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Articles 1 - 30 of 146
Full-Text Articles in Mechanical Engineering
Mechanical Properties And Microstructure Of Multi-Materials Fabricated Through A Combination Of Lpbf And Ded Additive Manufacturing Techniques, Christopher J. Bettencourt
Mechanical Properties And Microstructure Of Multi-Materials Fabricated Through A Combination Of Lpbf And Ded Additive Manufacturing Techniques, Christopher J. Bettencourt
All Graduate Theses and Dissertations, Fall 2023 to Present
This research explores the use of different metals combined through 3D-printing to enhance the performance of materials, with a focus on making heat exchangers more cost-effective for renewable energy. The goal is to replace a costly high-temperature alloy with a more affordable low-temperature alloy, using metal additive manufacturing for its benefits such as less material waste, faster production, reduced weight, and the ability to print entire assemblies in one go. The study delves into a unique combination of two 3D-printing techniques, Directed Energy Deposition and Laser Powder-Bed Fusion, to create a multi-material composed of stainless steel 316L and a nickel-based …
Additively Manufactured Nature Inspired Morphology For Redesign: Advancing Next Generation Energy Systems, Vanshika Singh
Additively Manufactured Nature Inspired Morphology For Redesign: Advancing Next Generation Energy Systems, Vanshika Singh
Doctoral Dissertations
To meet cleaner energy goals and increasing demand, energy systems such as gas turbines and power plants are required to be operated under harsh loading conditions like higher temperatures and pressures, fluctuating loads, and corrosive environments. Advanced manufacturing techniques such as additive manufacturing (AM) have put us on the trajectory for next-generation system designs, allowing complex geometries and high-temperature alloys with tailored material properties. We need new and systematic design philosophies to use AM's unique characteristics prudently. For a given functionality, nature tends to provide similar solutions in animate and inanimate structures. We propose to take inspiration from nature's repetitive …
Laser Assisted Direct Writing Of Liquid Metal For Microprinting Applications, Olga Vargas Cruz
Laser Assisted Direct Writing Of Liquid Metal For Microprinting Applications, Olga Vargas Cruz
Theses and Dissertations
This paper presents a research study for potential printing of a Liquid Metal (LM) Eutectic Gallium Indium alloy (EGaIn) through the applications of the innovative additive manufacturing technology LIFT (Laser Induced Forward Transfer). LIFT is a precise printing technology that allows to create small, detailed printing. The liquid metal in study, EGaIn, has demonstrated great potential for microelectronics applications due to its minimum toxicity and high conductivity. Throughout this research different printing parameters are studied to comprehend the behavior of EGaIn printing with LIFT technique, these include laser energy, laser pulse, receiver material substrate, donor layer thickness, and …
An Investigation Into The Challenges Of Contemporary Additive Manufacturing: Insights Into The Metallurgical Response Of Materials And Relevant Solution, Huan Ding
LSU Doctoral Dissertations
Additive Manufacturing (AM) has gained attention in recent years due to its unique capabilities in the fabrication of complex parts. As with any new research, there is still a lack of sufficient understanding in the field of additive manufacturing, and further investigation is needed to solve existing problems. Ultimately, the aim is to enable the widespread use of AM components across various industries.
Chapter One provides a brief introduction to the background and current bottlenecks of additive manufacturing technology. Chapter two focuses on the development of high-strength 7075 aluminum alloy (Al7075) for Fused Deposition Modeling and Sintering (FDMS) technology. Al7075 …
Spall Characteristics Of Additively Manufactured Stainless Steel, Kevin Lamb
Spall Characteristics Of Additively Manufactured Stainless Steel, Kevin Lamb
Doctoral Dissertations
Additive manufacturing (AM) has rapidly transformed from a novelty prototyping technology into a growing sector of production across a wide range of industries. Much work has been documented in literature to demonstrate the behavior of AM products under static and quasi-static loading conditions. However, the behavior of AM materials under high strain rate loading is not as well understood. This research attempts to advance the fundamental knowledge of the relationship between the unique aspects of AM and the mechanical performance under high velocity impact loading conditions.
