Engineering Commons^™

Review On Machining Of Additively Manufactured Nickel And Titanium Alloys, Navneet Khanna, Kishan Zadafiya, Tej Patel, Yusuf Kaynak, Rizwan Abdul, Rahman Rashid, Ana Vafadar

Research outputs 2014 to 2021

The machining of nickel and titanium-based superalloy components is very expensive and involves unusually high lead times compared with other engineering metals such as steels and aluminum. This has led to the development of most suitable additive manufacturing (AM) processes to fabricate these difficult-to-machine metals into near-net shape parts, thereby reducing the lead time and material waste, and significantly increasing productivity. Nonetheless, finish machining is still required on the AMed metal components to meet the dimensional and surface requirements of the application. Several research studies have investigated the machinability of AMed nickel and titanium alloy workpieces and have compared the …

Quality Assurance Of Lightweight Structures Via Phase-Based Motion Estimation, Ikenna E. Ifekaonwu

College of Graduate Studies: Theses & Dissertations

In recent years, lightweight structures have become mature and adopted in various applications. The importance of quality assurance cannot be overemphasized hence extensive research has been conducted to assess the quality of lightweight structures. This study investigates a novel process that exploits motion magnification to investigate the damage characteristics of lightweight mission-critical parts. The goal is to assure the structural integrity of 3D printed structures and composite structures by determining the inherent defects present in the part by exploiting their vibration characteristics. The minuscule vibration of the structure was recorded with the aid of a high-speed digital camera, and the …

Fabrication Of Silicon Nitride Parts By Ceramic On-Demand Extrusion Process, Sachin Choudhary

Masters Theses

“Ceramic On-Demand Extrusion (CODE) is a patented solid freeform fabrication method for manufacturing high-density monolithic ceramic parts. In the past 5-6 years, the technology has been successfully implemented to fabricate alumina and zirconia parts. The mechanical characterizations also show CODE’s high potential in achieving desired structural properties. The present study covers the fabrication of silicon nitride parts by CODE process, which entailed the design of paste formulation for achieving rheology suitable for dimensional control in fabricated parts and determining firing temperature and the content of sintering additives for silicon nitride green bodies fabricated by CODE. The density, hardness, and fracture …

Texture-Driven Image Clustering In Laser Powder Bed Fusion, Alexander H. Groeger

Browse all Theses and Dissertations

The additive manufacturing (AM) field is striving to identify anomalies in laser powder bed fusion (LPBF) using multi-sensor in-process monitoring paired with machine learning (ML). In-process monitoring can reveal the presence of anomalies but creating a ML classifier requires labeled data. The present work approaches this problem by printing hundreds of Inconel-718 coupons with different processing parameters to capture a wide range of process monitoring imagery with multiple sensor types. Afterwards, the process monitoring images are encoded into feature vectors and clustered to isolate groups in each sensor modality. Four texture representations were learned by training two convolutional neural network …

Texture-Driven Image Clustering In Laser Powder Bed Fusion, Alexander H. Groeger

Browse all Theses and Dissertations

The additive manufacturing (AM) field is striving to identify anomalies in laser powder bed fusion (LPBF) using multi-sensor in-process monitoring paired with machine learning (ML). In-process monitoring can reveal the presence of anomalies but creating a ML classifier requires labeled data. The present work approaches this problem by printing hundreds of Inconel-718 coupons with different processing parameters to capture a wide range of process monitoring imagery with multiple sensor types. Afterwards, the process monitoring images are encoded into feature vectors and clustered to isolate groups in each sensor modality. Four texture representations were learned by training two convolutional neural network …

Experimental Investigation Of Pressure Drop Performance Of Smooth And Dimpled Single Plate-Fin Heat Exchangers, Kanishk Rauthan, Ferdinando G. Guzzomi, Ana Vafadar, Kevin Hayward, Aakash Hurry

Research outputs 2014 to 2021

Passive heat exchangers (HXs) form an inseparable part of the manufacturing industry as they provide high-efficiency cooling at minimal overhead costs. Along with the aspects of high thermal cooling, it is essential to monitor pressure loss while using plate-fin HXs because pressure loss can introduce additional power costs to a system. In this paper, an experimental study was conducted to look at the effects of dimples on the pressure drop characteristics of single plate-fin heat exchangers. To enable this, different configurations of National Advisory Committee for Aeronautics (NACA) fins with smooth surfaces and 2 mm-diameter dimples, 4 mm-diameter dimples and …

