Mechanical Engineering Commons^™

Cobalt Chromium In Biomedical Applications And The Development Of A Pspp Map, Nouralhouda Jamal

Bagley College of Engineering Publications and Scholarship

During the world wars, Cobalt-Chromium (Co-Cr) alloys gained prominence for their use in aircraft engine components, where they exhibited high temperature strength and durability. They are used in a wide range of industries due to their unique set of qualities, particularly strength, corrosion resistance, and biocompatibility. They have emerged as versatile materials with a broad spectrum of applications, from aerospace and automotive components to biomedical implants.

This paper presents a thorough analysis of its composition, processing techniques, microstructure, mechanical properties, and performance characteristics. The primary goal of this project is to develop a PSPP (Process, structure, properties, and performance) map …

Additive Manufacturing For Medical Education, Michael Noon

College of Engineering Summer Undergraduate Research Program

A growing body of evidence is suggesting that anatomical knowledge, the keystone of many medical specialties, is suffering among new graduates. While a host of reasons are provided, one common thread that many point to is the decline of cadaver dissections in the classroom. Many virtual audio-visual tools are used to address this gap, yet evidence has shown their ineffectiveness. Given this gap, the high degree of flexibility found in additive manufacturing (AM), and the many uses AM has already found in the medical field, we propose its use to fill this gap, allowing for students to learn with touch …

Prediction Of Meltpool Depth In Laser Powder Bed Fusion Using In-Process Sensor Data, Part-Level Thermal Simulations, And Machine Learning, Grant King

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

The goal of this thesis is the prevention of flaw formation in laser powder bed fusion additive manufacturing process. As a step towards this goal, the objective of this work is to predict meltpool depth as a function of in-process sensor data, part-level thermal simulations, and machine learning. As motivated in NASA's Marshall Space Flight Center specification 3716, prediction of meltpool depth is important because: (1) it can serve as a surrogate to estimate process status without the need for expensive post-process characterization, and (2) the meltpool depth provides an avenue for rapid qualification of microstructure evolution. To achieve the …

Minimax Registration For Point Cloud Alignment, Zhaohui Geng, Mauro Garcia, Bopaya Bidanda

Manufacturing & Industrial Engineering Faculty Publications and Presentations

The alignment, or rigid registration, of three-dimensional (3D) point clouds plays an important role in many applications, such as robotics and computer vision. Recently, with the improvement in high precision and automated 3D scanners, the registration algorithm has become critical in a manufacturing setting for tolerance analysis, quality inspection, or reverse engineering purposes. Most of the currently developed registration algorithms focus on aligning the point clouds by minimizing the average squared deviations. However, in manufacturing practices, especially those involving the assembly of multiple parts, an envelope principle is widely used, which is based on minimax criteria. Our present work …

Grey-Taguchi Approach To Optimize Fused Deposition Modeling Process In Terms Of Mechanical Properties And Dimensional Accuracy, Md Asif Bin Syed, Qausar Rhaman, Hasan Md Shahriar, Mohammad Muhshin Aziz Khan

Graduate Student Scholarship

Fused Deposition Modeling (FDM) is a process that allows for the rapid production of functional parts through the deposition of fused material layers in a sequential manner. FDM has flexibility and the potential to create complicated parts. This study aims to optimize the FDM process parameters in terms of tensile strength, flexural strength, and longitudinal shrinkage using the Grey-Taguchi approach. The input parameters chosen to study the effects on dimension and mechanical properties are layer thickness, the raster angle, fill density, the number of contours, printing temperature, and printing speed. The Taguchi L27 orthogonal array is used as the statistical …

Workforce Development Strategies In Additive Manufacturing, Mel Cossette, Ismail Fidan, Gaffar Gailani, Angran Xiao

Publications and Research

Additive Manufacturing (AM), also known as 3D Printing (3DP), is one of the newest manufacturing technologies with growing utilization in our daily life. Parallel to this growth, new materials, machines, and specific processes are being developed to produce parts in better-finished quality, at lower cost, and with shorter production time. However, workforce education in this evolving field has not advanced at the same pace as the technology, lacking proven curriculums, high-quality/accredited degree programs, and specialized advanced degrees. In this paper, some best practices established by the authors are introduced. The list is far from exhaustive but is proven to be …

Fabricating Tinicu Ternary Shape Memory Alloy By Directed Energy Deposition Via Elemental Metal Powders, Yitao Chen, Xinchang Zhang, Mohammad Masud Parvez, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In this paper, a TiNiCu shape memory alloy single-wall structure was fabricated by the directed energy deposition technique with a mixture of elemental Ti, Ni, and Cu powders following the atomic percentage of Ti50Ni45Cu5 to fully utilize the material flexibility of the additive manufacturing process to develop ternary shape memory alloys. The chemical composition, phase, and material properties at multiple locations along the build direction were studied, using scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, Vickers hardness test-ing, tensile testing, and differential scanning calorimetry. The location-dependent compositions of martensitic TiNi and austenitic TiNi phases, mechanical properties, and functional properties …

