Manufacturing Commons^™

Multidisciplinary Inverse Robust Co-Design Of Materials, Products, And Manufacturing Processes, H M Dilshad Alam Digonta

Theses and Dissertations

Realizing the design for Integrated Computational Materials Engineering (ICME) requires the materials, product, and manufacturing-process disciplines to be designed together. Because these disciplines interact and influence one another's decisions, coordination is needed among their distributed decision-makers. Their interactions are captured through the processing-structure-property-performance (PSPP) linkages, which must be established from limited, costly data. Moreover, each discipline introduces its own sources of uncertainty, and these propagate through the process chain to influence final product performance. The effective realization of the product-material-manufacturing system, therefore, calls for a co-design approach that enables the concurrent coordination of the interacting disciplines while quantifying and managing …

The Effect Of Mwcnt-Oil Impregnation Of Sintered Components On Their Wear And Corrosion Resistance, Maha Khaled Abdelfadeel

Theses and Dissertations

Powder Metallurgy (PM) offers an advantageous route for manufacturing complex and near net-shape components. Their inherent interconnected porosity that promotes the action of self lubrication compromises their structural integrity by creating pathways for corrosion and excessive wear. This research investigates the efficacy of Multi-Walled Carbon Nanotubes (MWCNTs) as a nano additive within the impregnating base oil (SN-150 base oil). An experimental matrix was designed to evaluate the influence of MWCNTs with different concentrations of 0.05, 0.1, and 0.2 wt.% and ultrasonic dispersion with varying sonication times of 30 and 60 minutes on the tribological and electrochemical performance of sintered steel …

Harnessing Ml And Iiot For Traceability In Continuous Production Systems: A Conceptual Framework, Kholoud M. Abdelaal

Theses and Dissertations

In the era of rapid technological advancement, the manufacturing sector faces increasing pressure to leverage emerging technologies to enhance operational efficiency and minimize waste. In this context, traceability plays a pivotal role, as it provides complete visibility of processes and products throughout manufacturing systems, enabling them to identify areas for improvement and take corrective actions accordingly. Additionally, traceability ensures compliance, supports product recalls, provides a clear understanding of the system’s performance, and enables fact-driven decision-making in multiple aspects of the manufacturing system. Although the broad spectrum of traceability applications in batch production-based plants, traceability remains challenging to achieve in continuous …

Fused Filament Fabrication Additive Manufacturing Of 17-4 Ph Stainless Steel: Process–Structure–Property Relationships In Magnetic Materials, Maanav Patel

Theses and Dissertations

Additive manufacturing (AM) enables the fabrication of complex metallic components through layer-by-layer processing directly from digital models. Among AM techniques, material extrusion–based processes such as fused filament fabrication (FFF) provide an accessible method for producing metal parts using filament feedstocks composed of metal powders and polymer binders. When applied to precipitation-hardening stainless steels such as 17-4 PH, the processing route and heat treatments can influence the resulting microstructure and functional properties. This work investigates the magnetic behavior of 17-4 PH stainless steel fabricated using FFF and evaluates how heat treatment conditions influence measured magnetic properties. Samples were produced and analyzed …

Experimental Characterisation Of Laser Cladding Of Crniw And Crnifealzr Powders On H13 Tool Steel And Optimisation Of Process Parameters, Martin Vinoth S

Theses and Dissertations

In this work, laser cladding on H13 steel substrate with two different powder compositions CrNiW and CrNiFeAlZr has been carried out. The laser power, powder feed rate, and scanning speed were varied and the clad dimensions, aspect ratio, and dilution percentage were measured. The microhardness found in the CrNiW clad is 834 ± 20 HV0.5, which is higher than that of the CrNiFeAlZr clad (780 ± 20 HV0.5) as well as the substrate (548 ± 20 HV0.5).

The X-ray Diffraction (XRD) patterns identified the common phase creation of Ni3C and Fe3C for CrNiFeAlZr and CrNiW coatings, while the oxide formation …

Experimental And Theoretical Fracture Analysis Of Additively Manufactured Orthotropic V-Notches, Venkata Siva Sainath Bavapuram

Theses and Dissertations

This study presents a comprehensive investigation into the fracture behavior of additively manufactured orthotropic V-notched components made of Acrylonitrile Butadiene Styrene (ABS) material. The research integrates both theoretical and finite element approaches to evaluate stress intensity factors (SIFs) in Modes-I and II, which are fundamental in characterizing stress field distributions around notches under applied loading conditions. Unlike isotropic materials, where stress fields depend only on geometry of the component, the anisotropic nature of 3D-printed ABS introduces a dependency on material properties that necessitate different approaches to include anisotropy of the material.