This project examines the behavior of AM 316L stainless steel (SS) exposed to high …
In Situ Process Monitoring And Machine Learning Based Modeling Of Defects And Anomalies In Wire-Arc Additive Manufacturing, Eduardo Miramontes
In Situ Process Monitoring And Machine Learning Based Modeling Of Defects And Anomalies In Wire-Arc Additive Manufacturing, Eduardo Miramontes
Masters Theses
Wire Arc Additive Manufacturing (WAAM) has made great strides in recent years however, there remain numerous persistent challenges still hindering more widespread adoption. Defects in the parts produced degrade their mechanical performance. Inconsistency in the geometry of the weld beads or undesirable anomalies such as waviness, or humps can lead to loss of geometric accuracy and in extreme cases, when anomalies propagate to subsequent layers, build failure. Such defects can be mitigated by a controls framework, which would require a model that maps undesirable outcomes to information about the process that can be obtained in real time. This thesis explores …
Consumer 3d Printing For Remote Control Aircraft Wings: Development Of Novel Wingbox Structure, Ian Clark
Consumer 3d Printing For Remote Control Aircraft Wings: Development Of Novel Wingbox Structure, Ian Clark
University Honors Theses
Remote control aircraft construction and can be a very expensive and time-consuming hobby. With 3D printer consumer adoption rates skyrocketing, there is a gap between demand for RC aircraft and suitable well-designed models available to creators and hobbyists. By creating and testing two iterations of wingbox geometries, this research aims to help close that gap by producing an easily printable wing structure. While there are improvements that can be made on this work, this research has been effective in generating a novel wingbox structure for FFF 3D printing that has distinct advantages over other designs currently available.
Additive Manufacturing Of Stretchable Strain Sensors: Fabrication, Optimization And Application, John Nady Shihat Bastawrous
Additive Manufacturing Of Stretchable Strain Sensors: Fabrication, Optimization And Application, John Nady Shihat Bastawrous
Theses and Dissertations
In this project, a novel strain sensor design is fabricated employing different additive manufacturing techniques. The spring sensor's primary material is PLA-Like resin with a nanocomposite encapsulation layer as the functional material. The main principle of Straining the sensors results in a change in resistivity as the distances among the conductive carbon particles change according to the strain applied.
Sensor fabrication consists of two parts: spring manufacturing and development of nanocomposite encapsulation The nanocomposite matrix is developed through the dispersion of Graphene and Carbon nanotubes in Thermoplastic Polyurethane through sonication and magnetic hotplate stirring. While the spring itself is manufactured …
Feasibility Of Thermoplastic Extrusion Welding As A Joining Method For Vacuum-Assisted Additively Manufactured Tooling, Chase C. Flaherty
Feasibility Of Thermoplastic Extrusion Welding As A Joining Method For Vacuum-Assisted Additively Manufactured Tooling, Chase C. Flaherty
Electronic Theses and Dissertations
In recent years, additive manufacturing (AM) has been successfully utilized for the production of large-scale composite tooling. Within these endeavors, however, limited research has focused on joining methods between printed sections. This work evaluates the feasibility of thermoplastic extrusion welding as a joining method for additively manufactured tooling structures. This joining method was assessed based on industry specifications of conventional thermoset tooling for wind blade manufacturing utilizing the vacuum-assisted resin transfer molding (VARTM) process. The specifications include requirements for the mechanical strength, vacuum integrity, roughness, and hardness of the tool surface. The feasibility of this welded polymer joint was demonstrated …
A Method For Measuring The Spectral Emissivity Of Metal Powders At Different Temperatures And Applications In Laser Powder Bed Fusion, Emmanuel Levario
A Method For Measuring The Spectral Emissivity Of Metal Powders At Different Temperatures And Applications In Laser Powder Bed Fusion, Emmanuel Levario
Open Access Theses & Dissertations
Radiation thermometry monitoring methods used in powder bed fusion additive manufacturing (PBF-AM) are becoming increasingly more popular for quality assurance and repeatability. The dynamic nature of the PBF process and a lack of accuracy of metrics being captured for temperature monitoring lend great difficulty in the successful implementation of in-situ monitoring. There is currently no data on the emissivity, a metric used in non-contact temperature measurements, for metal powders used in AM. This work describes a method for measuring the spectral emissivity for metal powder sizes commonly used in AM using a multi-wavelength (MW), FMPI SpectroPyrometer, calibrated within the spectral …
