Mechanical Engineering Commons^™

Carbon Fiber Coil Spring Characterization And Manufacturing, Cooper Madrazo

UNLV Theses, Dissertations, Professional Papers, and Capstones

Helical coil springs are used in many mechanical design applications including industrial machines, devices, and vehicle suspension systems. It is desirable to minimize the weight of vehicle suspension systems as this can improve performance and handling. Most vehicle suspension coil springs are made from solid steel alloys or other metallic materials. Significant weight savings could be achieved if the metallic material were replaced by high performance fiber reinforced polymer composites. However, the coil spring geometry is a difficult manufacturing challenge for composite materials. The goal of this thesis was to investigate efficient and low-cost manufacturing methods to produce light-weight polymer …

Incorporating In-Situ Monitoring To Detect Anomalies In Additively Manufactured Kovar Steel On A Layer-To-Layer Basis, Matthew Aragon

Mechanical Engineering ETDs

Combining traditional methods of material analysis with in-situ monitoring of a Laser Powder Bed Fusion (LPBF) printed part, on a layer-to-layer basis, provides the data necessary to adjust printing parameters to achieve specific material properties. Additively manufactured technology has advanced in the ability to accommodate new materials and provide new use cases. Uncertainties in material properties have arisen alongside the advancements in additive manufacturing. The layer-wise print analysis will allow for detection and correlation of print anomalies to the material properties such as density, material strength, and surface roughness. The data processed from each layer will be used to further …

Ljm Rc Baja Vehicle Project Chassis And Suspension, Paul Lervick

All Undergraduate Projects

An RC car was designed, analyzed, and manufactured to compete in the ASME RC Baja competition. The focus was to optimize the suspension and chassis components to minimize the weight while maintaining the structural strength of the components which would intern supplement the overall speed and stability of the vehicle. Other components were the responsibility of the teammate Cam Jamison. To complete this there was extensive research done on Traxxas RC cars and what went into making a high-performing vehicle that would compete well in the 3 races that comprise the competition (slalom, sprint, and obstacle course). There were then …

Design And Testing Of A Hybrid Direct Ink Writing And Fused Deposition Modeling Multi-Process 3d Printer, Alexander X. Losada

Honors Undergraduate Theses

Multi-material 3D Printing allows the ability to fabricate parts with tuned mechanical properties, multi-process 3D printing widens the choices of available fabrication materials. The objective of this study is to build a custom 3D printing test bed that is capable of printing multi-material parts with fused deposition modeling and direct ink writing techniques. A 3D printer, controlled by an industrial motion control system, with FDM and DIW capabilities was built by combining FDM extruders with a pneumatic dispensing system on a single platform. By utilizing the Direct Ink Writing function, we expand the number of printable materials to include some …

Shape Memory Behavior Of Nitihf Alloys Fabricated By Laser Powder Bed Fusion, Guher Pelin Toker

Theses and Dissertations--Mechanical and Aerospace Engineering

NiTiHf-based alloys have emerged as potential materials for applications requiring high transformation temperatures (> 100 °C) with high strength and work output. Currently, it is challenging to produce complex shapes of these materials with tailored shape memory properties or reduce the material waste from machining operations given the cost of these materials. Additive manufacturing via Laser Powder Bed Fusion (L-PBF) represents an attractive way to fill this gap by producing unique geometries from powder-based feedstock. In this method, process parameters such as laser power, scanning speed, hatch spacing and energy density play significant roles in controlling the mechanical behavior and …

Vibration Bending Fatigue Analysis Of Additively Repaired Ti-6al-4v Airfoil Blades, Lucas Jordan Smith

Browse all Theses and Dissertations

Repairing airfoil blades is necessary to extend the life of turbine engines. Directed energy deposition (DED) additive manufacturing (AM) provides the ability to add material at a specific location on an existing component. In this work, AM repairs on Ti-6Al-4V airfoil blades were analyzed to determine what effect the repair will have on the blade performance in high cycle vibration fatigue testing. Targeted sections were cut out of airfoil blades near high stress locations and repaired using DED. To understand the defects that arose with this type of repair, computed tomography imaging was used to quantify the defects from the …

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 …

Workforce Development Strategies In Additive Manufacturing, Mel Cossette, Ismail Fidan, Gaffar Gailani, Angran Xiao

Publications and Research

Additive Manufacturing (AM), also known as 3D Printing (3DP), is one of the newest manufacturing technologies with growing utilization in our daily life. Parallel to this growth, new materials, machines, and specific processes are being developed to produce parts in better-finished quality, at lower cost, and with shorter production time. However, workforce education in this evolving field has not advanced at the same pace as the technology, lacking proven curriculums, high-quality/accredited degree programs, and specialized advanced degrees. In this paper, some best practices established by the authors are introduced. The list is far from exhaustive but is proven to be …

