Engineering Commons^™

Heat Treatments For Minimization Of Residual Stresses And Maximization Of Tensile Strengths Of Scalmalloy® Processed Via Directed Energy Deposition, Rachel Boillat-Newport, Sriram Praneeth Isanaka, Jonathan Kelley, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Scalmalloy® is an Al-Mg-Sc-Zr-Based Alloy Specifically Developed for Additive Manufacturing (AM). This Alloy is Designed for Use with a Direct Aging Treatment, as Recommended by the Manufacturer, Rather Than with a Multistep Treatment, as Often Seen in Conventional Manufacturing. Most Work with Scalmalloy® is Conducted using Powder Bed Rather Than Powder-Fed Processes. This Investigation Seeks to Fill This Knowledge Gap and Expand Beyond Single-Step Aging to Promote an overall Balanced AM-Fabricated Component. for This Study, Directed Energy Deposition (DED)-Fabricated Scalmalloy® Components Were Subjected to Low-Temperature Treatments to Minimize Residual Stresses Inherent in the Material Due to the Layer-By-Layer Build Process. …

Residual Stress Generation In Additive Manufacturing Of Complex Lattice Geometries, Katie Bruggeman, Nathan Klingbeil, Anthony N. Palazotto

Faculty Publications

Residual stresses developed during additive manufacturing (AM) can influence the mechanical performance of structural components in their intended applications. In this study, thermomechanical residual stress simulations of the laser powder bed fusion (LPBF) process are conducted for both simplified (plate and cube-shaped) geometries as well as five complex lattice geometries fabricated with Inconel 718. These simulations are conducted with the commercial software package Simufact Additive©, which uses a nonlinear finite element analysis and layer-by-layer averaging approach in determining residual stresses. To verify the efficacy of the Simufact Additive© simulations, numerical results for the plate and cube-shape geometries are analyzed for …

Advancements And Challenges In Additively Manufactured Functionally Graded Materials: A Comprehensive Review, Suhas Alkunte, Ismail Fidan, Vivekanand Naikwadi, Shamil Gudavasov, Mohammad Alshaikh Ali, Mushfig Mahmudov, Seymur Hasanov, Muralimohan Cheepu

Engineering Technology Faculty Publications

This paper thoroughly examines the advancements and challenges in the field of additively manufactured Functionally Graded Materials (FGMs). It delves into conceptual approaches for FGM design, various manufacturing techniques, and the materials employed in their fabrication using additive manufacturing (AM) technologies. This paper explores the applications of FGMs in diverse fields, including structural engineering, automotive, biomedical engineering, soft robotics, electronics, 4D printing, and metamaterials. Critical issues and challenges associated with FGMs are meticulously analyzed, addressing concerns related to production and performance. Moreover, this paper forecasts future trends in FGM development, highlighting potential impacts on diverse industries. The concluding section summarizes …

Energy Efficiency In Additive Manufacturing: Condensed Review, Ismail Fidan, Vivekanand Naikwadi, Suhas Alkunte, Roshan Mishra, Khalid Tantawi

Engineering Technology Faculty Publications

Today, it is significant that the use of additive manufacturing (AM) has growing in almost every aspect of the daily life. A high number of sectors are adapting and implementing this revolutionary production technology in their domain to increase production volumes, reduce the cost of production, fabricate light weight and complex parts in a short period of time, and respond to the manufacturing needs of customers. It is clear that the AM technologies consume energy to complete the production tasks of each part. Therefore, it is imperative to know the impact of energy efficiency in order to economically and properly …

Additive Manufacturing Of Novel Lightweight Insulation Refractory With Hierarchical Pore Structures By Direct Ink Writing, Saisai Li, Jiaxuan Xin, Ruoyu Chen, Haiming Wen

