Engineering Commons^™

Atmosphere Effects In Laser Powder Bed Fusion: A Review, Ben Brown, Cody Lough, Davis Wilson, Joseph Newkirk, Frank Liou

Materials Science and Engineering Faculty Research & Creative Works

The use of components fabricated by laser powder bed fusion (LPBF) requires the development of processing parameters that can produce high-quality material. Manipulating the most commonly identified critical build parameters (e.g., laser power, laser scan speed, and layer thickness) on LPBF equipment can generate acceptable parts for established materials and moderately intricate part geometries. The need to fabricate increasingly complex parts from unique materials drives the limited research into LPBF process control using underutilized parameters, such as atmosphere composition and pressure. As presented in this review, manipulating atmosphere composition and pressure in laser beam welding has been shown to expand …

Performance Enhancement Of Vanadium Redox Flow Battery With Novel Streamlined Design: Simulation And Experimental Validation, Abdulmonem Fetyan, Bronston P. Benetho, Tawaddod Alkindi, Anugrah Andisetiawan, Musbaudeen O. Bamgbopa, Ayoob Alhammadi, Gumaa A. El-Nagar

All Works

Electrolyte utilization and the consequent concentration polarization significantly limit the potential increase in power density and contribute to electrode degradation in vanadium redox flow batteries during cycling. This study investigates a novel curvature streamlined design, drawing inspiration from natural forms, aiming to enhance the performance of vanadium redox flow battery cells compared to conventional square and rectangular flow-through cell designs. The simulated 3D single-cell model shows a notably superior uniformity in both current and species' concentration distribution within the streamlined design compared to the square and rectangular shapes. Experimental analysis conducted on 3D-printed flow frames demonstrated 2 % enhanced energy …

High Mechanical Performance Of Lattice Structures Fabricated By Additive Manufacturing, Yuhua Li, Deyu Jiang, Rong Zhao, Xin Wang, Liqiang Wang, Lai Chang Zhang

Research outputs 2022 to 2026

Lattice structures show advantages in mechanical properties and energy absorption efficiency owing to their lightweight, high strength and adjustable geometry. This article reviews lattice structure classification, design and applications, especially those based on additive manufacturing (AM) technology. This article first introduces the basic concepts and classification of lattice structures, including the classification based on topological shapes, such as strut, surface, shell, hollow-strut, and so on, and the classification based on the deformation mechanism. Then, the design methods of lattice structure are analyzed in detail, including the design based on basic unit, mathematical algorithm and gradient structure. Next, the effects of …

Data-Driven Roughness Estimation Of Additively Manufactured Samples Using Build Angles, Jose Galarza, Jose Barron Jr., Farid Ahmed, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

Achieving control of Laser Powder Bed Fusion (L-PBF) over the quality of the print is the main motivation for finding an optimum set of parameters in the process. Surface roughness is one of the characteristics of the print that impacts the performance of the desired functionality. This research focus is to relate the build angle with the surface roughness on the L-PBF printed specimens and utilize machine learning methods for roughness estimation of geometric features with varying build angles. The EOS M290 L-PBF printer was used to print Inconel-718 coupons using standard process parameters while varying build angles from 20 …

Interpretation Of Surface Roughness Of Stainless Steel 316l In Laser Powder Bed Fusion Additive Manufacturing, Tianyu Zhang

Theses and Dissertations

Laser Powder Bed Fusion (L-PBF), a widely used metal additive manufacturing (AM) method, is emerging as a key technology in the modern manufacturing industry. Its applications span across aerospace, transportation, energy, and biomedical industries, aiming to maximize product functionality, quality, and manufacturing efficiency.

Surface roughness, an important measure of product quality, impacts geometrical tolerances and plays a critical role in mechanical and functional properties. Although post-process techniques such as machining, shot peening, and chemical processing can be used to refine surfaces, internal surfaces in complex geometries remain difficult to treat, limiting part performance due to undesired surface features. The …

An Overview Of Additively Manufactured Metal Matrix Composites: Preparation, Performance, And Challenge, Liang Yu Chen, Peng Qin, Lina Zhang, Lai Chang Zhang

Research outputs 2022 to 2026

Highlight Recent progresses in additive manufacturing on metal matrix composites are reviewed. Additive manufacturing technologies for metal matrix composites are summarized. The characteristics of feedstocks and reinforcements are introduced. Mechanical property of additively manufactured metal matrix composites is reviewed. Challenges of additively manufactured metal matrix composites are discussed.

