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Additive manufacturing

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Articles 151 - 180 of 333

Full-Text Articles in Mechanical Engineering

Experimental Investigation Of Additive Manufacturing Of Continuous Carbon Fiber Composites With Multifunctional Electro-Tensile Properties, Ritesh Ghimire, Frank W. Liou Nov 2021

Experimental Investigation Of Additive Manufacturing Of Continuous Carbon Fiber Composites With Multifunctional Electro-Tensile Properties, Ritesh Ghimire, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Manufacturing processes for monofunctional and multifunctional materials vary depending on the design optimization. Multifunctional continuous carbon fiber composites provide great potential in achieving coupled structural and electrical properties for their applications in aircraft, unmanned aircraft systems, and spacecraft. Proper optimization of tensile and electrical properties offers benefits early in the design and continuous operational safety phases to obtain coupled multifunctional properties. In this paper, fused filament fabrication additive manufacturing (AM) technique was used to fabricate continuous carbon fiber solid laminated composites test coupons. The proposed new method characterizes the electrical conductivity's coupled effects on the tensile properties, including the failure …

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Additive Manufacturing Of Stainless Steel -- Copper Functionally Graded Materials Via Inconel 718 Interlayer, Xinchang Zhang, Lan Li, Frank W. Liou Nov 2021

Additive Manufacturing Of Stainless Steel -- Copper Functionally Graded Materials Via Inconel 718 Interlayer, Xinchang Zhang, Lan Li, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The joining of dissimilar materials is becoming increasingly prevalent to integrate different material properties to enhance design flexibility and overall performance. This study introduced an innovative approach to additively manufacture copper on 316L stainless steel (SS316L) via Inconel 718 interlayers using directed energy deposition (DED). The novel multi-material structure was studied both experimentally and theoretically. The microstructure, tensile properties, microhardness, and thermal performance of the structure were characterized. Residual stress distribution over the structure was revealed by experimental-validated numerical modeling. The result exhibits that defect-free structures with excellent interfacial bonding can be achieved by introducing Inconel 718 interlayers. The bonding …

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A Novel Laser-Aided Machining And Polishing Process For Additive Manufacturing Materials With Multiple Endmill Emulating Scan Patterns, Mohammad Masud Parvez, Sahil Patel, Sriram Praneeth Isanaka, Frank W. Liou Oct 2021

A Novel Laser-Aided Machining And Polishing Process For Additive Manufacturing Materials With Multiple Endmill Emulating Scan Patterns, Mohammad Masud Parvez, Sahil Patel, Sriram Praneeth Isanaka, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In additive manufacturing (AM), the surface roughness of the deposited parts remains significantly higher than the admissible range for most applications. Additionally, the surface topography of AM parts exhibits waviness profiles between tracks and layers. Therefore, post-processing is indispensable to improve surface quality. Laser-aided machining and polishing can be effective surface improvement processes that can be used due to their availability as the primary energy sources in many metal AM processes. While the initial roughness and waviness of the surface of most AM parts are very high, to achieve dimensional accuracy and minimize roughness, a high input energy density is …

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Characterization And Enhancement Of Mechanical Properties In Thermoplastic Fff Parts Using In-Situ Annealing, Rhugdhrivya Rane Aug 2021

Characterization And Enhancement Of Mechanical Properties In Thermoplastic Fff Parts Using In-Situ Annealing, Rhugdhrivya Rane

Mechanical and Aerospace Engineering Dissertations - Archive

Fused filament fabrication is one of the most common and widely used additive manufacturing techniques. Owing to its ease of use, availability and cheap feedstock it provides a significant advantage over other AM techniques. But these advantages are overshadowed by the fact that FFF parts show high anisotropy and reduced mechanical properties as compared to conventional manufacturing techniques. Literature review of previous research works show multiple approaches to enhance the mechanical properties of FFF parts but each of these techniques have limitations to either the geometries that can be printed or involve complex expensive setups. In one such technique a …

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Investigation Of Different Hatch Strategies On High Entropy Alloy Fabrication By Selective Laser Melting, Joni Chandra Dhar Aug 2021