Cycle Time Reduction In Additive Manufacturing Using Peltier Thermoelectric Cooling Devices, Trevor Carlton
Cycle Time Reduction In Additive Manufacturing Using Peltier Thermoelectric Cooling Devices, Trevor Carlton
Honors College Theses
Thermoelectric cooling and the Peltier effect were discovered in 1834, over 188 years ago. Additionally, the first iterations of additive manufacturing (i.e., 3D printing) began in the early 1980s, more than 40 years ago. Despite these technologies’ age and years of advancements, the application of Peltier cooling-based devices in additive manufacturing has not yet been realized. These devices can be used for the active thermal management of print beds in 3D printers. Developing a mechanism to heat and cool a print bed can reduce the cycle time to manufacture a part. In 3D printing, waiting for the heated bed to …
Accelerating Manufacturing Decisions Using Bayesian Optimization: An Optimization And Prediction Perspective, Taofeeq Olajire
Accelerating Manufacturing Decisions Using Bayesian Optimization: An Optimization And Prediction Perspective, Taofeeq Olajire
Graduate Theses, Dissertations, and Problem Reports
Manufacturing is a promising technique for producing complex and custom-made parts with a high degree of precision. It can also provide us with desired materials and products with specified properties. To achieve that, it is crucial to find out the optimum point of process parameters that have a significant impact on the properties and quality of the final product. Unfortunately, optimizing these parameters can be challenging due to the complex and nonlinear nature of the underlying process, which becomes more complicated when there are conflicting objectives, sometimes with multiple goals. Furthermore, experiments are usually costly, time-consuming, and require expensive materials, …
An Active Voice Coil Negative Stiffness Vibration Isolator With Application To Mobile 3d Printing, Lucas M. Schloemp
An Active Voice Coil Negative Stiffness Vibration Isolator With Application To Mobile 3d Printing, Lucas M. Schloemp
Dissertations, Master's Theses and Master's Reports
Equipment whose performance degrades when exposed to base vibration is often deployed in vibration-rich environments. Using 3D printers in mobile applications, such as vehicles and ships, are typical examples where the extruder and bedplate are easily excited by base vibration. A versatile active vibration isolator is considered in this thesis constructed using a voice coil actuator and a laser displacement feedback sensor to achieve a wide range of dynamic response characteristics, including negative stiffness. This approach permits transmissibility shaping to meet band-limited base isolation requirements without active damping vibration control. A combination of simulation and hardware validation is used to …
An Experimental Study On The Mechanical Properties And Chemical Composition Of Lcd 3d Printed Specimens, Sebastian Gomez
An Experimental Study On The Mechanical Properties And Chemical Composition Of Lcd 3d Printed Specimens, Sebastian Gomez
Electronic Theses and Dissertations
Additive manufacturing technologies have been enhanced throughout the years yet have surprised the manufacturing industry due to their high-end surface finish and dimensional accuracy. Different experiments have been done to identify a specific phenomenon known in the vat-polymerization field. Distortion and dimensional inaccuracy tend to affect the overall properties of the process, either physical or chemical. This approach allows the understanding of how the physical properties have been affected and how to study the chemical properties to avoid this type of phenomenon. The chemical reaction between polymer and UV light has been studied and experimented with to the point that …
Characterization And Improvement Of Powder Properties Through Plasma Spheroidization For Use In The Laser Powder Bed Fusion Process, M. Hossein Sehhat
Characterization And Improvement Of Powder Properties Through Plasma Spheroidization For Use In The Laser Powder Bed Fusion Process, M. Hossein Sehhat
Doctoral Dissertations
