Manufacturing Commons^™

Simulation Of Cooling Rate Effects On Ti-48al-2cr-2nb Crack Formation In Direct Laser Deposition, Lei Yan, Wei Li, Xueyang Chen, Yunlu Zhang, Joseph William Newkirk, Frank W. Liou, David Dietrich

Materials Science and Engineering Faculty Research & Creative Works

Transient temperature history is vital in direct laser deposition (DLD) because it reveals the cooling rate at specific temperatures, which directly relates to phase transformation and types of microstructure formed in deposit. FEA simulation was employed to study the transient temperature history and cooling rate at different experimental setups in Ti-48Al-2Cr-2Nb DLD process. In this paper, an innovative model was described, which combines a moving Gaussian distribution heat source and element birth and death technology in ANSYS, help to analysis cooling rate control method and guide crack-free deposits build process.

Modeling And Experimental Investigation Of Pre-Mixed Multi-Powder Flow In Fabricating Functional Gradient Material By Laser Metal Deposition Process, Wei Li, Jingwei Zhang, Sreekar Karnati, Yunlu Zhang, Frank W. Liou, Joseph William Newkirk, Karen M. Brown Taminger, W. L. Seufzer

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Metal Deposition (LMD) is an effective process to fabricate Functionally Graded Material (FGM) from pre-mixed powders. Since the supplied multi-powder directly affects the deposited FGM’s composition, investigation on Pre-Mixed Multi-Powder (PMMP) flow during LMD is greatly needed. This paper presents a comprehensive numerical PMMP flow model. By solving discrete particle force balance equations coupled with continuity equations and momentum equations for carrier gas, the dynamic behavior of PMMP flow through powder feeder tube and out of nozzle was calculated. With this model, the particle sizes of multi-powder were optimized to obtain considered FGM composition. To verify the modeling results, …

Elevated Temperature Microstructure Stability Of Slm 304l Stainless Steel, Tarak Amine, Joseph William Newkirk

Materials Science and Engineering Faculty Research & Creative Works

With time at temperature, changes in metallurgical structure can be expected for almost any steel or alloy. In stainless steels, the changes can be grain growth, carbide precipitation, ferrite decomposition, or embrittlement. These phenomena can significantly effect the properties of the steel and would potentially change the functionality of the component. Therefore, to determine component stability, the elevated temperature microstructure stability of additive manufacturing materials was studied. This work investigates the influence of different aging times of additive material stainless steels (304L) fabricated with the Selective Laser Melting (SLM) process on microstructure and mechanical properties. Microstructure and mechanical properties were …

Effect Of Sparse-Build Internal Structure On Performance Of Fused Deposition Modeling Tools Under Pressure, S. Meng, L. Mason, Gregory Taylor, X. Wang, Ming-Chuan Leu, K. Chandrashekhara, Mike Matlack, James Castle

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Two different approaches to design a sparse-build tool for fabrication by the fused deposition modeling (FDM) process are compared. One approach uses a 2D lattice structure and the other approach is inspired by topology optimization. Ultem 9085 is used as the material, and the amount of material used to build the tool is kept constant to ensure a fair comparison. A solid tool is also included in the comparison. The performance of the tool under uniform pressure is simulated using finite element analysis (FEA) and the accuracy of the FEA results is verified by comparing them with experimentally measured data …

Investigation Of Tensile Properties Of Bulk And Slm Fabricated 304l Stainless Steel Using Various Gage Length Specimens, Sreekar Karnati, I. Axelsen, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The complex solidification dynamics and thermal cycling during Selective Laser Melting process is expected to result in non-equilibrium material characteristics. There is an essential need for characterization techniques which are critical towards the estimation of anisotropies. The current investigation is targeted towards establishing tensile testing methodologies and their relation to differing gage lengths. Dog-bone shaped specimen designs with gage lengths of 1”, 0.3” and 0.12” were employed in this research. The characterization was performed on hot rolled-annealed 304 stainless and SLM fabricated 304L stainless. It was theorized that smaller gage length specimens would be instrumental in mapping material property anisotropy …

Novel Extrusion-Based Additive Manufacturing Process For Ceramic Parts, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical density is introduced in this paper. In this process, an aqueous paste of ceramic particles with a very low binder content (< 1 vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Several sample parts for various applications were produced using this process and their properties were obtained. The results indicate that the proposed method enables fabrication of large, dense ceramic parts with complex geometries.