Investigation Of Different Hatch Strategies On High Entropy Alloy Fabrication By Selective Laser Melting, Joni Chandra Dhar

Theses and Dissertations

This study investigated the synthesis of CuCrFeNiTiAl high entropy alloy (HEA) from pure elements using selective laser melting (SLM). The objectives are to validate the feasibility of the HEA fabrication from elemental powder materials, and to examine the effect of various hatch strategies and energy densities on the microstructures and other materials properties. 3D samples of CuCrFeNiTiAl alloy were fabricated under different energy densities and with different scan vector lengths. The as-built samples were characterized by X-ray diffraction (XRD), and the microstructures were observed using scanning electron microscopy (SEM). The XRD results showed that face centered cubic, and body centered …

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Phase Change Temperature Sensor For High Radiation Environment: Material, Additive Technology And Structure Development, Al Amin Ahmed Simon Aug 2021

Phase Change Temperature Sensor For High Radiation Environment: Material, Additive Technology And Structure Development, Al Amin Ahmed Simon

Boise State University Theses and Dissertations

Performance of any sensor in a nuclear reactor involves reliable operation under a harsh environment (i.e., high temperature, neutron irradiation, and a high dose of ionizing radiation). In this environment, accurate and continuous monitoring of temperature is critical for the reactor's stability and proper functionality. Furthermore, during the development and testing stages of new materials and structural components for these systems, it is imperative to collect in-situ measurement data about the exact test conditions for real-time analysis of their performance. To meet the compelling need of such sensing devices, we propose radiation-hard temperature sensors based on the phase change phenomenon …

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Mechanical Properties And Microstructure Characteristics Of Alloy Parts Produced By Laser Powder Bed Fusion (Lpbf) Method, Hong Yao Jul 2021

Mechanical Properties And Microstructure Characteristics Of Alloy Parts Produced By Laser Powder Bed Fusion (Lpbf) Method, Hong Yao

LSU Doctoral Dissertations

Additive manufacturing (AM) is a rapid prototyping technology to produce fully functional and complex designing objects. As one of the AM methods, Laser Powder Bed Fusion (LPBF) has gained the most attention from both academic researchers and industrial companies. During the LPBF process, metal powders are applied layer by layer, which can be 20 microns to 50 microns in thickness. After a layer is prepared, a high-power laser, which is commonly controlled by a scanning head, is used to selectively melt the interested area of a 2D geometry which is designed in a computer aided designing software. LPBF method can …

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Computational Frameworks For Multi-Robot Cooperative 3d Printing And Planning, Laxmi Prasad Poudel Jul 2021

Computational Frameworks For Multi-Robot Cooperative 3d Printing And Planning, Laxmi Prasad Poudel

Graduate Theses and Dissertations

This dissertation proposes a novel cooperative 3D printing (C3DP) approach for multi-robot additive manufacturing (AM) and presents scheduling and planning strategies that enable multi-robot cooperation in the manufacturing environment. C3DP is the first step towards achieving the overarching goal of swarm manufacturing (SM). SM is a paradigm for distributed manufacturing that envisions networks of micro-factories, each of which employs thousands of mobile robots that can manufacture different products on demand. SM breaks down the complicated supply chain used to deliver a product from a large production facility from one part of the world to another. Instead, it establishes a network …

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Optimization Of 3d Printed Mold Performance For Injection Molding Via Hollow Infill Patterns, Alan Fong Jul 2021

Optimization Of 3d Printed Mold Performance For Injection Molding Via Hollow Infill Patterns, Alan Fong

University Honors Theses

The applicability of hollow infill patterns has been explored for its applications in making 3D printed polymer-based injection molds in the additive manufacturing industry. Hollow infill patterns offer a significant reduction in material costs as well as the opportunity for reducing the cooling times via pumping a coolant fluid through the hollow cavity in a similar fashion to traditional conformal cooling channels. A 3D Jacks Support Hollow mold model was determined to be the best performing design. FEA analysis was conducted to determine the maximum reduction in internal volume (percentage of material saved) that could be achieved without exceeding the …

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A State-Of-The-Art Review Of Laser-Assisted Bioprinting And Its Future Research Trends, Chaoran Dou, Victoria Perez, Jie Qu, Andrew Tsin, Ben Xu, Jianzhi Li Jun 2021

