Engineering Commons^™

Tini-Based Bi-Metallic Shape-Memory Alloy By Laser-Directed Energy Deposition, Yitao Chen, Cesar Ortiz Rios, Braden Mclain, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In this study, laser-directed energy deposition was applied to build a Ti-rich ternary Ti–Ni–Cu shape-memory alloy onto a TiNi shape-memory alloy substrate to realize the joining of the multifunctional bi-metallic shape-memory alloy structure. The cost-effective Ti, Ni, and Cu elemental powder blend was used for raw materials. Various material characterization approaches were applied to reveal different material properties in two sections. The as-fabricated Ti–Ni–Cu alloy microstructure has the TiNi phase as the matrix with Ti2Ni secondary precipitates. The hardness shows no high values indicating that the major phase is not hard intermetallic. A bonding strength of 569.1 MPa was obtained …

Multi-Material 3d-Printed Silicone Vocal Fold Models, Clayton Adam Young

Theses and Dissertations

Self-oscillating synthetic vocal fold (VF) models are often used to study human voice production. In this thesis, a method for fabricating multi-layer self-oscillating synthetic VF models using silicone 3D printing is presented. Multi-material 3D printing enables faster fabrication times with more complex geometries than traditional casting methods and builds a foundation for producing VF models with potentially more life-like geometries, materials, and vibratory characteristics. The printing method in this study used a custom dual extruder and slicing software to print UV-curable liquid silicone into a gel-like support matrix. The extruder was fabricated using high-torque stepper motors with high resolution leadscrews …

Particle Formation And Thermal Radiation In Laminar Diffusion Flames With Applications To Energy And Materials, Phillip Irace

McKelvey School of Engineering Graduate Student Theses & Dissertations

Fossil fuels supply over 80% of the world’s primary energy, and if current policy and technology trends continue, global energy and energy-related carbon dioxide (CO2) emissions are predicted to increase for at least several decades owing to population and economic growth, leading to serious concerns regarding global warming. Natural gas releases less CO2 than other fossil fuels (e.g., coal and oil) and can help meet future CO2 emission targets. Natural gas combustion, however, has poor radiation heat transfer when compared to other fossil fuels owing to its low propensity for soot formation, making it difficult to use as a drop-in …

Single Asperity Fretting Corrosion Of Traditional And Additively Manufactured Metallic Biomaterials: Quantitative Analysis From Acetabular Tapers To Micron And Nanometer Scale Tribocorrosion, Annsley Mace

All Dissertations

Mechanically assisted crevice corrosion (MACC) of metallic biomaterials continues to be a significant degradation mode. This is, in part, due to a lack of understanding of fundamental micron- and sub-micron scale mechanisms of metal degradation in biological environments. Metal-metal (or metal-hard) load bearing surfaces of hip arthroplasties are subjected to fretting crevice corrosion (FCC, one form of MACC). Current work in tribocorrosion involves large contact area tests with multiple asperities, with a distribution of load and wear that changes over time. A more systematic and controlled study of the FCC micro- and nanomechanics is needed.

Therefore, the goal of this …

Additive Manufacturing Of Variable Contrast Computed Tomography Anatomical Phantoms Using A Single Feedstock In Fused Filament Fabrication, Cory J. Darling

LSU New Orleans Theses and Dissertations

Anatomical phantoms used in biomedical education and training benefit greatly from Fused filament fabrication’s (FFF) ability to rapidly produce complex and unique models. Current materials and methods used in FFF have limited ability to accurately produce phantoms that can mimic the radiological properties of multiple biological tissues. This research demonstrates that the CT contrast of FFF produced models can be modified by varying the concentration of bismuth oxide in acrylonitrile butadiene styrene (ABS) filaments and a tunable CT contrast that mimics the CT contrast ranging from fatty tissue to cortical bone using a single composite filament without introducing artificial image …

Multistage Modeling Of Fatigue Of Ti-6al-4v Fabricated By Different Additive Manufacturing Techniques, Lionardo Lado, Saeed Ataollahi, Mohammad J. Mahtabi

Honors Theses

Thanks to its high strength-to-weight ratio and corrosion resistance, Ti-6Al-4V has gained a lot of attention in additive manufacturing (AM) of complex parts with aerospace and medical applications. The realistic loading condition in these applications is mostly cyclic. However, the main challenge with AM of this alloy - and in general AM of metallic parts - is fatigue resistance and durability of the part, which has been reported to be much lower than the conventional materials. In this study, fatigue life performance of three additive manufacturing methods was compared using the Multistage Fatigue model (MSF). MSF model predicts the fatigue …

