Mechanical Engineering Commons^™

Application Of Metamaterials For Multifunctional Satellite Bus Enabled Via Additive Manufacturing, Michael A. Macchia

Theses and Dissertations

Space systems require materials with superior stiffness to weight ratios to provide structural integrity while minimizing mass. Additive manufacturing processes enable the design of metamaterials that exceed the performance of naturally occurring materials in addition to allowing the integration of non-structural functions. This research explored the use of a high stiffness, high density, small melt pool track width AM material, Inconel 718, to enable the production of metamaterials with finer features possible than can possibly be created using a lower density aluminum alloy material. Various metamaterials were designed utilizing thin wall triply periodic minimal surface infilled sandwich structures. The performance …

Glocal Integrity In 420 Stainless Steel By Asynchronous Laser Processing, Michael P. Sealy, Haitham Hadidi, Cody Kanger, X. L. Yan, Bai Cui, J. A. Mcgeough

Department of Mechanical and Materials Engineering: Faculty Publications

Cold working individual layers during additive manufacturing (AM) by mechanical surface treatments, such as peening, effectively “prints” an aggregate surface integrity that is referred to as a glocal (i.e., local with global implications) integrity. Printing a complex, pre-designed glocal integrity throughout the build volume is a feasible approach to improve functional performance while mitigating distortion. However, coupling peening with AM introduces new manufacturing challenges, namely thermal cancellation, whereby heat relaxes favorable residual stresses and work hardening when printing on a peened layer. Thus, this work investigates glocal integrity formation from cyclically coupling LENS® with laser peening on 420 stainless steel.

Mechanical Characterization Of Anisotropic Fused Deposition Modeled Polylactic Acid Under Combined Monotonic Bending And Torsion Conditions, Aaron T. Santomauro

Honors Undergraduate Theses

Mechanical strength of polylactic acid (PLA) is increasingly relevant with time because of its attractive mechanical properties and 3D printability. Additive manufacturing (AM) methods, such as fused deposition modeling (FDM), stereolithography (SLA), and selective laser sintering (SLS), serve a vital role in assisting designers with cheap and efficient generation of the desired components. This document presents research to investigate the anisotropic response of multi-oriented PLA subjected to multiple monotonic loading conditions. Although empirical data has previously been captured for multi-oriented PLA under tensile and compressive loading conditions, the data has yet to be applied with regard to a representative component …

Energy Analysis For Process Parameter Prediction Of Direct Energy Deposition Metal Additive Manufacturing, Daniel John Pulscher

Graduate Research Theses & Dissertations

Metal Additive Manufacturing with the Direct Energy Deposition (DED) process allows for rapid prototyping and low-volume custom manufacturing of complex geometries at a lower cost than traditional manufacturing methods. Direct energy deposition is a complex process having many inter-related process parameters that effect the overall quality and mechanical properties of the build. When new powder feedstocks are used, calibrating these process parameters is typically done empirically in trials that can contain more than a hundred different combinations of parameters. This time-consuming process can be reduced by performing an analytical analysis on how the energy from the laser transfers into the …

An Energy Profile Model For Fused Deposition Modeling 3d Printing Process, Calvin Hawkins

Research Opportunities for Engineering Undergraduates (ROEU) Program 2018-19

This project develops a strategy to monitor and estimate the energy consumption of fused deposition modeling (FDM) additive manufacturing, which will benefit manufacturers and designers seeking to design and manufacture products with minimal energy consumption.

Rheological Properties Of Two Stainless Steel 316l Powders For Additive Manufacturing, Haijun Gong, Xiaodong Xing, Hengfeng Gu

Manufacturing Engineering: Faculty Publications (2015-2023)

This study measures the rheological properties of two stainless steel 316L powders which are used for the powder-bed-fusion based additive manufacturing process. The purpose is to evaluate the newly acquired powder in comparison with the used and recycled powder, so that both powders can be mixed with each other to supplement the powder usage. The powder rheology properties, such as dynamic property, bulk property, and shear property, are tested and compared. The results and analysis confirm the compatibility of powder mixing.