Modal Response As A Validation Technique For Metal Parts Fabricated With Selective Laser Melting, Joshua D. Pribe, Brian M. West, Michelle L. Gegel, Troy Hartwig, Toby Lunn, Ben Brown, Douglas A. Bristow, Robert G. Landers, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper investigates modal analysis as a validation technique for additively manufactured parts. The Frequency Response Function (FRF) is dependent on both the geometry and the material properties of the part as well as the presence of any defects. This allows the FRF to serve as a “fingerprint” for a given part of given quality. Once established, the FRF can be used to qualify subsequently printed parts. This approach is particularly attractive for metal parts, due to the lower damping as well as use in high-value applications where failure is unacceptable. To evaluate the efficacy of the technique, tensile specimens …

Investigation Of Heat-Affected 304l Ss Powder And Its Effect On Built Parts In Selective Laser Melting, Caitlin S. Kriewall, Austin T. Sutton, Ming-Chuan Leu, Joseph William Newkirk, Ben Brown

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective laser melting (SLM) is a powder bed based additive manufacturing process in which a layer of powder is laid over the surface of a substrate and a laser with sufficient energy is employed to selectively melt particles to build a part layer by layer. During the SLM process, dark smoke was observed coming off of the powder bed surface where the laser was interacting with powder. This phenomenon resulted from heat-affected powder that was visibly different than the base powder. Since the concentration of the heat-affected powder differs throughout the build chamber as a result of the recirculating argon …

Effect Of Powder Particle Size On The Fabrication Of Ti-6al-4v Using Laser Metal Deposition From Elemental Powder Mixture, Xueyang Chen, Lei Yan, Wei Li, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Direct Laser Metal Deposition (LMD) was used to fabricate thin-wall Ti-6Al-4V using the powder mixture of Ti-6 wt.%Al-4 wt.%V. Scanning electron microscopy (SEM), optical microscopy (OM) and energy dispersive spectroscopy (EDS) were employed to examine the chemical composition and microstructure of the as-deposited sections. Vickers hardness tests were then applied to characterize the mechanical properties of the deposit samples which were fabricated using pre-mixed elemental powders. The EDS line scans indicated that the chemical composition of the samples was homogenous across the deposit. X-ray diffraction (XRD) was used for the phase identification. After significant analysis, some differences were observed among …

Proposed Hybrid Processes For Part Building Using Fusion Welding And Friction Stir Processing, Megan A. Gegesky, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

It has been shown that a hybrid laser additive manufacturing and friction stir processing can deposit components with forged-like structures. This paper reports a hybrid fusion welding and friction stir process to create parts with quality structures. Combining traditional fusion welding and friction stir processing techniques for non-weldable aluminum alloys could facilitate the joining of difficult geometries in manufactured parts. This research illustrates mechanical property changes for non-weldable and weldable aluminum alloys. The Vickers hardness, and microhardness in the case of AA5052-H32, tensile strength and corrosion resistance of four processing states: base material, fusion welded material, friction stir welded material, …

Determining The Print Accuracy Of Four Three-Dimensional Printers, Kshiteej Dalal

Master of Technology Management Plan II Graduate Projects

Rapid prototyping [RP] or 3D printing [3DP] have existed for some time now. One of the major deficiencies of 3DP is the accuracy of the printed three dimensional parts. Even beyond that is the lack of studies that have been designed to measure the 3DP components. Measuring, verifying and determining the accuracy of 3DP parts is the focus of this study. As the accuracy is measured and approaches those of CNC machined parts, it will drive the development of additional additive manufacturing [AM] machinery. In this project a component is created in a solid modeling package. A solid model of …

Laser-Assisted Microchanneling On Pmma Substrate Utilizing Two-Pass Fabrication Method, Sijie Zhang, Yung C. Shin

The Summer Undergraduate Research Fellowship (SURF) Symposium

Microchannel is widely used in microfluidic devices for mixing, chemical reaction, detection, particle separation and etc. CO₂ laser-based microchanneling of PMMA as a low cost, rapid, noncontact fabrication method has attracted the attention of industry. However, the typical V-shape grooves fabricated by CO₂ laser microchanneling have limitations since the V-shape grooves will affect the flow behavior and heat transfer of the fluid, which are important to the performance of microfluidic devices. A two-pass fabrication method is proposed and investigated in this paper to improve the quality of the PMMA microchannel fabricated by CO₂ laser. It was found …

Laser Assisted Manufacturing: A Comparison Of Mechanical Properties Between Lam And Conventional Manufacturing Techniques, William Blakeslee, Neil S. Bailey, Kyung-Min Hong, Shunyu Liu, Yung C. Shin

The Summer Undergraduate Research Fellowship (SURF) Symposium

Laser assisted manufacturing methods, such as direct metal deposition (DMD) and laser beam welding (LBW), are promising methods because of their higher precision and greater productivity when compared to traditional manufacturing methods. Because these methods are relatively new, the mechanical properties of samples produced by laser assisted manufacturing are not well understood. In this study the mechanical properties of samples produced by laser assisted manufacturing methods are analyzed and compared with data obtained from traditional manufacturing methods. The DMD process used Fe-TiC and Ti-TiC metal matrix composites, while LBW used AISI 304 stainless steel. The results vary widely with the …

