Manufacturing Commons^™

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Parts, Logan Trimmer

Harrisburg University Other Works

Presentation covering the broad strokes of the project. The goal was to prove the viability of hybrid/additive manufacturing for high stress automotive applications. This project focused on recreating a piston from an old engine to examine if hybrid manufacturing could be used for such applications. On a small scale, hybrid manufacturing was able to be more cost effective if the costs of the equipment and electricity were ignored. The decision to ignore those costs came from the inability to find accurate prices for industrial casting.

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Components, Logan Trimmer

Harrisburg University Other Works

The goal of this research was to establish the viability of using hybrid manufacturing for automotive applications. By verifying that high-stress components can be created, it can be assumed that any other lower stress part could be made to match the strength requirements. A limiting factor of adoption for hybrid manufacturing is how new the technology is. Studies on time and cost were performed allowing for comparisons with traditional manufacturing technologies (casting, forging, milling) used in automotive applications. This research utilized a Haas Automation UMC750 5-axis CNC mill with a Meltio laser wire direct energy deposition attachment. Fusion 360 was …

Pin-Plane Electrical Discharge Driven By A Mosfet Dc Current Source, Myles Perry, Sidmar Holoman, Daniel Wozniak, Shirshak Kumar Dhali

Electrical & Computer Engineering Faculty Publications

The generation of atmospheric pressure nonequilibrium plasma using electrical discharges is an active area of research due to its significance in a wide spectrum of applications including medicine, combustion, and manufacturing. In our attempt to create a helium plasma jet in a pin-plane discharge with a constant current source, we observed self-pulsating behavior. We present the results of the electrical, optical, and spectroscopic measurements carried out to characterize the discharge. The duration of the discharge is a few tens of nanoseconds, and the repetition rate is in the few tens of kHz. The effect of the gap distance and gas …

Numerical Simulation Of Micro-Cutting Processes For The Estimation Of Material Fracture Toughness, Juan J. Lainez

Graduate Studies Theses and Dissertations 2026

Accurate determination of plane-strain fracture toughness is essential for structural integrity assessments of engineering components, yet conventional ASTM standardized testing methods require large, notched specimens that are impractical in many industrial and research contexts. This thesis presents a finite element method-based approach for estimating the mode I plane-strain fracture toughness of engineering materials from orthogonal micro-cutting simulations if the continuum damage mechanics-based fracture locus is calibrated. This method will eliminate the need for pre-cracked specimens while maintaining physically grounded fracture mechanics principles. The methodology applies to the Atkins energy-based cutting force model, in which the depth-independent intercept of the specific …

Multi-Criteria Decision Making Methods In The Organisations' Maturity Assessment: Prisma And Delphi Techniques Perspectives, Jailos Mrisho Mzumile, Victoria Mahabi, Ismail W. R. Taifa

Tanzania Journal of Engineering and Technology (TJET)

Researchers often find it challenging to identify the appropriate Multi-Criteria Decision Making Methods (MCDM) to employ in various research areas that involve prioritising conflicting alternatives or criteria. A systematic literature review was conducted using the PRISMA technique to determine the most frequently and commonly employed MCDM methods in assessing organisational maturity across its functional areas. A total of 120 articles were identified for review, and a bibliometric analysis was conducted to map the relationships within the identified articles using VOSviewer 1.6.20 software. Moreover, frequent content analysis was performed to determine the most frequently employed MCDM methods in assessing an organisation’s …

Virtual Process Modeling Of Metal Additive Manufacturing Basedon Direct Energy Deposition In-Situ Failure, Jachin J. Ramirez

2025 Fall Honors Capstones Projects - Archive

This study builds a mesoscale finite element simulation to examine how internal stresses form during additive metal manufacturing using directed energy deposition. The goal is to track how heat and stress develop layer by layer and determine where a failure criterion could appear during the print. The model uses temperature-dependent material properties for Inconel 718 and a moving heat source defined with custom G-code.

Thermal results are mapped into a mechanical simulation to watch stress accumulate as new layers are added. Different scan paths were tested to determine whether varying heat exposure could reduce the extent of a region exceeding …

Design And Development Of Evacuated Photovoltaic-Thermal Systems For Efficient Cogeneration Of Heat And Electricity, Behnam Roshanzadeh

Mechanical Engineering ETDs

In conventional PV systems, most of the solar energy is dissipated into the environment as heat. Accordingly, hybrid Photovoltaic-thermal systems have been developed to utilize the waste heat from PV cells for various thermal applications. However, most PVT systems suffer from low thermal performance compared to solar thermal collectors, as the absorber plate in PVT systems is partially or fully covered by PV cells. This dissertation focuses on improving the thermal performance of PVT systems by introducing the evacuated PVT systems.

