Engineering Commons^™

Effects Of Conformal Cooling Channels On Additively Manufactured Injection Molding Tooling, Tyler Blaine Whatcott

Theses and Dissertations

This study focuses on the cycle-averaged mold temperature of additively manufactured injection molding tooling and how it is affected by conformal cooling channels. This was done by producing a benchmark mold out of Digital ABS produced by Stratasys, an acrylic based photopolymer, which was then used to produce injection molded parts until tool failure. Another, more cost-effective material, High Temp Resin produced by Formlabs, another acrylic based photopolymer, was also tested but yielded very little success. Then the mold design was altered by adding conformal cooling channels and again tested by producing injection molded parts while tracking the mold temperature. …

Design, Fabrication, And Reliability Effects Of Additively Manufactured First Level Compliant Interconnects For Microelectronics Application, Tumininu David Olatunji

Graduate Theses and Dissertations

Semiconductor packaging and development is greatly dependent on the magnitude of interconnect and on-chip stress that ultimately limits the reliability of electronic components. Thermomechanical related strains occur because of the coefficient of thermal expansion mismatch from different conjoined materials being assembled to manufacture a device. To curb the effect of thermal expansion mismatch between conjoined parts, studies have been done in integrating compliant structures between dies, solder balls, and substrates. Initial studies have enabled the design and manufacturing of these structures using a photolithography approach which involves a high number of fabrication steps depending on the complexity of the structures …

Analysis For Hybrid Rocket Fuel Regression Using Stereolithographic Geometry, Michael P. King

Theses and Dissertations

Hybrid Rocket Engines (HRE) have characteristically low fuel regression that limits their performance. Additive manufacturing and rapid prototyping can possibly solve some of the problems with Hybrid propulsion regression by creating geometry not possible with conventional manufacturing. This work is attempting to make geometric regression simulation of HRE easier by using STereoLithography (STL files) as the geometry. This analysis sets flow conditions, boundary conditions, propellant selection, and allows for fuel geometry to be altered to simulate geometry’s effects on regression rate and propellant performance. This model can be used for more advanced geometric analysis to improve and predict performance.

Modeling And Analysis For Unit Cell Size, Material Anisotropy And Material Imperfection Effects Of Cellular Structures Fabricated By Powder Bed Fusion Additive Manufacturing., Yan Wu

Electronic Theses and Dissertations

Cellular structures are networks of interconnected struts or walls with porosities and are widely found in many natural load-bearing structures such as plants and bones. Cellular structures offer unique functional characteristics such as high stiffness to weight ratio, tailorable heat transfer coefficient, and enhanced mechanical energy absorption, which makes them highly attractive in various engineering disciplines such as biomedical implants, electrodes, heat exchangers, and lightweight structures. There exists an abundance of literatures that have investigated various mechanical properties of various cellular structures such as Poisson’s ratio, elastic modulus, ultimate strength, yield strength, and failure characteristics. Based on the classic cellular …

Additive Manufacturing Of Graphene-Based Devices For Flexible Hybrid Electronics, Twinkle Pandhi

Boise State University Theses and Dissertations

In this work, I investigate and enhance the fundamental sensing properties of printed electronic nanomaterials (e.g., graphene) in real-world environments while decreasing weight, cost, and power consumption. The dissertation addresses this issue with the following foci in mind: (1) developing a straightforward and repeatable process to synthesize graphene ink which is also compatible with Inkjet-printing (IJP) and Aerosol Jet printing (AJP). (2) Tuning additive manufacturing printing (IJP and AJP) parameters to establish a repeatable manufacturing process and print high performing (graphene-based) electrodes and interconnects, compatible with the underlying substrate. (3) Investigate power dissipation and electrical breakdown in AJP printed graphene …

Measurement And Analysis Of Pressure Profile For Nozzle Based Single Screw Extrusion Systems, Jake Dvorak

Masters Theses

Most large-scale material-extrusion (MatEx) AM systems utilize a single screw extruder. Simulating flow rate and operating pressures of extrusion systems is notoriously difficult without resorting to full finite element analysis due to the phase change and non-Newtonian nature of relevant polymers. This study characterized two machines of interest: a Big Area Additive Manufacturing (BAAM) system and a Randcastle Microtruder. A custom nozzle adapter was fabricated to gather pressure data within the nozzle and mimic the die design of the BAAM on the Microtruder system. Several theories were tested for overall machine output and max pressure. Feed and compression zone theories …

