Engineering Commons^™

Martensitic Transformation Induced Strength-Ductility Synergy In Additively Manufactured Maraging 250 Steel By Thermal History Engineering, Shahryar Mooraj, Shuai Feng, Matthew Luebbe, Matthew Register, Jian Liu, Tianyi Li, Baris Yavas, David P. Schmidt, Matthew W. Priddy, Michael B. Nicholas, Victor K. Champagne, Mark Aindow, Haiming Wen, Wen Chen

Materials Science and Engineering Faculty Research & Creative Works

Maraging steels are known for their exceptional strength but suffer from limited work hardening and ductility. Here, we report an intermittent printing strategy to tailor the microstructure and mechanical properties of maraging 250 steel via tuning the thermal history during wire-arc directed energy deposition. By introducing a dwell time between adjacent layers, the maraging 250 steel is cooled below the martensite start temperature, triggering thermally driven martensitic transformation during the printing process. Thermal cycling during subsequent layer deposition results in the formation of reverted austenite which shows a refined microstructure and induces elemental segregation between martensite and reverted austenite. The …

Mechanical Response Of Triply Periodic Minimal Surface Gyroid Structures Under Combined Loading, Jay B. Patel

Theses and Dissertations

This work explored combined tensile and torsional loads applied to additively manufactured Inconel 718 specimens employing Triply Periodic Minimal Surface (TPMS) structures. The gyroid TPMS unit cell was selected with two variations of cylindrical cell maps, a rectangular cell map, and a spherical cell map. All four variants were tested in an axial-torsion test frame at room temperature using equal parts of vertical and angular displacement control until failure. The combined loading in these tests utilized tension and torsion. The data from the tests were compared to finite element analysis (FEA) models to visualize when yielding was predicted. Finally, the …

Overview Of Porous Magnesium-Based Scaffolds: Development, Properties And Biomedical Applications, Amir Motaharinia, Jaroslaw Drelich, Safian Sharif, Ahmad Fauzi Ismail, Farid Naeimi, Alexandra G. Glover, Mahshid Ebrahiminejad, Hamid Reza Bakhsheshi-Rad

Michigan Tech Publications

Magnesium (Mg) and its alloys are revolutionizing the field of interventional surgeries in the medical industry. Their high biocompatibility, biodegradability, and a similar elastic modulus to natural bone make porous Mg-based structures potential candidates for orthopedic implants and tissue engineering scaffolding. However, fabricating and machining porous Mg-based structures is challenging due to their complexity and difficulties in achieving uniform or gradient porosity. This review aims to thoroughly explore various fabrication procedures used to create metallic scaffolds, with a specific focus on those made from Mg-based alloys. Both traditional manufacturing techniques, including the directional solidification of metal-gas eutectic technique, pattern casting, …

Design And Function Of Thermoresponsive-Ultrafast Stiffening Suspension Formulations For 3d Printing, Sharu Bhagavathi Kandy, Sebastian Remke, Thiyagarajan Ranganathan, Shubham Kiran Wani, Xiaodi Dai, Narayanan Neithalath, Aditya Kumar, Mathieu Bauchy, Edward Garboczi, Torben Gädt, Samanvaya Srivastava, Gaurav Sant

Materials Science and Engineering Faculty Research & Creative Works

An inability to accurately control the rate and extent of solidification of cementitious suspensions is a major impediment to creating geometrically complex structural shapes via 3D printing. In this work, we have developed a thermoresponsive rapid stiffening system that will stiffen suspensions of minerals such as quartz, limestone, portlandite, and Ordinary Portland Cement (OPC) over a wide pH range. When exposed to trigger temperatures between 40 °C and 70 °C, the polymer binder system undergoes a thermally triggered free radical polymerization (FRP) reaction, leading to an ultrafast stiffening of the suspension at an average rate on the order of 1 …

Additive Manufacturing Applications In Mission-Critical Operations: A Review, Arup Dey, Olusanmi Adeniran, Monsuru Ramoni

