Engineering Commons^™

Composites 4.0: Enabling The Modernization Of Legacy Manufacturing Assets In South Carolina, Amit Makarand Deshpande, Gayatri Keskar, Sai Aditya Pradeep, Saeed Farahani, Srikanth Pilla

Publications

Composites 4.0 is the implementation of Industry 4.0 concepts to plastics and composites manufacturing with the goal to overcome the complexities associated with these materials. Due to very complex process-structure-property relationships associated with plastics and composites, a wide range of process parameters need to be tracked and monitored. Furthermore, these parameters are often affected by the tool and machinery, human intervention and variability and should thus, be monitored by integrating intelligence and connectivity in manufacturing systems. Retrofitting legacy manufacturing systems with modern sensing and control systems is emerging as one of the more cost-effective approaches as it circumvents the substantial …

Rheological Characterization Of Ultra-High Performance Concrete For 3d Printing, Arun R. Arunothayan, Behzad Nematollahi, Kamal Khayat, Akilesh Ramesh, Jay G. Sanjayan

Civil, Architectural and Environmental Engineering Faculty Research & Creative Works

The authors recently developed a 3D-printable ultra-high performance fiber-reinforced concrete (3DP-UHPFRC) for additive construction of structural members with significantly reduced reliance on steel bars. This study investigates the rheological behavior of the developed 3DP-UHPFRC. The effects of two major factors affecting the performance of 3DP-UHPFRC, namely steel fiber volume (0, 1%, and 2%) and nano-clay (NC) content (0, 0.1%, and 0.2% by binder mass) on workability, static yield stress, dynamic yield stress, and apparent viscosity were determined. Test results showed that the inclusion of steel fibers and NC reduced the workability and led to a significant increase in the static …

Additive Manufacturing Of (Mgconicuzn)O High-Entropy Oxide Using A 3d Extrusion Technique And Oxide Precursors, Ruoyu Chen, Saisai Li, Qingfeng Yan, Haiming Wen

Materials Science and Engineering Faculty Research & Creative Works

This report presents an additive manufacturing approach, for the first time, to producing high-entropy oxides (HEOs) using a 3D extrusion-based technique with oxide precursors. The precursors were prepared by a wet chemical method from sulfates. Additives were utilized to optimize the rheological properties of the printing inks with these precursors, and the properties of the printed HEOs were improved by increasing the solid content of the inks. When ink with a solid content of 78 wt% was used for printing, the resulting HEO exhibited a relative density of 92% and a high dielectric constant after undergoing pressure less sintering at …

Effects Of Fiber Orientation On The Coefficient Of Thermal Expansion Of Fiber-Filled Polymer Systems In Large Format Polymer Extrusion-Based Additive Manufacturing, José Luis Colón Quintana, Lucinda Slattery, Jon Pinkham, Joanna Keaton, Roberto A. Lopez-Anido, Keith Sharp

Civil Engineering Faculty Scholarship

Large format polymer extrusion-based additive manufacturing has been studied recently due to its capacity for high throughput, customizable bead size and geometry, and ability to manufacture large parts. Samples from three fiber-filled amorphous thermoplastic materials 3D printed using a Masterprint 3X machine from Ingersoll Machine Tools were studied, along with their neat counterparts. Characterization techniques included thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and thermo-mechanical analysis (TMA). TGA results showed that the fillers decreased the degradation temperature for most of the materials investigated, with a 30°C decrease for polycarbonate (PC) and a 12°C decrease for polyethylene terephthalate glycol (PETG). For …

Fabricating Zirconia Parts 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 ⁰C to melt the PCL. The part is then …

Biopolymer Composites From High-Cellulose Pulps And/Or Nanocellulose, Fabiola Vilaseca

Composites at Lake Louise (CALL 2015)

Increasingly our society seeks an economy based on renewable resources (bio-based economy) with the goal of providing materials of high value and from renewable resources. One popular renewable resource is cellulose, or forest products in general. In this study, cellulose derivatives will be combined together with bio-plastics to produce granules of thermoplastic nano-biocomposites by melt processing. The intention is to get bio-based materials with highly advanced properties that can be shaped into complex geometries using widely used industrial melt-processes such as extrusion or injection molding.