Real-Time Monitoring Of Fdm 3d Printer For Fault Detection Using Machine Learning: A Bibliometric Study, Vaibhav Kisan Kadam, Satish Kumar, Arunkumar Bongale

Library Philosophy and Practice (e-journal)

Additive Manufacturing has wide application range including healthcare, Fashion, Manufacturing, Prototypes, Tooling etc. AM techniques are subjected to various defects that may be printing defects or anomalies in machine. There is gap between current AM techniques and smart manufacturing since current AM lacks in build sensors necessary for process monitoring and fault detection. Both of these issues can be solved by incorporating real-time monitoring into AM. So the study is carried out to identify recent work done in AM to improve current system. For this bibliometric study Scopus database is used, study is kept limited to year 2010-2021 and English …

Effects Of Process Parameters And Meso-Structures On Dissipative Properties Of Additively Manufactured Structures, Peter Berube

Honors College

With approximately 5.9 million vehicular collisions in the United States per year, the ability of a vehicle to absorb energy during a collision is critical to reducing the likelihood and severity of injuries. A primary means to absorb energy during a collision is a crush tube, which is a predominantly-prismatic-shaped, metallic structure located at the front or rear of a vehicle intended to absorb energy by progressively buckling in addition to dissipating energy, crush tubes must be light weight to reduce vehicular green-house gas emissions, resilient to fatigue, resilient to environmental exposure, and economically feasible to manufacture. Historically, these competing …

The Corrosion Of Stainless Steel Made By Additive Manufacturing: A Review, Gyeongbin Ko, Wooseok Kim, Kyungjung Kwon, Tae-Kyu Lee

Mechanical and Materials Engineering Faculty Publications and Presentations

The advantages of additive manufacturing (AM) of metals over traditional manufacturing methods have triggered many relevant studies comparing the mechanical properties, corrosion behavior, and microstructure of metals produced by AM or traditional manufacturing methods. This review focuses exclusively on the corrosion property of AM-fabricated stainless steel by comprehensively analyzing the relevant literature. The principles of various AM processes, which have been adopted in the corrosion study of stainless steel, and the corrosion behaviors of stainless steel depending on the AM process, the stainless steel type, and the corrosion environment are summarized. In this comprehensive analysis of relevant literature, we extract …

Absorption Of Nitrogen During Pulsed Wave L-Pbf Of 17-4 Ph Steel, Ben Brown, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In the fabrication of 17-4 PH by laser powder bed fusion (L-PBF) the well-documented occurrence of large amounts of retained austenite can be attributed to an elevated concentration of nitrogen present in the material. While the effects of continuous wave (CW) laser processing on in-situ nitrogen absorption characteristics have been evaluated, power modulated pulsed wave (PW) laser processing effects have not. In this study the effects of PW L-PBF processing of 17-4 PH on nitrogen absorption, phase composition, and mechanical performance are explored using commercially available PW L-PBF equipment and compared to samples produced by CW L-PBF. PW L-PBF samples …

Rheology Of Particulate Suspensions With Non-Newtonian Fluids In Capillaries, Bin Xia, Paul Krueger

Mechanical Engineering Research

This resource contains the processed experimental measurements of the flow consistency index and flow behavior index, along with their trendlines, for the particulate suspensions investigated in "Rheology of Particulate Suspensions with Non-Newtonian Fluids in Capillaries" by Bin Xia and Paul S. Krueger.

Additive Manufacturing And How 3d Printing Is Fighting Covid-19, Raghavan Srinivasan, Ahsan Mian, Joy Gockel, Laura M. Luehrmann

Mechanical and Materials Engineering Faculty Publications

This is the fourth installment in the Shelter in Place (SiP) Lecture series. This installment covers the creative ways that 3D printing has supported efforts to combat the pandemic. It covers the basics of what 3D printing is, some of the various creative projects that have used 3D printing to combat the pandemic, among other topics and questions by the pandemic.

Thermal Modeling Of Additive Manufacturing Using Graph Theory: Validation With Directed Energy Deposition, Jordan Severson

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Metal additive manufacturing (AM/3D printing) offers unparalleled advantages over conventional manufacturing, including greater design freedom and a lower lead time. However, the use of AM parts in safety-critical industries, such as aerospace and biomedical, is limited by the tendency of the process to create flaws that can lead to sudden failure during use. The root cause of flaw formation in metal AM parts, such as porosity and deformation, is linked to the temperature inside the part during the process, called the thermal history. The thermal history is a function of the process parameters and part design.