Manufacturing & Industrial Engineering Faculty Publications

Additive manufacturing (AM) is used to fabricate complex components from a wide variety of materials in an additive manner. AM brings several benefits, such as reduced lead times, on-demand production, creation of complex customized designs without tooling requirements, and remote design sharing. However, the use of AM for critical components is limited in large missions due to quality and reliability concerns, as is the case with many manufacturing technologies. Enhancing the acceptance of AM-built parts for mission-critical components can be achieved by producing highly reliable parts, establishing robust quality standards, and continually improving part properties. This review article comprehensively explores …

Biobased Acrylate Composites With Enhanced Strength For Additive Manufacturing, Nicole Wagner, Joseph Mcwherter

Engineering Faculty Articles and Research

With the expanding use of polymers in additive manufacturing, sustainable resins for use in vat photopolymerization are required to reduce their environmental impact. One promising approach to achieve this is to incorporate biobased fillers that replace the acrylates in photopolymer resins as ‘green’ alternatives. In this study, photopolymer composites consisting of a methacrylate resin with varying calcium carbonate powder content between 0 and 50 wt.% were investigated. A digital light processing technique was used to fabricate tensile test specimens for mechanical testing. Good printability, dimensional accuracy, and good interlayer adhesion were observed for composite resin formulations that incorporated calcium carbonate …

Oxidation–Reduction Of Ti-6al-4v In Direct Energy Deposition Subject To Minimum Argon Consumption, Bharadwaja Ragampeta, Prashansa Ragampeta, Todd Sparks, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Ti-6Al-4V is a well-known alloy for its low density and excellent corrosion resistance, making it popular in aerospace, marine, medical, and automotive applications. However, at elevated temperatures, the alloy forms oxides, leading to embrittlement. In additive manufacturing, particularly in the direct energy deposition (DED) process, which involves high temperatures, the alloy experiences oxidation. An inert gas chamber provides shielding during the process but limits the size of the manufactured components, and deposition in a vacuum chamber can alter the chemical composition of the alloy. Local shielding is a technique generally used for such applications, but it uses a high volume …

Parametric Design Of Easy-Connect Pipe Fitting Components Using Open-Source Cad And Fabrication Using 3d Printing, Abolfazl Taherzadeh Fini, Cameron K. Brooks, Alessia Romani, Anthony G. Straatman, Joshua M. Pearce

Electrical and Computer Engineering Publications

The amount of non-revenue water, mostly due to leakage, is around 126 billion cubic meters annually worldwide. A more efficient wastewater management strategy would use a parametric design for on-demand, customized pipe fittings, following the principles of distributed manufacturing. To fulfill this need, this study introduces an open-source parametric design of a 3D-printable easy-connect pipe fitting that offers compatibility with different dimensions and materials of pipes available on the market. Custom pipe fittings were 3D printed using a RepRap-class fused filament 3D printer, with polylactic acid (PLA), polyethylene terephthalate glycol (PETG), acrylonitrile styrene acrylate (ASA), and thermoplastic elastomer (TPE) as …

3d-Printable Pva-Based Inks Filled With Leather Particle Scraps For Uv-Assisted Direct Ink Writing: Characterization And Printability, Luca Guida, Alessia Romani, Davide Negri, Marco Cavallaro, Marinella Levi

Electrical and Computer Engineering Publications

Despite its significant environmental impacts, leather remains a popular material due to its durability, aesthetics, and mechanical properties. Recycling leather scraps is gaining increasing attention to reduce waste, pollutants, and emissions from pristine raw materials in the tanning industry. Material Extrusion additive manufacturing represents a promising way to recycle leather byproducts as secondary raw materials for new applications. This paper investigates the characterization and printability of photo- and thermal-curable PVA-based inks for UV-assisted Direct Ink Writing filled with leather filler scraps from the tanning industry, i.e., leather shavings. As a cold extrusion process, Direct Ink Writing reduces energy consumption and …

On Optimizing Sensor Data Collection, Processing, And Storage For Industrial Additive Manufacturing, Steven Thompson

Masters Theses

The widespread adoption of digital data management methods for transformative technologies, such as additive manufacturing (AM), within the aerospace industry is impeded by poor interoperability between AM component manufacturing processes. Moreover, data quality may be compromised due to sensor failures or other corruptions. Additionally, massive amounts of data are collected during these processes, often needing to remain accessible for decades. These storage costs can place a significant financial burden on smaller suppliers. This work aims to make digital data management methods more affordable and, therefore, approachable for smaller suppliers.

