Manufacturing Commons^™

Materials-Processing Relationships For Metal Fused Filament Fabrication Of Ti-6al-4v Alloy., Paramjot Singh

Electronic Theses and Dissertations

Additive manufacturing (AM) is at the mainstream to cater the needs for rapid tooling and small-scale part production. The metal AM of complex geometries is widely accepted and promoted in the industry. While several metal AM technologies exist and are matured to a level where expectation in terms of design and properties are possible to realize. But the metal AM suffers from the heavy expense to acquire equipment, isotropic property challenges, and potential hazards to work with loose reactive metal powder. With this motivation, the dissertation aims to develop the fundamental aspects to print metal parts with bound Ti-6Al-4V powder …

Selective Laser Melting 17-4 Ph Stainless Steel And The Effect Of Varied Thermal Treatments On Fatigue Behavior., Sean Daniel Dobson

Electronic Theses and Dissertations

Fatigue failure is the leading source of loss in industry. In order for new means of manufacturing to move towards mainstream use a complete understanding of material and mechanical behavior must be gained. This endeavor seeks to aide in that task by observing the fatigue behavior of selective laser melting (SLM) additive manufacturing (AM) specimens and the effect of differing thermal treatment conditions for an optimized AM process. Stainless steel 17-4 PH specimens were fabricated using SLM AM and thermally treated to three conditions: as-built, solutionized and hardened, and direct hardened. These specimens were characterized for material (powder quality, density, …

Spherical Cavity Expansion Approach For The Study Of Rigid-Penetrator’S Impact Problems, Mario Buchely, Alejandro Marañon

Materials Science and Engineering Faculty Research & Creative Works

In recent years, Spherical Cavity Expansion (SCE) theory has been extensively utilized to model dynamic deformation processes related to indentation and penetration problems in many fields. In this review, the SCE theory is introduced by explaining the different mathematical features of this theory, its solution, and a potential application to model the penetration of a rigid penetrator into a deformable target. First, a chronologically literature review of the most common models used to study this kind of penetration problems is introduced, focusing on the SCE theory. Then, the engineering model of penetration is presented using the SCE approach. The model …

Faculty Instruction Face Shield Project, David Holden, John Schneiderhan

Michigan Tech 3D Designs

Early in the spring of 2020 project contributors David Holden and John Schneiderhan began test printing a variety of open source Personal Protective Equipment (PPE)/Covid related items that could help protect or prevent the spread of the emerging virus. With assistance from Pete Baril of the Western Upper Peninsula Health Department (WUPHD) approval was obtained for the face shields to be used in the health care and nursing homes in the area. With the support and approval from university and library administration efforts were coordinated with Dr. Joshua Pearce and the students from the MOST lab to concentrate on the …

Thermal Modeling Of Additive Manufacturing Using Graph Theory: Validation With Directed Energy Deposition, Jordan Severson

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Metal additive manufacturing (AM/3D printing) offers unparalleled advantages over conventional manufacturing, including greater design freedom and a lower lead time. However, the use of AM parts in safety-critical industries, such as aerospace and biomedical, is limited by the tendency of the process to create flaws that can lead to sudden failure during use. The root cause of flaw formation in metal AM parts, such as porosity and deformation, is linked to the temperature inside the part during the process, called the thermal history. The thermal history is a function of the process parameters and part design.

Consequently, the first step …

Rc Mini Baja Car - Suspension And Chassis, Collin Mckenzie

All Undergraduate Projects

Two students have developed a unique design of the RC Baja Car to optimize functionality and performance. A Baja car is a remote controlled 1/10 scale car that is used for recreation or competition, usually meant for competing in the ASME Baja car competition versus various schools. The competition focuses on the best time achieved in different courses that utilize speed, turns, and jumps. The objective for the project was to create a unique suspension from previous individual’s projects by creating a four-link suspension in which allows more travel in the suspension of the car and maintains functionality with the …

Development Of An Anatomically And Electrically Conductive Brain Phantom For Transcranial Magnetic Stimulation, Hamzah A. Magsood