Autonomous Material Refill For Swarm 3d Printing, William C. Jones

Mechanical Engineering Undergraduate Honors Theses

3D printing currently offers robust and cheap rapid prototyping solutions. While standard 3D printing remains at the periphery of mass production, the technology serves as a starting point for the development of swarm manufacturing. Since swarm manufacturing is predicated upon autonomy, swarm technology companies such as AMBOTS are seeking to minimize human involvement in the swarm’s functions. At present, the 3D printing swarm consists of the printers, a transporter which can take them between job sites, and the floor tiles which provide power and support the build surfaces. To add to this ecosystem, this project is focused on the design …

Effects Of Sizing Agents On Mechanical Properties Of Carbon Fiber–Polymer Composites Via Fused Filament Fabrication Additive Manufacturing., Benjamin D. Mitchell

Electronic Theses and Dissertations

This study demonstrated the effects of changing the sizing agent parameter during the preparation of carbon fibers on the mechanical properties of composite made with acrylonitrile butadiene styrene (ABS) as the matrix material and carbon fibers as the fiber material. Three types of sizing agents produced by Allnex were used to coat three different batches of carbon fibers that were mixed with a torque rheometer and extruded with a barrel-style melt extruder into continuous spools of 1.75 mm filament for use with commercial 3D printers. Tensile tests were conducted on the filaments and tensile bars printed from the materials. Results …

Additive Manufacturing Of Sensors For Extreme Environments, Kiyo Tiffany Fujimoto

Boise State University Theses and Dissertations

Advanced manufacturing based direct-write technologies have emerged as the predominant enabler for the fabrication of active and passive sensors for use in harsh operating environments. The ability to directly write and integrate electronic components onto physical packaging can be achieved with additive manufacturing (AM) methods such as direct write technologies (DWT) which include aerosol jet printing (AJP), Ink Jet Printing (IJP), Plasma Jet Printing (PJP), and Micro-Dispense Printing (MDP). In this work, we investigate the use of these methods to accelerate, modernize, and enhance the functionality of sensors and instrumentation to achieve the goal of improving the safety and efficiency …

Optical Observation Of Large Area Projection Sintering, Derek Black

Theses and Dissertations

Polymer powder bed fusion (PBF/P) is one of many additive manufacturing (AM) processes utilized for producing polymer parts from digital 3D models. AM is preferred over traditional manufacturing methods in many applications due to advantages including tool-less manufacturing, high geometric complexity, short lead times, and reduced material waste. However, many industries that stand to benefit the most from AM are limited in their ability to use AM parts in large part due to low confidence in AM part quality. Among the polymer AM processes, PBF/P processes show significant promise for these applications due to their comparatively high isotropy and mechanical …

Effects Of Varied Oxygen Levels, Laser Powers, And Scanning Speeds On Manufactured Components By Laser-Based Powder Bed Fusion, Amelia Mcnamee

Honors College Theses

This project addresses the effects of oxygen concentration, laser power, and scanning speed on the melt pool geometry of laser-based powder bed fusion (L-PBF) additively manufactured components. A parametric analysis using the substrate alone was conducted to determine a range of desirable laser powers and scanning speeds. The parameter with the more significant effect will be decided upon based on the depth-to-width ratios (D/W) of the resultant laser weld bead. A range of oxygen levels and scan speeds was selected for the next phase. These samples were then be analyzed for depth-to-width ratios. It was expected that higher oxygen concentrations …

Elimination Of Extraordinarily High Cracking Susceptibility Of Aluminum Alloy Fabricated By Laser Powder Bed Fusion, Holden Hyer, Le Zhou, Sharon Park, Thinh Huynh, Abhishek Mehta, Saket Thapliyal, Rajiv S. Mishra, Yongho Sohn

Mechanical Engineering Faculty Research and Publications

Using the calculation of phase diagrams approach and Scheil solidification modeling, the Al-2.5Mg-1.0Ni-0.4Sc-0.1Zr alloy was designed, intentionally with an extraordinarily high cracking susceptibility, making it prime for solidification cracking during laser powder bed fusion. This study demonstrates the ability to mitigate even the most extreme solidification cracking tendencies in aluminum alloys with only minor alloying additions of Sc and Zr, 0.5 wt.% max. Furthermore, by employing a simple direct ageing heat treatment, good tensile mechanical properties were observed with a yield strength of 308 MPa, an ultimate tensile strength of 390 MPa, and a total elongation of 11%.