Materials Science and Engineering Faculty Research & Creative Works

A direct ink writing process using fly ash foaming slurries was employed for the additive manufacturing of lightweight mullite insulation refractory with hierarchical pore structures. The viscosity, thixotropy, and shear thinning behavior of the inks were analyzed to investigate the effect of the inorganic binder and dispersant of the foaming inks. A slurry exhibiting excellent rheological characteristics was identified, consisting of 45 wt% fly ash floating beads, 55 wt% water, 3.0 wt% additional dispersant, and 6.0 wt% additional binder. Furthermore, through the optimization of printing parameters such as printing pressure and printing speed, notable enhancements were achieved in the pore …

An Investigation Into Applications Of Canonical Polyadic Decomposition & Ensemble Learning In Forecasting Thermal Data Streams In Direct Laser Deposition Processes, Jonathan Storey

Theses and Dissertations

Additive manufacturing (AM) is a process of creating objects from 3D model data by adding layers of material. AM technologies present several advantages compared to traditional manufacturing technologies, such as producing less material waste and being capable of producing parts with greater geometric complexity. However, deficiencies in the printing process due to high process uncertainty can affect the microstructural properties of a fabricated part leading to defects. In metal AM, previous studies have linked defects in parts with melt pool temperature fluctuations, with the size of the melt pool and the scan pattern being key factors associated with part defects. …

Upcyclying Of Polyethylene Terephtalate By Addition Of Thermoplastic Elastomer, Diego Francisco Bermudez

Open Access Theses & Dissertations

Continual overconsumption of single-use plastics has generated challenges of solid waste management across the United States. Common plastic waste management solutions, such as landfill, have caused the migration of contaminants into the environment consequently affecting not only the health of wildlife, but also that of human beings. Alternative strategies for the handling of single-use plastic such as polyethylene terephthalate (PET), used in the food packaging industry, can ultimately help mitigate the noxious consequences of single-use plastics affecting entire ecosystems. This study demonstrates a potential avenue of materials upcycling by studying the effects of coupling PET with the thermoplastic elastomer styrene-ethylene-butylene-styrene …

Additive Manufacturing Of Composites For Sensing And Harsh Environments Application, Md Sahid Hassan

Open Access Theses & Dissertations

Composite materials are made by combining two or more materials, such as fibers and resins to create a material system that has improved mechanical and physical properties compared to its individual components. The use of 3D printing technology in composite manufacturing allows for the creation of complex and custom shapes with precise control over the placement of the materials. This makes it possible to create composite parts with enhanced performance characteristics and reduced weight. The work presented in this dissertation lies in the design and development of highly flexible impact propagation sensor through material extrusion 3D printing technique. By using …

Ultrasonic Non-Destructive Evaluation Of Additively Manufactured Polymer-Ceramic Composites, Christian Alexander Ruiz

Open Access Theses & Dissertations

Digital light processing (DLP) is an attractive additive manufacturing technique due to its ability to create ceramic parts with complex geometries. DLP uses ultraviolet light to polymerize a slurry comprised of ceramic powder and photosensitive resin in layers to create solid parts. Printing parameters such as light intensity and exposure time are critical when producing these parts. Improper parameters can lead to over or under-curing, adversely impacting print quality and strength. Samples were printed at varying layer exposure times and then tested using ultrasonics to determine the degree of conversion. Additionally, ultrasonics were used as a non-destructive technique to obtain …

Damage Detection With An Integrated Smart Composite Using A Magnetostriction-Based Nondestructive Evaluation Method: Integrating Machine Learning For Prediction, Christopher Nelon

All Dissertations

The development of composite materials for structural components necessitates methods for evaluating and characterizing their damage states after encountering loading conditions. Laminates fabricated from carbon fiber reinforced polymers (CFRPs) are lightweight alternatives to metallic plates; thus, their usage has increased in performance industries such as aerospace and automotive. Additive manufacturing (AM) has experienced a similar growth as composite material inclusion because of its advantages over traditional manufacturing methods. Fabrication with composite laminates and additive manufacturing, specifically fused filament fabrication (fused deposition modeling), requires material to be placed layer-by-layer. If adjacent plies/layers lose adhesion during fabrication or operational usage, the strength …

Design, Fabrication, And Integration Of Robotic Skin Sensors For Human Robot Interaction., Olalekan Olakitan Olowo