A State-Of-The-Art Review Of Laser-Assisted Bioprinting And Its Future Research Trends, Chaoran Dou, Victoria Perez, Jie Qu, Andrew Tsin, Ben Xu, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

Bioprinting is an additive manufacturing technology with great potential in medical applications. Among available bioprinting techniques, laser-assisted bioprinting (LAB) is a promising technique due to its high resolution, high cell viability, and the capability to deposit high-viscousity bioink. These characteristics allow the LAB technology to control cells precisely to reconstruct living organs. Recent developments of LAB technologies are reviewed in this paper, covering various designs of LAB printers, research progresses in energy-absorbing layer (EAL), the physical phenomenon that triggers the printing process in terms of bubble formation and jet development, printing process parameters, and major factors related to the post-printing …

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High Throughput Mechanical Testing Platform And Application In Metal Additive Manufacturing And Process Optimization, Ke Huang, Chris Kain, Nathalia Diaz-Vallejo, Yongho Sohn, Le Zhou Jun 2021

High Throughput Mechanical Testing Platform And Application In Metal Additive Manufacturing And Process Optimization, Ke Huang, Chris Kain, Nathalia Diaz-Vallejo, Yongho Sohn, Le Zhou

Mechanical Engineering Faculty Research and Publications

Agility of additive manufacturing (AM) warrants a development of an equally agile, high-throughput properties evaluation technique that can efficiently assess properties of AM specimens as functions of materials and process variables. High throughput (HTP) tensile testing rig has been developed, enabled by miniature sample design and Python based control codes for a full automation of testing and data processing. The rig is capable of testing 60 specimens per hour, much faster than conventional tensile testing. To luminate the merit of its use, an efficient process optimization workflow based on HTP testing is proposed and demonstrated on laser powder bed fusion …

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The Effect Of Nanostructures In Aluminum Alloys Processed Using Additive Manufacturing On Microstructural Evolution And Mechanical Performance Behavior, Rachel Boillat, Sriram Praneeth Isanaka, Frank W. Liou May 2021

The Effect Of Nanostructures In Aluminum Alloys Processed Using Additive Manufacturing On Microstructural Evolution And Mechanical Performance Behavior, Rachel Boillat, Sriram Praneeth Isanaka, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper reviews the status of nanoparticle technology as it relates to the additive manufacturing (AM) of aluminum-based alloys. A broad overview of common AM processes is given. Additive manufacturing is a promising field for the advancement of manufacturing due to its ability to yield near-net-shaped components that require minimal post-processing prior to end-use. AM also allows for the fabrication of prototypes as well as economical small batch production. Aluminum alloys processed via AM would be very beneficial to the manufacturing industry due to their high strength to weight ratio; however, many of the conventional alloy compositions have been shown …

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Evaluating The Thermal Performance Of Topology Optimized Low-Cost 3d Printed Heat Sink Made Of Copper, Bilal Taha May 2021

Evaluating The Thermal Performance Of Topology Optimized Low-Cost 3d Printed Heat Sink Made Of Copper, Bilal Taha

Mechanical and Aerospace Engineering Theses - Archive

The performance of a heat sink is highly dependent on the overall surface area available for heat transfer. Designing heat sinks with greater surface areas meant bigger size, weight, and volume of heat-exchanger thus making it unfeasible to produce. Design and manufacture of compact-sized heat sinks is a difficult task, as it would require the use of complex surface modeling and complex surface cutting. But with the advent of 3D printing technology, it has become easier to manufacture heat sinks having complex designs producing larger surface areas as they add material layer by layer rather than cutting it away. The …

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Investigation On Microstructure And Mechanical Properties Of Porous Structures Processed By Laser Powder Bed Fusion, Samarth Ramachandra May 2021

Investigation On Microstructure And Mechanical Properties Of Porous Structures Processed By Laser Powder Bed Fusion, Samarth Ramachandra