Formulation And Processing Of Dual Functional Adsorbent/Catalyst Structured Monoliths Using An Additively Manufactured Contactor For Direct Capture/Conversion Of Co2 With Cogeneration Of Ethylene, Shane Lawson, Khaled Baamran, Kyle Newport, Fateme Rezaei, Ali A. Rownaghi

Chemical and Biochemical Engineering Faculty Research & Creative Works

Utilizing CO₂ as a mild oxidant for oxidative dehydrogenation of ethane (ODHE) is an attractive way of recycling this greenhouse contaminant. Typically, CO₂ capture and conversion processes are performed in separate beds, however, combining these processes into one bed incurs advantages of lower thermal gradient and reduced energy costs. This study formulated the first generation of structured dual-functional materials (DFMs) by directly 3D printing metal-oxide-CaO/ZSM-5 inks into monolithic contactors. Specifically, we 3D-printed monoliths with V, Ga, Ni, or Ti dopants to perform metal screening and determine which metal generates the best structured DFM for combined CO₂ capture …

Potential Solution To Meet Growing Demands Of Refractory Metal: Selective Laser Melting Of Molybdenum-Tungsten Alloy, Jae Yu

Theses and Dissertations

Selective laser melting (SLM) of refractory metals has been of high interest in research due to the metals’ potential desirable characteristics in aeronautical and space applications. In particular, molybdenum and tungsten have been the focus of several studies in the search for high temperature and high strength purposes in applications like supersonic aircraft, re-entry vehicles, nuclear fission, power generation, and other space systems. However, there is still a significant knowledge gap to process defect-free alloys and making use of them in practical engineering functions. The aim of this study is to characterize the relationship between the microstructure and mechanical properties …

Critical Evaluation Of Construction Industry-Related Additive Manufacturing Research: A Scientometric Analysis, Tyler J. Brunjes

Theses and Dissertations

Review of construction-related AM literature is used to identify the advantages, challenges, and current trends of the research. Using a scientometric analysis of 522 bibliographic records, this research systematically analyzed construction related AM research to determine the key research areas and trends. Results showed that starting in 2015, the field has been growing at an exponential rate. Recent AM research focused on materials and reinforcement topics, which matched the most notable challenges of AM, which are material rheology, reinforcement, and lacking construction standards. This study provides an insight into AM research and identifies areas requiring more innovation before its commercial …

Investigation Of Additively Manufactured Molybdenum-Tungsten-Rhenium Alloys, Randolph T. Abaya

Theses and Dissertations

The process of creating metal components through additive manufacturing is changing the way different industries can avoid the shortcomings of traditional metal production. Metals such as tungsten, molybdenum, and rhenium have many advantages for different applications, especially when alloyed together. In this study, an additively manufactured alloy containing 70% molybdenum, 25% tungsten, and 5% rhenium (70Mo-25W-5Re) is tested for its strength, ductility, hardness, and porosity. The 70Mo-25W-5Re alloy is printed through Laser Powder Bed Fusion (LPBF) under different conditions such as printing speed and printing atmosphere. Additionally, the effects of post printing heat treatment are conducted to understand the advantages …

Effects Of A Nitrogen And Hydrogen Build Atmosphere On The Properties Of Additively Manufactured Tungsten, Dana C. Madsen

Theses and Dissertations

Additively manufactured tungsten was printed in pure nitrogen, nitrogen-2.5% hydrogen, and nitrogen-5% hydrogen atmospheres as part of a 2^3 full factorial designed experiment and subjected to room temperature and high-temperature three-point-bend testing, chemical analysis, hardness testing, and microstructural imaging techniques. The pure nitrogen specimens exhibited the highest strength and ductility at both high temperature and room temperature. Chemical analysis showed a 2-8x reduction in compositional oxygen relative to unprocessed powder. Hardness values for all samples was between 306.8 and 361.5 HV1. It is proposed that adding hydrogen into the build atmosphere reduced the available energy density for tungsten melting by …