Defect Detection Using Dynamic Analysis For Additive Manufactured Metals, Gita Deonarain

Dissertations, Master's Theses and Master's Reports

Additive manufacturing (AM) has the ability to produce parts with complex geometries and internal features, however, for demanding applications such as the automotive and aerospace industries, it is crucial that the parts can meet the demanding functional and geometric requirements. Quality control for AM parts focuses on nondestructive methods of testing, but many of the current methods are expensive and time-consuming. The research presented in this report explores various methods of nondestructive evaluation (NDE) using dynamic analysis on stainless steel parts produced with selective laser melting (SLM). Methods include, but are not limited to, frequency response functions (FRF), impedance-based measurements, …

Reducing Corrosion Of Additive Manufactured Magnesium Alloys By Interlayer Ultrasonic Peening, M. P. Sealy, R. Karunakaran, S. Ortgies, G. Madireddy, A. P. Malshe, K. P. Rajurkar

Department of Mechanical and Materials Engineering: Faculty Publications

Additive manufad (AM) magn alloys corrode rapidly due to tensile stress and coarse microstructures. Cyclically combining (hybridizing) additive manufacturing with interlayer ultrasonic peening was proposed as a solution to improve corrosion resistance of additive manufactured magnesium WE43 alloy through strengthening mechanisms and compressive residual stress. Applying interlayer peening work hardened discrete layers and formed a glocal integrity of regional grain refinement and subsurface compressive residual stress barriers. Tensile residual stress that typically accelerates corrosion decreased 90%. Results showed time-resolved control over corrosion was attainable by interlayer peening, and local corrosion within print cells decreased 57% with respect to as-printed WE43.

Effect Of Heat Treatment On Microstructure And Hardness Of A Worn Rail Repaired Using Laser Powder Deposition, Ershad Mortazavian, Zhiyong Wang, Hualiang Teng

Mechanical Engineering Faculty Research

The frequent replacement of worn rails on tracks brings an immense economic burden on the railroad industry, and also causes significant interruptions to railroad operation. Restoration of worn rails via laser powder deposition (LPD) can considerably reduce the associated maintenance costs. This study was focused on the use of LPD to repair the worn profile of a standard U.S. rail. The microstructure of the 304L stainless steel deposits with a minimum hardness of 85 HRB was composed of austenite, δ-ferrite, and sigma. Micropores were dispersed throughout the deposit, and microcracks were found at the rail-deposition interface. The pearlitic rail substrate …

A Theory-Supported Machine Learning Model For The Prediction Of Melt Pool Geometry And Optimal Process Window In Metal Additive Manufacturing, Sina Tayebati

Graduate Research Theses & Dissertations

Direct Energy Deposition (DED) is an additive manufacturing (AM) process capable of producing complicate-shaped or functionally graded components, and it is getting intense attention as a revolutionary technology to satisfy high demand in manufacturing process for the aerospace, automotive, and medical industries. However, the repeatability in geometries and properties of fabricated products is one of the most challenging issues for the DED process to be fully utilized, requiring comprehensive understanding of effect of processing conditions on the properties of fabricated parts, and development of relations among those conditions and properties. That is the motivation of this research. In this study, …

Fabrication, Characterization Of High-Entropy Alloys And Deep Learning-Based Inspection In Metal Additive Manufacturing, Wenyuan Cui

Doctoral Dissertations

"Alloying has been used to confer desirable properties to materials. It typically involves the addition of small amounts of secondary elements to a primary element. In the past decade, however, a new alloying strategy that involves the combination of multiple principal elements in high concentrations to create new materials called high- entropy alloys (HEAs) has been in vogue. In the first part, the investigation focused on the fabrication process and property assessment of the additive manufactured HEA to broaden its engineering applications. Additive manufacturing (AM) is based on manufacturing philosophy through the layer-by-layer method and accomplish the near net-shaped components …