Electronic Theses and Dissertations

Enhancing physical human-robot interaction in modern robotics relies on refining the tactile perception of robot skin sensors. This research focuses on crucial aspects of the development process, including fabrication techniques, miniaturization, and integration for a more efficient collaborative human-robot interface. The fabrication process of robot skin sensors, designed to mimic human skin, is explored both within and outside cleanroom environments. An enhanced technique is presented to increase fabrication yield and create more miniaturized sensor designs with feature sizes in the tens of microns. These sensors function as piezoresistive arrays using organic polymers like PEDOT: PSS as the pressure-sensing medium. Various …

Advancing Additive Manufacturing For Biomedical Applications: Antimicrobial And X-Ray Absorptive Composite Filaments For Fused Filament Fabrication, John M. Arnold Jr

University of New Orleans Theses and Dissertations

The objective of this research was to investigate the use of nano- and microparticle amendments for the creation of Poly-lactic Acid composite materials for use in biomedical applications using the Fused Filament Fabrication process of Additive Manufacturing. Composites were created with the goal of imparting the useful properties of antimicrobial activity and x-ray absorption to the material. In addition to testing the efficacy of the particle amendments in achieving the desired properties, the thermal and mechanical properties of the composite materials were tested to ensure that the composites would be compatible with the Fused Filament Fabrication process and would produce …

Characterization Of Interlayer Laser Shock Peening During Fused Filament Fabrication Of Polylactic Acid (Pla), Fabien Denise

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

The field of additive manufacturing (AM) has gained a significant amount of popularity due to the increasing need for more sustainable manufacturing techniques and the adaptive development of complex product geometries. The problem is that AM parts routinely exhibit flaws or weaknesses that affect functionality or performance. Over the years, surface treatments have been developed to compensate certain flaws or weaknesses in manufactured products. Combining surface treatments with the modularity of additive manufacturing could lead to more adaptable and creative improvements of product functions in the future. The current work evaluates the feasibility of pursuing a new research axis in …

Development Of A Potassium Permanganate Catalyst-Infused Fuel Grain For Hydrogen Peroxide Hybrid Thruster Ignition Enhancement, Ryan J. Thibaudeau

All Graduate Theses and Dissertations, Fall 2023 to Present

This thesis describes and addresses the need for reliable ignition in small satellite hybrid propulsion systems using hydrogen peroxide. It describes process of creating custom 3D printed ABS plastic fuel grains with small amounts of catalysts. These catalysts lead to a more reliable and energy-efficient ignition of a hybrid rocked propulsion system using catalyst-infused ABS and high-test hydrogen peroxide (HTP). Hydrogen peroxide is a high-density oxidizer and therefore more volumetrically efficient for a small satellite using hybrid rocket technology when compared to gaseous oxygen (GOX). The traditional ignition methods of hybrid rocket propulsion systems using HTP are compared to and …

Study On Debinding And Sintering Conditions In Extrusion-Based Additive Manufacturing Of 316l And 316l + Cu, Jean-François Silvain, Daniel Lincoln Gifford, Sébastien Fourcade, Laurent Cuzacq, Jean-Luc Grosseau-Poussard, Catherine Debiemme-Chouvy, Nicolas Tessier Doyen, Yongfeng Lu

Department of Electrical and Computer Engineering: Faculty Publications

This study investigates the use of a methylcellulose binder in extrusion additive manufacturing of 316L as an alternative to common wax-based binders. Various quantities of copper (Cu) powder were also added in the paste composition to attempt to reduce the sintering temperature by promoting persistent liquid phase sintering. Debinding experiments were conducted under different temperatures and dwell times using argon (Ar), Ar/5%H₂, and Ar/1%O₂ atmospheres. Debinding reduced carbon (C) content to 0.032 wt.% by using a two-step debinding process of Ar/5%H₂ and Ar/1%O₂ thermal treatments. Using this debinding process, sintering was conducted at 1200 ^{o …}

Understanding Melt Pool Characteristics In Laser Powder Bed Fusion: An Overview Of Single- And Multi-Track Melt Pools For Process Optimization, Jincheng Wang, Rui Zhu, Yujing Liu, Laichang Zhang