Design And Testing Of A Composite Compressor Rotor, Mauro Noel V. De Leon

Theses and Dissertations

Additive manufacturing (AM) and molding are manufacturing methods known for building representations or replicas of conceptualized engine components, but was considered impractical for manufacturing operating engine components. More recent technology has rendered composite materials (combining high-temperature polymers and fiber reinforcement) capable of withstanding the temperature and structural requirements to compete with conventional turbomachinery metals. This study explores the application of several high-temperature polymers (ULTEM 9085, Onyx-Carbon fiber, and Epoxy-Carbon fiber) and their survivability in the operating conditions of a P400 Engine compressor. The tests conducted for this study determined their viability as compressor materials. This study required conducting tensile specimen …

Computational Based Investigation Of Lattice Cell Optimization Under Uniaxial Compression Load, Derek G. Spear, Jeremiah S. Lane, Anthony N. Palazotto, Ryan A. Kemnitz

Faculty Publications

Structural optimization is a methodology used to generate novel structures within a design space by finding a maximum or minimum point within a set of constraints. Topology optimization, as a subset of structural optimization, is often used as a means for light-weighting a structure while maintaining mechanical performance. This article presents the mathematical basis for topology optimization, focused primarily on the Bi-directional Evolutionary Structural Optimization (BESO) and Solid Isotropic Material with Penalization (SIMP) methodologies, then applying the SIMP methodology to a case study of additively manufactured lattice cells. Three lattice designs were used: the Diamond, I-WP, and Primitive cells. These …

Effects Of Particle Size Distribution With Efficient Packing On Powder Flowability And Selective Laser Melting Process, Zachary Young, Minglei Qu, Meelap Michael Coday, Qilin Guo, Seyed Mohammad H. Hojjatzadeh, Luis I. Escano, Kamel Fezzaa, Lianyi Chen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by …

Effects Of Particle Size Distribution With Efficient Packing On Powder Flowability And Selective Laser Melting Process, Zachary Young, Minglei Qu, Meelap Michael Coday, Qilin Guo, Seyed Mohammad H. Hojjatzadeh, Luis I. Escano, Kamel Fezzaa, Lianyi Chen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by …

Data On The Validation To Determine The Material Thermal Properties Estimation Via A One-Dimensional Transient Convection Model, Lauren B. Tomanek, Daniel S. Stutts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

These data were acquired to estimate the parameters of a closed form solution of a one-dimensional transient convection heat diffusion PDE. The purpose was to demonstrate that the model could be used to determine the thermal conductivity. The system was tested for a wide range of thermal conductivity, 15-400 W/mK, in order to verify that the method was applicable for various materials. The data reported here refer to the study in the research articles, "Material Thermal Properties Estimation Via a One-Dimensional Transient Convection Model" [1] and "Influence of porosity on the thermal, electrical, and mechanical performance of selective laser melted …

Data On The Validation To Determine The Material Thermal Properties Estimation Via A One-Dimensional Transient Convection Model, Lauren B. Tomanek, Daniel S. Stutts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

These data were acquired to estimate the parameters of a closed form solution of a one-dimensional transient convection heat diffusion PDE. The purpose was to demonstrate that the model could be used to determine the thermal conductivity. The system was tested for a wide range of thermal conductivity, 15-400 W/mK, in order to verify that the method was applicable for various materials. The data reported here refer to the study in the research articles, “Material Thermal Properties Estimation Via a One-Dimensional Transient Convection Model” and “Influence of porosity on the thermal, electrical, and mechanical performance of selective laser melted stainless …

Assessing Leachable Cytotoxicity Of 3d-Printed Polymers And Facile Detoxification Methods, Venkatakrishnan Rengarajan, Angela Clyde, Jefferson Pontsler, Jonathan Valiente, Adreann Peel, Yu Huang

Biological Engineering Faculty Publications

Additive manufacturing of polymers is gaining momentum in health care industries by providing rapid 3D printing of customizable designs. Yet, little is explored about the cytotoxicity of leachable toxins that the 3D printing process introduced into the final product. We studied three printable materials, which have various mechanical properties and are widely used in stereolithography 3D printing. We evaluated the cytotoxicity of these materials through exposing two fibroblast cell lines (human and mouse derived) to the 3D-printed parts, using overlay indirect contact assays. All the 3D-printed parts were measured toxic to the cells in a leachable manner, with flexible materials …

Closed Loop Recycling Of Low Friction Polymers In Fused Granule Fabrication Additive Manufacturing Processes, Neil Thompson, Jason Weaver