Theses and Dissertations

Transcranial Magnetic Stimulation (TMS) is a non-invasive technique for diagnostics, prognostic, and treatments of various neurological diseases. However, the lack of anatomically realistic brain phantoms has made the experimental verification of stimulation strength in the form of induced electric fields/voltages in the brain tissues an impediment to developing new TMS coils, stimulators, and treatment protocols. There are significant technological, safety, and ethical limitations to test the potential TMS treatment procedures or develop enhancements and refine them on humans or animals. This work aims to bridge the gap by introducing and developing an innovative manufacturing and fabrications process to produce a …

Stress Generation In Ni50.3Ti29.7Hf20 Shape Memory Alloys, Utsav Shah

Theses and Dissertations--Mechanical and Aerospace Engineering

Shape memory alloys such as NiTiHf and NiTi have the ability to generate large recovery stresses when they are constrained after pre-straining and then heated above their Austenite Finish Temperature (A_f). In this work Ni_49.9Ti_50.1 (at.%), the most well-known SMA with impressive shape memory properties but limited temperature range and Ni_50.3Ti_29.7Hf₂₀, a promising high temperature shape memory alloy, were characterized to reveal their stress generation capabilities. The effects of pre-straining on stress generation were investigated via martensite reorientation method of NiTi and NiTiHf alloys by loading the samples till …

Jominy Hardenability Tester With In-Situ Heating, Luke Allen

Williams Honors College, Honors Research Projects

This project centers on building a Jominy Hardenability tester with In-Situ heating for the manufacturing lab at the University of Akron. A new process and setup will be designed using engineering concepts in order to make the testing more efficient and safer for the teaching and testing of metal hardness. The current Jominy testing setup has efficiency issues within the transfer of specimen from induction heater to testing rig. Our design will simplify the design by creating a test rig that removes the traveling aspect of the specimen which will limit the amount of premature cooling done and will be …

Table Top Dome Tester, Travis Bernard, Sarah Kassinger, Amanda O'Reilly, Scott Salerno

Williams Honors College, Honors Research Projects

The Erichsen Cupping Test was used as a basis to design a dome tester. The intention of a dome tester is to test sheet metal material properties in all directions. This was done by clamping a piece of sheet metal and using a piston and hydraulic press to punch through the material. The force used to punch the material and the height of the deforming material can be gathered and the sheet metal properties can then be calculated. At the end of the project the team was able to successfully design and manufacture a hydraulic dome tester. However, due to …

Tabletop Mechanical Tester, Jamie Dombroski, Brian English, Richard Leffler, Andrew Shirk

Williams Honors College, Honors Research Projects

The need for hands-on and face-to-face experiences in the engineering classroom is very great. The equations, principles, and concepts can all be learned, but without the visual and tactile application, these don’t always sink in or become concrete. A small-scale tensile test machine was designed, sourced, manufactured, and tested for the purpose of being applied in classroom settings to provide this experience to engineering students. Extensive research was performed concerning tensile machines on the market, the essential elements of which are the load cell, grips, crosshead, extensometer, motor, and frame. The raw materials for the frame were purchased and drawings …

Very High Cycle Fatigue Behavior Of Laser Beam-Powder Bed Fused Inconel 718 Considering The Layer Orientation And Surface Finish Effects, Palmer Frye

UNF Graduate Theses and Dissertations

Additive Manufacturing (AM) techniques have recently gained popularity for fabrication of parts used in aerospace applications. Some of these parts may be subjected to cyclic loading at very high frequencies, leading to service life requirements exceeding ten-million cycles (>10⁷ cycles). Therefore, understanding the very high-cycle fatigue (VHCF) behavior of these AM parts is an important step in their design and qualification processes. In this thesis, both high-cycle fatigue (HCF) and VHCF behaviors of Inconel 718, a Ni-base superalloy, manufactured via a Laser Beam-Powder Bed Fusion (LB-PBF) process, are investigated. Uniaxial, fully reversed force-controlled fatigue tests were conducted utilizing …

In-Situ X-Ray Imaging Of The Selective Laser Melting Process, Meelap M. Coday

Masters Theses

"Fusion-based metal additive manufacturing (AM) has garnered much interest in recent decades. Despite the popularity of fusion-based AM technologies such as selective laser melting (SLM), there are still fundamental questions and uncertainties that need to be addressed. In this work, we focus on the understanding of the undercooling in the SLM process and the uncertainties induced by the laser beam size, power, and scan speed. First, we report the estimation of undercooling in the SLM process from the solidification rate measured by in-situ high-speed synchrotron x-ray imaging, based on the dendrite growth velocity model. The undercooling changes as a function …