The challenges in this study deal with production technologies for the realization of nanocomposites for …

Combined Effect Of Hot Extrusion And Heat Treatment On The Mechanical Behavior Of 7055 Aa Processed Via Spray Metal Forming, J. M. Schreiber, Z. R. Omcikus, Timothy Eden, Mala Sharma, V. Champagne, S. N. Patankar

Faculty Journal Articles

The mechanical properties of 7xxx series alloys can be tailored by subjecting them to deformation pro- cessing and heat treatment. In the present study dealing with spray forming of 7055 AA, extrusion and heat treatment involving solutionizing followed by peak aging resulted in improved mechanical behavior. The strength and ductility obtained are comparable to that of extruded and heat treated as-cast 7055 AA (Mondal et al., 2011) [1]. Spray forming offers an alternate route to develop high strength aluminum alloys and the current study is an attempt that draws closer to the target value of 1GPa strength and 10% ductility …

Effect Of Different Extrusion Processing Parameters On Physical Properties Of Soy White Flakes And High Protein Distillers Dried Grains-Based Extruded Aquafeeds, Sushil Kumar Singh, Kasiviswanathan Muthukumarappan

Agricultural and Biosystems Engineering Publications

Nutritionally balanced ingredient blends for catla (Catla catla), belonging to the family Cyprinidae, were extruded using single screw extruder. The extrusion was carried out at five levels of soy white flakes content (21%, 29%, 40%, 52%, and 59% db), five levels of moisture content (15, 19, 25, 31, and 35% db) and five levels of barrel temperature (100, 110, 125, 140, and 150 ºC) using three different die nozzles (having L/D ratios 3.33, 5.83, and 7.25). Blends with net protein content of 32.5% contains soy white flakes, along with high protein distillers dried grains (HP-DDG), corn flour, corn gluten meal, …

Extrusion Printed Graphene/Polycaprolactone/ Composites For Tissue Engineering, Sepidar Sayyar, Rhys Cornock, Eoin Murray, Stephen Beirne, David L. Officer, Gordon G. Wallace

Australian Institute for Innovative Materials - Papers

In this work fibres and complex three-dimensional scaffolds of a covalently linked graphene-polycaprolactone composite were successfully extruded and printed using a melt extrusion printing system. Fibres with varying diameters and morphologies, as well as complex scaffolds were fabricated using an additive fabrication approach and were characterized. It was found that the addition of graphene improves the mechanical properties of the fibres by over 50% and in vitro cytotoxicity tests showed good biocompatibility indicating a promising material for tissue engineering applications.

Extrusion Printing Of Ionic-Covalent Entanglement Hydrogels With High Toughness, Shannon Bakarich, Marc In Het Panhuis, Stephen T. Beirne, Gordon G. Wallace, Geoffrey Maxwell Spinks

Australian Institute for Innovative Materials - Papers

Three-dimensional (3D) printing of hydrogels has recently been investigated for use in tissue engineering applications. One major limitation in the use of synthetic hydrogels is their poor mechanical robustness but the development of ‘tough hydrogels’ in conjunction with additive fabrication techniques will accelerate the advancement of many technologies including soft robotics, bionic implants, sensors and controlled release systems. This article demonstrates that ionic–covalent entanglement (ICE) gels can be fabricated through a modified extrusion printing process that facilitates in situ photopolymerisation. The rheological properties of alginate–acrylamide hydrogel precursor solutions were characterised to develop formulations suitable for extrusion printing. A range of …