Parametric Study Of Residual Stresses In Wire And Arc Additive Manufactured Parts, Hisham Khaled Jamil Abusalma

Mechanical & Aerospace Engineering Theses & Dissertations

Wire and Arc Additive Manufacturing (WAAM) is a cost-effective additive manufacturing process due to its capability to fabricate large metal parts with high deposition rate and low equipment cost. Although this method is gaining popularity in manufacturing industry, more research is needed to understand process parameters’ effects on residual stress (RS) distribution and part distortion. As such, a 3D thermo-elastic-plastic transient model was established in ABAQUS and employed to investigate the effect of process parameters such as the torch speed, the deposition power and the interlayer dwell time on RS distribution and distortion in WAAM part. The numerical model utilized …

The Effect Of Compaction Temperature And Pressure On Mechanical Properties Of 3d Printed Short Glass Fiber Composites, Pushpashree Jain Ajith Kumar Jain

Mechanical & Aerospace Engineering Theses & Dissertations

Among many thermoplastics that are used in engineering, polyamide 6 (nylon 6) is an extremely versatile engineering thermoplastic. Nylon filled with glass fibers has higher mechanical strength and high wear resistance than general purpose nylon. 3D printed composites, based on fused filament modeling, typically suffer from poor bead-to-bead bonding and relatively high void content, limiting their mechanical properties

This thesis explores the effect of compaction pressure and temperature on improving the mechanical properties of 3D printed composites. Engineering moduli in the printing and transverse to printing direction, as well as ultimate strength were measured using the tensile testing with Digital …

Modulating Mechanical Properties Of Polymer Composites Via Colloidal Particle Reinforcement, Yusheng Guo

LSU Master's Theses

Additive manufacturing allows the rapid process of complex objects with excellent design flexibility. However, the products often exhibit poor mechanical properties when pure polymer is applied as printable material. In this work, we demonstrate that printability of polymer can be dramatically improved when particle filler is added to form reinforced polymer composites. Furthermore, the interaction between filler and polymer matrix leads to the enhancement in mechanical properties of the printed product. The material reinforcement induced by addition of fillers enables the wide application of polymer composites to print structures with unique features. In the printing of silica-reinforced pNIPAM composite, we …

3d Printing For Solving Part Obscolescence, Ayman G. Alqarni

Theses and Dissertations

The purpose of this research was to highlight the issue of parts obsolescence and to highlight the possibility of using alternative methods to overcome parts shortage. Specifically, this thesis sought to answer the research question: is the three-dimensional printing technology (3D) an applicable approach to overcome part obsolescence. The research question was answered through data research and survey analysis. Notwithstanding, the diminished manufacturing sources and material shortages (DMSMS) management and other existing approaches, such as forecasting, contracting, and reverse engineering (RE), were discussed briefly in the literature review and profoundly in chapter IV to differentiate among applicable existing solutions toward …

Studies On Space Grade Nano-Iconic Radiation Sensors Using Additive Manufacturing Technology, Shah Mohammad Rahmot Ullah

Boise State University Theses and Dissertations

Though Additive manufacturing technology has been developing for 30 years, in recent years, it gets researchers’ and industries’ attention for new expansion in fabricated electronics devices, especially on a flexible substrate. This technology allows fabricating complex design of electronics devices with multi-functionality. Its application has been significantly expanded to different fields such as sensors and other device prototypes for nuclear facilities, aerospace manufacturing, bio-medical, solar energy, etc. due to its low-cost efficiency and sustainable manufacturing. It has a huge advantage over traditional methods such as lower materials waste during production, avoiding complex etching system and harmful chemicals, simplified assembly system …

Experimental Study Of Graphene Energy Absorbing Layer In Femtosecond Infrared Laser Assisted Bioprinting, Chaoran Dou

Theses and Dissertations

The bioprinting, as a new branch of additive manufacturing, already shown its potential in organ transplantation, medicine develop and personalized medicine. There are three types of bioprinting: droplet based bioprinting, extrusion based bioprinting and laser assisted bioprinting (LAB). Compared with other types of bioprinting, the LAB is the only bioprinting method that does not have a nozzle, which gives it the ability to print high viscosity bioink. The LAB also enjoys higher resolution and cell viability than other methods.