An evacuated-tube PVT system was designed and simulated for domestic hot water supply. The evacuated-tube PVT system demonstrated 40% …

Influence Of Build Plate Location On Tensile Properties And Residual Stresses In Lpbf-Fabricated Stainless Steel 316 Components, Yareli Zelaya Pavón

Honors Program Theses and Research Projects

Additive manufacturing (AM), particularly Laser Powder Bed Fusion (LPBF), enables rapid production of complex metal components with minimal waste. Stainless Steel 316 (SS316) is widely used in engineering applications due to its corrosion resistance and mechanical reliability. This study investigates the influence of build plate location on tensile properties and residual stresses in LPBF-fabricated SS316. Twelve tensile specimens and nine unsupported bridge structures were fabricated at different build plate positions using a “machine model.” Tensile testing provided stress-strain data to evaluate peak stress, elastic modulus, and strain at break, while bridge curvature measurements quantified residual stress through warping. Results indicate …

Experimental And Numerical Study On The Influence Of Carbon Fiber Reinforcement On The In-Plane Compressive Properties Of 3d Printed Hexagonal Honeycomb Core Structures, Deon Wallace

All Theses

There is difficulty with numerically replicating the behavior of composite honeycomb core structures numerically due to the trouble of gathering material properties from a hollow structure. Also, complex part geometries and carbon fiber reinforcement strategies can lead to unwanted structural weaknesses and variance in material properties that may not be reflected in numerical analysis when the part is additively manufactured. In this study, edgewise compressive testing is used to characterize the mechanical behavior and performance characteristics of these structures. The experimental results indicate an increase in the Young’s moduli of the honeycomb core structures as carbon fiber concentration increases. However, …

Multi-Criteria Decision-Making For Sustainable Design: Stakeholder Prioritization And Methodological Comparison In Solar And E-Bike Applications, Swagath Madhu Gowda

All Theses

This thesis focuses on using Multi-Criteria Decision-Making (MCDM) methods to support sustainable product design by addressing the trade-offs between environmental, economic, and social goals. The research is presented through two studies that demonstrate how both subjective and objective decision-making approaches can guide sustainability evaluations.

The first study applies the Analytic Hierarchy Process (AHP) to assess residential solar panels by incorporating stakeholder perspectives from sustainability experts, end users, and industry professionals. Using Life Cycle Sustainability Assessment (LCSA) data, this study identifies how different stakeholder groups prioritize sustainability criteria and applies Aggregation of Individual Priorities (AIP) to combine their judgments. A one-at-a-time …

Origami-Inspired Pneumatic Soft Robotic Gripper, Conor J. Schott

Master's Theses

This thesis presents the design and evaluation of a vacuum-actuated, origami-based soft robotic gripper. A custom Sea Urchin crease pattern forms a lightweight folding skeleton that collapses radially under vacuum. The system emphasizes low cost and accessibility through laser cutting, 3D printing, and silicone molding. The Sea Urchin geometry was selected after digital and physical screening of candidate crease patterns for smooth folding, low strain concentration, and uniform inward motion. The folding skeleton is laser cut from 4 mil drafting film and folded into a compliant core. Four membrane configurations were developed: an origami gripper with a 36-inch balloon (Design …

Detecting Non-Axisymmetric Instabilities In Fluid-Based Manufacturing Via Multi-View Tensor Analysis., Bidusi Khadka

Electronic Theses and Dissertations

Fluid-based manufacturing processes, such as inkjet printing and electrospinning, fabricate micro- and nano-scale structures with high precision, but are prone to complex fluid dynamics exhibiting axisymmetric and non-axisymmetric instabilities. Conventional monitoring often relies on single-camera inputs and symmetry assumptions, limiting the detection of three-dimensional anomalies like jet deflection. This study presents a novel multi-view streaming video-based anomaly detection framework to address this gap. The framework employs a modified Tensor Sequential Sampling (TSS) algorithm with edge-based sampling to capture geometric spatiotemporal features of each camera view using the videos obtained from an orthogonally positioned dual-camera setup. These features are fused with …

Full Factorial Design Of Carbon Content And Heating Temperature On Height Reduction In Bonnell Springs, Yurida Ekawati, Cendana Anggun Sasmitha, Mochamad Syamsul Ma’Arif

Journal of Mechanical Engineering Science and Technology (JMEST)

The durability of Bonnell springs, which are widely used in the manufacture of spring beds, is often compromised by height reduction during use, which negatively impacts product comfort and quality. This study aims to minimize spring height reduction by investigating the effects of heating temperature and carbon content in the spring steel. A full factorial experimental design was applied using two factors: heating temperature (250°C, 260°C, and 270°C) and carbon content (0.72%, 0.73%, and 0.74%). Nine treatment combinations were tested, with five replicates each, and the height reduction values were measured after 100 compression cycles. The data were analyzed using …

Experiential Learning And The Revitalization Of Manufacturing Education At The University Of Dayton, Sean Cahill

Research and Reflection on Learning and Teaching in Higher Education

This perspective paper explores the role of experiential learning in preparing future-ready manufacturing engineers at the University of Dayton, set against the backdrop of Dayton’s legacy as an industrial innovator and the broader national movement to revitalize domestic manufacturing. As automation, cyber-physical systems, and Industry 4.0 technologies reshape the manufacturing landscape, there is a growing need for engineers who possess both technical fluency and systems-thinking capabilities. To meet this need, the manufacturing engineering technology department implemented hands-on, integrated lab-and-lecture modules through support from the Experiential Learning Innovation Fund for Faculty (ELIFF). Grounded in Kolb’s Experiential Learning Theory and constructivist learning …