Tensile specimens are 3D-printed with specific material orientations to …

The Prototype Of A Fully Automated Pressuremeter For Various Geotechnical Applications, Anuar Akchurin

Theses and Dissertations

The geotechnical engineering field requires high-quality in-situ testing equipment that ensures consistency in the test execution. This research focuses on developing and testing a prototype of a fully automated pressuremeter control unit to allow the industry to obtain reliable and controlled stress-strain data, thereby improving efficiency and reducing testing time.

The objectives of this work are to design and develop a system with the necessary components to perform the pressuremeter test, integrate the testing procedure into the state machine design, enable automated testing, and validate the results by comparing the stress-strain data with that obtained from the existing hand-operated pressuremeter …

Co-Designing Manufacturing Systems For Robustness And Resilience: A Decision-Based Design Perspective, Mathew Baby

Theses and Dissertations

Manufacturing systems (MSs) comprise various stakeholders associated with the manufacture and supply of products required by customers and are interrelated by the flow of materials and information. The interrelated stakeholders make system-specific decisions and stakeholder-specific decisions across multiple levels of a decision hierarchy to satisfy many conflicting system-specific and stakeholder-specific requirements that define system and stakeholder performances. Given the stakeholder interrelations and conflicting nature of system-specific and stakeholder-specific requirements, system and stakeholder performances are correlated and conflicting.

In the Industry 5.0 era, there is an increased emphasis on the creation and equitable distribution of value among all the stakeholders in …

Autonomous Defect Detection In Additive Manufacturing, John Samuel Poindexter Iv

Theses and Dissertations

Additive manufacturing (AM) is the process of creating a product by applying layers of material to build up to the final product. AM has revolutionized the field of manufacturing and has allowed more complex products to be manufactured at reasonable cost, quicker manufacturing time, and optimized material usage. Traditional forms of manufacturing were based on subtractive manufacturing, where by a product would be created by removing material from its source. AM is a new manufacturing process and faces significant challenges when it comes to manufacturing due to defects. Defects can vary from type and severity and can overall weaken or …

Improvement Of Microcracking And Mechanical Properties Of Tungsten Fabricated Via Laser Powder Bed Fusion Through Alloying With Reactive Secondary Constituents, William S. Mockel

Theses and Dissertations

Tungsten (W), a Group VI transition metal, possesses a number of advantageous properties, most notably its impressive mechanical performance at extreme temperatures. While tungsten's nature render traditional manufacturing methods difficult, additive manufacturing through laser powder bed fusion (LPBF) presents a promising avenue for fabricating tungsten components. However, the material’s high ductile-to-brittle transition temperature combined with the embrittling effect of impurities mean that the residual stresses imparted by LPBF result in microcracking in tungsten, degrading its usefulness. This study sought to improve the characteristics of LPBF-W through the removal of embrittling oxygen content via alloying with low concentrations of reactive elements, …

Fabrication And Performance Of Scalable Bio-Engineered Porous Layers For Efficient Co2 Capture, Mary Sharon Rose Bondugula

Theses and Dissertations

This dissertation addresses the critical challenge of mitigating climate change by advancing CO2 capture technologies. As global CO2 emissions continue to rise, effective methods for capturing and separating CO2 from industrial processes are essential to combat climate change. Existing CO2 capture systems, such as Pressure Swing Adsorption (PSA) and Temperature Swing Adsorption (TSA), often rely on packed bed designs that face limitations, including poor heat and mass transfer, slow gas diffusion, and low thermal conductivity, reducing their efficiency. To overcome these challenges, this dissertation explores innovative solutions by developing advanced adsorbent coatings and scalable bed configurations.

