Manufacturing Commons^™

Detecting Non-Axisymmetric Instabilities In Fluid-Based Manufacturing Via Multi-View Tensor Analysis., Bidusi Khadka

Electronic Theses and Dissertations

Fluid-based manufacturing processes, such as inkjet printing and electrospinning, fabricate micro- and nano-scale structures with high precision, but are prone to complex fluid dynamics exhibiting axisymmetric and non-axisymmetric instabilities. Conventional monitoring often relies on single-camera inputs and symmetry assumptions, limiting the detection of three-dimensional anomalies like jet deflection. This study presents a novel multi-view streaming video-based anomaly detection framework to address this gap. The framework employs a modified Tensor Sequential Sampling (TSS) algorithm with edge-based sampling to capture geometric spatiotemporal features of each camera view using the videos obtained from an orthogonally positioned dual-camera setup. These features are fused with …

Material Extrusion 3d Printing Of Metal Alloy: Material, Methods And Application., Sihan Zhang

Electronic Theses and Dissertations

Material extrusion (MEX) additive manufacturing presents a promising pathway for producing metal components with complex geometries while avoiding the safety hazards associated with loose powder handling in conventional metal additive manufacturing processes. This dissertation investigates the development and optimization of MEX processes for aluminum alloys, addressing critical challenges in feedstock formulation, printing parameter optimization, and post-processing strategies. Three distinct approaches were explored to advance the capabilities of aluminum MEX: filament-based processing of 6061 aluminum, paste-based extrusion of 6061 aluminum, and development of a novel aluminum-magnesium-tin alloy system for space manufacturing applications. The filament-based approach successfully demonstrated the production of 6061 …

Greek Key-Inspired Fractal Metamaterials With Enhanced Flexibility And Energy Absorption., Zhennan Zhang

Electronic Theses and Dissertations

Architected materials with intricate three-dimensional (3D) geometries offer unique properties and functionalities but face challenges in manufacturing costs and complexity. This research explores the integration of simple 2D Greek Key-inspired lattices into fractal designs to achieve exceptional mechanical performance. Using 3D printing and kerfing, these fractal structures demonstrate enhanced flexibility and energy absorption capabilities. Through three-point bending and in-plane tensile tests, the 2D fractal lattices exhibited a 600-fold reduction in bending force and a tensile stretch capacity of up to 520%, significantly outperforming brittle parent materials. Out-of-plane compression tests revealed a five-fold increase in energy absorption compared to honeycomb structures, …

Modeling And Understanding Of Additive Manufacturing Periodic Cellular Structures With Heterogeneity: Property, Quality And Design Strategy., Naresh Koju

Electronic Theses and Dissertations

Lightweight cellular structures with their higher per mass performance capability, multifunctional designability and property tolerability are gaining much wider adaptation in many engineering applications ranging from aerospace, defense, biomedical, automotive to sports. However, to achieve the desired performance levels careful design must be carried out. The experimental-based empirical design often involves high manufacturing cost, and there are also certain information/knowledges about the cellular deigns that could not be easily obtained experimentally, such as the deformation local fracture initiation. Similarly, numerical modeling-based design approach commonly suffers from high computation cost and the lack of inverse designability. In addition, numerical models often …

Sensitive Grip Mounting Surfaces For Physical Human-Robot Interaction., Branden Shay

Electronic Theses and Dissertations

As the development of robotics becomes ever increasingly present in our society, the need for studying how humans and robots interact with each other becomes more of a necessity to be properly integrated in the changing world around us. In this thesis, we undertake the study and development of how to create a tactile human-robot operator interface to guide a robot perform a physical task. The implementation of tactile interfaces such as SkinCell sensor arrays emulating skin, and of a robotic handlebar fitted with tactile sensors are critical examples of the challenges that come with mounting and packaging such sensors …

Natural Fiber Reinforced Composites For Sustainable Additive Manufacturing., Athira Nair Surendran