Doping With Rare Earth Elements And Resultant Nano-Inclusions On The Electrical And Thermal Properties Of The Mis-Fit Layered Thermoelectric Oxide, Geoffroy Gauneau

Graduate Theses, Dissertations, and Problem Reports (ETD)

Thermoelectric generators produce electricity by directly converting temperature differences into electrical energy through Seebeck effect. Thermoelectric generators possess many unique features, such as having no moving part and being very reliable with a relatively long lifespan once built. They are solid-state waste heat harvesters. With various waste heat available throughout many industries, thermoelectric generators could offer economically competitive renewable energy. The current state of the art thermoelectric materials includes materials with relatively toxic elements and must work under vacuum, making them quite expensive to produce. Among the various thermoelectric materials, ceramic oxides have been proved to be more chemically stable …

Artificial Intelligence In Plasma Electrolytic Micro-Oxidation For Surface Hardening - Insights From Scholarly Citation Networks And Patents., Priya Jadhav, Dr.Arun Bongale, Dr.Satish Kumar, Dr.Amit Kumar Tiwari

Library Philosophy and Practice (e-journal)

Objective - The purpose of this article is to analyze the top work areas and patent domains in the field of surface hardening by micro-arc oxidation. Also, it is directed on the opportunities of data analysis by different machine learning tools. Material and methods - The www.lens.org database is used to collect articles from Elsevier, Trans tech publications, Springer New York, MDPI, etc. to review the relevant articles as well as patents related to the topic. The result - A total of 1057 articles were published in 60 different journals and 756 patents in the area of research under various …

An Investigation Of High-Speed Consolidation And Repair Of Carbon Fiber - Epoxy Composites Through Ultrasonic Welding, David A. Hoskins

LSU Master's Theses

Adhesive repair of carbon fiber composite structures is commonly done on damaged structures to extend the service life. This method requires careful preparation of the damaged surface with intricate steps to ensure good bonding between the repair patch and the parent structure by means of an adhesive film. As with many forms of composite manufacturing, it is required to perform vacuum bagging, debulking, and a heated cure depending on the resin. All these steps make the repair process costly and time consuming.

In this present work, an alternative method of repair is investigated which explores the experimental feasibility of using …

Comparison Of Fatigue Performance Between Additively Manufactured And Wrought 304l Stainless Steel Using A Novel Fatigue Test Setup, M. M. Parvez, Y. Chen, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In this research, a novel adaptive controlled fatigue testing machine was designed for bending type high cycle fatigue test. A unique dual gauge section Krouse type mini specimen was designed for simply supported transverse bending. Displacement controlled fatigue tests were implemented using an electromechanical actuator. The variation in the control signal and load observed during the test provides unique insights into realizing the deterioration of the specimen due to fatigue. These analyses were utilized to compare the fatigue performance of wrought and additively manufactured 304L stainless steel. The influence of the build direction on fatigue performance was also investigated by …

Effective Elastic Properties Of Additively Manufactured Metallic Lattice Structures: Unit-Cell Modeling, Okanmisope Fashanu, David Murphy, Myranda Spratt, Joseph William Newkirk, K. Chandrashekhara, Ben Brown, John Porter

Materials Science and Engineering Faculty Research & Creative Works

Lattice structures are lightweight materials, which exhibit a unique combination of properties such as air and water permeability, energy and acoustic absorption, low thermal conductivity, and electrical insulation. In this work, unit-cell homogenization was used to predict the effective elastic moduli of octet-truss (OT) lattice structures manufactured using selective laser melting (SLM). OT structures were manufactured using a Renishaw AM 250 SLM machine with various relative densities. Compression test was carried out at strain rate 5 x 10^-3 m^-1 using an MTS frame. Finite element analysis was used in the determination of the OT’s effective elastic properties. Results …