Evaluation Of The Mechanical Properties Of Pla Material Used For 3d Printing Solar E-Hub Component, Md Helal Uddin, Mohammad Nur-E-Alam, Abreeza Manap, Boon Kar Yap, Md Rokonuzzaman

Research outputs 2022 to 2026

The advent of additive manufacturing (AM) technologies revolutionized design and production processes across various industries. In renewable energy, AM enabled new possibilities for optimizing solar e-hub (solar energy harvesting module) configurations, enhancing efficiency and performance. This study examined critical considerations such as material selection, durability, and cost-effectiveness in solar hub development. This fast-prototyping technique was controlled by computer-aided design (CAD) software like CREO Parametric 7.0 and Creality Slicer 4.8. Experimental results indicated that PLA (Polylactic acid) materials exhibited superior strength, with an impact energy of 4.8 Joules. The deformation study revealed that the maximum load of 22 MPa aligned with …

Crystal Plasticity Modeling Of Heterogeneous Microstructure Of Additively Manufactured Metals, Md Mahabubur Rohoman

Theses and Dissertations

Additive manufacturing (AM) has emerged as a promising technique in the manufacturing industry for producing complex metal components as it provides shape freedom and simplistic processing chain.

Powder bed fusion is the widely used AM technique that uses laser or electron beam as the energy source to melt the metal powder and deposit it in a layer-by-layer fashion. While doing so, the previously molten layers are constantly are in re-heating and re-cooling processes which end up creating an intricate solidification for the deposited layers. Due to the complexity involved in the thermal cycles for the solidification process, columnar grains develop. …

Fatigue Performance Of 3d-Printed Poly-Lactic-Acid Bone Scaffolds With Triply Periodic Minimal Surface And Voronoi Pore Structures, Hamed Bakhtiari, Alireza Nouri, Majid Tolouei-Rad

Research outputs 2022 to 2026

Bone scaffolds serve a crucial role in tissue engineering, particularly in facilitating bone regeneration where natural repair is insufficient. Despite advancements in the fabrication of polymeric bone scaffolds, the challenge remains to optimize their mechanical resilience. Specifically, research on the fatigue behaviour of polymeric bone scaffolds is scarce. This study investigates the influence of pore architecture on the mechanical performance of poly-lactic-acid (PLA) scaffolds under quasi-static and cyclic compression. PLA scaffolds with a 60% porosity were fabricated using extrusion-based 3D printing in various designs: Gyroid, Lidinoid, Fischer–Koch, IWP, and Voronoi. Results demonstrated that Gyroid scaffolds had the highest compressive strength …

Towards Load-Bearing Biomedical Titanium-Based Alloys: From Essential Requirements To Future Developments, Yu-Wei Cui, Liqiang Wang, Lai-Chang Zhang

Research outputs 2022 to 2026

The use of biomedical metallic materials in research and clinical applications has been an important focus and a significant area of interest, primarily owing to their role in enhancing human health and extending human lifespan. This article, particularly on titanium-based alloys, explores exceptional properties that can address bone health issues amid the growing challenges posed by an aging population. Although stainless steel, magnesium-based alloys, cobalt-based alloys, and other metallic materials are commonly employed in medical applications, limitations such as toxic elements, high elastic modulus, and rapid degradation rates limit their widespread biomedical applications. Therefore, titanium-based alloys have emerged as top-performing …

Advancements In Aerial Vehicle Platforms: A Guide For Design, Validation, And Implementation Of 3d Printed Drones, Alan Salvador Urteaga

Theses and Dissertations

Additive manufacturing methods have revolutionized the way products are designed and developed through a product's entire design life cycle. This is in part correlated with the nature of additive manufacturing methods that differentiate them from traditional methods. Some of the benefits of additive manufacturing methods include customizability, rapid prototyping, the production of complex design geometry, and embedded assembly manufacturing. Unmanned aerial vehicles have been on the rise for various military, commercial, or personal applications. The focus of this study is to provide detailed instructions on how to engineer a viable drone design that is impact-resistant, modular, and customizable. This study …

Natural Fiber Reinforced Composites For Sustainable Additive Manufacturing., Athira Nair Surendran

Electronic Theses and Dissertations

Carbon fiber is widely known for its exceptional strength, making it a sought-after material in composite manufacturing, especially with thermosets and thermoplastics. Its major applications span aerospace, wind turbines, sports equipment, automotive interior and exterior parts, robotics and medical equipment. Recently, carbon fiber filament manufacturing has gained attention due to the availability of desktop 3D printers and the versatility and customizability that comes with the realm of 3D printing. Commercial carbon fiber production, primarily from polyacrylonitrile (PAN), is energy-intensive and derived from crude oil, contributing to significant environmental impacts and poor recyclability. Alternatively, lignocellulosic natural fibers present a possible sustainable …