This research begins by …

Shape Memory Alloy Capsule Micropump For Drug Delivery Applications, Youssef Mohamed Kotb

Theses and Dissertations

Implantable drug delivery devices have many benefits over traditional drug administration techniques and have attracted a lot of attention in recent years. By delivering the medication directly to the tissue, they enable the use of larger localized concentrations, enhancing the efficacy of the treatment. Passive-release drug delivery systems, one of the various ways to provide medication, are great inventions. However, they cannot dispense the medication on demand since they are nonprogrammable. Therefore, active actuators are more advantageous in delivery applications. Smart material actuators, however, have greatly increased in popularity for manufacturing wearable and implantable micropumps due to their high energy …

Synthesis Of Durable Zeolite 13x Insertion Coatings And Scaled-Up Experimental Demonstration For Co2 Capture, Daniel Jamil Hocheimy

Theses and Dissertations

Minimizing the energy requirement for capturing carbon dioxide (CO₂) from post-combustion sources is critical to efficient industrial decarbonization and subsequent mitigation of the effects of climate change. The current portfolio of CO₂ capture technologies includes absorption, membrane separation and packed bed adsorption, which suffer from high energy and temperature requirements, scalability, and location dependency issues. Adsorption-based systems could cater to these concerns; however, their current embodiments primarily use packed adsorbent bed design and electricity-driven vacuum pumps to regenerate them. While simple and easy to fabricate, these designs are not scalable and cannot use heat to regenerate them …

Shape Inverse Prediction Of Magnetic Field-Actuated Soft Robots By Neural Network Machine Learning, Lineth J. Perez Monsalve

Theses and Dissertations

Soft robotics has drawn tremendous interest in recent years because the compliance and motion of soft robotics enable biocompatibility and versatility for many applications, such as human-machine interaction, wearable and assistive devices, and health monitoring. This study introduces a novel predictive modeling approach using neural networks for shape control of magnetic soft robots. The robots are made of silicone materials embedded with hard magnetic particles, which respond to the external magnetic field provided by a ring-type of permanent magnet. These robots, free from physical connections to external devices, i.e., non-tethered actuation, hold significant potential for applications in healthcare, such as …

Towards The Automation Of Post-Processing Of Additive Manufacturing Using Collaborative Robots, Logan Schorr

Theses and Dissertations

Despite the incredible potential that collaborative robots have, they are underutilized in several industries that could benefit greatly. These specialized fields, such as additive manufacturing, face challenges that can be solved with the use of robotics, including advanced computer vision, end-effector tooling, and process refinement. My research aims to utilize collaborative robots in an effort to solve the above stated problems, for the specific fields of additive manufacturing. Specifically within this field is the automation of post-processing; this is normally completely manual, as the tools for automation are not sufficiently developed to handle the flexibility required for additive manufacturing. This …

Fabrication & Characterization Of Hybrid Piezoelectric/Triboelectric Nanocomposite Nanogenerators Via Fusion Deposition Modeling, Khaled El Toukhy

Theses and Dissertations

This thesis aims to discuss the potential of using piezoelectric and triboelectric nanogenerators (PTENGs) for energy harvesting, particularly in the sportswear industry. PTENG's main advantage is that it offers good flexibility making it suitable for high-strain applications. The piezoelectric effect is induced by embedding piezoelectric nanofillers into one of the two triboelectric layers. PTENGs can generate both piezoelectric and triboelectric signals when strained resulting in an enhanced output compared to regular piezoelectric nanogenerators (PENGs) and triboelectric nanogenerators (TENGs). TPU was adopted as the matrix for PTENGs advantageous due to their flexibility, low electrical resistivity, and compatibility with additive manufacturing techniques. …

Mechanical Characterization Of Functionally Graded M300 Maraging Steel Cellular Structures, Bradley Jay Sampson

Theses and Dissertations

Traditional methods for increasing the energy absorption of a structure involve using a stronger material or increasing the volume of the structure, resulting in a higher cost or additional weight. Additive manufacturing (AM) can be used to maximize the energy absorption of materials with the ability to create complex geometries such as cellular structures. Previous work has shown that the energy absorption of additively manufactured parts can be improved through functionally graded cellular structures; however, this strategy has not been applied to ultra-high strength steel materials. This work characterizes the effect of multiple functional-grading strategies (e.g. uniform, rod-graded, size-graded) on …

Laser Assisted Direct Writing Of Liquid Metal For Microprinting Applications, Olga Vargas Cruz

Theses and Dissertations

This paper presents a research study for potential printing of a Liquid Metal (LM) Eutectic Gallium Indium alloy (EGaIn) through the applications of the innovative additive manufacturing technology LIFT (Laser Induced Forward Transfer). LIFT is a precise printing technology that allows to create small, detailed printing. The liquid metal in study, EGaIn, has demonstrated great potential for microelectronics applications due to its minimum toxicity and high conductivity. Throughout this research different printing parameters are studied to comprehend the behavior of EGaIn printing with LIFT technique, these include laser energy, laser pulse, receiver material substrate, donor layer thickness, and …