"This research was conducted to characterize the powder properties using different characterization techniques to enhance the powder behavior in the Laser Powder Bed Fusion (LPBF) process. One of the shortcomings of LPBF process is the high cost of gas-atomized powder feedstock. To overcome this downside, the cheaper water-atomized powder was characterized and used in LPBF process, and its performance was compared with those of gas-atomized powder. Also, the plasma spheroidization process was used to improve the powder characteristics; if the spheroidized powder could function as well as the virgin powder, plasma spheroidization process could be applied to the used powders …
Thermoplastics 3d Printing Using Fused Deposition Modeling On Fabrics, Maxwell M. Blais
Thermoplastics 3d Printing Using Fused Deposition Modeling On Fabrics, Maxwell M. Blais
Electronic Theses and Dissertations
The creation of objects with integrated flexibility is desired and this can be achieved by additive manufacturing on fabric. We propose to use a textile fabric as a flexible joint and create to create an entire object with smaller parts called segments. Such a novel technique will bring integrated flexibility and folded assemblies using extrusion based additive manufacturing machines. The proposed process allows segments to be created flat one at a time on a continuous fabric, which will be suitable for flat to folded assemblies and eliminate size limitations of the 3D printer. Techniques considering object segmentation were used to …
Direct Ink Write And Thermomechanical Characterization Of Thermoset Composites, Sergio Dante Favela
Direct Ink Write And Thermomechanical Characterization Of Thermoset Composites, Sergio Dante Favela
Open Access Theses & Dissertations
This research will be divided into two sections. The first section discusses direct ink writing and thermomechanical characterization for thermoset composites. The thermoset ink is prepared with fillers aiding the printing process by modifying the rheology of the ink and geometry retention by allowing for the part to have an initial UV cure step. Three specimen formulations with different weight percentages were printed by material extrusion in the shape of tensile specimens following ASTM standard D638 to characterize the mechanical properties at room temperature, 100â?? and 200â??. Furthermore, the ink resin was characterized through DSC, TGA, and rheology testing. The …
A Machine Learning Approach To Robotic Additive Manufacturing Of Uv-Curable Polymers Using Direct Ink Writing, Luis A. Velazquez
A Machine Learning Approach To Robotic Additive Manufacturing Of Uv-Curable Polymers Using Direct Ink Writing, Luis A. Velazquez
LSU Master's Theses
This thesis presents the design and implementation of a robotic additive manufacturing system that uses ultraviolet (UV)-curable thermoset polymers. Its design considers future applications involving free-standing 3D printing by means of partial UV curing and the fabrication of samples that are reinforced with fillers or fibers to manufacture complex-shape objects.
The proposed setup integrates a custom-built extruder with a UR5e collaborative manipulator. The capabilities of the system were demonstrated using Anycubic resin formulations containing fumed silica (FS) at varying weight fractions from 2.8 to 8 wt%. To fully cure the specimens after fabrication, a UV chamber was used. Then, measurements …
Mobile 3d Printing Of Rail Track Surface For Rapid Repai, Ershad Mortazavian
Mobile 3d Printing Of Rail Track Surface For Rapid Repai, Ershad Mortazavian
UNLV Theses, Dissertations, Professional Papers, and Capstones
The frequent replacement of worn rails on tracks brings an immense economic burden on the railroad industry, and also causes significant interruptions to railroad operation. Restoration of worn rails via additive manufacturing, i.e., 3D printing, can considerably reduce the associated maintenance costs.The scope of this dissertation is to utilize metal additive manufacturing (AM) technology to repair worn rails that are used in the U.S. railway transportation system (e.g. 75-lb/yd light transit rails, or 136-lb/yd heavy freight rails). More specifically, this study aims to understand the interactive mechanisms between the deposited materials and the high-carbon rail steel to identify and alleviate …
Development And Characterization Of Bound Metal Deposition Including Laser Ablation, Alexander J. Watson
Development And Characterization Of Bound Metal Deposition Including Laser Ablation, Alexander J. Watson
Electronic Theses and Dissertations
Bound Metal Deposition (BMD) is a novel metal additive manufacturing technology in which a metal powder-binder composite paste is layer-wise extruded to form a part, which is then debound and sintered into a solid metal part. Although promising, BMD suffers from shrinkage-induced warpage and an inability to produce fine length scale features. This research addresses these problems by: (1) characterizing warpage of planar parts, and (2) developing a novel laser ablated process to create fine length scale features. First, a 12-factor resolution IV fractional-factorial design of experiments (DOE) was conducted to determine the warpage of planar parts as a function …