Mechanical and Aerospace Engineering Theses - Archive

Inconel 718 (i.e., IN718) is a prominent nickel-based, precipitation-hardening superalloy which exhibits exceptionally stable mechanical and corrosion resistant properties, even at temperature range of 650ºC to 700ºC, making it suitable for a wide range of applications such as aerospace, nuclear reactors, tooling, turbines, oil and gas applications. The high toughness and work hardening offered by this superalloy, however, greatly limits the choice of machinability. The presence of low levels of aluminum permits good weldability which further allows the use of laser-based additive manufacturing (AM) to efficiently fabricate IN718 parts without the limitations associated with conventional manufacturing methods. Thanks to AM …

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Investigation Of The Microstructural And Mechanical Properties Of Selectively Laser Melted In718 Overhangs Fabricated Without Support Structures, Manjunath Hanumantha May 2021

Investigation Of The Microstructural And Mechanical Properties Of Selectively Laser Melted In718 Overhangs Fabricated Without Support Structures, Manjunath Hanumantha

Mechanical and Aerospace Engineering Theses - Archive

Additive manufacturing is a new manufacturing technology that allows for extreme design freedom as well as the simultaneous production of many parts with high complexities. IN718 is a high-strength, corrosion-resistant super alloy of nickel and chromium. It is ideal for high-end applications such as rocket nozzles and turbines because it can handle exceptionally high pressure and heat. Because of its high stiffness qualities, conventional manufacturing of complex IN718 geometries is challenging. Various fabrication techniques have been developed, and this study focuses on selective laser melting (SLM) because of its potential to produce near-perfect parts at a low cost when working …

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High Strength We43 Microlattice Structures Additively Manufactured By Laser Powder Bed Fusion, Holden Hyer, Le Zhou, Qingyang Liu, Dazhong Wu, Shutao Song, Yuanli Bai, Brandon Mcwilliams, Kyu Cho, Yongho Sohn May 2021

High Strength We43 Microlattice Structures Additively Manufactured By Laser Powder Bed Fusion, Holden Hyer, Le Zhou, Qingyang Liu, Dazhong Wu, Shutao Song, Yuanli Bai, Brandon Mcwilliams, Kyu Cho, Yongho Sohn

Mechanical Engineering Faculty Research and Publications

WE43 is a high strength, high creep resistant Mg-alloy containing Y, Nd, and Zr, and has potential for many lightweight structural applications in the automotive, aerospace, and biomedical industries. Additive manufacturing technology such as laser powder bed fusion (LPBF) brings an opportunity to produce complex geometries such as lattice structures. In this study, fabrication, compressive behavior, and fracture modes of 24 different microlattice structures were investigated by varying unit cell type, strut diameter, and number of unit cells. These complex lattice structures were produced by LPBF using the parameter set: laser power = 200 W, scan speed = 1100 mm/sec, …

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Open Source 3d-Printable Planetary Roller Screw For Food Processing Applications, Marcello C. Guadagno, Jacob M. Loss, Joshua M. Pearce Apr 2021

Open Source 3d-Printable Planetary Roller Screw For Food Processing Applications, Marcello C. Guadagno, Jacob M. Loss, Joshua M. Pearce

Michigan Tech Publications, Part 1

Historically, open source agriculture (OSA) was based on grassroots technology generally manufactured by hand tools or with manual machining. The rise of distributed digital manufacturing provides an opportunity for much more rapid lateral scaling of open source appropriate technologies for agriculture. However, the most mature distributed manufacturing area is plastic, which has limited use for many OSA applications. To overcome this limitation with design, this study reports on of a completely 3D-printable planetary roller screw linear actuator. The device is designed as a parametric script-based computer aided design (CAD) package to allow for the easy adaption for a number of …

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In Situ Tem Characterization Of Microstructure Evolution And Mechanical Behavior Of The 3d-Printed Inconel 718 Exposed To High Temperature, Supriya Koul, Le Zhou, Omar Ahmed, Yongho Sohn, Tengfei Jiang, Akihiro Kushima Apr 2021

In Situ Tem Characterization Of Microstructure Evolution And Mechanical Behavior Of The 3d-Printed Inconel 718 Exposed To High Temperature, Supriya Koul, Le Zhou, Omar Ahmed, Yongho Sohn, Tengfei Jiang, Akihiro Kushima