Synergistic Strategies In Hybrid Mxed Matrix 3d Printing Of Thermoplastics & Thermosets: Design, Manufacturing, And Materials Development., Saleh Akram Khanjar

Electronic Theses and Dissertations

Composite manufacturing and mixed matrix structures have been produced using traditional manufacturing processes for various industrial applications due to their high mechanical properties to material weight and cost ratio. However implementation of composite and mixed matrix manufacturing with advanced manufacturing such as additive manufacturing is limited due to the hardware limitations of current 3d printing technologies and materials available for 3D printing applications. This work has developed and investigated a new hybrid 3D printing manufacturing process utilizing a variety of material systems (thermoplastic – thermoset, thermoplastic – thermoplastic, thermoset – thermoset, thermoplastic – thermoplastic – thermoset). This study developed thermoplastic …

A Survey On Fused Filament Fabrication To Produce Functionally Gradient Materials, Arup Dey, Monsuru Ramoni, Nita Yodo

Manufacturing & Industrial Engineering Faculty Publications

Fused filament fabrication (FFF) is a key extrusion-based additive manufacturing (AM) process for fabricating components from polymers and their composites. Functionally gradient materials (FGMs) exhibit spatially varying properties by modulating chemical compositions, microstructures, and design attributes, offering enhanced performance over homogeneous materials and conventional composites. These materials are pivotal in aerospace, automotive, and medical applications, where the optimization of weight, cost, and functional properties is critical. Conventional FGM manufacturing techniques are hindered by complexity, high costs, and limited precision. AM, particularly FFF, presents a promising alternative for FGM production, though its application is predominantly confined to research settings. This paper …

Modeling Powder Spreadability In Powder-Based Processes Using The Discrete Element Method, Austin T. Sutton, M. Hossein Sehhat, Ming C. Leu, Joseph W. Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Powder-bed fusion (PBF) processes refer to a subset of Additive Manufacturing (AM) techniques where powder is spread on the build-plate before melting (by a laser or electron beam). While PBF processes are attractive due to their ability for realizing complex structures that are either difficult or impossible to create through conventional means, the parts fabricated with these techniques can exhibit defects such as pores, inclusions, and excessive surface roughness. To minimize these defects, much research has been dedicated towards process maturation by optimizing laser or electron beam parameters. However, these developmental efforts typically do not address the recoating process where …

Examining The Progress In Additive Manufacturing In Supporting Lean, Green And Sustainable Manufacturing: A Systematic Review, Catherine Maware, Rumbidzai Muvunzi, Tinotenda Machingura, Ilesanmi Daniyan

Institute for Sustainable Manufacturing Faculty Publications

The quest for waste reduction and the development of manufacturing processes that meet the economic, social and environmental requirements necessitate this study. Additive manufacturing is an emerging digital technology that can be used to seamlessly develop a product through material deposition in layers. The study aims to investigate the progress made in the development of additive manufacturing to support lean, green and sustainable manufacturing. The study employs a systematic literature review approach, specifically the Preferred Reporting Items for Systematic Reviews and Meta-Analysis (PRISMA). A total of 158 articles identified from different academic databases that detailed empirical, conceptual and theoretical findings …

On The Correlation Between Pre-Processing Workflow And Dimensional Accuracy Of 3d Printed Parts In High-Precision Material Jetting, Karin Chen, Ahmed Elkaseer, Steffen Scholz, Veit Hagenmeyer

Mechanical Engineering

Material Jetting (MJ) is distinguished in the additive manufacturing field for its ability to create accurate multi-material functional objects with features in the range of few micrometers. Analyzing the impact of each step in MJ from virtual design to 3D printed object on the process response is essential for optimizing the technology’s capabilities. The current state-of-the-art reveals a gap in MJ regarding the fundamental understanding of the correlation between the pre-processing workflow and the geometrical and dimensional accuracy. This study aims to bridge this gap by examining factors such as utilization of different CAD software with diverse working principles, part-based …

Additively Manufactured Flexible Piezoelectric Wave-Based Multifunctional Sensor, Rishikesh Srinivasaraghavan Govindarajan

Doctoral Dissertations and Master's Theses

The demand for acoustic wave-based sensors has rapidly increased in the aerospace, chemical, gas, and biological fields due to their versatility in sensing measurands. This study aims to develop a flexible piezoelectric sensor exhibiting enhanced piezoelectric properties using additive manufacturing techniques that can detect mechanical strains and gas or volatile organic compounds (VOCs) by incorporating functional material into the sensing layer. This research explores piezoelectric substrate fabrication through diverse additive manufacturing techniques, including new material development made of polymer/nano-fillers with electrodes that are filled using different printing techniques. Notably, the design of the interdigital transducer (IDT) in the piezoelectric sensor …