Additively Manufactured Metallic Cellular Structures, Okanmisope Aziel Fashanu

Doctoral Dissertations

"Cellular structures are lightweight structures with excellent mechanical, thermal, and acoustic properties. They offer promise in a series of applications, including lightweight applications, sandwich cores, mechanical damping, acoustic absorption, strain isolation, and thermal management. The manufacturing of these complex cellular structures is expensive and time-consuming, which hinders the adoption of these structures in many industries. Advancement in manufacturing technologies, such as additive manufacturing (AM), however, have changed this. AM allows for the rapid and less expensive manufacturing of complex cellular structures. This work aimed to investigate the performance of additively manufactured cellular structures for lightweight and sandwich core applications. In …

Experimental Investigation And Comparison Of The Thermal Performance Of Additively And Conventionally Manufactured Heat Exchangers, Ana Vafadar, Ferdinando Guzzomi, Kevin Hayward

Research outputs 2014 to 2021

Air heat exchangers (HXs) are applicable in many industrial sectors because they offer a simple, reliable, and cost-effective cooling system. Additive manufacturing (AM) systems have sig-nificant potential in the construction of high-efficiency, lightweight HXs; however, HXs still mainly rely on conventional manufacturing (CM) systems such as milling, and brazing. This is due to the fact that little is known regarding the effects of AM on the performance of AM fabricated HXs. In this research, three air HXs comprising of a single fin fabricated from stainless steel 316 L using AM and CM methods—i.e., the HXs were fabricated by both direct …

Interface Joint Strength Between Ss316l Wrought Substrate And Powder Bed Fusion Built Parts - Data, Jason M. Weaver, John R. Linn, Michael P. Miles

ScholarsArchive Data

Data for Materials article "Interface Joint Strength between SS316L Wrought Substrate and Powder Bed Fusion Built Parts"

powder bed fusion; additive manufacturing; ss316l; interface strength

Understanding Flow Characteristics In Metal Additive Manufacturing, Carl R. Hartsfield, Travis E. Shelton, Gregory R. Cobb, Ryan A. Kemnitz, Joseph Weber

Faculty Publications

In fluid flow, the frictional effects from interior surfaces of flow components create pressure loss across the surface. Understanding this inherent pressure loss due to friction and other phenomena is important when designing a flow system. For conventional manufacturing, friction loss has been empirically studied and is well known in the engineering community. However, newer manufacturing techniques, such as laser powder bed fusion (LPBF), an additive manufacturing technique, need to be understood. The inherent flow conditions resulting from the additive processes were studied. Test samples were printed with the flow path oriented in the vertical direction with different channel diameters …

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 …

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 …

Laser Powder Bed Fusion Of Nitihf High-Temperature Shape Memory Alloy: Effect Of Process Parameters On The Thermomechanical Behavior, Mohammadreza Nematollahi, Guher P. Toker, Keyvan Safaei, Alejandro Hinojos, S. Ehsan Saghaian, Othmane Benafan, Michael J. Mills, Haluk E. Karaca, Mohammad Elahinia

Mechanical Engineering Faculty Publications

Laser powder bed fusion has been widely investigated for shape memory alloys, primarily NiTi alloys, with the goal of tailoring microstructures and producing complex geometries. However, processing high temperature shape memory alloys (HTSMAs) remains unknown. In our previous study, we showed that it is possible to manufacture NiTiHf HTSMA, as one of the most viable alloys in the aerospace industry, using SLM and investigated the effect of parameters on defect formation. The current study elucidates the effect of process parameters (PPs) on the functionality of this alloy. Shape memory properties and the microstructure of additively manufactured Ni-rich NiTiHf alloys were …

Direct 3d Printing Of Silica Doped Transparent Magnesium Aluminate Spinel Ceramics, John M. Pappas, Xiangyang Dong

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Transparent magnesium aluminate spinel ceramics were additively manufactured via a laser direct deposition method in this study. With a minimum porosity of 0.3% achieved, highly transparent spinel samples with the highest total optical transmittance of 82% at a wavelength of 632.8 nm, were obtained by a 3D printing approach. However, cracking was found to be a major issue affecting printed spinel samples. To control prevalent cracking, the effect of silica dopants was investigated. Increased silica dopants reduced average total crack length by up to 79% and average crack density by up to 71%. However, a high dopant level limited optical …

