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Articles 31 - 60 of 220
Full-Text Articles in Mechanical Engineering
Data-Driven Prediction Of Temperature Distribution In Multi-Laser Powder Bed Fusion Using Convolutional Neural Networks, Majid Dousti
Data-Driven Prediction Of Temperature Distribution In Multi-Laser Powder Bed Fusion Using Convolutional Neural Networks, Majid Dousti
Browse all Theses and Dissertations
Additive Manufacturing (AM), particularly Laser Powder Bed Fusion (L-PBF), has gained significant traction in fabricating complex, high-performance metallic components. However, the inherent complexity and computational cost of high-fidelity simulations pose challenges for real-time monitoring and optimization of multi-laser powder bed fusion processes. This study proposes a data-driven surrogate modeling approach using a deep learning architecture to efficiently and accurately predict three-dimensional temperature distributions during ML-PBF. A 3D convolutional neural network (CNN) model, named Decoder-CNN, is developed and trained on a dataset of simulated thermal fields corresponding to various process configurations, including different laser power, scanning speed, and beam arrangements. The …
Effect Of Build Orientation And Environmental Conditions On Mechanical And Geometric Properties Of Polymeric Parts Fabricated By The Powder Bed Fusion Process, Adedamola O. Adeyemi
Effect Of Build Orientation And Environmental Conditions On Mechanical And Geometric Properties Of Polymeric Parts Fabricated By The Powder Bed Fusion Process, Adedamola O. Adeyemi
Browse all Theses and Dissertations
Polyamide-12 (aka PA12) is a synthetic thermoplastic polymer that has been used in various applications, including the electronic and electrical, oil and gas industrial manufacturing and automotive industry. There are several ways to manufacture parts with PA12 and PA12 based composites. Injection molding, a traditional manufacturing process, has been the standard manufacturing route for polymers for a long time. Recently, however, additive manufacturing (AM) processes, such as powder bed fusion (PBF) and material extrusion (ME) have been introduced. PBF is a manufacturing process characterized by the selective sintering of successive layers of powdered material. It is the most effective AM …
Affordable And Sustainable: Innovating Filament Extrusion For Recycled Materials, Turab S. Rizvi
Affordable And Sustainable: Innovating Filament Extrusion For Recycled Materials, Turab S. Rizvi
Undergraduate Research Posters
The chemical stability, toxicity and non-biodegradability of the polymers pose a significant environmental threat. Addressing end-of-life treatment sustainability is crucial for mitigating these issues. The customized Lyman filament extruder in the Advanced Magnetic Materials Processing Laboratory represents an innovative approach to advancing sustainability in renewable energy production and CO₂ mitigation. Redesigning the thermal system and screw operation will tackle key challenges, including precise temperature control, consistent material flow to handle diverse recycled materials. Integrating an advanced thermal regulation system will reduce the energy consumption by maintaining optimal thermal conditions, thereby lowering the CO₂ footprint of the recycling process. The optimized …
Experimental Study Of Defects In Coaxial Wire-Based Laser Metal Deposition, Remy Mathenia
Experimental Study Of Defects In Coaxial Wire-Based Laser Metal Deposition, Remy Mathenia
Doctoral Dissertations
This work seeks to improve the usability and capability of coaxial wire-based laser metal deposition (LMD) through the experimental study of process parameters on output geometry, directional effects, and defect formation. Wire-based LMD is a directed energy deposition (DED) strategy that uses a focused laser heat source to melt and fuse metal wire as it is deposited. This process is used to build parts layer-by-layer until a desired geometry is accomplished. LMD enables the creation of complex components at a high build rate with low material and energy waste. This work focuses on the deposition of titanium wire in the …
Using Additive Manufacturing To Characterize Effects Of Sparse Infill Density And Sparse Infill Pattern On The Compressive Properties Of Short Strand Carbon Fiber Infused Petg, Luke C. Salisbury
Honors Theses
The advent of additive manufacturing has revolutionized the prototyping, design, and manufacturing of new and innovative products. Through the use of Fused Deposition Modeling (FDM), parts can be manufactured using different sparse infill percentages (the percentage of void space within a printed object) and sparse infill patterns (the lattice structure of material within the object). Through the manipulation of these variables, the same material and part can have different compressive and flexural properties. In addition to sparse infill, the thermoplastics used in fused deposition modeling can be reinforced with carbon fiber strands to create a printable composite material capable of …
Fatigue Endurance Of Alsi10mg Post Hip Heat Treatment With High Duration Thermal Aging, William Venable Newcomb
Fatigue Endurance Of Alsi10mg Post Hip Heat Treatment With High Duration Thermal Aging, William Venable Newcomb
Open Access Theses & Dissertations
