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Full-Text Articles in Engineering
Effect Of Surface Roughness On Ultrasonic Inspection Of Electron Beam Melting Ti‐6al‐4v, Evan T. Hanks, Anthony N. Palazotto, David Liu
Effect Of Surface Roughness On Ultrasonic Inspection Of Electron Beam Melting Ti‐6al‐4v, Evan T. Hanks, Anthony N. Palazotto, David Liu
Faculty Publications
Experimental research was conducted on the effects of surface roughness on ultrasonic non-destructive testing of electron beam melted (EBM) additively manufactured Ti-6Al-4V. Additive manufacturing (AM) is a developing technology with many potential benefits, but certain challenges posed by its use require further research before AM parts are viable for widespread use in the aviation industry. Possible applications of this new technology include aircraft battle damage repair (ABDR), small batch manufacturing to fill supply gaps and replacement for obsolete parts. This paper aims to assess the effectiveness of ultrasonic inspection in detecting manufactured flaws in EBM-manufactured Ti-6Al-4V. Additively manufactured EBM products …
Additively Manufactured Continuous Carbon Fiber Thermoplastic Composites For High-Performance Applications, Nekoda Van De Werken
Additively Manufactured Continuous Carbon Fiber Thermoplastic Composites For High-Performance Applications, Nekoda Van De Werken
Mechanical Engineering ETDs
The goal of this dissertation is to provide a foundation for the advancement of additive manufacturing (AM) toward production of high-performance carbon fiber reinforced polymer matrix composites (CFRPs). AM can provide valuable advantages over conventional composite manufacturing techniques, including the control over fiber orientation, capability of manufacturing complex geometries, out-of-autoclave processing, elimination of the need for composite tooling, and the ability to perform lights-out manufacturing. Currently, however, a suite of challenges related to modelling, design, manufacturing defects, and general limitations in the current understanding of the processing-structure-property relationships exist in AM of composites. To this end, this dissertation investigates novel …
Open Source Waste Plastic Granulator, Arvind Ravindran, Sean Scsavnicki, Walker Nelson, Peter Gorecki, Jacob Franz, Shane Oberloier, Theresa K. Meyer, Andrew Barnard, Joshua M. Pearce
Open Source Waste Plastic Granulator, Arvind Ravindran, Sean Scsavnicki, Walker Nelson, Peter Gorecki, Jacob Franz, Shane Oberloier, Theresa K. Meyer, Andrew Barnard, Joshua M. Pearce
Michigan Tech Publications
In order to accelerate deployment of distributed recycling by providing low-cost feed stocks of granulated post-consumer waste plastic, this study analyzes an open source waste plastic granulator system. It is designed, built, and tested for its ability to convert post-consumer waste, 3D printed products and waste into polymer feedstock for recyclebots of fused particle/granule printers. The technical specifications of the device are quantified in terms of power consumption (380 to 404 W for PET and PLA, respectively) and particle size distribution. The open source device can be fabricated for less than $2000 USD in materials. The experimentally measured power use …
Microstuctural Analysis Of Additively Manufactured 308l Stainless Steel Produced By Plasma Arc Welding, Ryan Foley
Microstuctural Analysis Of Additively Manufactured 308l Stainless Steel Produced By Plasma Arc Welding, Ryan Foley
Graduate Theses & Non-Theses
Additive Manufacturing (AM) is a technique to produce special products by depositing layers of material in a specific pattern. Wire and arc additive manufacturing (WAAM) is an AM technique that uses welding equipment that has been modified and automated to deposit layers of welding wire. Characterization of specimens produced by WAAM method is required to optimize the process parameters. This research focuses on the microstructure characterization of 308L stainless steel samples produced by a novel WAAM technique known as Plasma Arc Weld Print 3D (PP3D). PP3D consists of multiple plasma arc torches that can deposit material in two modes of …
Smart Additive Manufacturing: In-Process Sensing And Data Analytics For Online Defect Detection In Metal Additive Manufacturing Processes, Mohammad Montazeri
Smart Additive Manufacturing: In-Process Sensing And Data Analytics For Online Defect Detection In Metal Additive Manufacturing Processes, Mohammad Montazeri
Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research
The goal of this dissertation is to detect the incipient flaws in metal parts made using additive manufacturing processes (3D printing). The key idea is to embed sensors inside a 3D printing machine and conclude whether there are defects in the part as it is being built by analyzing the sensor data using artificial intelligence (machine learning). This is an important area of research, because, despite their revolutionary potential, additive manufacturing processes are yet to find wider acceptance in safety-critical industries, such as aerospace and biomedical, given their propensity to form defects. The presence of defects, such as porosity, can …