Bio-Ink Properties And Printability For Extrusion Printing Living Cells, Johnson H. Y Chung, Sina Naficy, Zhilian Yue, Robert Kapsa, Anita Quigley, Simon E. Moulton, Gordon G. Wallace

Australian Institute for Innovative Materials - Papers

Additive biofabrication (3D bioprinting) makes it possible to create scaffolds with precise geometries, control over pore interconnectivity and architectures that are not possible with conventional techniques. Inclusion of cells within the ink to form a “bio-ink” presents the potential to print 3D structures that can be implanted into damaged/diseased tissue to promote highly controlled cell-based regeneration and repair. The properties of an ‘ink’ are defined by its formulation and critically influence the delivery and integrity of structure formed. Importantly, the ink properties need to conform to biological requirements necessary for the cell system that they are intended to support and …

Freeze-Form Extrusion Fabrication Of Functionally Graded Material Composites Using Zirconium Carbide And Tungsten, Ang Li, Aaron S. Thornton, Bradley K. Deuser, Jeremy Lee Watts, Ming-Chuan Leu, Greg Hilmas, Robert G. Landers

Materials Science and Engineering Faculty Research & Creative Works

Ultra-high-temperature ceramics are being investigated for future use in aerospace applications due to their superior thermo-mechanical properties, as well as their oxidation resistance, at temperatures above 2000⁰C. However, their brittleness makes them susceptible to thermal shock failure. As graded composites, components fabricated as functionally-graded materials (FGMs) can combine the superior properties of ceramics with the toughness of an underlying refractory metal. This paper discusses the grading of two materials through the use of a Freeze-form Extrusion Fabrication (FEF) system to build FGM parts consisting of zirconium carbide (ZrC) and tungsten (W). Aqueous-based colloidal suspensions of ZrC and W were developed …

Freeze-Form Extrusion Fabrication Of Composite Structures, Ming-Chuan Leu, Lie Tang, Bradley K. Deuser, Robert G. Landers, Greg Hilmas, Shi C. Zhang, Jeremy Lee Watts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A Freeze-form Extrusion Fabrication (FEF) process capable of making three-dimensional (3D) parts and structures with graded composite materials is presented in this paper. The process development includes the design and manufacture of a gantry machine with a triple-extruder mechanism and the associated electronics hardware and computer software for fabricating functionally graded parts from multiple aqueous pastes. A rheological behavior study with Al₂O₃ paste is performed to identify an efficient binder for transforming the paste into a pseudoplastic with a high yield stress. A green part is first fabricated using the triple-extruder FEF machine in a layer-by-layer manner …

Extrusion And Alkali Extrusion Of Corn Stover To Improve Enzyme Saccharification, Shujing Zhang

Department of Biological Systems Engineering: Dissertations and Theses

Biomass pretreatment constitutes an important part in the whole process of bioethanol production. The main goals of pretreatment include improving cellulose accessibility to enzyme, enhancing sugar yields from hemicellulose, achieving low capital and energy costs, as well as low sugar degradation and low chemical requirements. Extrusion, as a continuous and high throughput pretreatment method, requires much less chemical compared to traditional alkali pretreatment. In this research, twin-screw extrusion was evaluated for its effect with regard to promoting sugar yields from corn stover. Also, the underlying factors contributing to this improvement were examined. It was found that extrusion with no chemicals …

Twin-Screw Extrusion Processing Of Distillers Dried Grains With Solubles (Ddgs)-Based Yellow Perch (Perca Flavescens) Feeds, Ferouz Y. Ayadi, Kurt A. Rosentrater, Kasiviswanathan Muthukumarappan, Michael L. Brown