AlSi10Mg is one of the cornerstones of additive manufacturing (AM), with its materialproperties and relatively low cost making it extremely popular as an AM metal choice, specifically using Laser Powder Bed Fusion (LPBF). Many publications have focused on this material, studying tensile strength, fatigue, heat treatments, and more. However, an area that requires further study is the effect of aging on the materials fatigue properties, with this study examining an industry standard heat treatment of Hot Isostatic Pressing (HIP). Using studies that have already been completed, AlSi10Mg was fatigue tested at near 100% UTS and 75% yield strength after HIP …
Development Of A Manifold Microchannel Heat Sink For The Electrification Of Aircraft, Joshua Mora Sanchez
Development Of A Manifold Microchannel Heat Sink For The Electrification Of Aircraft, Joshua Mora Sanchez
Mechanical Engineering Undergraduate Honors Theses
The miniaturization of microprocessors and power electronics is leading to critical thermal management challenges. For instance, the heat flux generated in modern computer chips is at the order of 100W/cm², which is well beyond the limit of air cooling. This high heat generation can cause a variety of thermal or mechanical failures in electronic devices. As such, there is a pressing need to devise effective cooling strategies for these microelectronic devices. Liquid cooling with microchannel heat sinks is a promising technology for high power loads. Nevertheless, traditional heat sinks with straight microchannels suffer from two critical challenges: high pressure drop …
Synthesis Of Materials For Additive Manufacturing Of Enhanced Polymers And Textured Ceramics, Diana Fontes
Synthesis Of Materials For Additive Manufacturing Of Enhanced Polymers And Textured Ceramics, Diana Fontes
Open Access Theses & Dissertations
This research will be divided into two sections. The first section investigates the development of textured Barium Titanate (BaTiO3) ceramics fabricated through Direct Ink Write Printing (DIW) integrated with Templated Grain Growth (TGG). This approach aims to develop lead-free piezoelectric materials with grain alignment during printing process to promote high piezoelectric performance comparable to those in lead-based ceramics. This research evaluates the impact of the DIW-TGG process on grain orientation, material densification, and piezoelectric response, illustrating its potential for developing high-performance ceramics for advanced applications such as sensors, actuators, and other piezoelectric devices. The second project explores the chemical stability …
Advancements In Polymer Synthesis And Ceramic Additive Manufacturing For Energy Applications, Sofia Gabriela Gomez
Advancements In Polymer Synthesis And Ceramic Additive Manufacturing For Energy Applications, Sofia Gabriela Gomez
Open Access Theses & Dissertations
The aim of this work was to create polymer and ceramic materials for integration into energy applications. The first part of this research was to fabricate polymer syntactic foams that exhibited high energy absorption capabilities. The fabrication of polymer syntactic foams was feasible through synthesizing hollow polysiloxane microspheres that were imbedded into a polydimethylsiloxane (PDMS) matrix. An array of characterization techniques was used to test the material and physical properties of the syntactic foams. The next step of this research was to fabricate a porous water emulsion foam ink for use in Direct-Ink-Write (DIW) additive manufacturing (AM) technologies. Unlike the …
Innovations In Additive Manufacturing For Socket Fabrication: An Overview, Linda Ziyadatul Faiza, Wahyu Caesarendra, Wahyu Dwi Lestari
Innovations In Additive Manufacturing For Socket Fabrication: An Overview, Linda Ziyadatul Faiza, Wahyu Caesarendra, Wahyu Dwi Lestari
Journal of Mechanical Engineering Science and Technology (JMEST)
Additive Manufacturing (AM) has transformed the prosthetics industry, particularly in socket production, which plays a critical role in the comfort, fit, and functionality of prosthetic limbs. This article examines the latest advancements in AM technologies and their applications in socket fabrication. Key techniques like stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM) have facilitated the production of highly personalized, lightweight, and durable prosthetic sockets. These methods not only improve design precision but also allow for the use of biocompatible, flexible materials, enhancing both comfort and functionality. Digital design tools have streamlined the production process, reducing lead times …
Experimental Study Of The Impact Of Droplet And Printing Parameters On Line Formation In Binder Jetting, Jacob E. Lawrence, Madi P. Lawrence, Nathan Crane
Experimental Study Of The Impact Of Droplet And Printing Parameters On Line Formation In Binder Jetting, Jacob E. Lawrence, Madi P. Lawrence, Nathan Crane
ScholarsArchive Data
This dataset consists of images of lines printed into 316 SS powder with varied droplet parameters (velocity, size, satellite or not) and print parameters (droplet spacing, printing frequency). Additionally, it includes data that was extracted from the images and some secondary measurements such as droplet height performed for some samples. The codes for the image processing routines are also included for reference as are the tables of data that were extracted from the images.