Electronic Theses and Dissertations

Carbon fiber is widely known for its exceptional strength, making it a sought-after material in composite manufacturing, especially with thermosets and thermoplastics. Its major applications span aerospace, wind turbines, sports equipment, automotive interior and exterior parts, robotics and medical equipment. Recently, carbon fiber filament manufacturing has gained attention due to the availability of desktop 3D printers and the versatility and customizability that comes with the realm of 3D printing. Commercial carbon fiber production, primarily from polyacrylonitrile (PAN), is energy-intensive and derived from crude oil, contributing to significant environmental impacts and poor recyclability. Alternatively, lignocellulosic natural fibers present a possible sustainable …

Development And Processing Of Shape Memory Polymer Composites (Smpcs) For Application In Structural Robotics And Robotic Sensors., Kavish Sudan

Electronic Theses and Dissertations

Shape Memory Polymers (SMPs) have attracted significant attention since their introduction in the 1980s due to their remarkable ability to regain their original shape from a temporarily deformed state when exposed to an external stimulus, typically heat. This shape memory effect, driven by thermal transitions such as the glass transition temperature (T_g) or melting temperature (T_m), has made SMPs highly attractive for applications in soft robotics, aerospace, and biomedical devices. However, SMPs face challenges such as limited mechanical strength, thermal stability, and electrical conductivity, which hinder their broader adoption in advanced applications. To address these challenges, …

Synergistic Strategies In Hybrid Mxed Matrix 3d Printing Of Thermoplastics & Thermosets: Design, Manufacturing, And Materials Development., Saleh Akram Khanjar

Electronic Theses and Dissertations

Composite manufacturing and mixed matrix structures have been produced using traditional manufacturing processes for various industrial applications due to their high mechanical properties to material weight and cost ratio. However implementation of composite and mixed matrix manufacturing with advanced manufacturing such as additive manufacturing is limited due to the hardware limitations of current 3d printing technologies and materials available for 3D printing applications. This work has developed and investigated a new hybrid 3D printing manufacturing process utilizing a variety of material systems (thermoplastic – thermoset, thermoplastic – thermoplastic, thermoset – thermoset, thermoplastic – thermoplastic – thermoset). This study developed thermoplastic …

Development, 3d Printing, And Sintering Of Aluminum-Magnesium Alloy Pastes For In-Space Manufacturing Applications, Fatou Ndiaye

Electronic Theses and Dissertations

This study explores the additive manufacturing process of paste printing, sintering, and de-binding for fabricating aluminum-magnesium alloy components. The paste formulation involved combining aluminum powder with varying magnesium concentrations, utilizing acrylic polyol, solvent, and plasticizer to create a homogeneous mixture. Printing parameters were optimized to ensure continuous pressure for improved extrusion. Sintering conditions involved incremental temperature increases with nitrogen flow to remove solvents. Density measurements, tensile tests, and shrinkage calculations were conducted to assess part quality post-sintering. The study revealed significant improvements in part quality with 5 wt.% magnesium incorporation within aluminum, although density and tensile strength fell short of …

Synergistic Strategies In Sinter-Based Material Extrusion (Mex) 3d Printing Of Copper: Process Development, Product Design, Predictive Maps And Models., Kameswara Pavan Kumar Ajjarapu

Electronic Theses and Dissertations

3D printing pure copper with high electrical conductivity and exceptional density has long been challenging. While laser-based additive manufacturing technologies suffered due to copper's highly reflective nature towards laser beams, parts printed via binder-assisted technologies failed to reach over 90% IACS (International Annealed Copper Standard), electrical conductivity. Although promising techniques such as binder jetting, filament, and pellet-based 3D printing that can print copper exist, they however still face difficulties in achieving both high sintered densities and electrical conductivity values. This is due to a lack of comprehensive understanding of property evolution from green to sintered states and the strategies that …