Consequently, the first step …

A Displacement Controlled Fatigue Test Method For Additively Manufactured Materials, Mohammad Masud Parvez, Yitao Chen, Sreekar Karnati, Connor Coward, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

A novel adaptive displacement-controlled test setup was developed for fatigue testing on mini specimens. In property characterization of additive manufacturing materials, mini specimens are preferred due to the specimen preparation, and manufacturing cost but mini specimens demonstrate higher fatigue strength than standard specimens due to the lower probability of material defects resulting in fatigue. In this study, a dual gauge section Krouse type mini specimen was designed to conduct fatigue tests on additively manufactured materials. The large surface area of the specimen with a constant stress distribution and increased control volume as the gauge section may capture all different types …

A Framework For Process Inspection Of Metal Additive Manufacturing, Chih-Kun Cheng, Frank W. Liou, Yi-Chien Cheng, Sheng-Chih Shen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In this paper, we propose a process inspection framework for metal additive manufacturing (AM) processes. AM, also known as 3D printing, is the process of joining materials to make objects on the basis of 3D model data and is envisioned to play a strategic role in maintaining economic and scientific dominance. Different from conventional manufacturing methods, the AM process is a point-by-point and layer-by-layer manufacturing. Thus, there are many opportunities to generate a process error that can cause quality issues in an AM part. A systematic AM process inspection is needed to yield acceptable performance of the part. The critical …

Design Rules For Additive Manufacturing – Understanding The Fundamental Thermal Phenomena To Reduce Scrap, M. Reza Yavari, Kevin D. Cole, Prahalada K. Rao

Department of Mechanical and Materials Engineering: Faculty Publications

The goal of this work is to predict the effect of part geometry and process parameters on the direction and magnitude of heat flow heat flux in parts made using metal additive manufacturing (AM) processes. As a step towards this goal, the objective of this paper is to develop and apply the mathematical concept of heat diffusion over graphs to approximate the heat flux in metal AM parts as a function of their geometry. This objective is consequential to overcome the poor process consistency and part quality in AM. Currently, part build failure rates in metal AM often exceed 20%, …

The Influence Of Build Parameters On The Compressive Properties Of Selective Laser Melted 304l Stainless Steel, Okanmisope Fashanu, Mario F. Buchely, R. Hussein, S. Anandan, Myranda Spratt, Joseph William Newkirk, K. Chandrashekhara, H. Misak, M. A. Walker

Materials Science and Engineering Faculty Research & Creative Works

Process parameters used during Selective Laser Melting (SLM) process have significant effects on the mechanical properties of the manufactured parts. In this study, the influence of two build parameters (build orientation and hatch angle) on the compressive properties of 304L stainless steel was evaluated. SLM 304L samples were manufactured using three hatch angles, 0°, 67°,105° and two orientations, z-direction and x-direction, and tested using a compression frame according to ASTM E9-09. Bulk density was measured according to ASTM C373-17 before compression. Properties evaluated were the bulk density, yield strength, strength at 15% plastic-strain and strength at 30% plastic-strain. Results showed …

Additive Manufacturing Of Metal Functionally Graded Materials: A Review, Yitao Chen, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Functionally graded materials (FGMs) have attracted a lot of research interest due to their gradual variation in material properties that result from the non-homogeneous composition or structure. Metal FGMs have been widely researched in recent years, and additive manufacturing has become one of the most important approaches to fabricate metal FGMs. The aim of this paper is to review the research progress in metal FGMs by additive manufacturing. It will first introduce the unique properties and the advantages of FGMs. Then, typical recent findings in research and development of two major types of metal additive manufacturing methods, namely laser metal …

Design Of Lattice Structures With Graded Density Fabricated By Additive Manufacturing, Wenjin Tao, Yong Liu, Austin T. Sutton, Krishna C. R. Kolan, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Lattice structures fabricated by Additive Manufacturing (AM) processes are promising for many applications, such as lightweight structures and energy absorbers. However, predicting and controlling of their mechanical behaviors is challenging due to the complexity of modeling and the uncertainties exist in the manufacturing process. In this paper, we explore the possibilities enabled by controlling the local densities. A set of lattice structures with different density gradients are designed using an implicit isosurface equation, and they are manufactured by Selective Laser Melting (SLM) process with 304L stainless steel. Finite element analysis and compression test are used to evaluate their mechanical properties. …

Additive Manufacturing Of High Entropy Alloys -- A Review, Wenyuan Cui, Xinchang Zhang, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

High-entropy alloys have attracted increasingly interest due to their unique compositions, microstructures and mechanical properties. Additive manufacturing has been recognized as a promising technology to fabricate the high-entropy alloys in the recent years. The purpose of this paper is to review the current research progress in high-entropy alloys by additive manufacturing process. It will first highlight the important theory of the high-entropy alloys. The next aspect is to summarize current additive manufacturing methods applied for the high entropy alloys. At last, the correlation between the microstructures and the mechanical properties of the high-entropy alloys will be examined and discussed.

Experimental Investigation Of Effect Of Environment Temperature On Freeze-Form Extrusion Fabrication, Xiyue Zhao, Michael S. Mason, Tieshu Huang, Ming-Chuan Leu, Robert G. Landers, Greg Hilmas, Samuel J. Easley, Michael W. Hayes

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Freeze-form Extrusion Fabrication (FEF) is an additive manufacturing technique that extrudes ceramic loaded aqueous pastes layer by layer below the paste freezing temperature for component fabrication. A computer controlled 3-D gantry system has been developed for the FEF process. The system includes a temperature control subsystem that allows for fabrication of components below the paste freezing temperature. The low temperature environment allows for larger component fabrication. Comparisons in terms of layer thickness, self-sustaining ability, and system response were performed between 0⁰C and -20⁰C for alumina sample fabrications. The minimum deposition angles without use of support material have been determined for …