Research outputs 2022 to 2026

Laser powder bed fusion (LPBF) has made significant progress in producing solid and porous metal parts with complex shapes and geometries. However, LPBF produced parts often have defects (e.g., porosity, residual stress, and incomplete melting) that hinder its large-scale industrial commercialization. The LPBF process involves complex heat transfer and fluid flow, and the melt pool is a critical component of the process. The melt pool stability is a critical factor in determining the microstructure, mechanical properties, and corrosion resistance of LPBF produced metal parts. Furthermore, optimizing process parameters for new materials and designed structures is challenging due to the complexity …

A Review Of The Mechanical Properties Of 17-4ph Stainless Steel Produced By Bound Powder Extrusion, Jaidyn Jones, Ana Vafadar, Reza Hashemi

Research outputs 2022 to 2026

17-4PH Stainless Steel is a mechanically high-performing alloy that is widely used across chemical and mechanical processing industries. The alloy is conventionally fabricated by cast methods, but emerging additive manufacturing techniques are presently offering an economic, efficient, and environmentally friendly alternative. Bound Powder Extrusion (BPE) is a relatively new additive manufacturing technique that is used to fabricate three-dimensional, free-form components. Investigation into the mechanical properties and behavior of 17-4PH stainless steel fabricated by BPE is vital to understanding whether this technique proposes a competitive substitute to the cast alloy within industry. Published literature has investigated the as-fabricated mechanical properties, microstructure, …

Numerical Study Of Solar Receiver Tube With Modified Surface Roughness For Enhanced And Selective Absorptivity In Concentrated Solar Power Tower, Shawn Hatcher, Mathew Z. Farias, Jianzhi Li, Peiwen Li, Ben Xu

Manufacturing & Industrial Engineering Faculty Publications and Presentations

Concentrated solar power (CSP) is a reliable renewable energy source that is progressively lowering its cost of energy. However, the heat loss due to reflected and emitted radiation hinders the maximum achievable thermal efficiency for solar receiver tubes on the solar tower. Current solar selective coatings cannot withstand the high temperatures that come with state-of-the-art CSP towers often needing to be recoated soon after initial operation. We intend to use Inconel 718 with different additive manufacturing (AM) practices to construct surfaces that allow for more light-trapping to occur. By adjusting printing parameters, we can tailor a surface to allow for …

Investigation Of Deformation Behavior Of Additively Manufactured Aisi 316l Stainless Steel With In Situ Micro-Compression Testing, Fei Teng, Ching-Heng Shiau, Cheng Sun, Robert C. O'Brien, Michael D. Mcmurtrey

Materials Science and Engineering Faculty Publications and Presentations

Additive manufacturing techniques are being used more and more to perform the precise fabrication of engineering components with complex geometries. The heterogeneity of additively manufactured microstructures deteriorates the mechanical integrity of products. In this paper, we printed AISI 316L stainless steel using the additive manufacturing technique of laser metal deposition. Both single-phase and dual-phase substructures were formed in the grain interiors. Electron backscatter diffraction and energy-dispersive X-ray spectroscopy indicate that Si, Mo, S, Cr were enriched, while Fe was depleted along the substructure boundaries. In situ micro-compression testing was performed at room temperature along the [001] orientation. The dual-phase substructures …

Investigating The Effect Of Bead Geometry On Fiber Orientation And Thermomechanical Properties For Large-Format Extrusion-Based Additive Manufacturing, Joanna F. Keaton

Electronic Theses and Dissertations

In large-format extrusion-based additive manufacturing of polymer composites, the relationship between material properties and processing parameters requires further investigation. This thesis focuses on the relationship between fiber orientation and thermomechanical properties for short fiber-filled thermoplastic polymer systems manufactured by extrusion-based additive manufacturing. Fiber orientation is particularly important in determining the thermomechanical properties of the composite material as properties in the direction of deposition are expected to be higher for highly aligned fibers than randomly aligned fibers. Fiber orientation distribution, which is related to processing parameters and deposition conditions, can be efficiently represented by the orientation tensor. The orientation tensor can …