The bubble/jet formation process is the most important process for the LAB, which deposits the bioink to the substrate. To utilize …

An Investigation Of The Effect Of Contour Process Parameters On The Surface Roughness And Dimensionality Of Overhanging Features In 17-4 Stainless Steel., Katherine Schneidau

Electronic Theses and Dissertations

The relationship between varying contour settings and part geometry provides insight into the attainable surface roughness and dimensional accuracy of parts fabricated in 17-4 stainless steel via selective laser melting (SLM). Varying the contour settings of laser power (W), scan speed (mm/s), and beam offset (mm) for unsupported inclined bars. The utilization of a coordinate measuring machine (CMM) and surface profilometer quantified the dimensional accuracy and average surface roughness (Ra) for upface, downface, and topface surfaces. Adjusting the laser power and scan speed had minimal affect to surface roughness compared to part geometry. Part dimensionality was affected by the …

Effects Of Powder Recycling In Selective Laser Melting, Nina L. Menon

Industrial and Manufacturing Engineering

The following report analyzes 316L stainless steel powder characteristics of new powder and powder that has been used in the selective laser melting process for 40-50 builds. A literature review was done of powder characteristics, different ways flowability can be tested, and effects of recycling other types of metal powders in Additive Manufacturing. Flowability improved over 21 reuses of the titanium alloy Ti-6Al-4V and resulted in stronger printed parts. Flow of S17-4 PH steel powder was measured with a Hall flowmeter and increased significantly over the course of 10 reuses. Heavily recycled (estimated 50 reuses) 316L SS powder and brand …

Design For Additive Manufacturing, Michael Charonnat, Leonardo Franco-Muñoz, Sam Noble, J.P. Purdom

Mechanical Engineering

This document outlines the critical design details and timeline for the Design for Additive Manufacturing Senior Project sponsored by Solar Turbines, Inc. The scope of this project encompasses the redesign of two of Solar Turbine’s cast parts for metal additive manufacturing in order to minimize lead time, cost, and weight. With the overall objective of performing in-depth analysis exploring affordability & feasibility, this redesign process will aid Solar Turbines in expanding their knowledge of Design for Additive Manufacturing principles and enable them to further incorporate the use of additive manufacturing into their production processes. The first part that the team …

Silicone 3d Printing Processes For Fabricating Synthetic, Self-Oscillating Vocal Fold Models, Taylor Eugene Greenwood

Theses and Dissertations

Synthetic, self-oscillating vocal fold (VF) models are physical models whose life-like vibration is induced and perpetuated by fluid flow. Self-oscillating VF models, which are often fabricated life-size from soft silicone elastomers, are used to study various aspects of voice biomechanics. Despite their many advantages, the development and use of self-oscillating VF models is limited by the casting process used to fabricate the models. Consequently, this thesis focuses on the development of 3D printing processes for fabricating silicone VF models. A literature review is first presented which describes three types of material extrusion 3D printing processes for silicone elastomers, namely direct …

Experimental And Numerical Study Of Process Parameters Effects Towards Part Quality And Porosity During Powder Bed Additive Manufacturing Processes., Subin Shrestha

Electronic Theses and Dissertations

Powder bed additive manufacturing (PB-AM) process utilizes an electron beam or a laser as a heat source to melt the metallic powder particles. These processes have the capability of freeform fabrication, however certain defects such as porosity, high surface roughness, etc. would hinder its application. It is important to understand the effect of the process parameters and the underlying physical phenomena, which lead to the formation of such defects. In this regard, a three-dimensional (3D) thermo-fluid model is developed to study the effect of beam speed on the surface morphology during powder bed electron beam additive fabrication (PB-EBAF). Besides, the …

Extremely Low Cycle Fatigue Behavior Of Additively Manufactured 17-4ph Stainless Steel, Kaley Collins

Civil Engineering Undergraduate Honors Theses

Steel structures survive seismic loading thanks to components capable of dissipating large amounts of energy through large deformations. Future optimizations of these components include complex free-form geometries that are difficult to fabricate with traditional casting processes. Additive manufacturing (AM) is an alternative for producing optimized free-form geometries. AM material contains significant differences in microstructural characteristics and mechanical behavior compared to its wrought counterparts. Research has been conducted to understand the effect of microscopic features in the high cycle fatigue (HCF) and low cycle fatigue (LCF) regimes. This study focuses on the behavior of 17-4 Precipitation Hardening (PH) stainless steel in …