The Effect Of Cell Size And Surface Roughness On The Compressive Properties Of Abs Lattice Structures Fabricated By Fused Deposition Modeling, Leah Hope Mason

Masters Theses

"Postprocessing is an important step in many manufacturing methods, but it is especially important for additive manufacturing. Researchers looking to improve the surface roughness of acrylonitrile butadiene styrene (ABS) parts fabricated by fused deposition modeling (FDM) have determined that acetone smoothing not only achieves improved surface roughness but increases compressive strength as well. This could be very beneficial to lattice structures, which are known for already having an excellent strength to weight ratio. If the compressive strength of ABS lattice structures could be improved even further using acetone smoothing, it could expand the applications for plastic lattice structures and improve …

Rasters Vs Contours For Thin Wall Ultem 9085 Fdm Applications, Vausman Kota

Browse all Theses and Dissertations

Currently many components are additively manufactured via fused deposition modeling (FDM). However, FDM results in gaps between passes which produces a poor surface finish and porous material that is difficult to hold pressure. Commercial scale air systems require a pressure to be maintained within thin walled components with minimal post processing and clean up after fabrication. A design of experiments (DOE) was created to identify the optimal raster vs contour ratio for UTLEM 9085 CG fabricated using FDM at different build angles and wall thicknesses. A custom-built pressurized test system was developed, the leak rates were calculated and the surfaces …

Additive Manufactured Ear Pinna For Spatial Cue Preservation In Custom Hearing Devices, Carlos Felipe Acosta Carrasco

Open Access Theses & Dissertations

Advancements in additive manufacturing/3D printing technologies has permitted the fabrication of intricate features such as the ones present in the human ear. The outer ear, also known as the pinna, allows for the spectral cues from incoming sound to be captured and identified. The hypothesis of the preservation of auditory localization and externalization relies on the fabrication of an ear pinna via additive manufacturing embedded into a headset for spectral cue preservation and hearing protection. Before exploring these custom circumaural hearing devices, a study on the fabrication process of AM pinnae was performed. The KEMAR system for acoustic research was …

Design And Mechanical Characterization Of 3d Printed Gradient Porosity Poly(Propylene Fumarate) Scaffolds, Andrea Felicelli

Williams Honors College, Honors Research Projects

Worldwide incidence of bone disorders and conditions, an already prevalent problem, is expected to double by 2020 from the rate in 2013 due to factors such as higher life expectancies and lower levels of physical activity. Every year in the United States, over half a million patients receive bone defect repairs, with costs greater than $2.5 billion. Current repairs are typically done with bone grafts, which are often costly and can result in added complications in the donor surgical site. Tissue engineering, a growing field that seeks to assist and enhance tissue defect repairs through the use of synthetic materials, …

3d Printing In Low Resource Healthcare Settings: Analysis Of Potential Implementations, Alenna Beroza

Dissertations, Master's Theses and Master's Reports

3D printing has gained significant momentum in the past ten years, and its unique advantages make it especially ideal for use in low resource healthcare settings, where many designs have already been successfully implemented. Yet, little has been studied on how 3D printing can be sustainably and functionally implemented in low resource healthcare systems as a manufacturing practice. In this report, three business models are proposed for this implementation: In-House Operator, Independent Operator, and Print Farm. These models were then tested over four months in Kisumu county, Kenya, at two workshops and seven public hospitals. I worked with local medical …

The Characterization And Fatigue Life Impact From Surface Roughness On Structurally Relevant Features Produced Using Additive Manufacturing, Eric-Paul Daniel Tatman

Browse all Theses and Dissertations

Additive manufacturing (AM) produces rough surfaces that are detrimental to the mechanical performance of the part. In this work, downward-facing surfaces were fabricated in alloy 718 using laser powder bed fusion and investigated with surface characterization and axial fatigue testing. Coupons with downward-facing surfaces at 45°, 60°, and 75° and flat axial fatigue bars with as-built and machined holes were built. Both specimens were fabricated with three levels of downskin laser power and the coupons with three levels of downskin laser speed. Surface characterization showed roughness increased as the downward-facing angle decreased. Fatigue testing with digital image correlation showed localized …

Freeform Extrusion Fabrication Of Advanced Ceramics And Ceramic-Based Composites, Wenbin Li

Doctoral Dissertations

"Ceramic On-Demand Extrusion (CODE) is a recently developed freeform extrusion fabrication process for producing dense ceramic components from single and multiple constituents. In this process, aqueous paste of ceramic particles with a very low binder content ( < 1 vol%) is extruded through a moving nozzle to print each layer sequentially. Once one layer is printed, it is surrounded by oil to prevent undesirable water evaporation from the perimeters of the part. The oil level is regulated just below the topmost layer of the part being fabricated. Infrared radiation is then applied to uniformly and partially dry the top layer so that the yield stress of the paste increases to avoid part deformation. By repeating the above steps, the part is printed in a layer-wise fashion, followed by post-processing. Paste extrusion precision of different extrusion mechanisms was compared and analyzed, with an auger extruder determined to be the most suitable paste extruder for the CODE system. A novel fabrication system was developed based on a motion gantry, auger extruders, and peripheral devices. Sample specimens were then produced from 3 mol% yttria stabilized zirconia using this fabrication system, and their properties, including density, flexural strength, Young's modulus, Weibull modulus, fracture toughness, and hardness were measured. The results indicated that superior mechanical properties were achieved by the CODE process among all the additive manufacturing processes. Further development was made on the CODE process to fabricate ceramic components that have external/internal features such as overhangs by using fugitive support material. Finally, ceramic composites with functionally graded materials (FGMs) were fabricated by the CODE process using a dynamic mixing device"--Abstract, page iv.