Utilization Of Sodium Flame Synthesis For The Formation And Deposition Of Pure Metal Materials For Applications In Additive Manufacturing, Zachariah Wargel
Utilization Of Sodium Flame Synthesis For The Formation And Deposition Of Pure Metal Materials For Applications In Additive Manufacturing, Zachariah Wargel
McKelvey School of Engineering Graduate Student Theses & Dissertations
Advanced material classes, such as high temperature alloys, ceramics, and refractory materials have become a key area of focus for expansion in the realm of additive manufacturing. Factors such as high melting points, material homogeneity, and physical properties such as ductility limit the application of popular additive manufacturing methods to these material classes. By utilizing sodium flame synthesis and deposition (SFD) technology, nanoparticle materials can be synthesized via combustion in a laminar co-flow diffusion burner and impacted such that the deposits can be used to manufacture designed components. By using the applicable precursor materials of metal chlorides and elemental sodium …
Capstone Review: Filament Unit Multiplexing Engine, Gal Cohen
Capstone Review: Filament Unit Multiplexing Engine, Gal Cohen
University Honors Theses
The Filament Unit Multiplexing Engine (FUME) is a Mechanical Engineering capstone project sponsored by Portland State University's Electronic Prototyping Lab (EPL). The project addresses the need for an automated system to manage 3D printing operations. The current manual process of selecting and routing a spool of filament to one of the available 3D printers is labor-intensive and limits the efficiency of the lab's 3D printing farm. FUME aims to create a custom solution tailored for a multi-user, multi-spool, and multi-printer environment. The designed system includes key components: a spool holder, an engine, a track and shuttle system, and a funnel. …
Focused Led Sintering, Dylan Defazio, Nilav Maulik, Branden Majors, Michael Fontillas
Focused Led Sintering, Dylan Defazio, Nilav Maulik, Branden Majors, Michael Fontillas
Mechanical Engineering
This report provides a detailed overview of the final design of our light-emitting diode (LED) focusing system. Our system incorporates a converging lens and a specially designed "glass funnel," which acts as a thick fiber optic that narrows the light to a fine point through internal reflection. The glass components of our system are precisely housed in a part made using advanced computer-numeric controlled (CNC) Mill and CNC Lathe manufacturing processes. This ensures high precision and durability of the overall system. Our LED focusing system is designed with a 60-watt stage light. The decision to use a glass funnel as …
Feasibility And Characterization Of Leak-Tight Single-Track Thin Walls Produced By Laser Powder Bed Fusion In 316l Stainless Steel, Peyton J. Archibald
Feasibility And Characterization Of Leak-Tight Single-Track Thin Walls Produced By Laser Powder Bed Fusion In 316l Stainless Steel, Peyton J. Archibald
Master's Theses
This thesis explores the optimization of process parameters for producing single-track thin walls using Laser Powder Bed Fusion (LPBF) additive manufacturing. Using two different coupon designs, the study assesses the feasibility of creating the thinnest possible leak-tight structures within LPBF and evaluating their mechanical properties, including burst pressure and modulus of elasticity under pressure loads. A series of experimental iterations were conducted, varying laser power and laser speed to identify optimal conditions. The findings indicate that a narrow range of process parameters can produce consistently leak-tight thin walls. The results contribute to understanding how to achieve high quality, reliable thin …
Mechanical Properties And Microstructure Of Multi-Materials Fabricated Through A Combination Of Lpbf And Ded Additive Manufacturing Techniques, Christopher J. Bettencourt
Mechanical Properties And Microstructure Of Multi-Materials Fabricated Through A Combination Of Lpbf And Ded Additive Manufacturing Techniques, Christopher J. Bettencourt
All Graduate Theses and Dissertations, Fall 2023 to Present
This research explores the use of different metals combined through 3D-printing to enhance the performance of materials, with a focus on making heat exchangers more cost-effective for renewable energy. The goal is to replace a costly high-temperature alloy with a more affordable low-temperature alloy, using metal additive manufacturing for its benefits such as less material waste, faster production, reduced weight, and the ability to print entire assemblies in one go. The study delves into a unique combination of two 3D-printing techniques, Directed Energy Deposition and Laser Powder-Bed Fusion, to create a multi-material composed of stainless steel 316L and a nickel-based …
