Relating Processing Of Selective Laser Melted Structures To Their Material And Modal Properties,
2017
Missouri University of Science and Technology
Relating Processing Of Selective Laser Melted Structures To Their Material And Modal Properties, Nicholas E. Capps, James S. Urban, Brian M. West, Cody S. Lough, Adriane Repogle, Troy Hartwig, Ben Brown, Douglas A. Bristow, Robert G. Landers, Edward C. Kinzel
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Selective Laser Melting (SLM) creates metal parts by fusing powder layer-by-layer. It provides significant design flexibility and the possibility of low-volume production. The engineering properties of the printed metal are a function of the local thermal history. This creates challenges for validating Additively Manufactured (AM) parts. This paper correlates the engineering properties (density, modulus, yield strength and ultimate strength) for tensile test specimens created with different process parameters with the resonant frequencies determined using modal testing. The paper shows that yield and ultimate strengths for these specimens can be determined using modal analysis.
Effect Of Optimizing Particle Size In Laser Metal Deposition With Blown Pre-Mixed Powders,
2017
Missouri University of Science and Technology
Effect Of Optimizing Particle Size In Laser Metal Deposition With Blown Pre-Mixed Powders, Wei Li, Jingwei Zhang, Xinchang Zhang, Sreekar Karnati, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Functionally Graded Material (FGM) is often fabricated by Laser metal deposition with pre-mixed multiple powders (PMM-powder). Since the supplied PMM-powder directly affects FGM’s composition, investigation on PMM-powder’s property is greatly needed. This paper employed experimental method to observe an important problem: PMM-powder separation in fabricating FGM. A novel particle size optimization method was introduced as solution to eliminate the powder separation. Pre-mixed pure Cu and 4047 Al powders were used to do two experiments. The first experiment result disclosed the existence of powder separation. By optimizing the particle size, the PMM-powder separation was effectively solved in the second experiment result.
Mechanical Properties Of 304l Parts Made By Laser-Foil-Printing Technology,
2017
Missouri University of Science and Technology
Mechanical Properties Of 304l Parts Made By Laser-Foil-Printing Technology, Chia-Hung Hung, Yiyu Shen, Ming-Chuan Leu, Hai-Lung Tsai
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Laser-Foil-Printing (LFP) is a novel laminated object manufacturing process for metal additive manufacturing. It fabricates three-dimensional metal parts by using a dual-laser system to weld and cut metal foils layer by layer. A main advantage of LFP is the higher cooling rate compared to powder-based laser additive manufacturing processes due to the thermal conductivity difference between foil and powder. This study focuses on the mechanical properties of 304L stainless steel parts built by the LFP process. The experimental results indicate that the yield strength and ultimate tensile strength of LFP fabricated 304L SS parts are higher by 9% and 8% …
Development Of A Hybrid Manufacturing Process For Precision Metal Parts,
2017
Missouri University of Science and Technology
Development Of A Hybrid Manufacturing Process For Precision Metal Parts, Leon Hill, Todd E. Sparks, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
This paper summarizes the research and development of a hybrid manufacturing process to produce fully dense metal parts with CNC-level precision. High performance metals, such as titanium alloys, nickel superalloys, tool steels, stainless steels, etc. can benefit from this process. Coupling the additive and the subtractive processes into a multi-axis workstation, the hybrid process, can produce and repair metal parts with accuracy. The surface quality of the final product is similar to the industrial milling capability. To achieve such a system, issues of the metal deposition process and the automated process planning of the hybrid manufacturing process will be discussed.