Design, Fabrication, And Characterization Of Functionally Graded Materials, Sreekar Karnati

Doctoral Dissertations

“The aim of this research was to investigate the feasibility of fabricating custom designed, graded materials using Laser Metal Deposition (LMD) that will cater for functionality and unconventional repair. The ultimate goal of the project is to establish the versatility of LMD for fabricating advanced materials and tackling problems that have been conventionally difficult or in cases infeasible. In order to accomplish these goals, this research involved investigations into, the feasibility of using elemental powders as modular feedstocks, the feasibility of fabricating tailored gradients with these custom compositions, and finally leveraging the advantages of grading materials using LMD to successfully …

Remanufacturing Of Precision Metal Components Using Additive Manufacturing Technology, Xinchang Zhang

Doctoral Dissertations

"Critical metallic components such as jet engine turbine blades and casting die/mold may be damaged after servicing for a period at harsh working environments such as elevated temperature and pressure, impact with foreign objects, wear, corrosion, and fatigue. Additive manufacturing has a promising application for the refurbishment of such high-costly parts by depositing materials at the damaged zone to restore the nominal geometry. However, several issues such as pre-processing of worn parts to assure the repairability, reconstructing the repair volume to generate a repair tool path for material deposition, and inspection of repaired parts are challenging. The current research aims …

Enhancing Tensile Strength Of Fdm Parts Using Thermal Annealing And Uniaxial Pressure, Rhugdhrivya Rane

Mechanical and Aerospace Engineering Theses - Archive

Additive manufacturing has been a revolutionary and disruptive technological development in the field of design and manufacturing with Fused deposition modelling (FDM) being at the forefront of this technology. But it is seen that parts printed using FDM suffer from an inherent deficiency of weak tensile strength in the out of plane direction (z-direction) thus limiting their application. This issue of weak z-direction strength is due to the weak Inter-bead bond strength of adjacent polymer interfaces. The purpose of this work is to increase this Inter-Bead bond strength thus increasing the overall tensile strength of the part. In this work, …

Process Calibration For Elastically Scaled 3d Printed Models Using Fused Deposition Modeling, Edgar Bernardo Mares

Mechanical and Aerospace Engineering Theses - Archive

With the increase in additive manufacturing capabilities the use of 3D printed models characterize a critical point for evaluating aerodynamic and aeroelastic properties on aircraft configuration. An experimental and computational approach beginning with elastically scaled 3D printed models enables for a case to be defined, developed, and extracted to match aeroelastic test behavior. The basis of this work is supported by aeroelastic tailoring and scaling methods in the application of 3D printed models. To accomplish this, stiffened 3D printed plates are scaled from elastically scaled 3D printed models for stiffness through geometric configurations, different build orientations, and bead thickness as …

Analysis Of Printed Electronic Adhesion, Electrical, Mechanical, And Thermal Performance For Resilient Hybrid Electronics, Clayton Neff

USF Tampa Graduate Theses and Dissertations

Today’s state of the art additive manufacturing (AM) systems have the ability to fabricate multi-material devices with novel capabilities that were previously constrained by traditional manufacturing. AM machines fuse or deposit material in an additive fashion only where necessary, thus unlocking advantages of mass customization, no part-specific tooling, near arbitrary geometric complexity, and reduced lead times and cost. The combination of conductive ink micro-dispensing AM process with hybrid manufacturing processes including: laser machining, CNC machining, and pick & place enables the fabrication of printed electronics. Printed electronics exploit the integration of AM with hybrid processes and allow embedded and/or conformal …

Ultrafast X-Ray Imaging Of Laser-Metal Additive Manufacturing Processes, Niranjan D. Parab, Cang Zhao, Ross Cunningham, Luis I. Escano, Kamel Fezzaa, Wes Everhart, Anthony D. Rollett, Lianyi Chen, Tao Sun