Spectral Behavior Of Fiber Bragg Gratings During Embedding In 3d-Printed Metal Tensile Coupons And Cyclic Loading, Farid Ahmed, Md Shahriar Forhad, Mahmudul Hasan Porag

Manufacturing & Industrial Engineering Faculty Publications

Additive manufacturing (AM) enables the spatially configurable 3D integration of sensors in metal components to realize smart materials and structures. Outstanding sensing capabilities and size compatibility have made fiber optic sensors excellent candidates for integration in AM components. In this study, fiber Bragg grating (FBG) sensors were embedded in Inconel 718 tensile coupons printed using laser powder bed fusion AM. On-axis (fiber runs through the coupon’s center of axis) and off-axis (fiber is at 5° and 10° to the coupon’s center of axis) sensors were buried in epoxy resin inside narrow channels that run through the coupons. FBGs’ spectral evolutions …

Recent Innovations In Laser Additive Manufacturing Of Titanium Alloys, Jinlong Su, Fulin Jiang, Jie Teng, Lequn Chen, Ming Yan, Guillermo Requena, Lai-Chang Zhang, Y. Morris Wang, Ilya V. Okulov, Hongmei Zhu, Chaolin Tan

Research outputs 2022 to 2026

Titanium (Ti) alloys are widely used in high-tech fields like aerospace and biomedical engineering. Laser additive manufacturing (LAM), as an innovative technology, is the key driver for the development of Ti alloys. Despite the significant advancements in LAM of Ti alloys, there remain challenges that need further research and development efforts. To recap the potential of LAM high-performance Ti alloy, this article systematically reviews LAM Ti alloys with up-to-date information on process, materials, and properties. Several feasible solutions to advance LAM Ti alloys are reviewed, including intelligent process parameters optimization, LAM process innovation with auxiliary fields and novel Ti alloys …

Novel Equimolar Medium Entropy Alloy (Ti-W-Mo) Via Selective Laser Melting For High Temperature Applications, Lindsey A. Salazar

Theses and Dissertations

High-temperature strength and high environmental resistance are necessary characteristics for materials under extreme working conditions in aerospace, nuclear, and chemical industries. In this study, a novel refractory medium entropy alloy (MEA) was developed from tungsten (W), titanium (Ti), and molybdenum (Mo) via an additive manufacturing process, selective laser melting (SLM). Through process optimization, (i) the formation of brittle intermediate phases was suppressed, (ii) the complete melting of tungsten particles was achieved, and (iii) a pure solid solution was formed. Due to the addition of Ti and Mo, the resultant alloy showed outstanding high-temperature strength compared to other tungsten alloys. The …

The Effects Of Additive Manufacturing On Canine Hind Limb Repairment Surgery, Annabel Keers

Honors Theses

The intention of this project is to explore some of the ways that additive manufacturing is affecting veterinary medicine. I will specifically be delving into canine hind limb repairment surgeries, such as cranial cruciate ligament reconstruction. 3D printed prototypes have been utilized in the human medical field for quite a while, and it has inspired such technology to expand into the world of veterinary medicine. Such emerging research is expected to take-off as the pet market grows in size and level of care for the health of our animals.

I took special interest in this field as I will be …

Characterization Of Chopped Carbon Fiber Reinforced Composites Produced Using Fused Deposition Modeling, Jonathon Tran, Rachel Shubella

Student Research Symposium

Fused deposition modeling (FDM) is an additive manufacturing (AM) process which can create parts with complex geometries in their final shape without need for additional specialized tools or devices. The FDM process builds parts by adding material layer by layer only where it is needed, saving energy, costs, production time for complex parts, and minimizing waste. Fiber reinforcement can significantly enhance the mechanical properties of a polymer material and depends significantly on the fiber length distribution and fiber orientation distribution of the final part. In this research, we investigated the various infill patterns of FDM printed Markforged onyx which is …

Novel Vector Assignment Approach For Inherent Strain Modeling Of Laser Powder Bed Fusion Manufacturing, Lucas M. Morand

All Dissertations

The expansion of the design space due to additive manufacturing (AM) has been a large motivator for the success of this family of processes. Despite the complexity of the physics in metal laser powder bed fusion AM causing significant stresses and strains in finished parts, the design advantages and subsequent performance improvements continue to drive the expansion of AM. Because the trial-and-error approach to AM part development is cost prohibitive, simulation of prints has become crucial. However, full thermo-mechanical simulation is susceptible to the same pitfall of time and computational cost in order to attain part-scale results. The development of …