Mechanical Characterization Of Automated Fiber Placement And Additive Manufacturing Hybrid Composites, Lucan Haviland

Electronic Theses and Dissertations

This thesis presents the optimization of processing parameters based on the mechanical properties of Continuous Fiber-Reinforced Thermoplastic (CFRTP) Unidirectional (UD) consolidated tapes. The UD tapes were consolidated using an AFP head and a thermoforming press for comparison. The adhesive strength of hybrid parts consisting of CFRTP UD tape bonded to a 3D-printed substrate with the same matrix system were investigated. Large Area Additive Manufacturing (LAAM) was utilized for the 3D-printed parts. Different types of thermoplastic composite materials were explored, including Glass Fiber reinforced Polyethylene Terephthalate Glycol (GF/PETG), Carbon Fiber reinforced Polyethylene Terephthalate Glycol (CF/PETG), Carbon Fiber reinforced Polycarbonate (CF/PC), and …

Additive Manufacturing Of High-Performance Nanolamellar Eutectic High-Entropy Alloys, Jie Ren

Doctoral Dissertations

Additive manufacturing, also called three-dimensional (3D) printing, is an emerging technology for printing net-shaped components layer by layer for applications in automotive, aerospace, biomedical and other industries. In addition to the vast design freedom offered by this approach, metal 3D printing via laser powder-bed fusion (L-PBF) involves large temperature gradients and rapid cooling and provides exciting opportunities for producing microstructures and mechanical properties beyond those achievable by conventional processing routes. Although these extreme printing conditions enable microstructural refinement to the nanoscale for achieving high strength. However, high-strength nanostructured alloys by laser additive manufacturing often suffer from limited ductility. Eutectic high-entropy …

Fatigue And Fracture Of Electron Beam Melting Ti-6al-4v, William A. Grell

Electronic Theses and Dissertations

For applications in the aerospace field, selection of materials for a given design requires an understanding of critical properties, like fatigue and fracture, in addition to static mechanical and physical properties. With the ongoing advancements in metallic additive manufacturing techniques and the interest in applying the process to aerospace applications, there is a clear need to fully characterize properties. Arguably, the most attractive alloy for applications in aerospace is the Ti-6Al-4V alloy. The current dissertation examines the mechanical properties of the alloy, made by the Electron Beam Melting (EBM) Powder Bed Fusion (PBF) method. As illustrated in this work, the …

Design Of Machine Tool Cross Beam Using Metal Big Area Additive Manufacturing, Tyler Poon

Masters Theses

The modern world would not be what it is now without machine tools. Advances in materials and processes, such as carbon fiber and additive manufacturing (AM), enable the design space for machine tool components to expand. However, machine tool components require accurate geometry, which is not available from parts produced by metal Big Area Additive Manufacturing (mBAAM). This project outlines the process in which a traditionally manufactured machine tool component, a welded box structure on an existing machine tool, was redesigned to be made using mBAAM. The goal was to design a structure that was printable using the MedUSA system …

Creep Resistance And Microstructure In Binary Aluminum Cerium Alloy Produced By Laser Powder Bed Fusion, Jillian Ann Stinehart

Master's Theses (2009 -)

Currently, the only commercially available aluminum alloy for additive manufacturing (AM) is AlSi10Mg, which is not suitable for high temperature applications. Al-Ce based alloys have been shown to be highly printable, cost-efficient alloys. Compared to cast Al-Ce alloys, the eutectic features are refined (<1μm), which give AM Al-10Ce favorable strength and ductility at room temperature. The low diffusivity and solubility of cerium in aluminum improve the retention of mechanical properties at high temperatures. In order to quantify the effect of cerium on the thermal stability of AM aluminum and show its suitability for high-temperature applications, Al-10Ce was creep tested between 60-77% of its absolute melting temperature. The creep performance of AM Al-10Ce was favorable compared to that of cast binary Al-Ce and AM AlSi10Mg and was comparable to that of cast ternary Al-Ce alloys. The stress exponent, n, was approximately 1 in the low stress regime and 5-7 in the high stress regime. The activation energy was 231kJ/mol. In comparison, both cast binary Al-Ce and AM AlSi10Mg have higher stress exponents and lower activation energies, showing AM Al-10Ce to be more creep resistant. After creep testing, slight grain coarsening was observed, while grain orientation remained unchanged. The melt pool boundaries (MPBs) faded in appearance after creep testing, and the number of columnar grains decreased.