Intelligent Real-Time Flotation Froth Stability Monitoring Using Embedded Computer Vision: Lead (Pb) Processing Case Study, Ahmed Bendaouia, Taha Ismaili, Ismail Najib, Oussama Hasidi, Intissar Benzakour, Jianzhi Li, El Hassan Abdelwahed

Manufacturing & Industrial Engineering Faculty Publications

Froth stability in flotation refers to the ability of the froth layer to remain intact and avoid collapsing during the flotation process. A stable froth layer is crucial to maximizing mineral recovery and ensuring the efficient operation of flotation cells. Several factors influence the stability of the froth, including the depth of the froth, the crowding, the size of the bubbles, and the rate of movement of the froth. In this study, our main objective is to analyze and evaluate froth stability in real time, since it plays a critical role in process optimization for flotation-based mineral processing. We propose …

Bending Fatigue In Additively Manufactured Metals: A Review Of Current Research And Future Directions, Md Bahar Uddin, Sriram Praneeth Isanaka, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Metal additive manufacturing (MAM), also referred to as 3D printing, has proven remarkable in the fabrication of complex metal components in multiple sectors. However, the assessment of this revolutionary process through bending fatigue is frequently impeded due to concerns about mechanical and physical conditions of the printed components. The unique layer-by-layer production process results in varied microstructures, anisotropy, and intrinsic defects that considerably differ from traditionally manufactured wrought metals. This review article aims to integrate and evaluate historical and contemporary research on the bending fatigue of additively manufactured materials. More specifically, the impact of process parameters, build orientation, surface conditions, …

Process-Driven Manufacturability Constraints In Design For Wire Arc Additive Manufacturing, Monsuru Ramoni, Sampson Gholston, Albert E. Patterson

Manufacturing & Industrial Engineering Faculty Publications

Wire arc additive manufacturing (WAAM) has emerged as a useful option for large-scale metal additive manufacturing. It has gained widespread use in the aerospace industry and other applications that require large and complex custom parts. The process is a combination of a precise control system and a welding process, typically GTAW or MIG welding. It is a member of the directed energy deposition (DED) family of AM processes. Compared with many metal AM processes, it is relatively simple and cost-effective but almost always requires a significant amount of postprocessing before parts can be used. The AM-based nature of the process …

Enabling Assembly And Repair Of Dissimilar Thermoplastic Composites For Space Applications Via Ultrasonic Welding, Emily Nicole Friedman

LSU Master's Theses

Interest in the repair and reuse of thermoplastic composites (TPCs) is growing, especially for lightweight space/lunar structures. Ultrasonic welding (USW) is a promising joining technique by which vibration is applied to create heat. An energy director (ED) is used at the joint interface to concentrate heat generation to the desired surface. This work explores the effect of dissimilar ED materials on the disassembly repair of TPCs using USW, to potentially tailor weld properties for specific applications. Single lap joints were created using carbon fiber (CF)/polyether ether ketone (PEEK) adherends with PEEK, polyphenylene sulfide (PPS), polyetherimide (PEI), and low melt polyaryletherketone …

Characterizing Surface Waviness Of Aluminum Alloy: An Approach To Minimize Post-Processing In Wire Arc Additive Manufacturing (Waam) Production, Shammas Mahmood Shafi, Anis Fatima, Nicholas V. Hendrickson

Michigan Tech Publications

Wire Arc Additive Manufacturing (WAAM) offers high deposition rates and cost-effective production of large metal components but suffers from poor surface quality, particularly surface waviness, which increases post-processing requirements and limits industrial adoption. Since waviness directly impacts structural integrity, resource efficiency, and industrial applicability, understanding how process parameters govern this feature is critical for reducing post-processing requirement. This study systematically investigated the influence of voltage, travel speed, and wire feed speed on surface waviness in aluminum alloy walls fabricated by WAAM. A two-level factorial design with 16 experiments was conducted, and surface waviness was quantified using height gauge measurements relative …

Hydrogen Embrittlement In Shot-Peened Steel, Jia-Huei Tien, David R. Johnson, David Bahr

15th International Conference on Shot Peening

This work investigates the role of shot peening on hydrogen embrittlement resistance in quenched and tempered 1070 steel. Thermal desorption spectroscopy results revealed that shot-peened specimens contained nearly twice the hydrogen (H) content of unpeened samples when charged under the same electrochemical conditions, suggesting the introduction of additional trapping sites occur during peening. The mechanism underlying this behavior can be associated with increased dislocation density and is more consistent with the HELP mechanism. Residual stress measurements show a significant relaxation of compressive stresses in shot-peened specimen after H charging, indicating H enhanced dislocation rearrangement. Both unpeened and peened specimens exhibited …