Design And Fabrication Of Functionally Graded Material From Ti To Γ-Tial By Laser Metal Deposition,
2017
Missouri University of Science and Technology
Design And Fabrication Of Functionally Graded Material From Ti To Γ-Tial By Laser Metal Deposition, Xueyang Chen, Lei Yan, Joseph William Newkirk, Frank W. Liou
Materials Science and Engineering Faculty Research & Creative Works
Functionally graded material (FGM) is one kind of advanced material characterized by a gradual change in properties as the position varies. The spatial variation of compositional and microstructure over volume is aimed to control corresponding functional properties. In this research, when 100% γ-TiAl was directly deposited on pure Ti substrate, cracks were formed within the γ-TiAl layer. Then a six-layer crack-free functionally graded material of Ti/TiAl was designed and fabricated by laser metal deposition (LMD) method, with composition changing from pure Ti on one side to 100% γ-TiAl on the other side. The fabricated FGM was characterized for material properties …
Effects Of Area Fraction And Part Spacing On Degradation Of 304l Stainless Steel Powder In Selective Laser Melting,
2017
Missouri University of Science and Technology
Effects Of Area Fraction And Part Spacing On Degradation Of 304l Stainless Steel Powder In Selective Laser Melting, Cairlin S. Kriewall, Austin T. Sutton, Sreekar Karnati, Joseph William Newkirk, Ming-Chuan Leu
Materials Science and Engineering Faculty Research & Creative Works
In selective laser melting (SLM) systems, a large portion of powder remains unconsolidated and therefore recycling powder could make SLM more economical. Currently, a lack of literature exists specifically targeted at studying the reusability of powder. Furthermore, the definition of powder reusability is complex since powder degradation depends on many factors. The goal of the current research is to investigate the effects of area fraction and part spacing on the degradation of 304L powder in SLM. An experimental study was conducted where various area fractions and part distances were chosen and powder characterization techniques for determination of particle size distributions, …
Towards Defect Detection In Metal Slm Parts Using Modal Analysis "Fingerprinting",
2017
Missouri University of Science and Technology
Towards Defect Detection In Metal Slm Parts Using Modal Analysis "Fingerprinting", James Urban, Nick E. Capps, Brian M. West, Troy Hartwig, Ben Brown, Robert G. Landers, Douglas A. Bristow, Edward C. Kinzel
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The validation of Additively Manufactured (AM) materials is a difficult and expensive process because the local engineering properties are a function of the thermal history. The thermal history varies with the process parameters, as well as the part geometry. This paper presents a case study using modal testing to identify defects in realistic AM parts. A setup consisting of a Scanning Laser Doppler Vibrometer (LDV) was used to identify the resonant frequencies for several geometrically identical parts on a build plate. Parts with suboptimal process parameters from purposely varying the process parameters, are identified by a shift in the mode …
Studying Chromium And Nickel Equivalency To Identify Viable Additive Manufacturing Stainless Steel Chemistries,
2017
Missouri University of Science and Technology
Studying Chromium And Nickel Equivalency To Identify Viable Additive Manufacturing Stainless Steel Chemistries, Zachary T. Hilton, Joseph William Newkirk, Ronald J. O'Malley
Materials Science and Engineering Faculty Research & Creative Works
Chromium and nickel equivalency modeling has long been used in welding to determine the weldability of steel chemistries. A study was conducted to determine the applicability of Cr-Ni modeling to the additive manufacturing process. Many AM methods involve rapid solidification of small melt pools, similar to welding. Chemistries with varying Cr/Ni ratios were selected for use in a selective laser melting process and modeled using known models. Initial results indicate that the standard "safe welding zone" may not directly apply to additive manufacturing. The capability to build with chemistries outside the weldability “safe zone” could result in improved and varied …
Aluminum Matrix Syntactic Foam Fabricated With Additive Manufacturing,
2017
Missouri University of Science and Technology
Aluminum Matrix Syntactic Foam Fabricated With Additive Manufacturing, M. Spratt, Joseph William Newkirk, K. Chandrashekhara
Materials Science and Engineering Faculty Research & Creative Works
Syntactic foams are lightweight structural composites with hollow reinforcing particles embedded in a soft matrix. These materials have applications in transportation, packaging, and armor due to properties such as relatively high specific stiffness, acoustic dampening, and impact absorption. Aluminum matrices are the most widely studied of metal matrix syntactic foams, but there is little to no research in regards to processing the foams with additive manufacturing. It is theorized that the fast cooling rates and limited kinetic energy input of additive could reduce two issues commonly associated with processing syntactic foams: microsphere flotation in the melt and microsphere fracture during …