Low-Cost Open Source Ultrasound-Sensing Based Navigational Support For The Visually Impaired, Aliaksei Petsiuk, Joshua M. Pearce
Low-Cost Open Source Ultrasound-Sensing Based Navigational Support For The Visually Impaired, Aliaksei Petsiuk, Joshua M. Pearce
Michigan Tech Publications
Nineteen million Americans have significant vision loss. Over 70% of these are not employed full-time, and more than a quarter live below the poverty line. Globally, there are 36 million blind people, but less than half use white canes or more costly commercial sensory substitutions. The quality of life for visually impaired people is hampered by the resultant lack of independence. To help alleviate these challenges this study reports on the development of a low-cost, open-source ultrasound-based navigational support system in the form of a wearable bracelet to allow people with the lost vision to navigate, orient themselves in their …
Increasing The Functionality Of Additive Manufacturing Through Atmospheric Microplasma And Nanotechnology, Alexander Jon Ulrich
Increasing The Functionality Of Additive Manufacturing Through Atmospheric Microplasma And Nanotechnology, Alexander Jon Ulrich
Doctoral Dissertations
Additive Manufacturing (AM) has been changing the manufacturing landscape for the last 20 years. As the interest and demand for both polymer and metal-based 3D printing has grown, the materials and machines used have increased in capabilities. Despite the growth and advancement, there are still a large number of improvements that can be made to add functionality to 3D printers. Metal AM, a subcategory of 3D printing, has garnered much attention among industrial applications with large companies such as General Electric trying to implement the technology to increase innovative designs for motors. Some of the limitations on AM have to …
Evaluation Of Tensile Properties For Selective Laser Melted 316l Stainless Steel And The Influence Of Inherent Process Features, Paul Swartz
Master's Theses
Optimal print parameters for additively manufacturing 316L stainless steel using selective laser melting (SLM) at Cal Poly had previously been identified. In order to further support the viability of the current settings, tensile material characteristics were needed. Furthermore, reliable performance of the as-printed material had to be demonstrated. Any influence on the static performance of parts in the as-printed condition inherent to the SLM manufacturing process itself needed to be identified. Tensile testing was conducted to determine the properties of material in the as-printed condition. So as to have confidence in the experimental results, other investigations were also conducted to …
Mechanical Properties And Applications Of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing, Matthew J. Reich, Aubrey Woern, Nagendra Gautam Tanikella, Joshua M. Pearce
Mechanical Properties And Applications Of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing, Matthew J. Reich, Aubrey Woern, Nagendra Gautam Tanikella, Joshua M. Pearce
Michigan Tech Publications
Past work has shown that particle material extrusion (fused particle fabrication (FPF)/fused granular fabrication (FGF)) has the potential for increasing the use of recycled polymers in 3D printing. This study extends this potential to high-performance (high-mechanical-strength and heat-resistant) polymers using polycarbonate (PC). Recycled PC regrind of approximately 25 mm2 was 3D printed with an open-source Gigabot X and analyzed. A temperature and nozzle velocity matrix was used to find useful printing parameters, and a print test was used to maximize the output for a two-temperature stage extruder for PC. ASTM type 4 tensile test geometries as well as ASTM-approved …
Open Source Completely 3-D Printable Centrifuge, Salil S. Sule, Aliaksei Petsiuk, Joshua M. Pearce
Open Source Completely 3-D Printable Centrifuge, Salil S. Sule, Aliaksei Petsiuk, Joshua M. Pearce
Michigan Tech Publications
Centrifuges are commonly required devices in medical diagnostics facilities as well as scientific laboratories. Although there are commercial and open source centrifuges, the costs of the former and the required electricity to operate the latter limit accessibility in resource-constrained settings. There is a need for low-cost, human-powered, verified, and reliable lab-scale centrifuges. This study provides the designs for a low-cost 100% 3-D printed centrifuge, which can be fabricated on any low-cost RepRap-class (self-replicating rapid prototyper) fused filament fabrication (FFF)- or fused particle fabrication (FPF)-based 3-D printer. In addition, validation procedures are provided using a web camera and free and open …
A Study On Ultrasonic Energy Assisted Metal Processing : Its Correeltion With Microstructure And Properties, And Its Application To Additive Manufacturing., Anagh Deshpande
Electronic Theses and Dissertations
Additive manufacturing or 3d printing is the process of constructing a 3-dimensional object layer-by-layer. This additive approach to manufacturing has enabled fabrication of complex components directly from a computer model (or a CAD model). The process has now matured from its earlier version of being a rapid prototyping tool to a technology that can fabricate service-ready components. Development of low-cost polymer additive manufacturing printers enabled by open source Fused Deposition Modeling (FDM) printers and printers of other technologies like SLA and binder jetting has made polymer additive manufacturing accessible and affordable. But the metal additive manufacturing technologies are still expensive …