Analyzing The Effects Of Ultrafast Laser Processing On Mechanical Properties Of 3d-Printed Pla Parts, Darshan Pramodbhai Yadav

Theses and Dissertations

Recent advances in additive manufacturing technologies have already led to wide-scale adoption of 3D-printed parts in various industries. The expansion in choice of materials that can be processed, particularly using Fused Deposition Modeling (FDM), and the steady advancements in dimensional accuracy control have extended the range of applications far beyond rapid prototyping. However, additive manufacturing still has considerable limitations compared to traditional and subtractive manufacturing processes. This work addresses limitations associated with the as-deposited surface roughness of 3D-printed parts. The effects of roughness-induced stress concentrations were studied on ultimate tensile strength and fatigue life. The samples were manufactured using a …

Investigation On Mechanical, Tribological And Corrosion Resistance Properties Of Nano Sized Tio2/ Corrosion Resistance Properties Of Nano Sized Tio2/ B4c / Graphene Reinforced Aa 7075 Surface Composites B4c / Graphene Reinforced Aa 7075 Surface Composites Fabricated By Frictional Stir Processing Fabricated By Frictional Stir Processing, Majed Mohammed Hotami

Theses and Dissertations

Today, significant research efforts in the field of manufacturing engineering are focused on developing new lightweight, fuel-efficient and high-performance materials. The evolution of composite materials and related technologies has brought great advantages to material development throughout history. Composites are versatile materials with unique mechanical and physical properties tailored to specific application needs. Composites allow engineers to make design choices that traditional monolithic (unreinforced) materials cannot offer. Particle Reinforced Metal Matrix Composites (MMCs) offer a variety of advantages, including increased stiffness, improved fatigue resistance, increased wear resistance, and a low coefficient of thermal expansion. Aluminum MMC (AMMC) material systems outperform monolithic …

Developing Control System For Manufacturing Processes, Md Shahriar Forhad

Theses and Dissertations

Process control has been a critical component in today's manufacturing industry. Industrialists nowadays want reliable control to assure precision manufacturing. Modern control systems must be more dynamic, so that any needed modifications may be made quickly to accomplish the desired product change. For innovative research and development, system customization is critical to ensure freedom for experimental works. In addition, full control of manufacturing systems is necessary to realize and implement Industry 4.0. Often, it is difficult to achieve such control due to limited access to proprietary equipment. To this end, this thesis focuses on developing a custom control platform for …

Image Segmentation With Human-In-The-Loop In Automated De-Caking Process For Powder Bed Additive Manufacturing, Vincent Opare Addo Asare-Manu

Theses and Dissertations

Additive manufacturing (AM) becomes a critical technology that increases the speed and flexibility of production and reduces the lead time for high-mix, low-volume manufacturing. One of the major bottlenecks in further increasing its productivity lies around its post-processing procedures. This work focuses on tackling a critical and inevitable step in powder-bed additive manufacturing processes, i.e., powder cleaning or de-caking. Pressing concerns can be raised with human involvement when performing this task manually. Therefore, a robot-driven automatic powder cleaning system could be an alternative to reducing time consumption and increasing safety for AM operators. However, since the color and surface texture …

Additive Manufacturing Of Stretchable Strain Sensors: Fabrication, Optimization And Application, John Nady Shihat Bastawrous

Theses and Dissertations

In this project, a novel strain sensor design is fabricated employing different additive manufacturing techniques. The spring sensor's primary material is PLA-Like resin with a nanocomposite encapsulation layer as the functional material. The main principle of Straining the sensors results in a change in resistivity as the distances among the conductive carbon particles change according to the strain applied.

Sensor fabrication consists of two parts: spring manufacturing and development of nanocomposite encapsulation The nanocomposite matrix is developed through the dispersion of Graphene and Carbon nanotubes in Thermoplastic Polyurethane through sonication and magnetic hotplate stirring. While the spring itself is manufactured …

Developing Executable Digital Models With Model-Based Systems Engineering – An Unmanned Aerial Vehicle Surveillance Scenario Example, Viviana Guadalupe Lopez

Theses and Dissertations

There is an increase in complexity in modern systems that causes inconsistencies in the iterative exchange loops of the system design process and in turn, demands greater quality of system organization and optimization techniques. A recent transition from document-centric systems engineering to Model-Based Systems Engineering (MBSE) is being documented in literature from various industries to address these issues. This study aims to investigate how MBSE can be used as a starting point in developing digital twins (DT). Specifically, the adoption of MBSE for realizing DT has been investigated, resulting in various literature reviews that indicate the most prevalent methodologies and …