Development Of Oxide Dispersion Strengthening (Ods) Alloys Powder For Additive Manufacturing, Changyu Ma

Graduate Theses, Dissertations, and Problem Reports (ETD)

Additive manufacturing (AM) fabricated oxide dispersion strengthened (ODS) alloys are given high expectations for critical structural components such as the first stage turbine blade for their excellent creep strength and oxidation resistance compared to superalloys. However, the powder feedstock processing is still an open question since current state-of-the-art processes are not capable of achieving ultrafine strengthening elements such as Y₂O₃ in powder which leads to agglomeration issues in as-consolidated alloys. In this research, the oxidation behavior and stability of ultrafine oxide in AM-printed alloys using mechanically alloyed powders were evaluated at 1100 ^oC. In addition, a …

A Study Of Reduced Activation Ferritic Martensitic Metal Core Wire For Wire Arc Additive Manufacturing, Alexander L. Reichenbach

College of Graduate Studies: Theses & Dissertations

This study seeks to determine the technical feasibility of fabricating reduced activation ferritic martensitic (RAFM) steel parts, using a wire arc additive manufacturing (WAAM) process. The WAAM process, manufactures a part by depositing layers of metal onto a substrate to build a large scale near net shape part. RAFM alloy steels are next generation steels designed to resist radiation effects in the radiation intense working environments, such as nuclear reactors. To achieve this, process development and testing to design the WAAM production process with the custom RAFM filler wire was carried out. Several welding waveform modes were tested, and it …

Nonmetallic Jet Impingement Thermal Management For Power Electronics Via Additive Manufacturing, Reece Whitt

Graduate Theses and Dissertations

The increase in energy demanded by transportation and energy sectors has necessitated highly efficient thermal management for reliable power electronics operations. Conventional cooling techniques are limited by their inability to target switching location hot spot temperatures, leading to non-uniform thermal gradients. These devices, such as cold plates and heat sinks, also utilize heavy metallic structures that can accentuate electromagnetic interferences generated by high voltage switching processes. This work proposes a non-metallic jet impingement cooler for more customized thermal management, while simultaneously reducing the harmful effects of electromagnetic interferences. Additive manufacturing is utilized to enable jet impingement zones to target individual …

Electron Beam Melted Parameter Development Of Pure Tungsten & Post-Processing Hip And Heat Treatment Of Gamma Titanium Aluminide, Kurtis Isami Watanabe

Open Access Theses & Dissertations

Pure tungsten is a refractory metal and has been gaining interest for the use in nuclear fusion reactors as a plasma facing material. Titanium Aluminide (TiAl) has been growing in popularity as a possibly to phase out Nickel based superalloys due to its high specific strength at elevated temperatures. These two materials suffer from poor machinability due to being brittle at room temperature. Additive manufacturing (AM) is a recently developed manufacturing method that is fundamentally different than formative or subtractive. AM is a layer-by-layer process that has the potential to manufacture metals to a near net shape. Since the AM …

Design And Fabrication Of A Polymer Fdm Printer Capable Of Build Parameter Monitoring And In-Sit Geometric Monitoring Via Photogrammetry, Travis Roberts

All Theses

Additive manufacturing, or 3D printing, is a complex process that creates free-form geometric objects by sequentially placing material in a location to construct an object, usually as a layer-by-layer process. One of the most widespread methods is Fused Deposition Modeling (FDM). FDM is used in many of the consumer-grade polymer 3D printers available today. While consumer grade machines are cheap and plentiful, they lack many of the features desired in a machine used for research purposes and are often closed-source platforms. Commercial-grade models are more expensive and are also usually closed-source platforms that do not offer flexibility for modifications often …

Additive Manufacturing Of Cork, A Cold Spray Technology, Kimberly Kay Dickey

Theses and Dissertations

Cold Spray Additive Manufacturing is a technology capable of mass manufacturing components with complicated geometry and coating substrates in hard-to-reach areas. In addition, cold spray also has the ability of conducting a green manufacturing process, with zero waste of renewable feed material, and zero gas and chemical emission. This paper investigates solely cold spray as an additive manufacturing technology with cork as the natural material. CFD results were used to predict the physical behavior of air and the cork particles. After unsuccessful coatings, final results showed that when moisture is added, cork is successfully cold sprayed, and agglomeration is experienced. …

Laser Surface Treatment And Laser Powder Bed Fusion Additive Manufacturing Study Using Custom Designed 3d Printer And The Application Of Machine Learning In Materials Science, Hao Wen

LSU Doctoral Dissertations

Selective Laser Melting (SLM) is a laser powder bed fusion (L-PBF) based additive manufacturing (AM) method, which uses a laser beam to melt the selected areas of the metal powder bed. A customized SLM 3D printer that can handle a small quantity of metal powders was built in the lab to achieve versatile research purposes. The hardware design, electrical diagrams, and software functions are introduced in Chapter 2. Several laser surface engineering and SLM experiments were conducted using this customized machine which showed the functionality of the machine and some prospective fields that this machine can be utilized. Chapter 3 …