Additive Manufacturing Of Piezoelectric Photopolymer Ferroelectrets, Rami Abu Shammeh
Additive Manufacturing Of Piezoelectric Photopolymer Ferroelectrets, Rami Abu Shammeh
Electronic Thesis and Dissertation Repository
Electroactive polymers are an emerging branch of smart materials that possess the capability to change shape in the presence of an electric field. Particularly, ferroelectrets are films of electrostatically charged dielectric polymer foam that comprise a growing portion of EAP literature. Ferroelectrets are characterized by a piezoelectric response and a quasi-permanent charge polarization owing to the dipoles created when the air cavities in the polymer matrix undergo dielectric breakdown. However, these cavities are often irregular in shape, size, and distribution when produced with conventional preparation methods. To overcome this, we employ a light-based additive manufacturing technique to create a hybrid …
Remanufacturing Of Precision Metal Components Using Additive Manufacturing Technology, Xinchang Zhang
Remanufacturing Of Precision Metal Components Using Additive Manufacturing Technology, Xinchang Zhang
Doctoral Dissertations
"Critical metallic components such as jet engine turbine blades and casting die/mold may be damaged after servicing for a period at harsh working environments such as elevated temperature and pressure, impact with foreign objects, wear, corrosion, and fatigue. Additive manufacturing has a promising application for the refurbishment of such high-costly parts by depositing materials at the damaged zone to restore the nominal geometry. However, several issues such as pre-processing of worn parts to assure the repairability, reconstructing the repair volume to generate a repair tool path for material deposition, and inspection of repaired parts are challenging. The current research aims …
Freeform Extrusion Fabrication Of Advanced Ceramics And Ceramic-Based Composites, Wenbin Li
Freeform Extrusion Fabrication Of Advanced Ceramics And Ceramic-Based Composites, Wenbin Li
Doctoral Dissertations
"Ceramic On-Demand Extrusion (CODE) is a recently developed freeform extrusion fabrication process for producing dense ceramic components from single and multiple constituents. In this process, aqueous paste of ceramic particles with a very low binder content ( < 1 vol%) is extruded through a moving nozzle to print each layer sequentially. Once one layer is printed, it is surrounded by oil to prevent undesirable water evaporation from the perimeters of the part. The oil level is regulated just below the topmost layer of the part being fabricated. Infrared radiation is then applied to uniformly and partially dry the top layer so that the yield stress of the paste increases to avoid part deformation. By repeating the above steps, the part is printed in a layer-wise fashion, followed by post-processing. Paste extrusion precision of different extrusion mechanisms was compared and analyzed, with an auger extruder determined to be the most suitable paste extruder for the CODE system. A novel fabrication system was developed based on a motion gantry, auger extruders, and peripheral devices. Sample specimens were then produced from 3 mol% yttria stabilized zirconia using this fabrication system, and their properties, including density, flexural strength, Young's modulus, Weibull modulus, fracture toughness, and hardness were measured. The results indicated that superior mechanical properties were achieved by the CODE process among all the additive manufacturing processes. Further development was made on the CODE process to fabricate ceramic components that have external/internal features such as overhangs by using fugitive support material. Finally, ceramic composites with functionally graded materials (FGMs) were fabricated by the CODE process using a dynamic mixing device"--Abstract, page iv.
The Effect Of Cell Size And Surface Roughness On The Compressive Properties Of Abs Lattice Structures Fabricated By Fused Deposition Modeling, Leah Hope Mason
The Effect Of Cell Size And Surface Roughness On The Compressive Properties Of Abs Lattice Structures Fabricated By Fused Deposition Modeling, Leah Hope Mason
Masters Theses
"Postprocessing is an important step in many manufacturing methods, but it is especially important for additive manufacturing. Researchers looking to improve the surface roughness of acrylonitrile butadiene styrene (ABS) parts fabricated by fused deposition modeling (FDM) have determined that acetone smoothing not only achieves improved surface roughness but increases compressive strength as well. This could be very beneficial to lattice structures, which are known for already having an excellent strength to weight ratio. If the compressive strength of ABS lattice structures could be improved even further using acetone smoothing, it could expand the applications for plastic lattice structures and improve …