Determining The Efficacy Of Additive Manufacturing For The Aerospace Spare Parts Supply Chain, Kyle O'Brien

Electronic Theses and Dissertations

This thesis investigates how additive manufacturing (AM) based on-demand part production can supplement or replace the traditional production and inventory in typical aerospace’s spare parts supply chain systems. This study focuses on the operational characteristics of AM and its impacts on the overall logistics of plant-level operations. To capture the microscopic operational aspects of the AM production, a discrete-event simulation based approach was adopted, with key AM operation resources (e.g. AM system, operator) and attributes (e.g. AM manufacturing speed, individual part characteristics and demands) accounted for in the modeling process. In addition, a benchmark warehouse inventory model was also established …

Influences Of Material Extrusion Additive Manufacturing (Meam) Parameters And Additives On Polyvinylidene Fluoride (Pvdf) Properties., Niknam Momenzadeh

Electronic Theses and Dissertations

Beyond the beneficial characteristics of smart polymers associated with all polymers such as flexibility and cost fabrication, smart materials exhibit multifunctional behaviors. The prospect of integrating structural and sensing/actuation capabilities into a single structure gives design engineers an ability to innovate highly novel, multi-functional creations. Polyvinylidene Fluoride (PVDF) is one of the widely used multi-functional materials which offers a variety of desirable material properties. It possesses exceptional chemical and UV resistance, biocompatibility, low processing temperature and affordable price making it a competitive choice for many commercial applications. In addition, among polymers, PVDF is simply the most dominant piezoelectric polymer. On …

Selective Laser Melting 17-4 Ph Stainless Steel And The Effect Of Varied Thermal Treatments On Fatigue Behavior., Sean Daniel Dobson

Electronic Theses and Dissertations

Fatigue failure is the leading source of loss in industry. In order for new means of manufacturing to move towards mainstream use a complete understanding of material and mechanical behavior must be gained. This endeavor seeks to aide in that task by observing the fatigue behavior of selective laser melting (SLM) additive manufacturing (AM) specimens and the effect of differing thermal treatment conditions for an optimized AM process. Stainless steel 17-4 PH specimens were fabricated using SLM AM and thermally treated to three conditions: as-built, solutionized and hardened, and direct hardened. These specimens were characterized for material (powder quality, density, …

Investigation Of Ultem 9085 For Use In Printed Orbital Structures, William R. Gallagher

Theses and Dissertations

Additive manufacturing is revolutionizing industries ranging from medicine to space. However, the structural characteristics of plastic parts created by these methods are not as well understood as their more established counterparts. This research explored two relevant areas: how the structural characteristics of ULTEM 9085 plastic behaved after exposure to orbital conditions and the design of the cross-sectional area of a beam to be 3-D printed in microgravity based on the expected loads from the printer. To study orbital effects, ULTEM 9085 was printed into 1/4th scale ASTM D638- 14 dogbones using a Stratasys 450mc printer. These dogbones were placed in …

Solution Anneal Heat Treatments To Enhance Mechanical Performance Of Additively Manufactured Inconel 718, David J. Newell

Theses and Dissertations

The nickel-based superalloy Inconel 718 (IN718) is an excellent candidate among aerospace alloys for laser powder-bed fusion (LPBF) manufacturing. As-built LPBF IN718 has a vertically aligned columnar (001) microstructure which translates into orthotropic mechanical behavior. The post-process heat treatments for IN718 were developed 60 years ago for wrought and cast processes and do not mitigate the columnar microstructure of the LPBF process. Recrystallization is required to remove the columnar microstructure, which would allow for parts to be fabricated on different machines or in different orientations but still achieve the same properties. This research investigated the microstructure of LPBF IN718 as …

An Analysis Of The Viability Of 3d-Printed Construction As An Alternative To Conventional Construction Methods In The Expeditionary Environment, Jeneé A. Jagoda

Theses and Dissertations

Conventional construction is believed by some to have reached its technological limit of performance, making it increasingly difficult for conventional construction methods to meet the U.S. military’s core standards of quality, cost, and timeliness in the expeditionary environment. While still in its infancy, 3D-printed construction has the potential to revolutionize the way the military performs construction in deployed environments. This research conducts a systematic review of the viability of 3D-printed construction to investigate whether or not it is now or could be a viable replacement for conventional construction methods, specifically in remote environments where conventional construction capability may be limited. …