Mechanical Engineering Faculty Research and Publications

This in situ transmission electron microscopy work presents a nanoscale characterization of the microstructural evolution in 3D-printed Inconel 718 (IN718) while exposed to elevated temperature and an associated change in the mechanical property under tensile loading. Here, we utilized a specially designed specimen shape that enables tensile testing of nano-sized thin films without off-plane deformations. Additionally, it allows a seamless transition from the in situ heating to tensile experiment using the same specimen, which enables a direct correlation of the microstructure and the mechanical property of the sample. The method was successfully used to observe the residual stress relaxation and …

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Composition-Dependent Solidification Cracking Of Aluminum-Silicon Alloys During Laser Powder Bed Fusion, Holden Hyer, Le Zhou, Abhishek Mehta, Sharon Park, Thinh Huynh, Shutao Song, Yuanli Bai, Kyu Cho, Brandon Mcwilliams, Yongho Sohn Apr 2021

Composition-Dependent Solidification Cracking Of Aluminum-Silicon Alloys During Laser Powder Bed Fusion, Holden Hyer, Le Zhou, Abhishek Mehta, Sharon Park, Thinh Huynh, Shutao Song, Yuanli Bai, Kyu Cho, Brandon Mcwilliams, Yongho Sohn

Mechanical Engineering Faculty Research and Publications

Consistent manufacturing of volumetrically dense engineering components, free of solidification cracks by laser powder bed fusion (LPBF), has been demonstrated for Al-Si alloys such as AlSi10Mg and Al12Si. The success in LPBF of these alloys is attributed to the near eutectic composition with a small freezing range. To illuminate this observation, cracking susceptibility was examined from Scheil-Gulliver solidification modeling by calculating the hot cracking susceptibility, |dT/dfS1/2|. To validate the findings from hot cracking susceptibility calculations, six binary Al-Si alloys, whose compositions were strategically chosen at hypo-, near-, and hyper-eutectic compositions, were gas atomized into alloy powders, and …

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Experimental And Numerical Investigation In Directed Energy Deposition For Component Repair, Lan Li, Xinchang Zhang, Frank W. Liou Mar 2021

Experimental And Numerical Investigation In Directed Energy Deposition For Component Repair, Lan Li, Xinchang Zhang, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Directed energy deposition (DED) has been widely used for component repair. In the repair process, the surface defects are machined to a groove or slot and then refilled. The sidewall inclination angle of the groove geometry has been recognized to have a considerable impact on the mechanical properties of repaired parts. The objective of this work was to investigate the feasibility of repairing various V-shaped defects with both experiments and modeling. At first, the repair volume was defined by scanning the defective zone. Then, the repair volume was sliced to generate the repair toolpath. After that, the DED process was …

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Wind Blade Manufacturing For The Cal Poly Wind Power Club, Benjamin E. Thompson, Jake R. Lund, Claudia C. Angeles Mar 2021

Wind Blade Manufacturing For The Cal Poly Wind Power Club, Benjamin E. Thompson, Jake R. Lund, Claudia C. Angeles

Mechanical Engineering

The Cal Poly Wind Power Club is entering the 2021 Collegiate Wind Competition (CWC) in June. Last year, three senior project teams were assigned to collaborate and assist the club with the pitching mechanism, the rotor balancing, and the manufacturing process. As the manufacturing team, the goal of our project was to design a manufacturing process for the bladegeometry given. The manufacturing process was required to meet the team’s expectations and CWC’s performance requirements to place highly in the competition taking place in June 2021.These expectations included creating a manufacturing process that is repeatable and reliable for future competitions. The …

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Recurrence Network Analysis Of Design-Quality Interactions In Additive Manufacturing, Ruimin Chen, Prahalada K. Rao, Yan Lu, Edward W. Reutzel, Hui Yang Jan 2021

Recurrence Network Analysis Of Design-Quality Interactions In Additive Manufacturing, Ruimin Chen, Prahalada K. Rao, Yan Lu, Edward W. Reutzel, Hui Yang