Characterization Of Heat-Affected Powder Generated During Selective Laser Melting Of 304l Stainless Steel Powder,
2017
Missouri University of Science and Technology
Characterization Of Heat-Affected Powder Generated During Selective Laser Melting Of 304l Stainless Steel Powder, Austin T. Sutton, Caitlin S. Kriewall, Ming-Chuan Leu, Joseph William Newkirk
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The selective laser melting (SLM) process is an Additive Manufacturing (AM) technique that uses a laser to fuse successive layers of powder into near fully dense components. Due to the large energy input from the laser during processing, vaporization and instabilities in the melt pool occur causing the formation of condensate and laser spatter, collectively known as heat-affected powder. Since heat-affected powder settles into the powder bed, the properties of the unconsolidated powder may be altered compromising its reusability. In this study, characterization of 304L heat-affected powder was performed through particle size distribution measurements, x-ray diffraction, metallography, energy-dispersive spectroscopy mapping, …
Influence Of Gage Length On Miniature Tensile Characterization Of Powder Bed Fabricated 304l Stainless Steel,
2017
Missouri University of Science and Technology
Influence Of Gage Length On Miniature Tensile Characterization Of Powder Bed Fabricated 304l Stainless Steel, Sreekar Karnati, Jack L. Hoerchler, Frank W. Liou, Joseph William Newkirk
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Miniature tensile specimens with varying aspect ratios were fabricated from 304L stainless steel (SS) made using powder bed additive manufacturing (AM) process. The tensile characteristics measured from these specimens were analyzed to assess the impact of gage length. The study found no impact upon varying gage length on yield and ultimate strength measurements. However, a significant impact was observed on strain measurements. This data was also used to perform Weibull statistics to estimate the stochastic performance of the material. Fractography was performed to visually identify the types of flaws. A comparative study with specimens fabricated from cold rolled annealed 304 …
Fabricating Zirconia Components With Organic Support Material By The Ceramic On-Demand Extrusion Process,
2017
Missouri University of Science and Technology
Fabricating Zirconia Components With Organic Support Material By The Ceramic On-Demand Extrusion Process, Wenbin Li, Amir Ghazanfari, Devin Mcmillen, Andrew Scherff, Ming-Chuan Leu, Greg Hilmas
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Ceramic On-Demand Extrusion (CODE) is an extrusion-based additive manufacturing process recently developed for fabricating dense, functional ceramic components. This paper presents a further development of this process and focuses on fabricating 3 mol% yttria-stabilized zirconia (3YSZ) components that cannot be fabricated without using support structures. The 3YSZ paste is deposited through the main nozzle, and a polycaprolactone (PCL) pellet feedstock is melted and deposited through an auxiliary nozzle to build support structures. After a green part is printed and dried, the support structures are removed by heating the part to ~70°C to melt the PCL. The part is then sintered …
Additive Manufacturing Of High Entropy Alloys -- A Review,
2017
Missouri University of Science and Technology
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.
Defects Classification Of Laser Metal Deposition Using Acoustic Emission Sensor,
2017
Missouri University of Science and Technology
Defects Classification Of Laser Metal Deposition Using Acoustic Emission Sensor, Haythem Gaja, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Laser metal deposition (LMD) is an advanced additive manufacturing (AM) process used to build or repair metal parts layer by layer for a range of different applications. Any presence of deposition defects in the part produced causes change in the mechanical properties and might cause failure to the part. In this work, defects monitoring system was proposed to detect and classify defects in real time using an acoustic emission (AE) sensor and an unsupervised pattern recognition analysis. Time domain and frequency domain, and relevant descriptors were used in the classification process to improve the characterization and the discrimination of the …
Additive Manufacturing Of High Solids Loading Hybrid Rocket Fuel Grains,
2017
Olivet Nazarene University
Additive Manufacturing Of High Solids Loading Hybrid Rocket Fuel Grains, Stephen P. Johnson, Michael Baier, Ibrahim E. Gunduz, Steven F. Son
The Summer Undergraduate Research Fellowship (SURF) Symposium
Hybrid rocket motors offer many of the benefits of both liquid and solid rocket systems. Like liquid engines, hybrid rocket motors are able to be throttled, can be stopped and restarted, and are safer than solid rocket motors since the fuel and oxidizer are in different physical states. Hybrid rocket motors are similar to solid motors in that they are relatively simple and have a high density-specific impulse. One of the major drawbacks of hybrid rocket motors is a slower burning rate than solid rocket motors. Complex port geometries provide greater burning surface area to compensate for lower burning rates …