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 …

A Review Of Inkjet Printed Graphene And Carbon Nanotubes Based Gas Sensors, Twinkle Pandhi, Ashita Chandnani, Harish Subbaraman, David Estrada

Materials Science and Engineering Faculty Publications and Presentations

Graphene and carbon nanotube (CNT)-based gas/vapor sensors have gained much traction for numerous applications over the last decade due to their excellent sensing performance at ambient conditions. Inkjet printing various forms of graphene (reduced graphene oxide or modified graphene) and CNT (single-wall nanotubes (SWNTs) or multiwall nanotubes (MWNTs)) nanomaterials allows fabrication onto flexible substrates which enable gas sensing applications in flexible electronics. This review focuses on their recent developments and provides an overview of the state-of-the-art in inkjet printing of graphene and CNT based sensors targeting gases, such as NO₂, Cl₂, CO₂, NH_{3 …}

Open Source Arc Analyzer: Multi-Sensor Monitoring Of Wire Arc Additive Manufacturing, Adam M. Pringle, Shane Oberloier, Aliaksei Petsiuk, Paul G. Sanders, Joshua M. Pearce

Michigan Tech Publications, Part 1

Low-cost high-resolution metal 3-D printing remains elusive for the scientific community. Low-cost gas metal arc wire (GMAW)-based 3-D printing enables wire arc additive manufacturing (WAAM) for near net shape applications, but has limited resolution due to the complexities of the arcing process. To begin to monitor and thus control these complexities, the initial designs of the open source GMAW 3-D printer have evolved to include current and voltage monitoring. Building on this prior work, in this study, the design, fabrication and use of the open source arc analyzer is described. The arc analyzer is a multi-sensor monitoring system for quantifying …

Open Source High-Temperature Reprap For 3-D Printing Heat-Sterilizable Ppe And Other Applications, Noah G. Skrzypczak, Nagendra G. Tanikella, Joshua M. Pearce

Michigan Tech Publications, Part 1

Thermal sterilization is generally avoided for 3-D printed components because of the relatively low deformation temperatures for common thermoplastics used for material extrusion-based additive manufacturing. 3-D printing materials required for high-temperature heat sterilizable components for COVID-19 and other applications demands 3-D printers with heated beds, hot ends that can reach higher temperatures than polytetrafluoroethylene (PTFE) hot ends and heated chambers to avoid part warping and delamination. There are several high temperature printers on the market, but their high costs make them inaccessible for full home-based distributed manufacturing required during pandemic lockdowns. To allow for all these requirements to be met …

Parametric Nasopharyngeal Swab For Sampling Covid-19 And Other Respiratory Viruses: Open Source Design, Sla 3-D Printing And Uv Curing System, Nicole Gallup, Adam M. Pringle, Shane Oberloier, Nagendra G. Tanikella, Joshua M. Pearce

Michigan Tech Publications, Part 1

Access to nasopharyngeal swabs for sampling remain a bottleneck in some regions for COVID-19 testing. This study develops a distributed manufacturing solution using only an open source manufacturing tool chain consisting of two types of open source 3-D printing and batch UV curing, and provides a parametric fully free design of a nasopharyngeal swab. The swab was designed using parametric OpenSCAD in two components (a head with engineered break point and various handles), which has several advantages: i) minimizing print time on relatively slow SLA printers, ii) enabling the use of smaller print volume open source SLA printers, iii) reducing …

Towards Distributed Recycling With Additive Manufacturing Of Pet Flake Feedstocks, Helen A. Little, Nagendra Gautam Tanikella, Matthew J. Reich, Matthew J. Fiedler, Samantha L. Snabes, Joshua M. Pearce

Michigan Tech Publications, Part 1

This study explores the potential to reach a circular economy for post-consumer Recycled Polyethylene Terephthalate (rPET) packaging and bottles by using it as a Distributed Recycling for Additive Manufacturing (DRAM) feedstock. Specifically, for the first time, rPET water bottle flake is processed using only an open source toolchain with Fused Particle Fabrication (FPF) or Fused Granular Fabrication (FGF) processing rather than first converting it to filament. In this study, first the impact of granulation, sifting, and heating (and their sequential combination) is quantified on the shape and size distribution of the rPET flakes. Then 3D printing tests were performed on …