Natural Resource Management Faculty Publications

Increases in global aquaculture production, compounded with limited availabilities of fish meal for fish feed, has created the need for alternative protein sources. Twinscrew extrusion studies were performed to investigate the production of nutritionally balanced feeds for juvenile yellow perch (Perca flavescens). Five isocaloric (~3.06 kcal/g) ingredient blends, adjusted to a target protein content of 36.7% db, were formulated with 0%, 10%, 20%, 30%, and 40% distillers dried grains with solubles (DDGS) at an initial moisture content of 5–7%db, with appropriate amounts of fish meal, fish oil, whole wheat flour, corn gluten meal, and vitamin and mineral premixes. …

Freeze Extrusion Fabrication Of 13-93 Bioactive Glass Scaffolds For Bone Repair, Tieshu Huang, Nikhil D. Doiphode, M. N. Rahaman, Ming-Chuan Leu, B. Sonny Bal, D. E. Day

Materials Science and Engineering Faculty Research & Creative Works

There is an increasing demand for synthetic scaffolds with the requisite biocompatibility, internal architecture, and mechanical properties for the bone repair and regeneration. In this work, scaffolds of a silicate bioactive glass (13-93) were prepared by a freeze extrusion fabrication (FEF) method and evaluated in vitro for potential applications in bone repair and regeneration. The process parameters for FEF production of scaffolds with the requisite microstructural characteristics, as well as the mechanical and cell culture response of the scaffolds were evaluated. After binder burnout and sintering (60 min at 700°C), the scaffolds consisted of a dense glass network with interpenetrating …

Mechanical, Microstructure And Texture Properties Of Interstitial-Free Steel And Copper Subjected To Equal Channel Angular Extrusion And Cold-Rolling, A A. Gazder, S S. Hazra, C F. Gu, W Q. Cao, C H J Davies, E V. Pereloma

Faculty of Engineering - Papers (Archive)

Interstitial-free steel and OFHC copper were subjected to 8 passes, route B_C room temperature ECAE followed by cold-rolling up to 97.5% thickness reduction. Uniaxial tensile tests and Electron Back-Scattering Diffraction were used to characterise the evolution in mechanical properties, microstructure refinement and micro-texture. IF-steel showed continuous increase in strength whereas Cu returned reduced strength and a small gain in ductility at 97.5% reduction. In both metals substructure refinement was accompanied by an increase in high-angle boundary fraction, average misorientation and a slight increase in Σ3 boundaries. An evolution of crystallographic orientations from negative shear to predominantly cold-rolled textures after …

Preparation And Characterization Of Tapioca Starch–Poly(Lactic Acid) Nanocomposite Foams By Melt Intercalation Based On Clay Type, Siew-Yoong Lee, Han Chen, Milford Hanna

Department of Biological Systems Engineering: Dissertations and Theses

Abstract Tapioca starch (TS), poly(lactic acid) (PLA), and four different organoclays (Cloisite 10A, Cloisite 25A, Cloisite 93A and Cloisite 15A) were used to produce nanocomposite foams by melt-intercalation. Structural, thermal, physical and mechanical properties were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and an Instron universal testing machine, respectively. The first XRD peaks for all four nanocomposite foams, were observed to shift to lower angles, indicating that intercalation occurred. The extent of intercalation depended on the type of organoclay and was exhibited in the sequence of Cloisite 10A > 25A > 93A > 15A. Glass transition temperatures …

An Ebsd Investigation Of Interstitial-Free Steel Subjected To Equal Channel Angular Extrusion, Azdiar A. Gazder, Wenquan Q. Cao, Christopher H.J. Davies, E V. Pereloma

Faculty of Engineering - Papers (Archive)

The microstructural evolution of interstitial-free (IF) steel subjected to Φ = 90° equal channel angular extrusion (ECAE) for up to 4 passes via routes A, B_A, C and up to 8 passes via routes B_C was studied using electron back-scattering diffraction (EBSD). Routes B_C and B_A recorded the smallest grain size and aspect ratios and the largest average misorientation and area fraction of high-angle grain boundaries (HAGBs). During multiple passes, microstructure refinement continues until a convergence in effective subgrain and grain diameters occurs; following which the rate of HAGB formation reduces slightly. The percentage rise …

