Mechanical Engineering Commons^™

Investigation Of 2195 And 2219 Post Weld Heat Treatments For Additive Friction Stir Lap Welds, Matthew Champagne

University of New Orleans Theses and Dissertations

To evaluate potential uses for friction stir welding in additive manufacturing, two separate parts were fabricated, one of 2195-T84 and the other 2219-T87, utilizing fixed pin techniques and additive lap welds. The parts were cut into samples, artificially aged and subjected to Rockwell hardness (HRB), Vickers hardness, micrographic photography, and metallographic imaging on both pre- and post- heat treatment. Additionally, tensile testing was performed on the heat-treated samples. A comparisons of test results showed a minimal increase in the yield strength of the 2195-T84 samples compared to as-welded tensile results obtained from a previous project. The ultimate tensile strength was …

Large Area Sintering Test Platform Design And Preliminary Study On Cross Sectional Resolution, Christopher J. Gardiner

USF Tampa Graduate Theses and Dissertations

Additive manufacturing involves the layer-wise patterned addition of material to create 3D parts, allowing for parts with complex geometries that traditional subtractive manufacturing processes cannot create, while offering good value for low run production parts by eliminating the cost of tooling. Large Area Sintering is a form of powder based additive manufacturing where entire layer cross sections are heated and fused in a single continuous exposure process. This layer by layer powder sintering process is similar to selective laser sintering, but by heating the cross section at a slower and controllable rate there is an opportunity to achieve tighter control …

Effects Of Support Structure Geometry On Slm Induced Residual Stresses In Overhanging Features, Ryan Baskett

Master's Theses

Selective laser melting (SLM) is a new and rapidly developing manufacturing method for producing full-density, geometrically complex metal parts. The SLM process is time and cost effective for small-scale production; however, wide-spread adoption of this technique is severely limited by residual stresses that can cause large deformations and in-process build failures. The issues associated with residual stress accumulation are most apparent in parts with overhanging features. Due to the complexity of the SLM process, the accumulation of residual stresses is difficult to assess a priori. The deformations and in-process failures caused by residual stress accumulation often lead to an expensive …

Effect Of Composition And Build Direction On Additively Manufactured Hastelloy X Alloys, Justin A. Spitzer, Jeffrey T. Schloetter, Sarah Zerga

Materials Engineering

Microcracking has caused premature failure and reduction in properties in additively manufactured (AM) Hastelloy X. The purpose of this research is to meet or exceed the mechanical properties of wrought Hastelloy X by modifying the composition and build direction of Hastelloy X manufactured using Direct Metal Deposition (DMD). Tensile testing, scanning electron microscopy (SEM), and metallography were performed on the samples. ANOVA was used to analyze the dependence that the properties had on build direction and composition. The nominal composition wrought samples had a yield strength of 310.1 MPa and a 60.79% Elongation. Alloy P60-X18 in a horizontal build had …

High-Throughput Tensile Testing Reveals Stochastic Properties In Additively Manufactured Steel, Bradley C. Salzbrenner

Mechanical Engineering ETDs

An adage within the Additive Manufacturing (AM) community is that “complexity is free”. Complicated geometric features that normally drive manufacturing cost and limit design options are not typically problematic in AM. While geometric complexity is usually viewed from the perspective of part design, this advantage of AM also opens up new options in rapid, efficient material property evaluation and qualification. This Thesis demonstrates how 100’s of miniature tensile bars can be produced and tested for comparable cost and in comparable time to a few conventional tensile bars. With this technique, it is possible to evaluate the stochastic nature of mechanical …

Design Optimization For Heat Dissipation In Polymer Additive Manufacturing With Joule Heating, Tania Alejandra Ventura

Open Access Theses & Dissertations

Nowadays, the use of additive manufacturing (AM) is mainly focused on the production of prototypes with the purpose of evaluating a design. This industry has become a subject of constant reinvention; in fact, an emerging application of AM is focused on creating parts with embedded electronics. However, the development of both traditional and additive manufactured electronics has led to an increase in power densities and size reduction. Consequently, thermal management has become essential in electronics, as overheating decreases reliability of the component leading to a premature failure.

In this study, a polycarbonate component design with integral electrical circuitry that is …

Low Velocity Impact And Rf Response Of 3d Printed Heterogeneous Structures, Sandeep Keerthi

Browse all Theses and Dissertations

Three-dimensional (3D) printing, a form of Additive manufacturing (AM), is currently being explored to design materials or structures with required Electro-Mechanical-Physical properties. Microstrip patch antennas with a tunable radio-frequency (RF) response are a great candidate for 3D printing process. Due to the nature of extrusion based layered fabrication; the processed parts are of three-layer construction having inherent heterogeneity that affects structural and functional response. The purpose of this study is to identify the relationship between the anisotropy in dielectric properties of AM fabricated acrylonitrile butadiene styrene (ABS) substrates in the RF domain and resonant frequencies of associated patch antennas and …

Comprehensive Finite Element Modeling Of Ti-6al-4v Cellular Solids Fabricated By Electron Beam Melting, Edel Arrieta

Open Access Theses & Dissertations

Additive manufacturing permits the fabrication of cellular metals which are materials that can be highly customizable and possess multiple and extraordinary properties such as damage tolerance, metamorphic and auxetic behaviors, and high specific stiffness. This makes them the subject of interest for innovative applications. With interest in these materials for energy absorption applications, this work presents the development of nonlinear finite element models in commercial software platforms (MSC Patran/Nastran) that permit the analysis of the deformation mechanisms of these materials under compressive loads. In the development of these models, a detailed multiscale study on the different factors affecting the response …

Additive Manufacturing Of Glass Using A Filament Fed Process, Junjie Luo

Doctoral Dissertations

"There are many scientific and engineering applications of glass including optics, communications, electronics, and hermetic seals, there has been minimal research towards the Additive Manufacturing (AM) of transparent glass parts. The special thermal and optical properties of glasses make them hard to be printed using conventional AM techniques. In this dissertation, two different AM techniques for glass AM were developed, Selective Laser Melting (SLM) and filament fed process.