Design, Development, And Testing Of A Low Cost, Additively-Manufactured, Centrifugal Compressor, Aaron P. Bauer

Theses and Dissertations

The three objectives of this research were to: 1.) design, build, and test AM compressors to substitute into COTS micro-gas turbine engines, 2.) provide initial correlations between FEA and compressor failure speed, and 3.) characterize the effects of AM on compressor performance. These goals improved the design cycle cost and the design-validation time cycle. ULTEM 9085, 300-AMB, and Onyx-Kevlar temperature-dependent tensile properties were measured. FEA-predicted failure speeds of stock compressor designs led design improvements, potentially fulfilling the original compressor requirements. Physical testing of the stock and ULTEM 9085 compressors occurred. Comparing these compressors' performances demonstrated that low cost, AM materials …

Analysis Of Additively Manufactured Rings Under Compression Loading For Use In A Vacuum Lighter Than Air Vehicle Structure, Kevin D. Greenoe

Theses and Dissertations

A Vacuum Lighter Than Air Vehicle (VLTAV) utilizes a lightweight structure paired with an internal vacuum to achieve buoyancy; this allows it to float through-out a given atmosphere. The pressure differential between the internal vacuum andexternal atmosphere places the vehicle under intense loading. A specific structure under investigation is the celestial icosahedron, which features nine intersecting rings that have an outer diameter of 0.2032m and circular cross-sectionalthickness of 5.08mm.The celestials rings are positioned in three different orientations and are analyzed both experimentally and analytically.

Structural Dynamic And Inherent Damping Characterization Of Additively Manufactured Airfoil Components, Andrew W. Goldin

Theses and Dissertations

The push for low cost and higher performance/efficient turbine engines have introduced a new demand for novel technologies to improve robustness to vibrations resulting in High Cycle Fatigue (HCF). There have been many proposed solutions to this, some passive and some active. With the advent of Additive Manufacturing (AM), new damping techniques can now be incorporated directly into the design and manufacture process to suppress the vibrations that create HCF. In this study, this novel unfused pocket damping technology is applied to a blade structure and the resulting damping effectiveness is quantified. The application of this technology to complex geometries …

Synthesis And Advanced Manufacturing Of Polymer Structures And Their Composites, Bethany Rose Wilburn

Open Access Theses & Dissertations

The following research work performed embodies three unique studies of polymer structures and their composites. In general, polymers are viscoelastic, insulative materials that are used for a wide variety of applications within industrial, aerospace, and biomedical fields. Polymers have been studied and optimized for any particular use by chemically synthesizing unique micro-structures, altering the physical properties through fabrication and post-processing, and utilizing 3D printing to achieve complex geometries. In the past decade, additive manufacturing (AM) has drawn extensive attention across academia, industry, and government agencies. It offers unprecedented advantages such as design freedom, rapid prototyping, and customization. In this work, …

Additive Manufacturing Of Linear Shaped Charges To Address Run Up And Run Down Phenomena, Jason Ho

Masters Theses

”A shaped charge is an explosive device used to focus detonation energy in a desired direction. Additive Manufacturing (AM) can allow greater design freedom and geometric complexity for the liner portion of the shaped charge.

In this work, the following hypotheses were tested: 1) Adjusting the initial apex angle of a linear shaped charge liner reduces the amount of run up that occurs, and 2) implementing a backstop at the end of a linear shaped charge liner reduces the amount of run down that occurs.

Linear shaped charge liners with a continuously changing apex angle were created with additive manufacturing. …

In-Situ X-Ray Imaging Of The Selective Laser Melting Process, Meelap M. Coday

Masters Theses

"Fusion-based metal additive manufacturing (AM) has garnered much interest in recent decades. Despite the popularity of fusion-based AM technologies such as selective laser melting (SLM), there are still fundamental questions and uncertainties that need to be addressed. In this work, we focus on the understanding of the undercooling in the SLM process and the uncertainties induced by the laser beam size, power, and scan speed. First, we report the estimation of undercooling in the SLM process from the solidification rate measured by in-situ high-speed synchrotron x-ray imaging, based on the dendrite growth velocity model. The undercooling changes as a function …