Mechanics of Materials Commons^™

Made On Mars: Design And Manufacturing Of Structural Polymer-Regolith Composites, Pailey M. Vitale

Williams Honors College, Honors Research Projects

Human exploration of Mars is constrained by harsh environmental conditions and the prohibitive cost of transporting materials from Earth. Long-term sustainability requires the local production of mechanical and structural components using resources available on Mars, thereby minimizing payload mass. This project investigates polymer–regolith composites derived from atmospheric CO₂ and mineral-rich regolith as a pathway toward in-situ manufacturing. These composites, when compatible with additive manufacturing, could replace imported plastics, enable on-demand fabrication, and support closed-loop recycling systems. The objective is to design and evaluate polymer–regolith composites that maintain mechanical integrity and environmental resistance under Martian conditions, including extreme temperature swings, radiation …

Powder Degradation Analysis In Reused Pure Tungsten For Electron Beam Melting (Ebm), Hernan Valenzuela

Open Access Theses & Dissertations

Additive manufacturing (AM) enables unparalleled design freedom and geometric complexity, driving its adoption in aerospace and medical fields. A major advantage of metal powder AM technologies, such as Electron Beam Melting (EBM), is its ability to reuse unused metal powder, reducing material waste and costs. However, reusing powder repeatedly alters its properties, affecting the final product. Despite its significance, research on powder degradation remains limited, primarily focusing on alloys like Ti-6Al-4V. This thesis investigates the degradation of pure tungsten powder reused over multiple Electron Beam Melting (EBM) cycles. A literature review revealed general powder-reuse mechanisms across additive manufacturing (AM) technologies …

Laser Scan Path Design For Controlled Microstructure In Additive Manufacturing With Integrated Reduced-Order Phase-Field Modeling And Deep Reinforcement Learning, Augustine Twumasi

Open Access Theses & Dissertations

Laser Powder Bed Fusion (L-PBF) is a well-established additive manufacturing technique for fabricating intricate metal components with exceptional precision. A significant challenge in L-PBF is the formation of complex microstructures that influence final material properties. We propose a physics-guided, machine learning-aided approach to optimize scan paths for desired microstructure outcomes, such as equiaxed grains. We employed a phase-field method (PFM) to model the evolution of the crystalline grain structure. To reduce computational costs, we trained a surrogate machine learning model, a 3D U-Net convolutional neural network, using single-track phase-field simulations with varying laser powers to predict crystalline grain orientations based …

Development Of Porous Separators For Lithium-Ion Batteries Via 3d Printing And Thermally Induced Phase Separation, Abraham Enchinton

Open Access Theses & Dissertations

Additive manufacturing processes allow the development of custom-shape rechargeable batteries, but research in custom filaments for fused deposition modeling (FDM) of battery separators has remained limited until now. This study discusses the development and optimization of a composite thermoplastic filament feedstock to 3D print separator membranes. A number of post-processing steps - leveraging the thermally induced phase separation (TIPS) of the composite filament - are introduced in tandem with FDM to promote microporosity formation through the removal of the sacrificial diluent phase within 3D printed samples. Three distinct compositions of varying polymer/diluent ratios were developed and thoroughly investigated through thermogravimetric …

Tailoring Functional And Sensing Properties Of Polymer-Ceramic Composites Via 3d Printing, Alexis Lopez

Open Access Theses & Dissertations

Section 1.1. Abstract This chapter investigates the use of direct ink write (DIW) additive manufacturing to control grain orientation in non-toxic barium titanate (BTO) ceramics by blending spherical and platelet-shaped particles in the ink. A series of inks containing 0–40 wt.% BTO platelets were formulated with poly(vinyl alcohol), polyethylene glycol, poly(acrylic acid-co-maleic acid), and ammonium hydroxide to ensure printability and homogeneous dispersion. Cylindrical specimens (20 mm × 3 mm) were printed using a Hyrel 30M DIW system and subjected to de-binding (650 °C, 2 h) followed by a two-step sintering schedule (T₁: 1200–1350 °C; T₂: 700–850 °C; 24 h dwell). …