Image Segmentation With Human-In-The-Loop In Automated De-Caking Process For Powder Bed Additive Manufacturing, Vincent Opare Addo Asare-Manu

Theses and Dissertations

Additive manufacturing (AM) becomes a critical technology that increases the speed and flexibility of production and reduces the lead time for high-mix, low-volume manufacturing. One of the major bottlenecks in further increasing its productivity lies around its post-processing procedures. This work focuses on tackling a critical and inevitable step in powder-bed additive manufacturing processes, i.e., powder cleaning or de-caking. Pressing concerns can be raised with human involvement when performing this task manually. Therefore, a robot-driven automatic powder cleaning system could be an alternative to reducing time consumption and increasing safety for AM operators. However, since the color and surface texture …

Monitoring Additive Manufacturing Machine Health, Jeremy Hale

Doctoral Dissertations

Additive manufacturing (AM) allows the production of parts and goods with many benefits over more conventional manufacturing methods. AM permits more geometrically complex designs, custom and low-volume production runs, and the flexibility to produce a wide variety of parts on a single machine with reduced pre-production cost and time requirements. However, it can be difficult to determine the condition, or health, of an AM machine since complex designs can increase the variability of part quality. With fewer parts produced, destructive testing is less desirable and statistical methods of tracking part quality may be less informative. Combined with the relatively more …

Multifunctional Additive Manufacturing And Multiphysics Numerical Investigations Of Carbon Fiber Structural Battery Composite Using A Drop-On-Demand Method With In-Situ Consolidation, Xiangyang Dong, Yuekun Chen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Lightweight Carbon Fiber Structural Battery Composite Has Great Potential in Increasing Structural Energy Storage Efficiency for Multifunctional Applications. However, It is Still Challenging to Design Carbon Fiber Multifunctional Composite Due to Lack of Proper Manufacturing Methods. in This Study, an Integrated Multifunctional Design and Fabrication Approach is Developed by Combining a Drop-On-Demand Additive Manufacturing Method with a Multiphysics Numerical Model to Guide the Development of the New Multifunctional Composite. through Deposition with In-Situ Consolidation, the Function and Thickness of Each Carbon Fiber Layer as Well as its Fiber Volume Fraction Are Accurately Controlled. Decreasing Layer Thickness Improves Flexural Properties. the …

Correlating Large-Format Additive Manufacturing Processing Parameters To Fiber Length And The Mechanical Performance Of Reinforced Polymer Composites, Andrew Phillip Rhodes

Masters Theses

The Big Area Additive Manufacturing (BAAM) system at Oak Ridge National Laboratory has been used to produce carbon fiber reinforced structures for several years, including vehicles, building constituents, composite tooling, etc. While the development of a large-format polymer additive manufacturing (AM) system has moved quickly, the impact of the BAAM’s extruder on the length of carbon fiber feedstock has not been systematically studied. Numerous studies in processing fiber reinforced thermoplastics in plasticizing and injection molding systems have shown that fibers are subjected to significant shear as they are processed, which can cause a drastic reduction in fiber length which negatively …

Point Heat Source Correlation To Microstructural Evolution In Advanced Manufacturing, Mark Anderson

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Although there are different ways that advanced manufacturing can be performed, the use of single-point heat sources has become the standard to control a final product’s properties. It is imperative to understand how the heat source used in the different advanced manufacturing processes affect the microstructure of interest. The intimate relationship between the heat source and microstructure allows for controlling and tailoring a part’s properties. Utilizing different microstructural analysis, the cross-correlation of various point heat sources to developed microstructure was conducted in this dissertation.

Laser powder bed fusion allows for unique print-to-part protocols, but the dynamics of the process makes …