Compressive And Bending Performance Of Selectively Laser Melted Alsi10mg Structures, D. Murphy, O. Fashanu, Myranda Spratt, Joseph William Newkirk, K. Chandrashekhara, H. Misak, D. Klenosky

Materials Science and Engineering Faculty Research & Creative Works

Selective laser melting (SLM) is a widely used additive manufacturing technique that effectively manufactures complex geometries such as cellular structures. However, challenges such as anisotropy and mechanical property variation are commonly found due to process parameters. In a bid to utilize this method for the commercial production of cellular structures, it is important to understand the behavior of a material under different loading conditions. In this work, the behavior of additively manufactured AlSi10Mg under compression, bending, and tension loads was investigated. Vertical and horizontal build directions are compared for each type of loading. Specimens were manufactured using the reduced build …

Elevated Temperature Mechanical And Microstructural Characterization Of Slm Ss304l, G. R. Hecht, Sriram Praneeth Isanaka, Joseph William Newkirk

Materials Science and Engineering Faculty Research & Creative Works

SLM built SS304L was annealed and water quenched to minimize residual stress and avoid carbide precipitation. Mini-tensile characterization of strength and elongation at temperature conditions up to 800°C, along with observations of the associated microstructural transformations were utilized to understand the changes produced in SLM SS304L. As-built and annealed specimens were found to exhibit decreasing strength and elongation with increasing temperature as expected. Carbide precipitates appeared after short times at high temperatures within both as-built and annealed specimens for all cases, but no brittle intermetallic phase development was observed for any of the temperatures investigated. While the lack of Sigma, …

Development Of Experimental And Finite Element Models To Show Size Effects In The Forming Of Thin Sheet Metals, Jeffrey D. Morris

LSU New Orleans Theses and Dissertations

Abstract

An experimental method was developed that demonstrated the size effects in forming thin sheet metals, and a finite element model was developed to predict the effects demonstrated by the experiment. A universal testing machine (UTM) was used to form aluminum and copper of varying thicknesses (less than 1mm) into a hemispherical dome. A stereolithography additive manufacturing technology was used to fabricate the punch and die from a UV curing resin. There was agreement between the experimental and numerical models. The results showed that geometric size effects were significant for both materials, and these effects increased as the thickness of …

A Displacement Controlled Fatigue Test Method For Additively Manufactured Materials, Mohammad Masud Parvez, Yitao Chen, Sreekar Karnati, Connor Coward, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

A novel adaptive displacement-controlled test setup was developed for fatigue testing on mini specimens. In property characterization of additive manufacturing materials, mini specimens are preferred due to the specimen preparation, and manufacturing cost but mini specimens demonstrate higher fatigue strength than standard specimens due to the lower probability of material defects resulting in fatigue. In this study, a dual gauge section Krouse type mini specimen was designed to conduct fatigue tests on additively manufactured materials. The large surface area of the specimen with a constant stress distribution and increased control volume as the gauge section may capture all different types …

Stress Corrosion Cracking Resistance Of Cold-Sprayed Al 6061 Deposits Using A Newly Developed Test Fixture, Mala M. Sharma, Jeremy Schreiber, Timothy Eden, Victor Champagne

Faculty Journal Articles

The stress corrosion cracking (SCC) response of Al 6061 bulk deposits produced by high-pressure cold spray (HPCS) was investigated and compared to commercial wrought Al 6061-T6 material. Representative tensile coupons were stressed to 25%, 65% and 85% of their respective yield strength and exposed to ASTM B117 salt fog for 90 days. After exposure, the samples were mechanically tested to failure, and subsequently investigated for stress corrosion cracking via optical and scanning electron microscopy with energy-dispersive X-ray spectroscopy (EDS). The results were compared to the wrought Al 6061-T6 properties and correlated with the observed microstructures. Wrought samples showed the initiation …

Bioprinting With Human Stem Cell-Laden Alginate-Gelatin Bioink And Bioactive Glass For Tissue Engineering, Krishna C. R. Kolan, Julie A. Semon, Bradley Bromet, D. E. Day, Ming-Chuan Leu