Analysis Of Additively Manufactured Inconel 718 Combustion Behavior In Promoted Oxygen Environments, Dominic George Dieguez

Open Access Theses & Dissertations

Promoted combustion testing is a vital tool for engineers to establish the combustion and flammability characteristics of materials (metallic or otherwise) in oxygen enriched environments. Historically, much of the established data for metallic promoted combustion has been with regards to materials in their cast and wrought forms. However, with the emergence of additive manufacturing as a preferred method of fabrication, the need exists to evaluate how metals in that form behave. Recent testing has demonstrated that even if a metal or alloy is nominally the same with regards to chemistry, flammability between samples in the wrought form can differ significantly …

The Effects Of Laser Shock Peening On The Fatigue Life Of Additive Manufactured Alsi10mg, Jacob L. Biddlecom

All Dissertations

Additive manufacturing (AM) is becoming a manufacturing process that is well established, even with all the resources and attention that has been brought to it, the field is still lacking some key understandings. Currently, there are certain aspects that are difficult to overcome. Some of the intrinsic obstacles include process-induced defects, such as porosity from lack of fusion and gaseous bubble entrapment, as well as complex thermal gradients. These defects can lead to altered material response especially when looking at the fatigue life. The fatigue behaviors of AM components can change from print to print as well as when compared …

Sulfonated Styrene Grafted Sebs/Abs Made By Additive Manufacturing For Ion Exchange Applications, Avianna Elaine Gallegos

Open Access Theses & Dissertations

An interpenetrating polymer network (IPN) for cation exchange applications was synthesized from a blend of styrene-ethylene/butylene-styrene (SEBS) and acrylonitrile butadiene styrene (ABS), which was 3D printed, grafted with crosslinked polystyrene (PS), and sulfonated. A method for styrene grafting was applied to reduce the damage to polymer phases caused by the sulfonation reaction. Styrene and divinylbenzene monomers were introduced to the IPN and induced with heat treatment to polymerize in situ. The graft copolymerization reaction was enhanced with varying quantities of benzoyl peroxide as a chemical initiator. The samples were subsequently sulfonated with chlorosulfonic acid in dichloroethane and functionalized for ion …

Suitability Of Low-Cost Additive Manufacturing For Polymer Electrolyte Fuel Cells, David Alexander

Open Access Theses & Dissertations

The purpose of this dissertation is to study the feasibility of low-cost additive manufacturing to fabricate polymer electrolyte fuel cell bipolar plate materials. Traditional manufacturing techniques include molding, milling, hollow embossing, hydro-forming, rolling, and electromagnetic forming. These processes are employed when a design has been selected due to higher costs at low volumes. The combination of high initial costs and bipolar plates being the most expensive component of the polymer electrolyte fuel cell creates incentive to mitigate this obstacle. The feasibility of low-cost additive manufactured bipolar plates will be proven by fabrication, post-processing, and characterization of printed test specimen. The …

Material Synthesis And Machine Learning For Additive Manufacturing, Jaime Eduardo Regis

Open Access Theses & Dissertations

The goal of this research was to address three key challenges in additive manufacturing (AM), the need for feedstock material, minimal end-use fabrication from lack of functionality in commercially available materials, and the need for qualification and property prediction in printed structures. The near ultraviolet-light assisted green reduction of graphene oxide through L-ascorbic acid was studied with to address the issue of low part strength in additively manufactured parts by providing a functional filler that can strengthen the polymer matrix. The synthesis of self-healing epoxy vitrimers was done to adapt high strength materials with recyclable properties for compatibility with AM …

Recycled Printer Filament, Charlotte Hyland, Troy D. Molinar

Williams Honors College, Honors Research Projects

The purpose of this research is to examine the effects of recycling PLA filament for 3D printing on its material properties. After examining these effects, PLA and carbon fiber additives were mixed with recycled PLA pellets in different ratios to attempt to regain material properties lost in the recycling process. To complete these findings, an experiment was design and executed.