Optimal Additive Fabrication Of Patient-Specific Bone Tissue Scaffolds Through Material Formulation, Computational Flow Simulation, And Material Deposition Monitoring, Ethan O’Malley
Theses, Dissertations and Capstones
The advancement of additive manufacturing technologies has opened new avenues for fabricating biocompatible and structurally functional bone tissue scaffolds, essential in treating osseous fractures, defects, and diseases. This research aims to develop mechanically strong, dimensionally precise, and patient-specific porous bone tissue scaffolds that provide both structural integrity and biological functionality. Through three interconnected studies, several key challenges in the fabrication of these structures using the PME additive manufacturing process are addressed. First, the influence of polysaccharide and hydroxyapatite concentrations on the compressive modulus of PME-printed porous scaffolds is investigated. By creating structures with varying hydroxyapatite and polysaccharide compositions, the study …
Numerical Design, Fabrication, And Characterization Of Porous Tissue Scaffolds For Bone Regeneration, Brandon Coburn
Numerical Design, Fabrication, And Characterization Of Porous Tissue Scaffolds For Bone Regeneration, Brandon Coburn
Theses, Dissertations and Capstones
With the recent advancements within biomedical engineering of bone tissue scaffolds, there is still a need to develop mechanically robust and biocompatible with low immunogenicity for bone regeneration. Additionally, the evaluation of the fluid dynamics of the porous Triply Periodic Minimal Surfaces (TPMS) bone scaffold also shows the need for investigation due to the complex fluid interaction of hemodynamics that occurs with the scaffold internal and external domains. To aid in the development of treating bone fractures, defects, and diseases. Furthermore, with the induction of a wide variety of TPMS architecture that yields different topologies, the Convolutional Neural Network (CNN) …
High-Pressure Infiltration Process For Additively Manufactured Ceramic Matrix Composites, Samuel Weiler
High-Pressure Infiltration Process For Additively Manufactured Ceramic Matrix Composites, Samuel Weiler
Masters Theses
"Ceramic matrix composites were developed in order to increase the fracture toughness, thermal shock resistance, and elongation of ceramic materials, while maintaining the very high temperature capabilities of these materials. A renewed focus has been placed on ceramic matrix composites due to the need for materials that maintain good mechanical strength at very high temperatures, for use in the extreme environments encountered by hypersonic vehicles, jet turbine blades, and the like. However, conventional methods to manufacture CMCs are costly and time consuming. The aim of this work is to develop a method for creating additively manufactured ceramic matrix composites using …
Development And Characterization Of Vegetable Oil Based, Acrylated Resins For Stereolithography 3d Printing, Julius A. Adeyera
Development And Characterization Of Vegetable Oil Based, Acrylated Resins For Stereolithography 3d Printing, Julius A. Adeyera
College of Graduate Studies: Theses & Dissertations
The increase in the demand for additively manufactured parts and the drive towards a sustainable economy with less environmental pollution has necessitated the need for renewable materials for use in 3D printing. This study shows the development and characterization of vegetable oil based, acrylated resins for 3D printing. Bio-based 3D resins were formulated using bio-based oils with a minimum of 70% bio-based content and were ready to be polymerized using the stereolithography (SLA) 3D printing process. Two distinct vegetable oils were used to develop biobased photopolymers. Biobased acrylated epoxidized photopolymers were successfully developed that have good mechanical and chemical properties. …
Development Of Digital Twin For Fdm Printer With Preventive Cyber-Attack And Control Algorithms, Md Hazrat Ali, Asad Malik, Nursultan Jyeniskhan, Muhammad Arif Mahmood, Essam Shehab, Frank Liou
Development Of Digital Twin For Fdm Printer With Preventive Cyber-Attack And Control Algorithms, Md Hazrat Ali, Asad Malik, Nursultan Jyeniskhan, Muhammad Arif Mahmood, Essam Shehab, Frank Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