Department of Mechanical and Materials Engineering: Faculty Publications

Powder bed fusion (PBF) additive manufacturing (AM) provides a great level of flexibility in the design-driven build of metal products. However, the more complex the design, the more difficult it becomes to control the quality of AM builds. The quality challenge persistently hampers the widespread application of AM technology. Advanced imaging (e.g., X-ray computed tomography scans and high-resolution optical images) has been increasingly explored to enhance the visibility of information and improve the AM quality control. Realizing the full potential of imaging data depends on the advent of information processing methodologies for the analysis of design-quality interactions. This paper presents …

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Process-Structure Relationship In The Directed Energy Deposition Of Cobalt-Chromium Alloy (Stellite 21) Coatings, Ziyad M. Smoqi, Joshua Toddy, Harold (Scott) Halliday, Jeffrey E. Shield, Prahalada K. Rao Jan 2021

Process-Structure Relationship In The Directed Energy Deposition Of Cobalt-Chromium Alloy (Stellite 21) Coatings, Ziyad M. Smoqi, Joshua Toddy, Harold (Scott) Halliday, Jeffrey E. Shield, Prahalada K. Rao

Department of Mechanical and Materials Engineering: Faculty Publications

In this work, we accomplished the crack-free directed energy deposition (DED) of a multi-layer Cobalt- Chromium alloy coating (Stellite 21) on Inconel 718 substrate. Stellite alloys are used as coating materials given their resistance to wear, corrosion, and high temperature. The main challenge in DED of Stellite coatings is the proclivity for crack formation during printing. The objective of this work is to characterize the effect of the input energy density and localized laser-based preheating on the characteristics of the deposited coating, namely, crack formation, microstructural evolution, dilution of the coating composition due to diffusion of iron and nickel from …

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Layer-To-Layer Feedback Control For Direct Energy Deposition Additive Manufacturing, Michelle Gegel Jan 2021

Layer-To-Layer Feedback Control For Direct Energy Deposition Additive Manufacturing, Michelle Gegel

Doctoral Dissertations

"Additive manufacturing (AM) has garnered much attention in recent years, some calling it the fourth industrial revolution. It was first used to create rapid prototypes, although recent efforts have been made to advance the technology towards production of functional parts. This requires advancement in the materials used in AM, as well as the ability to produce quality parts repeatably. More specifically, direct energy deposition (DED) of metal powders is a process capable of producing and repairing parts with complex geometries; however, it is not widely used in industry due to challenges with quality control. In this process, metal powder is …

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Direct Selective Laser Synthesis Of Cucrfenitial High Entropy Alloy From Elemental Powders Through Selective Laser Melting, Joni Dhar, Lazaro Lopez, Shanshan Zhang, Ben Xu, Mohammed Jasim Uddin, Jianzhi Li Jan 2021

Direct Selective Laser Synthesis Of Cucrfenitial High Entropy Alloy From Elemental Powders Through Selective Laser Melting, Joni Dhar, Lazaro Lopez, Shanshan Zhang, Ben Xu, Mohammed Jasim Uddin, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

This study investigated the synthesis of CuCrFeNiTiAl high entropy alloy (HEA) from pure elements using selective laser melting (SLM). The objectives are to validate the feasibility of the HEA fabrication from elemental powder materials, and to examine the effect of various process conditions in SLM, such as laser power, point distance and laser exposure time, on the microstructures formed. The as-built samples under high, medium and low energy densities were characterized by X-ray diffraction (XRD), and the microstructures were observed using scanning electron microscopy (SEM). The XRD results showed that five major crystal structure phases (hexagonal, monoclinic, orthorhombic, body-centered cubic …

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Experimental Characterization And Crystal Plasticity Modeling Of Mechanical Properties And Microstructure Evolution Of Additively Manufactured Inconel 718 Superalloy, Saeede Ghorbanpour Jan 2021

Experimental Characterization And Crystal Plasticity Modeling Of Mechanical Properties And Microstructure Evolution Of Additively Manufactured Inconel 718 Superalloy, Saeede Ghorbanpour