Development And Evaluation Of Modeling Approaches For Extrusion-Based Additive Manufacturing Of Thermoplastics, Christopher C. Bock
Development And Evaluation Of Modeling Approaches For Extrusion-Based Additive Manufacturing Of Thermoplastics, Christopher C. Bock
Electronic Theses and Dissertations
This work focuses on evaluating different modeling approaches and model parameters for thermoplastic AM, with the goal of informing more efficient and effective modeling approaches. First, different modeling approaches were tested and compared to experiments. From this it was found that all three of the modeling approaches provide comparable results and provide similar results to experiments. Then one of the modeling approaches was tested on large scale geometries, and it was found that the model results matched experiments closely. Then the effect of different material properties was evaluated, this was done by performing a fractional factorial design of experiments where …
Modelling, Sensing, And Control Of Weld Beads In Gravity Aligned And Non-Gravity Aligned Orientations For Wire Arc Additive Manufacturing, Joshua J. Penney
Modelling, Sensing, And Control Of Weld Beads In Gravity Aligned And Non-Gravity Aligned Orientations For Wire Arc Additive Manufacturing, Joshua J. Penney
Doctoral Dissertations
Wire Arc Additive Manufacturing (WAAM) has recently developed into a viable manufacturing process for large, complex metal parts. The WAAM process uses a Gas Metal Arc Welding (GMAW) torch mounted to an automated motion platform to execute a predetermined path plan based on a desired CAD geometry. As the desired geometry becomes more complex, it is advantageous to utilize out-of-position welding techniques used by human welders to stabilize the weld pool during the deposition of large overhangs. To ensure part accuracy and quality, adding layers of real-time control to manage various aspects of the WAAM process is critical. First, a …
Carbon Fiber Coil Spring Characterization And Manufacturing, Cooper Madrazo
Carbon Fiber Coil Spring Characterization And Manufacturing, Cooper Madrazo
UNLV Theses, Dissertations, Professional Papers, and Capstones
Helical coil springs are used in many mechanical design applications including industrial machines, devices, and vehicle suspension systems. It is desirable to minimize the weight of vehicle suspension systems as this can improve performance and handling. Most vehicle suspension coil springs are made from solid steel alloys or other metallic materials. Significant weight savings could be achieved if the metallic material were replaced by high performance fiber reinforced polymer composites. However, the coil spring geometry is a difficult manufacturing challenge for composite materials. The goal of this thesis was to investigate efficient and low-cost manufacturing methods to produce light-weight polymer …
Suitability Of Low-Cost Additive Manufacturing For Polymer Electrolyte Fuel Cells, David Alexander
Suitability Of Low-Cost Additive Manufacturing For Polymer Electrolyte Fuel Cells, David Alexander
Open Access Theses & Dissertations
The purpose of this dissertation is to study the feasibility of low-cost additive manufacturing to fabricate polymer electrolyte fuel cell bipolar plate materials. Traditional manufacturing techniques include molding, milling, hollow embossing, hydro-forming, rolling, and electromagnetic forming. These processes are employed when a design has been selected due to higher costs at low volumes. The combination of high initial costs and bipolar plates being the most expensive component of the polymer electrolyte fuel cell creates incentive to mitigate this obstacle. The feasibility of low-cost additive manufactured bipolar plates will be proven by fabrication, post-processing, and characterization of printed test specimen. The …
Material Synthesis And Machine Learning For Additive Manufacturing, Jaime Eduardo Regis
Material Synthesis And Machine Learning For Additive Manufacturing, Jaime Eduardo Regis
Open Access Theses & Dissertations
The goal of this research was to address three key challenges in additive manufacturing (AM), the need for feedstock material, minimal end-use fabrication from lack of functionality in commercially available materials, and the need for qualification and property prediction in printed structures. The near ultraviolet-light assisted green reduction of graphene oxide through L-ascorbic acid was studied with to address the issue of low part strength in additively manufactured parts by providing a functional filler that can strengthen the polymer matrix. The synthesis of self-healing epoxy vitrimers was done to adapt high strength materials with recyclable properties for compatibility with AM …