Biological Sciences Faculty Research & Creative Works

Three-dimensional (3D) bioprinting technologies have shown great potential in the fabrication of 3D models for different human tissues. Stem cells are an attractive cell source in tissue engineering as they can be directed by material and environmental cues to differentiate into multiple cell types for tissue repair and regeneration. In this study, we investigate the viability of human adipose-derived mesenchymal stem cells (ASCs) in alginate-gelatin (Alg-Gel) hydrogel bioprinted with or without bioactive glass. Highly angiogenic borate bioactive glass (13-93B3) in 50 wt% is added to polycaprolactone (PCL) to fabricate scaffolds using a solvent-based extrusion 3D bioprinting technique. The fabricated scaffolds …

Nano Fab Lab 63, Brian K. Deemer, Josh Clemons, Nick Brodine, Delaney Fitzsimmons

Mechanical Engineering

Lawrence Livermore National Laboratories (LLNL) has several steps in the production process for ceramic nanofiber tubes that they would like to improve - electrospinning, cutting, rolling, sealing and heat treating. We undertook the challenge to deliver LLNL with a semi-automated process that efficiently integrates the steps of cutting, rolling, and sealing to save time and improve control over end dimensions. In this document, we discuss the technical background of the manufacturing steps currently followed to create nanofiber tubes, identify which steps are incorporated in our prototype and explain how they will interface with one another, define the design requirements, present …

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

Master's Theses

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

Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator

Materials Engineering

PCC Structurals, an industry leader in superalloy investment castings, has observed inconsistencies in the stress rupture performance of polycrystalline nickel-based superalloy PWA 1455. PCC has changed their casting parameters to reduce the thermal gradient during cooling but have been unable to correlate these changes with an increase in stress rupture elongation. Metallographic examination of past samples indicated microstructures composed of non- equiaxed dendritic grains with mean diameter of .021 inches along the test axis. A similar study on polycrystalline superalloys has indicated that excessive superheat temperatures above the liquidus can result in large grains identical to those observed, limiting the …

Design And Control Of Fiber Encapsulation Additive Manufacturing, Matt Saari

Mechanical Engineering Research Theses and Dissertations

This work presents the design, development, and analysis of the Fiber Encapsulation Additive Manufacturing (FEAM) system developed at the Laboratory for Additive Manufacturing Robotics \& Automation at the Lyle School of Engineering at Southern Methodist University. The innovation introduced by FEAM is the ability to insert a continuous fiber of different material into the flowing extrudate. Correctly positioning the fiber feed inside the extrudate while turning the fiber in arbitrary directions is a critical aspect of the technology. This will allow for the full exploitation of the capabilities of the FEAM technology to produce robotic components that actuate and sense. …

Development Of A Multi-Probe Kelvin Scanner Device For Industrially-Relevant Characterization Of Surface-Activated Carbon Fiber Reinforced Thermoplastic Composites, Kirby Simon

McKelvey School of Engineering Graduate Student Theses & Dissertations

Carbon fiber reinforced thermoplastic (CFRTP) composites are becoming increasingly attractive materials in manufacturing due to their lightweight nature, mechanical strength, and corrosion resistance. Surface activation of these materials is usually required during processing to increase the bond strength of assemblies (aerospace and automotive industries) or improve adhesion with implants (biomedical industry). Industrially-relevant, nondestructive quality control methods for assessing the activation state of these materials do not currently exist, however. Applying principles discovered through the use of scanning probe microscopy, a multiple-probe Kelvin scanning (MPKS) device has been developed that can assess the uniformity of the activation state of plasma-treated CFRTP …

A Study On Ultrasonic Energy Assisted Metal Processing : Its Correeltion With Microstructure And Properties, And Its Application To Additive Manufacturing., Anagh Deshpande

Electronic Theses and Dissertations

Additive manufacturing or 3d printing is the process of constructing a 3-dimensional object layer-by-layer. This additive approach to manufacturing has enabled fabrication of complex components directly from a computer model (or a CAD model). The process has now matured from its earlier version of being a rapid prototyping tool to a technology that can fabricate service-ready components. Development of low-cost polymer additive manufacturing printers enabled by open source Fused Deposition Modeling (FDM) printers and printers of other technologies like SLA and binder jetting has made polymer additive manufacturing accessible and affordable. But the metal additive manufacturing technologies are still expensive …