality optics due to its high transmissivity and thermal stability. Fused quartz filaments are fed into a CO2 laser-generated molten region, smoothly depositing ...


Selective Laser Melting Of Ni-Rich Niti: Selection Of Process Parameters And The Superelastic Response, Narges Shayesteh Moghaddam, Soheil Saedi, Amirhesam Amerinatanzi, Ehsan Saghaian, Ahmadreza Jahadakbar, Haluk E. Karaca, Mohammad Elahinia Mar 2018

Selective Laser Melting Of Ni-Rich Niti: Selection Of Process Parameters And The Superelastic Response, Narges Shayesteh Moghaddam, Soheil Saedi, Amirhesam Amerinatanzi, Ehsan Saghaian, Ahmadreza Jahadakbar, Haluk E. Karaca, Mohammad Elahinia

Mechanical Engineering Faculty Publications

Material and mechanical properties of NiTi shape memory alloys strongly depend on the fabrication process parameters and the resulting microstructure. In selective laser melting, the combination of parameters such as laser power, scanning speed, and hatch spacing determine the microstructural defects, grain size and texture. Therefore, processing parameters can be adjusted to tailor the microstructure and mechanical response of the alloy. In this work, NiTi samples were fabricated using Ni50.8Ti (at.%) powder via SLM PXM by Phenix/3D Systems and the effects of processing parameters were systematically studied. The relationship between the processing parameters and superelastic properties ...