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The high-speed synchrotron X-ray imaging technique was synchronized with a custom-built laser-melting setup to capture the dynamics of laser powder-bed fusion processes in situ. Various significant phenomena, including vapor-depression and melt-pool dynamics and powder-spatter ejection, were captured with high spatial and temporal resolution. Imaging frame rates of up to 10 MHz were used to capture the rapid changes in these highly dynamic phenomena. At the same time, relatively slow frame rates were employed to capture large-scale changes during the process. This experimental platform will be vital in the further understanding of laser additive manufacturing processes and will be particularly …

Finding Balance In Generative Product Design, Alex Lobos

Presentations and other scholarship

Generative design develops complex forms and structures similar to those found in nature, taking advantage of automated tasks and high-scale computing power. This approach benefits designers in the creation systems that are efficient, resilient and visually engaging. These systems follow specific rules for form generation and meet clear design goals in terms of shape, strength, mass, and other physical attributes.

There is a large number of methods for creating generative systems, based on establishing desired outcomes and behaviors for how components relate to each other. Examples of methods include L-Systems, Shape Grammars, Swarm Intelligence, Form Optimization, Lattice Design, and many …

Development Of Pre-Repair Machining Strategies For Laser-Aided Metallic Component Remanufacturing, Xinchang Zhang, Wenyuan Cui, Leon Hill, Wei Li, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Remanufacturing worn metallic components can prolong the service life of parts that need frequent replacement but are extremely costly to manufacture, such as aircraft titanium components, casting dies. Additive manufacturing (AM) technology enables the repair of such valuable components by depositing filler materials at the worn area layer by layer to regenerate the missing geometry. In general, damaged parts would be inspected and pre-machined prior to material deposition to remove oil, residue, oxidized layers or defects located in inaccessible regions. Therefore, the motivation of this paper is to introduce pre-repair machining strategies for removing contaminated materials from damaged components and …

Mechanical Properties Of Zr-Based Bulk Metallic Glass Parts Fabricated By Laser-Foil-Printing Additive Manufacturing, Yingqi Li, Ming-Chuan Leu, Hai-Lung Tsai

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The application of bulk metallic glasses (BMGs) has been traditionally limited to parts with small dimensions and simple geometries, due to the requirement of fast cooling during the conventional process of casting. This research exemplifies a promising additive manufacturing method, i.e., laser-foil-printing (LFP), to fabricate high-quality BMG parts with large dimensions and complex geometries. In this study, Zr_52.5Ti₅Al₁₀Ni_14.6Cu_17.9 BMG parts were fabricated by LFP technology in which MG foils are laser welded layer-by- layer upon a substrate. The mechanical properties of the fabricated BMG parts were measured using micro-indentation, tensile test …

Fast Prediction Of Thermal Distortion In Metal Powder Bed Fusion Additive Manufacturing: Part 2, A Quasi-Static Thermo-Mechanical Model, Hao Peng, Morteza Ghasri-Khouzani, Shan Gong, Ross Attardo, Pierre Ostiguy, Ronald B. Rogge, Bernice Aboud Gatrell, Joseph Budzinski, Charles Tomonto, Joel Neidig, M. Ravi Shankar, Richard Billo, David B. Go, David Hoelzle

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The additive manufacturing (AM) process metal powder bed fusion (PBF) can quickly produce complex parts with mechanical properties comparable to that of wrought materials. However, thermal stress accumulated during Metal PBF may induce part distortion and even cause failure of the entire process. This manuscript is the second part of two companion manuscripts that collectively present a part-scale simulation method for fast prediction of thermal distortion in Metal PBF. The first part provides a fast prediction of the temperature history in the part via a thermal circuit network (TCN) model. This second part uses the temperature history from the TCN …

Experimental And Theoretical Investigation Of Mechanical Response Of Laser-Sintered Diamond Lattice Structures, Clayton Neff, Neil Hopkinson, Nathan B. Crane

Faculty Publications

Typically additive manufacturing (AM) processes are limited to a single material per part while many products benefit from the integration of multiple materials with varied properties. To achieve the benefits of multiple materials, the geometric freedom of AM could be used to build internal structures that emulate a range of different material properties such as stiffness, Poisson’s ratio, and elastic limit using only one build material. This paper examines the range of properties that can be simulated using diamond lattice structures manufactured from Nylon 12 with a commercial laser sintering process. Diamond lattices were fabricated with a unit cell length …