This paper presents a developed model of a Digital Twin (DT) for a fused deposition modeling (FDM) printer, real-time defect detection, and proposed frameworks for preventing cyber-attacks in real-time. It also highlights a model predictive control (MPC) algorithm for controlling the material feed based on a real-time feedback system. The system is designed and developed based on DT, and MPC with integrated machine learning (ML) algorithms to establish real-time process control and enhance the safety and reliability of the physical plant. ML algorithm is used for anomaly detection based on the convolutional neural network (CNN) model. The developed system can …
An Elasto-Plastic Constitutive Model With Phase-Field Fracture For Additively Manufactured Metallic Materials, Nolan Ruble
An Elasto-Plastic Constitutive Model With Phase-Field Fracture For Additively Manufactured Metallic Materials, Nolan Ruble
Dissertations, Master's Theses and Master's Reports
The advent of additive manufacturing (AM), commonly known as 3D printing, has revolutionized the production of metallic components across various industries. This technology, which builds objects layer by layer, has shifted paradigms in manufacturing, allowing for unprecedented design freedom, material efficiency, and rapid prototyping. Metal additive manufacturing, in particular, has shown remarkable promise due to its ability to produce complex geometries that are difficult or impossible to achieve with traditional subtractive methods. In addition, additively manufactured (AM) materials are gaining popularity in thanks to their often superior and controllable properties in comparison to their wrought counterparts. In the present work, …
Mechanical Reliability Of Aerosol Jet Printed Sensors And Interconnects, Lemuel A. Duncan
Mechanical Reliability Of Aerosol Jet Printed Sensors And Interconnects, Lemuel A. Duncan
Browse all Theses and Dissertations
Heterogeneous integration (HI) is currently being investigated to maintain the pace of technological progress in the electronics industry. With the recent acceleration witnessed in additive manufacturing (AM) technology, interest has been expressed in introducing aerosol jet (AJ) printing to the fabrication process for sensors and electronic packages. Integrating AM technology in these areas promises design flexibility and minimal material waste. Three AJ printed applications investigated in this work include strain sensors, electrical interconnects, and metal embedded chip assemblies. Before moving forward with the use of AJ printing in these applications, it is necessary to evaluate their performance under standard mechanical …
Materials Testing For Large Format 3d Printing, William Jenkins
Materials Testing For Large Format 3d Printing, William Jenkins
Williams Honors College, Honors Research Projects
An ABS Carbon Fiber blend was printed into single walled hexagons at a variety of settings on a Cincinnati BAAM large format 3D printer. These hexagons were then cut down into sheets and had tensile and flexural test samples cut out of them, in order for materials testing to be performed. Tensile strength, tensile strain, young’s modulus, flexural strength, deflection and elastic modulus were all determined. A desktop CNC machine and a planer were purchased for the manufacturing of these samples, and an efficient cutting procedure was designed and optimized. After all data collection concluded, this data was thoroughly analyzed, …
Short Strand Carbon Fiber Reinforced Polylactic Acid Filament For Additive Manufacturing, Dale Chenoweth, Lukas Seggi, Luke Phillips
Short Strand Carbon Fiber Reinforced Polylactic Acid Filament For Additive Manufacturing, Dale Chenoweth, Lukas Seggi, Luke Phillips
Williams Honors College, Honors Research Projects
In this design project, the additive manufacturing filament of short strand carbon fiber (SSCF) reinforced polylactic acid (PLA) composite was developed. The micro-size, precision cut SSCFs were mixed with the PLA pellets through a melting homogenization process. Through this process the composite material block is cut and divided into pieces for ease of pelletizing. The material block pieces are then pelletized to be fed through the single screw extruder to develop the SSCF-PLA composite filament. The SSCF-PLA filaments were manufactured with a varying amount of SSCF ranging from 0.5% to 10% of the material block's weight. Development of a 1% …