All-In-One Multi3d System: Exploring Potential Of 5-Axis Material Extrusion Additive Manufacturing, Angel Vega
All-In-One Multi3d System: Exploring Potential Of 5-Axis Material Extrusion Additive Manufacturing, Angel Vega
Open Access Theses & Dissertations
Additive Manufacturing (AM) has experienced consistent growth since its inception across its seven process categories, especially Material Extrusion (MEX) with systems that can be seen in commercial and industrial settings. As MEX evolves, innovation can be traced in the growing variety of available process materials and new system capabilities leading to greater interest in the technology across various industries including automotive, aerospace and even nuclear weapons. This has created an increasing demand for end-use parts from MEX systems leading to more complex machines with additional Degrees of Freedom (DoF), specialized workflows, and expanded post processing that address the drawbacks of …
Incorporating In-Situ Monitoring To Detect Anomalies In Additively Manufactured Kovar Steel On A Layer-To-Layer Basis, Matthew Aragon
Incorporating In-Situ Monitoring To Detect Anomalies In Additively Manufactured Kovar Steel On A Layer-To-Layer Basis, Matthew Aragon
Mechanical Engineering ETDs
Combining traditional methods of material analysis with in-situ monitoring of a Laser Powder Bed Fusion (LPBF) printed part, on a layer-to-layer basis, provides the data necessary to adjust printing parameters to achieve specific material properties. Additively manufactured technology has advanced in the ability to accommodate new materials and provide new use cases. Uncertainties in material properties have arisen alongside the advancements in additive manufacturing. The layer-wise print analysis will allow for detection and correlation of print anomalies to the material properties such as density, material strength, and surface roughness. The data processed from each layer will be used to further …
Vibration Bending Fatigue Analysis Of Additively Repaired Ti-6al-4v Airfoil Blades, Lucas Jordan Smith
Vibration Bending Fatigue Analysis Of Additively Repaired Ti-6al-4v Airfoil Blades, Lucas Jordan Smith
Browse all Theses and Dissertations
Repairing airfoil blades is necessary to extend the life of turbine engines. Directed energy deposition (DED) additive manufacturing (AM) provides the ability to add material at a specific location on an existing component. In this work, AM repairs on Ti-6Al-4V airfoil blades were analyzed to determine what effect the repair will have on the blade performance in high cycle vibration fatigue testing. Targeted sections were cut out of airfoil blades near high stress locations and repaired using DED. To understand the defects that arose with this type of repair, computed tomography imaging was used to quantify the defects from the …
Ljm Rc Baja Vehicle Project Chassis And Suspension, Paul Lervick
Ljm Rc Baja Vehicle Project Chassis And Suspension, Paul Lervick
All Undergraduate Projects
An RC car was designed, analyzed, and manufactured to compete in the ASME RC Baja competition. The focus was to optimize the suspension and chassis components to minimize the weight while maintaining the structural strength of the components which would intern supplement the overall speed and stability of the vehicle. Other components were the responsibility of the teammate Cam Jamison. To complete this there was extensive research done on Traxxas RC cars and what went into making a high-performing vehicle that would compete well in the 3 races that comprise the competition (slalom, sprint, and obstacle course). There were then …
Development Of Oxide Dispersion Strengthening (Ods) Alloys Powder For Additive Manufacturing, Changyu Ma
Development Of Oxide Dispersion Strengthening (Ods) Alloys Powder For Additive Manufacturing, Changyu Ma
Graduate Theses, Dissertations, and Problem Reports
Additive manufacturing (AM) fabricated oxide dispersion strengthened (ODS) alloys are given high expectations for critical structural components such as the first stage turbine blade for their excellent creep strength and oxidation resistance compared to superalloys. However, the powder feedstock processing is still an open question since current state-of-the-art processes are not capable of achieving ultrafine strengthening elements such as Y2O3 in powder which leads to agglomeration issues in as-consolidated alloys. In this research, the oxidation behavior and stability of ultrafine oxide in AM-printed alloys using mechanically alloyed powders were evaluated at 1100 oC. In addition, a …