First, the design and initial implementation of an affordable and adaptable …

A Comparative Study Of Aluminium Properties Manufactured Using Additive Friction Stir Deposition (Afsd) And Wire Arc Additive Manufacturing (Waam), Numan Habib, Ana Vafadar, Ferdinando Guzzomi

Research outputs 2022 to 2026

Wire arc additive manufacturing (WAAM) has recently gained considerable attention due to its capability to manufacture large-size metal with a length of one meter or above, with good microstructural and mechanical properties. However, the manufacture of critical components exposed to extreme environmental conditions, such as high stresses, remains the focus of most research studies. The applications of WAAM in high-tech industries, such as aerospace and marine modes, remain limited due to metallurgical challenges such as oxidation, porosity, cracking, and deformation, especially for high-strength aluminium alloys, including 6XXX and 7XXX series. The aforementioned metallurgical challenges in WAAM are minimized to some …

Fatigue Properties Of 3d-Printed Polymeric Metamaterials: A Review, Ani Daniel, Hamed Bakhtiari, Alireza Nouri, Barun K. Das, Muhammad Aamir, Majid Tolouei-Rad

Research outputs 2022 to 2026

The present article provides an in-depth review of the fatigue properties of polymeric metamaterials, with particular emphasis on those manufactured using 3D printing techniques. Despite the significant potential of 3D-printed metamaterial polymers in the biomedical field, there has been limited studies dedicated to their fatigue behaviour. The article highlights the significance of fatigue behaviour in determining the reliability and longevity of polymeric materials under cyclic loading, which is crucial for biomedical applications. The effects of different 3D printing parameters, metamaterial designs, and polymer properties on fatigue life are explored. The fatigue response of metamaterials depends on material properties, geometric factors, …

Mechanical And Thermal Characterization Of Additively Manufactured Carbon/Nylon 12 And Carbon/Peek Composites, Matik Heskin, Bradley Deuser, Thomas P. Schuman, K. Chandrashekhara, John Bayldon, Jeff Degrange, Steven Patterson, Neiko Levenhagen

Chemistry Faculty Research & Creative Works

This study explores additive manufacturing of carbon fiber-reinforced thermoplastic composites using the Composite-Based Additive Manufacturing (CBAM) process. Carbon/Nylon 12 and Carbon/PEEK composites were fabricated and evaluated through mechanical (compression, tensile, flexural, and impact) and thermal (DSC and TGA) tests. Carbon/PEEK exhibited superior mechanical performance, with 97.5% higher tensile strength, 79.8% higher elastic modulus, and 59.6% higher flexural strength compared to Carbon/Nylon 12. Thermal testing showed that Carbon/PEEK had higher thermal stability, beginning degradation at 350 °C versus 298 °C for Carbon/Nylon. These results indicate that CBAM-fabricated Carbon/PEEK composites are suitable for applications requiring high strength and temperature resistance.

Synthesis And Assessment Of Biobased Acrylated Epoxidized Soybean Oil Resins For Stereolithography 3d Printing Of Microfluidic Devices, Natalie S. Romero Figueroa

College of Graduate Studies: Theses & Dissertations

This research focuses on the development and characterization of a biobased photocurable resin synthesized from soybean oil for use in stereolithography (SLA) 3D printing of microfluidic devices. The study explores a sustainable alternative to petroleum-based resins by performing an acrylation reaction on epoxidized soybean oil (ESO) to produce acrylated epoxidized soybean oil (AESO), which was then formulated into a photocurable resin with the addition of a photo initiator. The fabrication process involved designing microfluidic molds in SolidWorks and printing them using an Elegoo Mars 4 SLA printer under various exposure and layer thickness parameters. The printed samples consisted of microchannels …

Design And Manufacturing Of Multifunctional Piezoelectric Composites, Huan Zhao

Dartmouth College Ph.D Dissertations

Piezoelectric materials possess a unique ability to convert mechanical energy into electrical signals and have broad industrial applications. However, monolithic piezoelectric materials such as piezoceramics and piezopolymers often suffer from inherent trade-offs among mechanical strength, elasticity, and durability. Piezoelectric composites, typically consisting of a polymer matrix with ceramic reinforcements, offer a solution by combining the advantages of each constituent. Nevertheless, maintaining stable mechanical performance in high-temperature environments remains a significant challenge as conventional polymer matrices usually experience structural degradation.