Fatigue And Fracture Of Electron Beam Melting Ti-6al-4v, William A. Grell

Electronic Theses and Dissertations

For applications in the aerospace field, selection of materials for a given design requires an understanding of critical properties, like fatigue and fracture, in addition to static mechanical and physical properties. With the ongoing advancements in metallic additive manufacturing techniques and the interest in applying the process to aerospace applications, there is a clear need to fully characterize properties. Arguably, the most attractive alloy for applications in aerospace is the Ti-6Al-4V alloy. The current dissertation examines the mechanical properties of the alloy, made by the Electron Beam Melting (EBM) Powder Bed Fusion (PBF) method. As illustrated in this work, the …

Engineering 3d Architected Metamaterials For Enhanced Mechanical Properties And Functionalities., Huan Jiang

Electronic Theses and Dissertations

Compared with conventional materials, architected metamaterials have shown unprecedented mechanical properties and functionalities applications. Featured with controlled introduction of porosity and different composition, architected metamaterials have demonstrated unprecedent properties not found in natural materials. Such design strategies enable researchers to tailor materials and structures with multifunctionalies and satisfy conflicting design requirements, such as high stiffness and toughness; high strength with vibration mitigation properties, etc. Furthermore, with the booming advancement of 3D printing technologies, architected materials with precisely defined complex topologies can be fabricated effortlessly, which in turn promotes the research significantly. The research objectives of this dissertation are to achieve …

Mechanical Properties Evaluation Of 3d Printed Petg And Pctg Polymers, Kalpesh Krishnarao Bhosale

Electronic Theses and Dissertations

3D printing is also known as additive manufacturing (AM) which has become a popular manufacturing trend over the years. Due to its unique advantages of fast production rate, ability to create complex geometrical features, toolless manufacturing and many more attracts various industries from Aerospace to general cosmetics. Along with the advancement in material science, various polymers including Polylactic Acid (PLA), Polyethylene terephthalate glycol (PETG) and many more are available for 3D printing. Due to the wide range of applications in PLA, it is necessary to improve its toughness to make it more suitable by adding Poly Cyclohexylenedimethylene Terephthalate glycol (PCTG) …

Additive Manufacturing Of Aluminum Alloy By Metal Fused Filament Fabrication (Mf3)., Luke J. Malone

Electronic Theses and Dissertations

This research studies metal-fused filament fabrication (MF3) for manufacturing aluminum alloy parts. An aluminum alloy powder-based feedstock with a polymer-binder system was extruded via capillary rheometry to form a filament. The filament was used to print green parts that were involved in a two-step debinding process combining solvent and thermal extraction of the polymer binder, then sintered in a partial vacuum. Resulting grain structure, sintered density, and mechanical properties will be characterized and compared to metal injection molded (MIM) specimens. The main objective is to gain an understanding of the MF3 process characteristics and the ensuing material properties and microstructure …

Properties Of 25cr7ni Stainless Steel Fabricated Through Laser-Powder Bed Fusion., Arulselvan Arumugham Akilan

Electronic Theses and Dissertations

Stainless steel is a low carbon high alloyed system with higher concentrations of Cr& Ni, which impart high corrosion resistance to them. Alloys with approximately 25% Cr & 7% Ni in their chemical composition are commercially referred to as ‘Super Duplex Stainless Steel’. They have a unique phase composition of approximately 50% ferrite & 50% austenite, yielding a robust combination of high mechanical strength & corrosion resistance. They find extensive interest & application in the fields which demand a longer service life under intense mechanical / corrosive environment such as offshore oil rigs & pipelines in nuclear power plants. Traditional …

Effects Of Sizing Agents On Mechanical Properties Of Carbon Fiber–Polymer Composites Via Fused Filament Fabrication Additive Manufacturing., Benjamin D. Mitchell

Electronic Theses and Dissertations

This study demonstrated the effects of changing the sizing agent parameter during the preparation of carbon fibers on the mechanical properties of composite made with acrylonitrile butadiene styrene (ABS) as the matrix material and carbon fibers as the fiber material. Three types of sizing agents produced by Allnex were used to coat three different batches of carbon fibers that were mixed with a torque rheometer and extruded with a barrel-style melt extruder into continuous spools of 1.75 mm filament for use with commercial 3D printers. Tensile tests were conducted on the filaments and tensile bars printed from the materials. Results …