3d Printed Drone (Body And Controls), Michael Dick, Hayden Pinkelman, Tanner Henderson, Logan Prince
3d Printed Drone (Body And Controls), Michael Dick, Hayden Pinkelman, Tanner Henderson, Logan Prince
Williams Honors College, Honors Research Projects
The objective is to build a scaled down model of a 3D printed drone capable of carrying a payload scalable to 50 lbs. for a wide array of applications. Some applications of the drone could include delivering support materials during natural disasters, such as foam to put out fire or medical aid packs to provide aid to injured people, food or package delivery, or military applications. The project has been split up into two groups. One group will be focusing on the propulsion aspect of the project, such as the electric motors and airfoil. Simultaneously, this group will design the …
Resonant Ultrasound Spectroscopy(Rus) For Material Characterization Of Metal Am Parts, Malik Marks
Resonant Ultrasound Spectroscopy(Rus) For Material Characterization Of Metal Am Parts, Malik Marks
College of Graduate Studies: Theses & Dissertations
Additive manufacturing (AM) has revolutionized the manufacturing industry by offering flexibility, customization, and rapid prototyping capabilities. However, ensuring the quality and reliability of AM parts remains a significant challenge due to variations in material properties and process parameters. The NDE method used in this study is Resonant Ultrasound Spectroscopy (RUS). This method was used to evaluate and understand its ability to detect internal voids and defects. Dog-bone samples were made using the 316L stainless steel alloy which were fabricated by powder bed fusion (PBF) AM technique at different processing conditions and post processing conditions. These samples were tested to find …
Extrusion-Based Additive Manufacturing Of Magnetic Heat Exchange Structures For Caloric Applications, Vaibhav Sharma
Extrusion-Based Additive Manufacturing Of Magnetic Heat Exchange Structures For Caloric Applications, Vaibhav Sharma
Theses and Dissertations
Currently, the commercial building sector accounts for 18% of total U.S. end-use energy consumption, of which almost a third was from on-site combustion of fossil fuels for space and water heating. Magnetic heat pumping (MHP) technology is an energy-efficient, sustainable, environmentally-friendly alternative to conventional vapor-compression cooling technology. Several MHP designs today are predicted to be highly energy efficient, on condition that suitable working materials can be developed. This materials challenge has proven to be daunting due to issues associated with intricate synthesis/post-processing protocols and complications related to shaping the mostly brittle magnetocaloric alloys into thin-walled channeled regenerator structures to facilitate …
Influence Of Heat Treatment And Shielding Gas Environment On The Very High Cycle Fatigue Behavior Of 17-4 Precipitation Hardened Stainless Steel, Jade Welsh
UNF Graduate Theses and Dissertations
Additive manufacturing (AM) for stainless steel components has proved useful in a variety of industries ranging from aerospace to biomedical engineering. Many of these components are subject to very high cycle fatigue (VHCF) loading and must have tailored mechanical properties to ensure failures do not occur before a service life is reached. Testing the fatigue strength AM materials exposed to VHCF loading is paramount to compare with the expected life cycles of their wrought counterparts. In this thesis, AM 17-4 precipitation hardened (PH) stainless steel (SS) were fabricated using laser powder bed fusion (L-PBF) technique, while the wrought 17-4 PH …
Assessment Of Surface Waviness In A Wire Arc Additive Manufacturing Process, Shammas Mahmood Shafi
Assessment Of Surface Waviness In A Wire Arc Additive Manufacturing Process, Shammas Mahmood Shafi
Dissertations, Master's Theses and Master's Reports
Wire Arc Additive Manufacturing (WAAM) is increasingly recognized for its ability to produce metal components with high deposition rates and efficiency, particularly in the aerospace and automotive sectors. However, one significant challenge that WAAM faces is achieving surface quality that complies with industry standards, as well as creating geometries that closely resemble the initial design. A crucial factor contributing to this challenge is surface waviness, which is an inherent characteristic of the WAAM process. This waviness arises from the geometry of the weld beads and the overlap distance between them. It can adversely affect the fusion quality of successive layers, …