Development Of A Laser Solder Process For Use With Material Extrusion Additive Manufacturing And Rapid Electronics Prototyping In Embedded Sensing Applications, Emerson Roland Armendariz

Open Access Theses & Dissertations

Industrial and rapid prototyping (RP) trends toward miniaturization of electronic devices containing temperature sensitive electronics and surrounding materials are calling for highly controllable, selective laser soldering technologies. Laser soldering is a non-contact technique that eliminates the risk of marring or damaging sensitive components by precisely focusing a laser beam on a solder filler alloy, leading to a fast and non-destructive electrical joint. Using the benefits of accurate and controlled heat delivery via inexpensive low power laser diodes (LPDL's) in conjunction with ever-increasing additive manufacturing capability in producing complex internal features and geometries, development and testing of a laser application system …

A Framework To Aid Decision Making For Smart Manufacturing Technologies In Small-And Medium-Sized Enterprises, Purvee Bhatia

USF Tampa Graduate Theses and Dissertations

The fourth industrial revolution or Industry 4.0 has changed today’s manufacturing scenario. The transition to smart manufacturing technologies has been evolving over the last few years and has recently accelerated due to the pandemic. The need to make manufacturing systems agile, adaptive, resilient, and robust has expediated the adoption and implementation of smart manufacturing technologies.

Despite the interest of manufacturers in smart manufacturing, the adoption rate has been slow due to the lack of decision-making tools that can provide a clear strategic roadmap for effective execution. Small and medium sized enterprises (SMEs) are especially slow in adoption due to the …

Med-Drop Pill Dispenser, Cole Pike, Taylor Morris, Christopher Bruni, Jose Gomez

Mechanical Engineering

Veterans’ Affairs home care nurses currently spend anywhere from thirty minutes to two hours filling out monthly prescriptions one pill at a time to veterans who are unable to leave their homes. The goal of this project was to create an easy-to-use device that could be left at a patient’s home that nurses could use to quickly and accurately dispense medication into the patient’s monthly pill box.

Fabricating Tinicu Ternary Shape Memory Alloy By Directed Energy Deposition Via Elemental Metal Powders, Yitao Chen, Xinchang Zhang, Mohammad Masud Parvez, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In this paper, a TiNiCu shape memory alloy single-wall structure was fabricated by the directed energy deposition technique with a mixture of elemental Ti, Ni, and Cu powders following the atomic percentage of Ti50Ni45Cu5 to fully utilize the material flexibility of the additive manufacturing process to develop ternary shape memory alloys. The chemical composition, phase, and material properties at multiple locations along the build direction were studied, using scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, Vickers hardness test-ing, tensile testing, and differential scanning calorimetry. The location-dependent compositions of martensitic TiNi and austenitic TiNi phases, mechanical properties, and functional properties …

Real-Time Monitoring Of Fdm 3d Printer For Fault Detection Using Machine Learning: A Bibliometric Study, Vaibhav Kisan Kadam, Satish Kumar, Arunkumar Bongale

Library Philosophy and Practice (e-journal)

Additive Manufacturing has wide application range including healthcare, Fashion, Manufacturing, Prototypes, Tooling etc. AM techniques are subjected to various defects that may be printing defects or anomalies in machine. There is gap between current AM techniques and smart manufacturing since current AM lacks in build sensors necessary for process monitoring and fault detection. Both of these issues can be solved by incorporating real-time monitoring into AM. So the study is carried out to identify recent work done in AM to improve current system. For this bibliometric study Scopus database is used, study is kept limited to year 2010-2021 and English …

Multiscale And Multimaterial 3d Printing: Impact Of Feedstock Properties And Processing Parameters On Printed Parts, Kazi Md Masum Billah

Open Access Theses & Dissertations

Material extrusion additive manufacturing (AM) technology is one of the most commonly used technology to fabricate functional prototypes and end-use application parts with custom design. The evolution of the extrusion technology led this particular AM process to grow in many aspects such as new materials development, new design thinking, fabrication of parts in multiscale length, and manufacturing of monolithic parts with multiple functionalities. The research presented in this Dissertation results in the creation of knowledge in material extrusion AM technology with the length scale of production-grade to large-scale 3D printing machine those were used to enable the fabrication of multimaterial …

Prediction Of Residual Stress And Distortion In Laser Powder Bed Fusion Additive Manufacturing, Bhanuprakash Sairam Kosaraju

Theses and Dissertations

Additive Manufacturing (AM) has its proven advantages to unlock the design space and manufacturing capabilities for complex geometries with lightweights. Distortion is one of the most common defects that occur in Laser Powder Bed Fusion Additive Manufacturing (LPBFAM), which is caused by the significant residual stress during the printing process. This can lead to numerous process iterations to achieve the requisite form and fit tolerances.