Digital Design And Thermomechanical Process Simulation For 3d Printing With Abs And Soyhull Fibers Reinforced Abs Composites., Saleh Khanjar

Electronic Theses and Dissertations

Recent demonstrations with fused filament fabrication (FFF) 3D printing have shown to produce prototypes as well as production components. Additionally, due to the FFF process platforms being low-cost and readily available there has been a high-demand to produce on-demand parts for various applications in automotive, in-space manufacturing and electronic industries. However, current limitations such as limited availability of advanced composites materials, and guidelines for design-for-manufacturing make the process prone to trial-and-error experiments both at the materials development, product design and manufacturing stage. In this work, new thermomechanical process simulations platform, Digimat-AM has been evaluated to address and demonstrate digital design …

Materials And Process Design For Ceramic Fused Filament Fabrication (Cf3) Of Hydroxyapatite., Kavish Sudan

Electronic Theses and Dissertations

Ceramic fused filament fabrication (CF3) enables the fabrication of highly customizable ceramic parts at relatively lower costs compared to other AM technologies. Advanced ceramics, having specific or niche applications, call for a high level of accuracy to meet the performance requirements. For achieving the desired level of accuracy in any manufacturing process, it is important to know the effect of involved parameters at different stages of fabrication. CF3 has been around for a while but there has been a severe lack of literature dealing with understanding the effect of process parameters on the final part properties. In this study, Hydroxyapatite …

Additive Manufacturing Using Robotic Manipulators, Fdm, And Aerosol Jet Printers., Alexander Curry

Electronic Theses and Dissertations

Additive manufacturing has created countless new opportunities for fabrication of devices in the past few years. Advances in additive manufacturing continue to change the way that many devices are fabricated by simplifying processes and often lowering cost. Fused deposition modeling (FDM) is the most common form of 3D printing. It is a well-developed process that can print various plastic materials into three-dimensional structures. This technology is used in a lot of industries for rapid prototyping and sometimes small batch manufacturing. It is very inexpensive, and a prototype can be created in a few hours, rather than days. This is useful …

An Investigation Into Energy-Material Properties Interaction In Additive Manufacturing Of Polymers., Pu Han

Electronic Theses and Dissertations

Additive manufacturing (AM), known as three-dimensional (3D) printing, is a fabrication process to build 3D objects layer by layer based on computer aided design (CAD) model or digital 3D model. Fused filament fabrication (FFF) has become a preferred method for additive manufacturing due to its cost-effectiveness and flexibility. However, the parts built using FFF process suffer from lower mechanical strength compared to that fabricated using traditional method and rough surface finish. With this motivation, this dissertation aims to develop and implement a novel in-process laser assisted technique on FFF to heal the microstructure of FFF built objects by enhancing reptation …

Rapid Annealing Of Perovskite Solar Cell Thin Film Materials Through Intense Pulse Light., Amir Hossein Ghahremani

Electronic Theses and Dissertations

Perovskite solar cells (PSCs) have garnered a great attention due to their rapid efficiency improvement using cheap and solution processable materials that can be adapted for scalable high-speed automated manufacturing. Thin film perovskite photovoltaics (PVs) are typically fabricated in an inert environment, such as nitrogen glovebox, through a set of deposition and annealing steps, each playing a significant role on the power conversion efficiency (PCE), reproducibility, and stability of devices. However, atmospheric processing of PSCs would achieve lucrative commercialization. Therefore, it is necessary to utilize materials and methods that enable successful fabrication of efficient PSCs in the ambient environment. The …

Design For Metal Fused Filament Fabrication (Dfmf3) Of Ti-6al-4v Alloy., Mohammad Qasim Shaikh