Fast Prediction Of Thermal Distortion In Metal Powder Bed Fusion Additive Manufacturing: Part 1, A Thermal Circuit Network Model, Hao Peng, Morteza Ghasri-Khouzani, Shan Gong, Ross Attardo, Pierre Ostiguy, Bernice Aboud Gatrell, Joseph Budzinski, Charles Tomonto, Joel Neidig, M. Ravi Shankar, Richard Billo, David B. Go, David Hoelzle

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The additive manufacturing (AM) process metal powder bed fusion (PBF) can quickly produce complex parts with mechanical properties comparable to wrought materials. However, thermal stress accumulated during PBF induces part distortion, potentially yielding parts out of specification and frequently process failure. This manuscript is the first of two companion manuscripts that introduce a computationally efficient distortion and stress prediction algorithm that is designed to drastically reduce compute time when integrated in to a process design optimization routine. In this first manuscript, we introduce a thermal circuit network (TCN) model to estimate the part temperature history during PBF, a major computational …

A Study Of Effect Of Bond Length On Bond Strength Using Transient Heat Transfer Analysis, Junaid Mohamed Baig

Mechanical and Aerospace Engineering Theses - Archive

It is important to understand the mechanical properties of the bonding between the adjacent layers of 3D printed parts build by fused deposition modeling. The bonding process is highly nonlinear and depends on various geometrical and thermal process parameters. This work aims to quantify the degree of bonding by calculating bond potential between the extruded layers using finite element heat transfer analysis. Successive transient analysis were carried out using this model by constantly updating the boundary conditions and geometric model during the deposition of the extruded bead. Temperatures at critical points were calculated over a period to calculate the bond …

Microstructure And Mechanical Properties Of Selective Laser Melted Superalloy Inconel 625., Md Ashabul Anam

Electronic Theses and Dissertations

Selective Laser Melting (SLM), a powder based Additive Manufacturing (AM) process, has gained considerable attention in the aerospace, biomedical and automotive industries due to its many potential benefits, such as, capability of fabricating complex three-dimensional components, shortened design to product time, reduction in process steps, component mass reduction and material flexibility. This process uses metallic powder and is capable of fabricating complex structures with excellent microstructure which make SLM not only an improvement over other manufacturing processes but also innovative material processing technology. Inconel 625, a nickel-based super alloy is widely popular in aerospace, chemical and nuclear industries. This alloy …

Impact Of Extended Sintering Times On Mechanical Properties In Pa-12 Parts Produced By Powderbed Fusion Processes, Garrett Craft, Justin Nussbaum, Nathan B. Crane, J. P. Harmon

Faculty Publications

Additive Manufacturing provides many advantages in reduced lead times and increased geometric freedom compared to traditional manufacturing methods, but material properties are often reduced. This paper considers powder bed fusion of polyamide 12 (PA12, Nylon 12) produced by three different processes: laser sintering (LS), multijet fusion (MJF)/high speed sintering (HSS), and large area projection sintering (LAPS). While all utilize similar PA12 materials, they are found to differ significantly in mechanical properties especially in elongation to break. The slower heating methods (MJF/HSS and LAPS) produce large elongation at break with the LAPS process showing 10x elongation and MJF/HSS exhibiting 2.5x the …

Modeling And Validations Of Control Parameters For Material Extrusion-Based Additive Manufacturing Of Thixotropic Aluminum Alloys., Lars Herhold

Electronic Theses and Dissertations

Additive Manufacturing (AM) with metals has been accomplished mainly through powder bed fusion processes. Initial experiments and simulations using Material Extrusion Additive Manufacturing (MEAM) have been performed by various researchers especially using low melting alloys. Recently Stratasys Inc. submitted a patent application for the use of their Material Extrusion technology also called Fused Deposition Modeling (FDM) where they describe the process using thixotropic semi-solid alloys. Currently this process using semi-solid, engineering type alloys such as A356 or THIXALLOY 540 aluminum have not been researched to evaluate the control parameters. This research combines the in-depth knowledge of applying thixotropic semi-solid aluminum …

Tooling For Injection Molding Using Laser-Powder Bed Fusion., Mohith Ram Buxani

Electronic Theses and Dissertations

Laser-Powder Bed Fusion (L-PBF) has been considered for some time by the injection molding industry for the fabrication of tooling for injection molding in order to address large lead times and costs for tool-making. Computer-aided simulations are also routinely used to evaluate new part and mold designs as well as understanding the effects of material compositions and processing conditions on part quality and overall productivity. However, there remains a significant need to integrate the perspectives from injection molding, 3D printing, metal powders, and component design and process simulation to better utilize LPBF for fabricating tooling required for injection molding. The …