Material Property Dependence Of Nanoparticle Silicon Carbide Alloying In Additively Manufactured Molybdenum, Andrew P. Mason

Theses and Dissertations

The structural performance of additively manufactured Mo printed by LPBF can be significantly improved by nanoparticle alloying. Previous AFIT studies of SiC nanoparticle addition conducted by Ellsworth (2022) et al. demonstrated increased powder consolidation, leading to reduced porosity, increased microhardness, and a shift in atomic defect concentrations. The addition of defected SiC particles is proposed to reduce in situ oxidation by acting as a sacrificial oxidizing agent and contributing to the formation of Mo disilicide secondary phases. This study investigated the relationship between laser powder bed fusion Mo microscale and nanoscale properties with varying SiC particle size while maintaining a …

Development Of Novel Turbomachinery Manufacturing Methods, Timothy P. Winkler

Theses and Dissertations

Compact turbine engines are of increasing interest as a means of propulsion for small, lightweight, low cost, unmanned aerial systems. This study looks to leverage advancements in novel manufacturing technology to produce turbomachinery components while simultaneously reducing costs and manufacturing time. To determine the feasibility of drop-in replacements for stock components this study focused on several research areas. This included materials research on both polymer-reinforced and ceramic materials, specimen tensile testing to determine temperature-dependent material properties, finite element analysis of multiple candidate materials, design and fabrication of a spin test rig, and physical spin testing of manufactured components to predict …

Material Extrusion-Based Additive Manufacturing: G-Code And Firmware Attacks And Defense Frameworks, Haris Rais

Theses and Dissertations

Additive Manufacturing (AM) refers to a group of manufacturing processes that create physical objects by sequentially depositing thin layers. AM enables highly customized production with minimal material wastage, rapid and inexpensive prototyping, and the production of complex assemblies as single parts in smaller production facilities. These features make AM an essential component of Industry 4.0 or Smart Manufacturing. It is now used to print functional components for aircraft, rocket engines, automobiles, medical implants, and more. However, the increased popularity of AM also raises concerns about cybersecurity. Researchers have demonstrated strength degradation attacks on printed objects by injecting cavities in the …

The Deflection And Heat Transfer Analysis Of Injection Mold Cavity With Sla Cooling Channel Insert, Olumide Temidayo Aladesiun

Theses and Dissertations

Fast cooling in injection molding is the critical in the process economy. Among many different cooling channel designs available, conformal cooling offers the best and the most efficient cooling. However, limited awareness, accessibility, complexity, cost, knowledge, and experience limit the use of conformal cooling channels to be used into the mold in a molding process.

Typically, SLM(Selective Laser Melting) method is used to create cavity inserts with conformal cooling channels, however, due to the difficulties listed above, applications of conformal cooling channels are very limited. For an inexpensive alternative SLA (Stereolithography Apparatus) can print cavity inserts with conformal cooling channels. …

Fabrication Of Solar Absorber Tube With Internal Fin Structure With In718 And Effect Of Boron With In718 For Solar Absorber Tube Using Selective Laser Melting 3d Printing Technology, Naznin Nuria Afrin

Theses and Dissertations

This research aimed to fabricate Solar Absorber Tubes for Solar-Thermal Power Plant with internal fin structures using Selective Laser Melting (SLM) technology. In this study, we investigated the effect of B with IN718 in 3D printing using SLM for solar absorber tubes. The objective was to study the material-process-properties relationship with goal to identify and validate the optimal parameters for the SLM process. Material selected for this study was IN718 with 0.5% and 1% B particle mixed using a V-shape mixing machine. The flowability test was conducted using the Angle of Repose (AOR) method. 3D printed samples …

A Numerical Simulation Of The Powder Bed Additive Manufacturing Process With Molecular Dynamics Simulation, Yeasir Mohammad Akib

Theses and Dissertations

Many manufacturing industries utilize powder bed fusion (PBF) since it can produce microscale precision 3D parts. During PBF, powder particles are selectively fused layer by layer using thermal energy. The build quality in the PBF process relies heavily on powder bed properties and thermal energy deposition. Powder flowability, spreadability, and packing fraction are some of the insightful factors that determine the quality of the powder bed. In this study, a two-dimensional powder bed is developed using the LAMMPS package. A cloud-based pouring of powders with varying volumes and initialization is adopted for the work. A blade-type and circular recoater is …