Electronic Theses and Dissertations

Additive manufacturing (AM) offers unmatchable freedom of design with the ability to manufacture parts from a wide range of materials. The technology of producing three-dimensional parts by adding material layer-by-layer has become relevant in several areas for numerous industries not only for building visual and functional prototypes but also for small and medium series production. Among others, while metal AM technologies have been established as production method, their adoption has been limited by expensive equipment, anisotropy in part properties and safety concerns related to working with loose reactive metal powder. To address this challenge, the dissertation aims at developing the …

Modeling And Analysis For Unit Cell Size, Material Anisotropy And Material Imperfection Effects Of Cellular Structures Fabricated By Powder Bed Fusion Additive Manufacturing., Yan Wu

Electronic Theses and Dissertations

Cellular structures are networks of interconnected struts or walls with porosities and are widely found in many natural load-bearing structures such as plants and bones. Cellular structures offer unique functional characteristics such as high stiffness to weight ratio, tailorable heat transfer coefficient, and enhanced mechanical energy absorption, which makes them highly attractive in various engineering disciplines such as biomedical implants, electrodes, heat exchangers, and lightweight structures. There exists an abundance of literatures that have investigated various mechanical properties of various cellular structures such as Poisson’s ratio, elastic modulus, ultimate strength, yield strength, and failure characteristics. Based on the classic cellular …

Dynamic Analysis And Fabrication Of A Bi-Stable Structure Designed For Mems Energy Harvesting Applications., Masoud Derakhshani

Electronic Theses and Dissertations

Thanks to the rapid growth in demand for power in remote locations, scientists’ attention has been drawn to vibration energy harvesting as an alternative to batteries. Over the past ten years, the energy harvesting community has focused on bistable structures as a means of broadening the working frequency range and, by extension, the effective efficiency of vibration-based power scavenging systems. In the current study, a new method is implemented to statically and dynamically analyze a bistable buckled, multi-component coupled structure designed specifically for low-frequency vibration energy harvesting systems in both macro and MEMS-scale sizes. Furthermore, several micro-fabrication steps using advanced …

Experimental And Numerical Study Of Process Parameters Effects Towards Part Quality And Porosity During Powder Bed Additive Manufacturing Processes., Subin Shrestha

Electronic Theses and Dissertations

Powder bed additive manufacturing (PB-AM) process utilizes an electron beam or a laser as a heat source to melt the metallic powder particles. These processes have the capability of freeform fabrication, however certain defects such as porosity, high surface roughness, etc. would hinder its application. It is important to understand the effect of the process parameters and the underlying physical phenomena, which lead to the formation of such defects. In this regard, a three-dimensional (3D) thermo-fluid model is developed to study the effect of beam speed on the surface morphology during powder bed electron beam additive fabrication (PB-EBAF). Besides, the …

Impact Of Magnetocaloric Material Properties On Performance Of A Magnetocaloric Heat Pump., Michael G. Schroeder

Electronic Theses and Dissertations

In the field of magnetocaloric heat pumps much research has been performed around machine design and theoretical machines, but little has been researched around practical problems such as variability in material properties. The present work defines a simulation tool that has been proven with experimental data. Magnetocaloric material cascades were statistically analyzed and parameterized, such that they could be recreated parametrically using a split Lorentz function with normally distributed parameters. Correlated curve-defining values with standard deviations were used as input into the simulation tool to determine the effect of variation on cooling heat pump performance for a household refrigerator application. …

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, …

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 …

Experimental Investigation Of The Manufacture Of Tunable Graphene Oxide Filter Membranes Using Intense Pulse Light, Joshua H Kotter

Electronic Theses and Dissertations

Reduced graphene oxide is a thin, strong, and inexpensive material with a channel and pore structure that make it a promising candidate for a filtration material. Reduced graphene oxide has been produced and tested in the laboratory, but a lack of scalable manufacturing techniques have limited its commercial use.

This thesis has shown that graphene oxide can be rapidly manufactured with an industrially scalable flash reduction process. The flash reduction process uses 0.58 millisecond pulses from a xenon lamp to reduce the graphene oxide film in less than a minute. Results for partially reduced graphene oxide membranes tuned by the …