Doctoral Dissertations

In this thesis, the mechanical behavior of the additively manufactured (AM) IN718 nickel-based superalloy and their correlations with the evolution of microstructure are studied comprehensively. The effects of manufacturing parameters, build orientations, and post processing procedures, i.e. standard heat treatment and hot isostatic pressing (HIP), on various mechanical properties including monotonic compression and tension strength, low cyclic fatigue performance, high cyclic fatigue behaviour, and fatigue crack growth behavior are investigated. Due to the high temperature applications of the IN718 alloy, elevated temperature properties are examined as well. Electron Backscattered Diffraction (EBSD) technique is employed to measure the initial and deformed …

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Quality Assurance Of Lightweight Structures Via Phase-Based Motion Estimation, Ikenna E. Ifekaonwu Jan 2021

Quality Assurance Of Lightweight Structures Via Phase-Based Motion Estimation, Ikenna E. Ifekaonwu

College of Graduate Studies: Theses & Dissertations

In recent years, lightweight structures have become mature and adopted in various applications. The importance of quality assurance cannot be overemphasized hence extensive research has been conducted to assess the quality of lightweight structures. This study investigates a novel process that exploits motion magnification to investigate the damage characteristics of lightweight mission-critical parts. The goal is to assure the structural integrity of 3D printed structures and composite structures by determining the inherent defects present in the part by exploiting their vibration characteristics. The minuscule vibration of the structure was recorded with the aid of a high-speed digital camera, and the …

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Fabrication Of Silicon Nitride Parts By Ceramic On-Demand Extrusion Process, Sachin Choudhary Jan 2021

Fabrication Of Silicon Nitride Parts By Ceramic On-Demand Extrusion Process, Sachin Choudhary

Masters Theses

“Ceramic On-Demand Extrusion (CODE) is a patented solid freeform fabrication method for manufacturing high-density monolithic ceramic parts. In the past 5-6 years, the technology has been successfully implemented to fabricate alumina and zirconia parts. The mechanical characterizations also show CODE’s high potential in achieving desired structural properties. The present study covers the fabrication of silicon nitride parts by CODE process, which entailed the design of paste formulation for achieving rheology suitable for dimensional control in fabricated parts and determining firing temperature and the content of sintering additives for silicon nitride green bodies fabricated by CODE. The density, hardness, and fracture …

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Defect Detection Using Dynamic Analysis For Additive Manufactured Metals, Gita Deonarain Jan 2021

Defect Detection Using Dynamic Analysis For Additive Manufactured Metals, Gita Deonarain

Dissertations, Master's Theses and Master's Reports

Additive manufacturing (AM) has the ability to produce parts with complex geometries and internal features, however, for demanding applications such as the automotive and aerospace industries, it is crucial that the parts can meet the demanding functional and geometric requirements. Quality control for AM parts focuses on nondestructive methods of testing, but many of the current methods are expensive and time-consuming. The research presented in this report explores various methods of nondestructive evaluation (NDE) using dynamic analysis on stainless steel parts produced with selective laser melting (SLM). Methods include, but are not limited to, frequency response functions (FRF), impedance-based measurements, …

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Reducing Corrosion Of Additive Manufactured Magnesium Alloys By Interlayer Ultrasonic Peening, M. P. Sealy, R. Karunakaran, S. Ortgies, G. Madireddy, A. P. Malshe, K. P. Rajurkar Jan 2021

Reducing Corrosion Of Additive Manufactured Magnesium Alloys By Interlayer Ultrasonic Peening, M. P. Sealy, R. Karunakaran, S. Ortgies, G. Madireddy, A. P. Malshe, K. P. Rajurkar

Department of Mechanical and Materials Engineering: Faculty Publications

Additive manufad (AM) magn alloys corrode rapidly due to tensile stress and coarse microstructures. Cyclically combining (hybridizing) additive manufacturing with interlayer ultrasonic peening was proposed as a solution to improve corrosion resistance of additive manufactured magnesium WE43 alloy through strengthening mechanisms and compressive residual stress. Applying interlayer peening work hardened discrete layers and formed a glocal integrity of regional grain refinement and subsurface compressive residual stress barriers. Tensile residual stress that typically accelerates corrosion decreased 90%. Results showed time-resolved control over corrosion was attainable by interlayer peening, and local corrosion within print cells decreased 57% with respect to as-printed WE43.

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