Faculty Publications

Plastic waste is a critical worldwide problem that impacts additive manufacturing (AM). Extensive research has explored how plastic waste in AM can be reduced by recycling prints into new filament, with varying success. An alternative to filament-based extrusion is “fused granule fabrication” (FGF), which extrudes from pellets or granules. This method is often used for large area additive manufacturing (LAAM) of polymers. This paper expands upon the knowledge base from previous research on LAAM and examines the extent to which PETG can be recycled and reprinted through the same FGF tool without significant loss to its material properties. The metric …

Additive Manufacturing Of Continuous Carbon Fiber-Reinforced Sic Ceramic Composite With Multiple Fiber Bundles By An Extrusion-Based Technique, Ruoyu Chen, Adam Bratten, Joshua Rittenhouse, Ming-Chuan Leu, Haiming Wen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Due to the high cost, complex preparation process and difficulty in structural design, the traditional methods for carbon fiber reinforced SiC ceramic composite preparation have great limitations. This paper presents a technique for the additive manufacturing multiple continuous carbon fiber bundle-reinforced SiC ceramic composite with core-shell structure using an extrusion-based technique. A conventional nozzle system was modified to print simultaneously a water based SiC paste with continuous carbon fibers. Different levels of binder contents were investigated to optimize the stickiness, viscosity, thixotropy and viscoelasticity of the paste. After sintering, SiC whiskers were generated on the surface of fiber, which is …

Microstructural Development In Inconel 718 Nickel-Based Superalloy Additively Manufactured By Laser Powder Bed Fusion, Thinh Huynh, Abhishek Mehta, Kevin Graydon, Jeongmin Woo, Sharon Park, Holden Hyer, Le Zhou, D. Devin Imholte, Nicolas E. Woolstenhulme, Daniel M. Wachs, Yongho Sohn

Mechanical Engineering Faculty Research and Publications

Excellent weldability and high temperature stability make Inconel 718 (IN718) one of the most popular alloys to be produced by additive manufacturing. In this study, we investigated the effects of laser powder bed fusion (LPBF) parameters on the microstructure and relative density of IN718. The samples were fabricated with independently varied laser power (125–350 W), laser scan speed (200–2200 mm/s), and laser scan rotation (0°–90°). Archimedes’ method, optical microscopy, and scanning electron microscopy were employed to assess the influence of LPBF parameters on the relative density and microstructure. Optimal processing windows were identified for a wide range of processing parameters, …

A Convolutional Neural Network (Cnn) For Defect Detection Of Additively Manufactured Parts, Musarrat Farzana Rahman

Masters Theses

“Additive manufacturing (AM) is a layer-by-layer deposition process to fabricate parts with complex geometries. The formation of defects within AM components is a major concern for critical structural and cyclic loading applications. Understanding the mechanisms of defect formation and identifying the defects play an important role in improving the product lifecycle. The convolutional neural network (CNN) has been demonstrated to be an effective deep learning tool for automated detection of defects for both conventional and AM processes. A network with optimized parameters including proper data processing and sampling can improve the performance of the architecture. In this study, for the …

Additive Manufacturing Waste Management System - Plastic Extrusion Process, Gabriel Bennett, Lindsay Liebrecht, David Lyogky, Wilson Woods

Williams Honors College, Honors Research Projects

3D printing is a fast-growing market with its main source of waste being PLA and ABS plastics. In 2019, the global additive manufacturing market grew to over $10.4 billion, crossing the pivotal double-digit billion threshold for the first time in its nearly 40-year history. (SmarTech Analysis, 2020 Additive Manufacturing Market Outlook and Summary of Opportunities Report). The waste is generated from failed prints and rejected support structures which are common occurrences for personal use. Plastic recycling has become one of the leading discussions of environmental protection and waste management. The 3D market currently does not offer an effective and affordable …

Printing, Characterization, And Mechanical Testing Of Additively Manufactured Refractory Metal Alloys, Brianna M. Sexton

Browse all Theses and Dissertations

Refractory metal alloys in the tungsten molybdenum rhenium ternary system were additively manufactured using laser power bed fusion. Four ternary alloys with varying concentrations of tungsten, molybdenum, and rhenium were manufactured and manufactured again with an addition of 1 wt% hafnium carbide. Samples were heat treated to heal cracks, reduce porosity, and reduce inhomogeneity. Material microstructure was characterized before and after heat treatment using microscopy, energy dispersive x-ray spectroscopy, and electron backscatter diffraction mapping. Mechanical testing was conducted on both three-point bend specimens and compression specimens, resulting in maximum bending strengths of 677.86 MPa, and maximum compression 0.2% yield strengths …