The research found that tensile strength during multiple iterations of recycling remained mostly unaffected, however, the strain degraded exponentially. In the PLA additive study, high ratios of PLA additive were able to increase the strength and strain properties of the …

Tailoring Texture, Microstructure, And Shape Memory Behavior Of Niti Alloys Fabricated By L-Pbf-Am, Sayed Ehsan Saghaian N.E.

Theses and Dissertations--Mechanical and Aerospace Engineering

Laser Powder Bed Fusion (L-PBF) is one of the most promising Additive Manufacturing (AM) methods to fabricate near net-shape metallic materials for a wide range of applications such as patient-specific medical devices, functionally graded materials, and complex structures. NiTi shape memory alloys (SMAs) are of great interest due to a combination of unique features, such as superelasticity, shape memory effect, high ductility, work output, corrosion resistance, and biocompatibility that could be employed in many applications in automotive, aerospace, and biomedical industries. Due to the difficulties with traditional machining and forming of NiTi components, the ability to fabricate complex parts, tailor …

Comparison Of Additively Manufactured And Wrought 17-4 Ph Stainless Steels In Ultra Low Cycle Fatigue, Timothy Strasser

Graduate Theses and Dissertations

Additive manufacturing (AM) processes allow for creation of complex geometries that are otherwise impractical to fabricate with traditional subtractive methods. AM technology has potential to improve the optimization of seismic lateral force resisting components which dissipate seismic energy through large plastic strains; however, the ultra low-cycle fatigue performance of AM metals are not yet well understood. Void formation during the AM fabrication process has potential to affect performance. This study compares the performance of heat-treated and non-heat-treated AM and wrought 17-4PH stainless steel in Ultra Low Cycle Fatigue. To understand ULCF performance differences between the AM and wrought specimens, post …

Design Rules For Additive Manufacturing – Understanding The Fundamental Thermal Phenomena To Reduce Scrap, M. Reza Yavari, Kevin D. Cole, Prahalada K. Rao

Department of Mechanical and Materials Engineering: Faculty Publications

The goal of this work is to predict the effect of part geometry and process parameters on the direction and magnitude of heat flow heat flux in parts made using metal additive manufacturing (AM) processes. As a step towards this goal, the objective of this paper is to develop and apply the mathematical concept of heat diffusion over graphs to approximate the heat flux in metal AM parts as a function of their geometry. This objective is consequential to overcome the poor process consistency and part quality in AM. Currently, part build failure rates in metal AM often exceed 20%, …

Direct Write 3d Printing Of Functional Ceramics, Jorge Angel Diaz

Open Access Theses & Dissertations

Humidity sensors are used in many industries and are important for ensuring quality and safety. Ceramic sensors are preferred because of their quick response time, ability to withstand high temperatures and excellent Chemical and mechanical stability. The manufacturing world has been moving toward additive manufacturing which is a form of synthesizing 3D tangible layer by layer in witch minimal waste is produced. Additive manufacturing also is known as 3D printing has opened new possibilities to design engineers by giving them design freedom and access to the layers of a part to allow embedded sensors. There is a category of ceramics …

Investigating Using Titanium Zirconium Molybdenum For Additively Manufacturing Aerospace Components, Justin Hunter Vanhoose

Open Access Theses & Dissertations

Mankind throughout history has possessed an innate characteristic to explore, migrating to new frontiers.The requirement for this travel is most broadly associated with the need to pursue more resources. Rockets have been used as a means of weapons since the Sung Dynasty in the thirteenth empire and have now been integrated for travel/transport. The sophistication of rocketry and propulsion has reached a level to where it is plausible that mankind will be a multi-planetary species. The space industry has grown significantly with the advancement of the sophistication of these rocket technologies. However, a specific challenge to overcome in the space …

A New Approach To Multiplanar, Real-Time Simulation Of Physiological Knee Loads And Synthetic Knee Components Augmented By Local Composition Control In Fused Filament Fabrication, Joshua Taylor Green