Explainable Machine Learning For The Regulatory Environment: A Case Study In Micro-Droplet Printing, Elaine Harris, Darragh F. Ryan, Gerard M. O'Connor

Articles

Micro-droplet printing remains an invaluable tool for the additive manufacturing industry due to its versatility, efficiency and cost-effectiveness. The design and deployment of a disposable micro-droplet dispenser seeks to facilitate a quick and easy way to alternate between different printing materials (such as ink, metals, bio-materials, pharmaceuticals, etc.) without the need for thorough cleaning or separate delivery systems. While this works well in principle, in practice achieving consistent performance between dispensers can prove challenging. This paper aims to tackle this issue through the use of Machine Learning (ML) in order to (1) build a model that predicts dispenser performance from …

Progress In Selective Laser Sintering Ofmultifunctional Polymer Composites For Strain- And Self-Sensing Applications, Muhammad Umar Azam, Imane Belyamani, Andreas Schiffer, Shanmugam Kumar, Khalid Askar

All Works

Recent decades have witnessed significant advancements in additive manufacturing (AM) of polymer composites, leading to the development of material systems with intricate architecture and composition. Selective laser sintering (SLS), among various AM methods, offers numerous advantages such as high mechanical strength in printed parts, recyclability of unused powders, and the ability to print large batches without support structures. Moreover, SLS has remarkably succeeded in fabricating electrically conductive polymer composites (ECPCs) with exceptional functional performance which is attributed primarily to the formation of a segregated filler network along the powder particle boundaries. This review aims to delve into SLS for processing …

Analysis Of Drying Behavior Of Robocasted Barium Titanate, Abigail Ortega

Open Access Theses & Dissertations

Finding an adequate ceramic formulation for material extrusion is a time-consuming process. The necessary equipment may be unavailable to perform the desired test. This study demonstrated an alternative to observe a material after extrusion to understand its drying process. This study focused on 55 solid loading volume percent and a 39 solid loading volume percent, each with two different binder treatments focusing on fresh same day made binder, a 30 day old, aged binder and lastly an artificial binder obtained by a fuming process. Firstly, a formulation was created and loaded onto a pressure-based syringe to be extruded with a …

Titanium Dioxide Nanomaterial Ink Production Through Laser Ablation Synthesis In Solution For Printed Electronics Applications, Devyn Duryea, Nicholas Mckibben, Jacob Manzi, Taylor Brennan, Harish Subbaraman, David Estrada, Nirmala Kandadai

Electrical and Computer Engineering Faculty Publications and Presentations

Flexible and printed electronics have become increasingly popular as they make possible the production of flexible, low-cost, multifunction devices that are unachievable through traditional manufacturing methods. The printed films are significantly impacted and thus limited by the existing ink production process. Herein, an alternate technique of generating high-quality titanium dioxide (TiO₂) nanoparticle ink compatible with aerosol jet printing using laser ablation synthesis in solution (LASiS) is showcased. Dynamic light scattering data and transmission electron microscopy confirm the particle size distribution. UV–vis measurements are performed, and the Beer–Lambert relationship is used to determine the concentration of the generated ink. …

Process-Structure-Property-Performance Modeling For Semicrystalline Thermoplastics And Composites, Tatiana Stepanova

All Dissertations

With a growing focus on reducing the adverse effects of transportation on the environment, industries are seeking fuel-efficient and sustainable solutions. Fuel efficiency can be improved in several ways, but structural lightweighting has demonstrated overall effectiveness. In this regard, thermoplastic composites and additive manufacturing (AM) thermoplastics have become viable candidates for use in the automotive industry, given the need for weight reduction and efficiency improvement.

The advantages of AM include simplifying supply chains, simplifying part geometry, and enabling mass customization. In order to design high-performance AM structures, extensive modeling and simulation are required. AM thermoplastics are similar to conventional manufacturing …

Multi-Scale Modeling Of Selective Laser Sintering: From Manufacturing Process And Microstructure To Mechanical Performance In Semi-Crystalline Thermoplastics, Cameron Zadeh

All Dissertations

Selective laser sintering is an additive manufacturing process that opens many design possibilities but is limited in its reliability and reproducibility. Numerical simulations validated by experimental data yield insights into the process and resulting part properties, allowing users to make more informed decisions. In this dissertation, a model for the process and microstructure is developed and validated, followed by a coupling to mechanical models to predict part performance. Further developments include a new addition of a reaction kinetics model to the process model to describe the interplay between thermal degradation and melt pool properties, and an exploration of the parameter …