Structural Materials Commons^™

Direct Ink Writing Of Functional Fiber/Granular Composites, Zhuoyuan Yang

Doctoral Dissertations and Master's Theses

Direct ink writing provides a versatile manufacturing route for fabricating functional fiber and granular composites with controlled architecture, tunable interfaces, and customized material distributions. Fiber reinforced composites offer high stiffness, strength, fatigue resistance, and functional anisotropy, while granular composites provide scalable access to particle based structures with high material efficiency and broad resource compatibility. However, the additive manufacturing of these composite systems remains challenging. For fiber based composites, precise control of fiber placement, matrix impregnation, interfacial bonding, and freestanding deposition is difficult to achieve during printing. For granular composites, stable particle flow, controllable packing, binder infiltration, and shape retention are …

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 …

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 …

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 …

Experimental Investigations And Optimization Of 3d Printed Cellular Structures For Protection Against Traumatic Brain Injury, Aaron R. Jackson

Mechanical and Aerospace Engineering Dissertations - Archive

Traumatic Brain Injury (TBI) disrupts brain function due to head impacts, blast exposures, and ballistic penetrations. It is a significant cause of mental health issues and disability, particularly among military personnel. Historically, combat helmets were designed primarily to protect against fragments. However, recent data highlights the need for helmets that also protect against blast and blunt impacts. Effective TBI prevention requires helmets that address various energy threats while remaining lightweight. A critical metric in this effort is head acceleration, which is closely linked to injury across different scales of brain damage.

Four lattice structures were 3D printed using Digital ABS …

Fatigue And Fracture Of Electron Beam Melting Ti-6al-4v, William A. Grell

Electronic Theses and Dissertations

For applications in the aerospace field, selection of materials for a given design requires an understanding of critical properties, like fatigue and fracture, in addition to static mechanical and physical properties. With the ongoing advancements in metallic additive manufacturing techniques and the interest in applying the process to aerospace applications, there is a clear need to fully characterize properties. Arguably, the most attractive alloy for applications in aerospace is the Ti-6Al-4V alloy. The current dissertation examines the mechanical properties of the alloy, made by the Electron Beam Melting (EBM) Powder Bed Fusion (PBF) method. As illustrated in this work, the …

Additively Manufactured Continuous Carbon Fiber Thermoplastic Composites For High-Performance Applications, Nekoda Van De Werken

Mechanical Engineering ETDs

The goal of this dissertation is to provide a foundation for the advancement of additive manufacturing (AM) toward production of high-performance carbon fiber reinforced polymer matrix composites (CFRPs). AM can provide valuable advantages over conventional composite manufacturing techniques, including the control over fiber orientation, capability of manufacturing complex geometries, out-of-autoclave processing, elimination of the need for composite tooling, and the ability to perform lights-out manufacturing. Currently, however, a suite of challenges related to modelling, design, manufacturing defects, and general limitations in the current understanding of the processing-structure-property relationships exist in AM of composites. To this end, this dissertation investigates novel …

Evaluation Of Tensile Properties For Selective Laser Melted 316l Stainless Steel And The Influence Of Inherent Process Features, Paul Swartz

Master's Theses

Optimal print parameters for additively manufacturing 316L stainless steel using selective laser melting (SLM) at Cal Poly had previously been identified. In order to further support the viability of the current settings, tensile material characteristics were needed. Furthermore, reliable performance of the as-printed material had to be demonstrated. Any influence on the static performance of parts in the as-printed condition inherent to the SLM manufacturing process itself needed to be identified. Tensile testing was conducted to determine the properties of material in the as-printed condition. So as to have confidence in the experimental results, other investigations were also conducted to …

Calphad-Based Materials Genome And Its Applications To Additive Manufacturing, Wei Xiong

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

Characterizing Strain Accumulation, Residual Stress, And Microstructure Of Additive Manufactured Materials, Hannah K. Woods, Todd A. Book, Catalina Parada, Michael D. Sangid

The Summer Undergraduate Research Fellowship (SURF) Symposium

Additive Manufacturing (AM) is a rapidly evolving fabrication technology beneficial for its cost-saving potential to produce complex, low-volume shapes. However, AM materials are currently limited to nonstructural applications due to variability in their structural integrity, particularly their fatigue lives. IN718, Ti64, and Al10MgSi specimens manufactured by Direct Metal Laser Sintering (DMLS) were characterized based on variation of post-processing techniques and build direction. To understand the impact of each variable, surface roughness, hardness, residual stresses, microstructure, and strain accumulation in response to Low Cycle Fatigue (LCF) were studied. The use of Electron Backscatter Diffraction (EBSD) provided grain orientation and grain size …