In this thesis, a novel piezoelectric composite is developed using a preceramic polymer (PCP) matrix with barium titanate (BTO) inclusions. PCPs …

Effect Of Bioactive Glass On Pxdda / Pxdda-Co-Pla Nanocomposite For Hard Tissue Reconstruction: Synthesis And Characterization, Ehsan Vafa, Lobat Tayebi, Fatemeh Azizli, Somayeh Parham, Katayoon Rezaeeparto, Sedigheh Azadi, Ali Mohammad Amani, Mohammad Javad Azizli, Hesam Kamyab, Shreeshivadasan Chelliapan, Saravanan Rajendran

Electrical & Computer Engineering Faculty Publications

Newer bone graft materials face various challenges in achieving optimal mechanical strength, bioactivity, and antibacterial action simultaneously, which can result in suboptimal regeneration outcomes and increased infection risks In the present study, we developed a novel nanocomposite of poly (xylitol-co-dodecanedioic acid) (PXDDA) and poly (lactic acid) (PLA) with 1-10 wt% incorporation of bioactive glass (BG), utilizing a a PXDDAco-PLA compatibilizer for maintaining homogeneity. Extensive characterization techniques including, Fourier infrared spectroscopy (FTIR), X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), Brunauere Emmette Teller (BET), Proton Nuclear Magnetic Resonance (¹H NMR) and contact angle measurements, revealed that the addition …

Laser Based Metal 3d Printer, Inura Goonawardena

All Graduate Theses, Dissertations, and Other Capstone Projects

The technology and applications of additive manufacturing (AM) have advanced significantly in recent years. Research from hobbyist to industrial scale has evolved and has seen advancements in materials that can be utilized for industrial manufacturing. The Institute for Machine Tools and Industrial Management at the Technical University of Munich (TUM) developed the reAM250, an open-source research platform for Powder Bed Fusion with a Laser (LPBF). It was made available to facilitate study into component-level innovation, control techniques, and process monitoring without the budgetary and intellectual property constraints of commercial machines. This paper delves into the concept and production of the …

Pulsed Arc Additive Manufacturing Of A Functionally Graded Er2209 Duplex Stainless Steel And Hsla-100 Structure: Morphology, Characterization, And Mechanical Performance, Stevens G. Hill Jr

College of Graduate Studies: Theses & Dissertations

Wire arc additive manufacturing is a process well suited to the efficient production of large structures. Duplex stainless steel exhibits high corrosion resistance and good strength which can be highly beneficial for industrial use. However, its use is limited due to its cost and complexity in controlling microstructure to achieve desired properties. In many cases, it can be highly beneficial to manufacture a component which uses specialty steel grades such as duplex stainless steel only where necessary, and utilizes more affordable, commonly available steels for reinforcement or bulk structural support. A functionally graded material satisfies these requirements by providing a …

Additive Manufacturing Of Multifunctional Materials And Composites, John Michael Pappas

Doctoral Dissertations

"This research focused on developing fundamental knowledge of process-material interactions for additive manufacturing of multifunctional materials that are highly desirable in high-tech industries for potential weight and space savings. Multifunctional materials are very sensitive to defects, which severely hinder performance. Thus, defect formation was systematically studied to develop strategies and methodologies to efficiently fabricate high-performance materials and composites. Blown-powder-based laser additive manufacturing of transparent spinel ceramics was investigated to reduce porosity and cracking, defects that hindered transparency and mechanical properties. A systematic study of processing parameters revealed that laser power and powder flow rate had the largest effects on defect …