Optimization And Control Of Production Of Graphene,
2017
Purdue University
Optimization And Control Of Production Of Graphene, Atharva Hans, Nimish M. Awalgaonkar, Majed Alrefae, Ilias Bilionis, Timothy S. Fisher
The Summer Undergraduate Research Fellowship (SURF) Symposium
Graphene is a 2-dimensional element of high practical importance. Despite its exceptional properties, graphene’s real applications in industrial or commercial products have been limited. There are many methods to produce graphene, but none has been successful in commercializing its production. Roll-to-roll plasma chemical vapor deposition (CVD) is used to manufacture graphene at large scale. In this research, we present a Bayesian linear regression model to predict the roll-to-roll plasma system’s electrode voltage and current; given a particular set of inputs. The inputs of the plasma system are power, pressure and concentration of gases; hydrogen, methane, oxygen, nitrogen and argon. This …
Impact Of Diy Home Manufacturing With 3d Printing On The Toy And Game Market,
2017
Michigan Technological University
Impact Of Diy Home Manufacturing With 3d Printing On The Toy And Game Market, Emily Peterson, Joshua M. Pearce
Department of Materials Science and Engineering Publications
The 2020 toy and game market is projected to be US$135 billion. To determine if 3D printing could affect these markets if consumers offset purchases by 3D printing free designs, this study investigates the 100 most popular downloaded designs at MyMiniFactory in a month. Savings are quantified for using a Lulzbot Mini 3D printer and three filament types: commercial filament, pellet-extruded filament, and post-consumer waste converted to filament with a recyclebot. Case studies probed the quality of: (1) six common complex toys; (2) Lego blocks; and (3) the customizability of open source board games. All filaments analyzed saved the user …
Maximizing Operating Room Performance Using Portfolio Selection,
2017
University of Kentucky
Maximizing Operating Room Performance Using Portfolio Selection, Vivek Reddy Gunna, Amin Abedini, Wei Li
Mechanical Engineering Faculty Publications
The operating room (OR) is responsible for most hospital admissions and is one of the most cost and work intensive areas in the hospital. From recent trends, we observe an ironic parallel increase among expenditure and waiting time. Therefore, improving OR scheduling has become obligatory, particularly in terms of patient flow and benefit. Most of the hospitals rely on average patient arrivals and processing times in OR planning. But in practice, variations in arrivals and processing times causes high instability in OR performance. Our model of optimization provides OR schedules maximizing patient flow and benefit at a fixed level of …
An Optimization Model For Operating Room Scheduling To Reduce Blocking Across The Perioperative Process,
2017
University of Kentucky
An Optimization Model For Operating Room Scheduling To Reduce Blocking Across The Perioperative Process, Amin Abedini, Wei Li, Honghan Ye
Mechanical Engineering Faculty Publications
Operating room (OR) scheduling is important. Because of increasing demand for surgical services, hospitals must provide high quality care more efficiently with limited resources. When constructing the OR schedule, it is necessary to consider the availability of downstream resources, such as intensive care unit (ICU) and post anaesthesia care unit (PACU). The unavailability of downstream resources causes blockings between every two consecutive stages. In this paper we address the master surgical schedule (MSS) problem in order to minimize blockings between two consecutive stages. First, we present a blocking minimization (BM) model for the MSS by using integer programming, based on …
Three Hundred And Sixty Degree Real-Time Monitoring Of 3-D Printing Using Computer Analysis Of Two Camera Views,
2017
Michigan Technological University
Three Hundred And Sixty Degree Real-Time Monitoring Of 3-D Printing Using Computer Analysis Of Two Camera Views, Siranee Nuchitprasitchai, Michael C. Roggemann, Joshua M. Pearce
Department of Materials Science and Engineering Publications
Prosumer (producing consumer)-based desktop additive manufacturing has been enabled by the recent radical reduction in 3-D printer capital costs created by the open-source release of the self-replicating rapid prototype (RepRap). To continue this success, there have been some efforts to improve reliability, which are either too expensive or lacked automation. A promising method to improve reliability is to use computer vision, although the success rates are still too low for widespread use. To overcome these challenges an open source low-cost reliable real-time optimal monitoring platform for 3-D printing from double cameras is presented here. This error detection system is implemented …