Applications Of Additive Manufacturing Techniques In Making Energetic Materials, Peter A. Cattani, Trevor J. Fleck, Jeff F. Rhoads, Steven F. Son, I. Emre Gunduz

The Summer Undergraduate Research Fellowship (SURF) Symposium

Energetic materials are currently manufactured using methods such as casting, which can only produce certain geometries. Additive manufacturing enables more flexible fabrication and the potential for improved material consistency. Additive manufacturing has transformed many industries, but has only recently been applied to the manufacturing of energetic materials. This paper describes the development of two processes to apply additive manufacturing methods to energetic materials. Method one applies a fused deposition modelling approach (FDM). 5 µm aluminum powder and PVDF were mixed and made into filaments using a Filabot Original filament extruder. Energetic filaments were created composed of 90:10, 80:20, and 75:25 …

Design For Manufacturability: Off-Road Toyota Bumper, Drew Donlon

Industrial and Manufacturing Engineering

The purpose of this project is to design a new off-road bumper that is improved from the stock form of a 1996-2002 Toyota 4Runner and a 1996-2004 Toyota Tacoma. The current state of the component is too weak to endure to off-road endeavors, and a kit bumper market is virtually untapped for these vehicles. The objectives of this project were met by redesigning the stock front bumper, conducting a finite element analysis on the model to test for strength, prototyping the bumper with CNC cut cardboard, and conducting a full cost analysis including the costs for waterjet and laser cutting …

Evolution Of The Automotive Body Coating Process—A Review, Nelson K. Akafuah, Sadegh Poozesh, Ahmad Salaimeh, Gabriela Patrick, Kevin Lawler, Kozo Saito

Mechanical Engineering Faculty Publications

Automotive coatings and the processes used to coat automobile surfaces exemplify the avant-garde of technologies that are capable of producing durable surfaces, exceeding customers’ expectations of appearance, maximizing efficiency, and meeting environmental regulations. These accomplishments are rooted in 100 years of experience, trial-and-error approaches, technique and technology advancements, and theoretical assessments. Because of advancements directed at understanding the how, why, when, and where of automobile coatings, the progress in controlling droplets and their deposition attributes, and the development of new technologies and paint chemistries, a comprehensive and up-to-date review of automobile coatings and coating technologies was considered to be of …

Gold Contamination In Non-Lead Surface Mount Solder Joints, Richard Alexander Garrison

Industrial and Manufacturing Engineering

Abstract

Solder joints are critical to the reliability of circuit boards. If gold is introduced to the solder joint, brittle AuSn4 intermetallic compounds develop which affect reliability of that solder joint. To determine the effects of gold when dissolved into a non-lead solder joint, a process was developed in order to apply gold content onto SAC305 solder paste. The gold was transferred as a paste from a micropipette onto each individual solder bump. This process was designed to apply a range of gold content from 1.0 wt. % to 10 wt. % to each individual solder joint. The test board …

Improving The Mechanical Performance Of 3d Printed Parts Using Fused Filament Fabrication, Inderpreet Binning

Industrial and Manufacturing Engineering

The 3D printing industry has seen rapid growth in the last 10 years and has been called the next industrial revolution. There are several different processes used in 3D printing, but the most popular process is called Fused Filament Fabrication (FFF) or Fused Deposition Modeling (FDM). This is the process where (most commonly) plastic filament enters a nozzle, is heated to a semi-liquid state, and then deposited into a pattern to create a print. One major drawback to this process is that the prints are anisotropic. This means that the strength of the print varies with the orientation that it …

Design & Analysis Of A Bicycle Towing Device, Austin Lynch, William Max Mcewan, Fredrik Stenson

Industrial and Manufacturing Engineering

A local businessman had the idea to build a device that allows a bicycle to tow another bicycle. He built a prototype to demonstrate his idea but he wanted help in developing a product that could fit more bikes, did not require a rear rack to operate, and be manufacturable at his facility. He also expressed interest in an economic evaluation of production and marketing of the device. An analysis of customer needs led to adding reduction of weight and ease of attachment to the design requirements.

This report is about improving the original design and presents the process of …

Haas Automation Umc750 5axis Mill Assembly Process Improvement, Mason A. Garcia, Gregory R. Gunion, Juan Pablo Quinonez Weston

Industrial and Manufacturing Engineering

The improvement of the current assembly of the motor and casting components for the Haas UMC-750 5-Axis vertical CNC mill includes the evaluation, development and proposal of a new pair of material handling carts. To meet these deliverables, a student team began by assessing the assembly workstation, defining the problem to be solved, researching ergonomics in material handling equipment and drafting the final design of the improved cart models using SolidWorks. The final design considered the initial improvement request from the client, as well as better ergonomic features to enhance the safety of the operators. It was estimated that the …