In this study, Finite Element (FE) model that utilizes the element birth approach was developed to predict the residual stress and distortion in the LPBFAM process. The methodology leverages a simplified approach where the detailed …

The Corrosion Of Stainless Steel Made By Additive Manufacturing: A Review, Gyeongbin Ko, Wooseok Kim, Kyungjung Kwon, Tae-Kyu Lee

Mechanical and Materials Engineering Faculty Publications and Presentations

The advantages of additive manufacturing (AM) of metals over traditional manufacturing methods have triggered many relevant studies comparing the mechanical properties, corrosion behavior, and microstructure of metals produced by AM or traditional manufacturing methods. This review focuses exclusively on the corrosion property of AM-fabricated stainless steel by comprehensively analyzing the relevant literature. The principles of various AM processes, which have been adopted in the corrosion study of stainless steel, and the corrosion behaviors of stainless steel depending on the AM process, the stainless steel type, and the corrosion environment are summarized. In this comprehensive analysis of relevant literature, we extract …

Absorption Of Nitrogen During Pulsed Wave L-Pbf Of 17-4 Ph Steel, Ben Brown, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In the fabrication of 17-4 PH by laser powder bed fusion (L-PBF) the well-documented occurrence of large amounts of retained austenite can be attributed to an elevated concentration of nitrogen present in the material. While the effects of continuous wave (CW) laser processing on in-situ nitrogen absorption characteristics have been evaluated, power modulated pulsed wave (PW) laser processing effects have not. In this study the effects of PW L-PBF processing of 17-4 PH on nitrogen absorption, phase composition, and mechanical performance are explored using commercially available PW L-PBF equipment and compared to samples produced by CW L-PBF. PW L-PBF samples …

Corrosion Performance Of Additively Manufactured Alloys And Hot Corrosion, Ali Hemmasian Ettefagh

LSU Doctoral Dissertations

Additive manufacturing (AM) has gained attention in recent years due to its unique properties in the fabrication of complex parts. Same as any other new topics, in some areas, there is still a lack of enough knowledge and there is the need for further investigations to enable the applications of AM parts widely in industries. ‎Chapter 2, and ‎Chapter 5 to ‎Chapter 8 of this report are focused on the corrosion properties of the parts and coatings fabricated using the laser powder bed fusion based AM method or laser surface processing method, including a comprehensive review. Laser powder bed fusion …

Rheology Of Particulate Suspensions With Non-Newtonian Fluids In Capillaries, Bin Xia, Paul Krueger

Mechanical Engineering Research

This resource contains the processed experimental measurements of the flow consistency index and flow behavior index, along with their trendlines, for the particulate suspensions investigated in "Rheology of Particulate Suspensions with Non-Newtonian Fluids in Capillaries" by Bin Xia and Paul S. Krueger.

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 …

Design For Additive Manufacturing (3d Printing), Michael O'Donnell, Michael J. Levy

Williams Honors College, Honors Research Projects

The goal of this project is to study the performance of a 3D printed mechanical part subjected to topology optimization. A part that is somewhat complex in its load bearing and geometry will be selected. That part will then be designed, finite element analysis will be performed on it to optimize its topology, and then it will be 3D printed and tested. The goal of topology optimization is to either save material cost and/or part weight due to the ability of 3D printing to manufacture parts with complex and obscure geometry.

Feasibility Of Additive Manufacturing For Vibration Isolation Systems, Matthew Youngblood, Christian Velo, Gary Facemyer

Williams Honors College, Honors Research Projects

During transport sensitive payloads can become subject to a multitude of vibration or shock environments that can lead to damage. Using only additive manufacturing we seek to design an isolation system that can provide enough vibration and shock damping to properly protect the payload. Using modern FEA software we were able to quickly analyze a variety of solutions and determine the best one. Based on the results we have achieved through analysis, as well as pushing the manufacturing capabilities of 3D printers, we believe it is plausible to use additive manufacturing to create a fully capable vibration isolation system.

Numerical And Experimental Study Of Mechanical Properties For Laser Metal Deposition (Lmd) Process Part, Lan Li

Doctoral Dissertations

"Laser Metal Deposition (LMD), also called as, Laser Engineered Net Shaping (LENS), Directed Energy Deposition (DED), is a typical Additive Manufacturing (AM) technology, is used for advanced free-form fabrication. It creates parts by directly melting materials and depositing them on the workpiece layer by layer. In this process, the metal powder or fiber is melted within the melting pool by laser beam or electron beam and quickly solidifies to the deposited layer. LMD technology shows great advantages over traditional manufacturing on complex structure fabrication, including high building rates, easy material replacement and reduced material waste. These merits make the wide …