The Strengthening Mechanisms And Incipient Plasticity Of Additively Manufactured Biomedical Refractory High Entropy Alloys, Changxi Liu, Liqiang Wang, Miao Luo, Kuaishe Wang, Marco De Battista, Ling Zhang, Weijie Lu, Lai Chang Zhang, Di Zhang

Research outputs 2022 to 2026

Owing to the cellular structure that limits dislocation motion upon stress loading, additively manufactured (AM) refractory high-entropy alloys (HEAs) exhibit an excellent strength-plasticity synergy. This work integrates micro/nano-mechanical experiments with statistical physics modeling to examine dislocation nucleation and slip in AM-fabricated TiNbTaZrMo HEA. Computational results indicated that the activation volume for initial dislocation nucleation is about one atomic volume, facilitating dislocation initiation. Nanoindentation and in-situ micro-pillar compression reveal no significant pop-in events, indicating that the cellular structure impedes dislocation slip and thus prevents plasticity reduction from dislocation slipping near grain boundaries. This work provides a thorough investigation into the interplay …

A Comparison Of Polymers By Layer Deposition And Open Molding Additive Processes Through Fused Granulate Fabrication, Alexander Ray Gibson

Theses and Dissertations

Additive manufacturing (AM) continues to offer new possibilities in both production and economics. Various industries have quickly adopted AM to rapidly produce parts that would be difficult or cost prohibitive otherwise. Despite ongoing innovations that expand the technology's capabilities, significant limitations persist. Most AM processes are restricted by materials available, an inability to produce large parts, or by not achieving material deposition speeds and volumes to allow for certain products feasible. In addition, tight tolerances for features and surfaces cannot be produced without substantial post processing. Some of the post-processing techniques can even affect the material properties of the finished …

Custom Cathode Optimization For Electropolishing Additively Manufactured 316l Stainless Steel, Kasandra Escarcega Herrera

Mechanical Engineering ETDs

Laser powder bed fusion (LPBF) has become increasingly popular for its ability to rapidly manufacture complex metallic parts. However, the surface properties of as-built LPBF parts may degrade overall performance due to tortuous surface features. Consequently, post-processing like electropolishing (EP) to reduce the surface asperities is often needed for LPBF parts to perform as expected. Utilizing experimental and computational approaches, this project aims to more uniformly EP complex shaped parts made from LPBF 316L. For the experimental approach, parts with a three-dimensional T-shape were printed out of 316L stainless steel and EP using an acidic-based and a polyethylene glycol/NaCl-based electrolyte. …

Data Intensive Method For Processing Defect Detection And Mitigation For Composites, Deepak Kumar

Doctoral Dissertations and Master's Theses

Composite manufacturing without processing defects is a crucial step in satisfying the production, performance, and quality requirements of composite materials in various industries. Autoclave processing enables manufacturing of high-quality composite parts with excellent mechanical properties, whereas additive manufacturing (AM) offers adaptability to complex designs and streamlined processes. However, each method presents unique challenges; despite the benefits, autoclave processes can still result in processing defects, and AM is particularly susceptible to processing anomalies owing to the novelty of the process. Ensuring the quality and reliability of composite manufacturing is essential to fully capitalize on the advantages offered by both techniques. Artificial …

Fpga-Based Sensors For Distributed Digital Manufacturing Systems: A State-Of-The-Art Review, Laraib Khan, Sriram Praneeth Isanaka, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The combination of distributed digital factories (D2Fs) with sustainable practices has been proposed as a revolutionary technique in modern manufacturing. This review paper explores the convergence of D2F with innovative sensor technology, concentrating on the role of Field Programmable Gate Arrays (FPGAs) in promoting this paradigm. A D2F is defined as an integrated framework where digital twins (DTs), sensors, laser additive manufacturing (laser-AM), and subtractive manufacturing (SM) work in synchronization. Here, DTs serve as a virtual replica of physical machines, allowing accurate monitoring and control of a given manufacturing process. These DTs are supplemented by sensors, providing near-real-time data to …

Neural Operator And Physics-Informed Deep Learning Approaches For Inverse Design Of Composites And Manufacturing Processes, Minglei Lu