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 …

Grain Size, Misorientation, And Texture Evolution Of Copper Processed By Equal Channel Angular Extrusion And The Validity Of The Hall-Petch Relationship, Florian H. Dalla Torre, Azdiar A. Gazder, Cheng F. Gu, Christopher H.J. Davies, E V. Pereloma

Faculty of Engineering - Papers (Archive)

The microstructure and texture of copper subjected to equal channel angular extrusion (ECAE) via route B _C for up to 16 passes have been assessed using electron backscatter diffraction (EBSD), transmission electron microscopy (TEM), X-ray diffraction (XRD) peak broadening, and texture analysis. The differences in grain size measured by these techniques allows for an understanding of microstructural evolution. A gradual decrease in grain size occurs with an increasing number of passes, while the subgrain size remains approximately constant. Up to four passes, the fraction of high-angle grain boundaries (HAGBs) (>15 deg) increases from 15 to 45 pct, but remains …

Freeform Extrusion Of High Solids Loading Ceramic Slurries, Part I: Extrusion Process Modeling, Michael S. Mason, Tieshu Huang, Robert G. Landers, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A novel, solid freeform fabrication method has been developed for the manufacture of ceramic-based components in an environmentally friendly fashion. The method is based on the extrusion of ceramic slurries using water as the binding media. Aluminum oxide (Al₂O₃) is currently being used as the part material and solids loading as high as 60 vol. % has been achieved. This paper describes a novel manufacturing machine that has been developed for the extrusion of high solids loading ceramic slurries. A critical component of the machine is the deposition system, which consists of a syringe, a plunger, …

Freeform Extrusion Of High Solids Loading Ceramic Slurries, Part Ii: Extrusion Process Control, Michael S. Mason, Tieshu Huang, Robert G. Landers, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Part I of this paper provided a detailed description of a novel fabrication machine for high solids loading ceramic slurry extrusion processes and presented an empirical model of the ceramic extrusion process, viewing ram velocity as the input and extrusion force as the output. A constant extrusion force is desirable as it correlates with a constant material deposition rate and, thus, good part quality. The experimental results used to construct the model demonstrated that a constant ram velocity will not necessarily produce a constant extrusion force. In some instances the extrusion force increased until ram motor skipping occurred, and process …

Modeling Of Transport Phenomena And Melting Kinetics Of Starch In A Co-Rotating Twin-Screw Extruder, Lijun Wang, David D. Jones, Curtis L. Weller, Milford Hanna

Department of Biological Systems Engineering: Papers and Publications

A mathematical model was developed to simulate fluid flow, heat transfer, and melting kinetics of starch in a co-rotating intermeshing twin-screw extruder (TSE). The partial differential equations governing the transport phenomena of the biomaterial in the extruder were solved by a finite element scheme. For validating the model, the predicted product pressure, bulk temperature at the entrance of the die, and minimum residence time of the biomaterial in the extruder were compared with experimental data. Standard errors of product pressure, bulk temperature at the die entrance, and minimum residence time were about 8.8, 2.8, and 17.3%. Simulations were carried out …

Freeze-Form Extrusion Fabrication Of Ceramics, Tieshu Huang, Michael S. Mason, Greg Hilmas, Ming-Chuan Leu

Materials Science and Engineering Faculty Research & Creative Works

A novel, environmentally friendly solid freeform fabrication method called Freeze-form Extrusion Fabrication (FEF) has been developed for the fabrication of ceramic-based components. The method is based on deposition of ceramic pastes using water as the media. The ceramic solids loading can be 50 vol. % or higher and initial studies have focused on the use of aluminum oxide (Al₂O₃). The FEF system components and their interaction are examined, and the main process parameters affecting part geometry defined. 3-D shaped components have been fabricated by extrusion deposition of the ceramic paste in a layer-by-layer fashion. The feasibility …