Semi-transparent parts were printed with SLM process. However, the filament fed process was found to be more robust and promising for printing optically transparent glass parts. Therefore, this dissertation is focused on …

Error Mapping Of Build Volume In Selective Laser Melting, Ninad Kulkarni

Masters Theses

“Selective laser melting is one of the commonly used additive manufacturing processes employed for production of functional part. Therefore, quality aspects such as dimensional accuracy have become a point of great interest. Like all of the other additive manufacturing processes selective laser melting process suffers from the issue if having wide range of process parameters making the process control a complex task. Additionally, issues specific to the selective laser melting process such as position dependency of accuracy of the part, makes it difficult to predict the resulting dimensional inconsistencies in the part manufactured by this processes. This research is an …

Design And Development Of A Foil Application Tool For A Foil Embedding Process In The Multi3d Manufacturing System, Betty Elizabeth Mckenzie

Open Access Theses & Dissertations

Additive manufacturing (AM) encompasses different technologies, including material extrusion 3D printing, a technology commonly referred to as fused deposition modeling (FDM), which is the focus of the work described in this manuscript. Additive manufacturing is a growing technology with many applications in numerous fields from the air force to medical offices. FDM is a process that uses thermoplastics, in this case polycarbonate (PC), where the PC is heated and selectively dispensed in a layer-by-layer process to create a 3D printed part. Currently, FDM systems have advantages over subtractive manufacturing or machining because cavities and other components (e.g., microchips, valves, and …

On-Orbit Autonomous Repair: Systems Design And Project Management Of The Orbital Factory Ii Cube-Satellite, Mike Louis Everett

Open Access Theses & Dissertations

In 2016, a group of faculty, staff and students from the University of Texas at El Paso submitted a formal entry to the ULA CubeCorp competition to launch a 1U Cube Satellite into Orbit. In September of 2016, the team was awarded a launch opportunity to a prestigious GTO orbit to test and validate electrically conductive printing on within the Van Allen Radiation belts. This Dissertation is focused upon the management plan and specific decision that were implemented to accomplish this goal within a one year time frame and on a conservative budget.

In 2018 this satellite will launch aboard …

Design And Testing Of Scalable 3d-Printed Cellular Structures Optimized For Energy Absorption, Sagar Dilip Sangle

Browse all Theses and Dissertations

Sandwich panel structures are widely used due to their high compressive and flexural stiffness and strength-to-weight ratios, good vibration damping, and low through-thickness thermal conductivity. These structures consist of solid face sheets and low-density cellular core structures that are often based upon honeycomb topologies. Interest in additive manufacturing (AM), popularly known as 3D printing (3DP), has rapidly grown in past few years. The 3DP method is a layer-by-layer approach for the fabrication of 3D objects. Hence, it is very easy to fabricate complex structures with complex internal features that cannot be manufactured by any other fabrication processes. Due to the …

Low-Velocity Impact Behavior Of Sandwich Panels With 3d Printed Polymer Core Structures, Andrew Joseph Turner

Browse all Theses and Dissertations

Sandwich panel structures are widely used in aerospace, marine, and automotive applications because of their high flexural stiffness, strength-to-weight ratio, good vibration damping, and low through-thickness thermal conductivity. These structures consist of solid face sheets and low-density cellular core structures, which are often based upon honeycomb topologies. The recent progress of additive manufacturing (AM) (popularly known as 3D printing) processes has allowed lattice configurations to be designed with improved thermal-mechanical properties. The aim of this work is to design and print lattice truss structures (LTS) keeping in mind the flexible nature of AM. Several 3D printed core structures were created …

Resilience And Toughness Behavior Of 3d-Printed Polymer Lattice Structures: Testing And Modeling, Mohammed Al Rifaie

Browse all Theses and Dissertations

This research focuses on the energy absorption capability of additively manufactured or 3D printed polymer lattice structures of different configurations. The Body Centered Cubic (BCC) lattice structure is currently being investigated by researchers for energy absorption applications. For this thesis, the BCC structure is modified by adding vertical bars in different arrangements to create three additional configurations. Four designs or sets of the lattice structure are selected for comparison including BCC, BCC with vertical bars added to all nodes (BCCV), BCC with vertical bars added to alternate nodes (BCCA), and BCC with gradient arrangements of vertical bars (BCCG). Both experimental …

Shape Memory Behavior Of Dense And Porous Niti Alloys Fabricated By Selective Laser Melting, Soheil Saedi

Theses and Dissertations--Mechanical Engineering

Selective Laser Melting (SLM) of Additive Manufacturing is an attractive fabrication method that employs CAD data to selectively melt the metal powder layer by layer via a laser beam and produce a 3D part. This method not only opens a new window in overcoming traditional NiTi fabrication problems but also for producing porous or complex shaped structures. The combination of SLM fabrication advantages with the unique properties of NiTi alloys, such as shape memory effect, superelasticity, high ductility, work output, corrosion, biocompatibility, etc. makes SLM NiTi alloys extremely promising for numerous applications.

The SLM process parameters such as laser power, …