All Dissertations

In this dissertation, artificial intelligence (AI) models are designed and used to accelerate inverse design of composites and manufacturing processes. The critical bottlenecks in machine learning (ML) including data availability, data quality, model generalization and adaptation, interpretability, physical consistency, and the ’black box’ nature of models for the inverse design are addressed. And the proposed AI models are tested under different engineering scenarios. Firstly, a fast deep neural operator (DNO) structure was developed to significantly reduce training time. This model was tested in the context of additive manufacturing, a transformative industrial technology that allows for the creation of materials with …

Multiphysics Modeling And Experimental Validation Of High-Strength Steel In Laser Powder Bed Fusion Process, M. Rangapuram, S. Babalola, J. W. Newkirk, L. N. Bartlett, F. W. Liou, K. Chandrashekhara, Stephen R. Cluff

Materials Science and Engineering Faculty Research & Creative Works

Laser powder bed fusion (LPBF) is a subset of the additive manufacturing process in which a laser beam selectively joins the metal powder into a desired part in a sequential layer process. Owing to its complex nature of rapid heating and cooling of the melt pool, there is a need to understand the melt pool behavior and its effects on the final manufactured part. a densely packed powder bed is highly desirable for fabricating a superior part using the LPBF process. in this work, discrete element model was used to generate powder beds with realistic powder properties and various factors …

Modeling And Understanding Of Additive Manufacturing Periodic Cellular Structures With Heterogeneity: Property, Quality And Design Strategy., Naresh Koju

Electronic Theses and Dissertations

Lightweight cellular structures with their higher per mass performance capability, multifunctional designability and property tolerability are gaining much wider adaptation in many engineering applications ranging from aerospace, defense, biomedical, automotive to sports. However, to achieve the desired performance levels careful design must be carried out. The experimental-based empirical design often involves high manufacturing cost, and there are also certain information/knowledges about the cellular deigns that could not be easily obtained experimentally, such as the deformation local fracture initiation. Similarly, numerical modeling-based design approach commonly suffers from high computation cost and the lack of inverse designability. In addition, numerical models often …

An Efficient Computational Frameworks For Design And Analysis Of Metamaterials, Raj Pradip Khawale

All Dissertations

Advancement in additive manufacturing helps in building artificial lattice structures with unique properties that are not available in naturally occurring materials or in continuum structures. Specifically, beam-based lattices are well known for producing lightweight structures with very high strength, auxetic behavior, and energy absorption capabilities. In recent years, numerous research studies have been conducted on generating algorithms and frameworks to obtain unusual properties based on the variation in the cell geometry and material properties. However, the exploration of the full design space is hampered in practice primarily due to restrictions on cell tiling variation. Additionally, the lattices are very intricate, …

Machine Learning-Driven Process Analysis And Optimization In Solid-State Welding And Fusion-Based Additive Manufacturing, Radif Uddin Ahmed

Master's Theses

In the modern era of advanced manufacturing, optimizing process parameters is pivotal in ensuring the quality and reliability of sophisticated component fabrication. This study presents a novel, data-driven approach to parameter optimization in two cutting-edge manufacturing techniques: Friction Stir Welding (FSW) and Laser Powder Bed Fusion (LPBF). By leveraging machine learning methodologies, this research addresses the critical challenge of efficiently determining optimal process parameters, a task traditionally relying on time-consuming and resource-intensive trial-and-error methods. This study will lead to a robust data-driven framework for process analysis of more advanced manufacturing techniques like the Additive Friction Stir Deposition (AFSD) process. Friction …

Machine Vision To Provide Quantitative Analysis Of Meltpool Stability For A Coaxial Wire Directed Energy Deposition Process, Braden Mclain, Remy Mathenia, Todd Sparks, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Wire-based additive manufacturing (AM) is at the forefront of complex metal fabrication because of its scalability for large components, potential for high deposition rates, and ease of use. A common goal of wire directed energy deposition (DED) is preserving a stable process throughout deposition. If too little energy is put into the deposition, the wire will stub into the substrate and begin oscillating, creating turbulence within the melt pool. If too much energy exists, the wire will overheat, causing surface tension to take over and create liquid drips as opposed to a solid bead. This paper proposes a computer vision …