Open Access Theses & Dissertations

Despite numerous advances in biomedical engineering, few developments in surgical simulation have been made outside of computational models. Cadavers remain the primary media on which surgical research and simulation is conducted. Most attempts to quantify the effects of orthopedic surgical methods fail to achieve statistical significance due to limited quantities of cadaver specimen, large variations among the cadaver population, and a lack of repeatability among measurement techniques. The general purpose of the research covered in this dissertation is to develop repeatable simulation of physiological loads and develop techniques to fabricate a synthetic-based replacement of cadaver specimens. Future work applying this …

Comprehensive Finite Element Modeling Of Ti-6al-4v Cellular Solids Fabricated By Electron Beam Melting, Edel Arrieta

Open Access Theses & Dissertations

Additive manufacturing permits the fabrication of cellular metals which are materials that can be highly customizable and possess multiple and extraordinary properties such as damage tolerance, metamorphic and auxetic behaviors, and high specific stiffness. This makes them the subject of interest for innovative applications. With interest in these materials for energy absorption applications, this work presents the development of nonlinear finite element models in commercial software platforms (MSC Patran/Nastran) that permit the analysis of the deformation mechanisms of these materials under compressive loads. In the development of these models, a detailed multiscale study on the different factors affecting the response …

Effects Of Fabrication Conditions On Mechanical Properties Of Ti-6al-4v Fabricated By Powder Bed Fusion Additive Manufacturing, Paola Azani

Open Access Theses & Dissertations

At the writing of this Thesis, additive manufacturing (AM) also known as 3D printing, has been popularized for its diversity in applications ranging from home and personal use, medical, industrial, consumer products, aerospace, architecture, automotive, military, fashion, food, art and more. Industries taking advantage of the design freedom and complexity offered by AM have exploded the growth of the technologies. Specifically, technologies that process metals using electron and laser beams have been recognized by the aerospace industry as a promising avenue for re-engineered components leading to reduced weight and improved engineering efficiencies for components like engine brackets and nozzles. However, …

Reducing Metal Alloy Powder Costs For Use In Powder Bed Fusion Additive Manufacturing: Improving The Economics For Production, Fransisco Medina

Open Access Theses & Dissertations

Titanium and its associated alloys have been used in industry for over 50 years and have become more popular in the recent decades. Titanium has been most successful in areas where the high strength to weight ratio provides an advantage over aluminum and steels. Other advantages of titanium include biocompatibility and corrosion resistance. Electron Beam Melting (EBM) is an additive manufacturing (AM) technology that has been successfully applied in the manufacturing of titanium components for the aerospace and medical industry with equivalent or better mechanical properties as parts fabricated via more traditional casting and machining methods. As the demand for …

The Influence Of Build Parameters On The Microstructure During Electron Beam Melting Of Ti6al4v, Karina Puebla

Open Access Theses & Dissertations

With the demand of devices to replace or improve areas, such as: electronic, biomedical and aerospace industries. Improvements in these areas of engineering have been in need due to the customer’s needs for product properties requirements. The design of components must exhibit better material properties (mechanical or biocompatible) close to those of any given product. Rapid prototyping (RP) technologies that were originally designed to build prototypes may now be required to build functional end-use products. To carry out the transition, from RP to rapid manufacturing (RM), the available materials utilized in RP must provide the performance required for RM. The …

Microstructural Architecture Developed In The Fabrication Of Solid And Open-Cellular Copper Components By Additive Manufacturing Using Electron Beam Melting, Diana Alejandra Ramirez

Open Access Theses & Dissertations

The fabrication of Cu components were first built by additive manufacturing using electron beam melting (EBM) from low-purity, atomized Cu powder containing a high density of Cu2O precipitates leading to a novel example of precipitate-dislocation architecture. These microstructures exhibit cell-like arrays (1-3µm) in the horizontal reference plane perpendicular to the build direction with columnar-like arrays extending from ~12 to >60 µm in length and corresponding spatial dimensions of 1-3 µm. These observations were observed by the use of optical metallography, and scanning and transmission electron microscopy. The hardness measurements were taken both on the atomized powder and the Cu components. …