Manufacturing Commons^™

Advances In Cellulose Nanomaterial-Based Foams For Environmental Applications, Md Musfiqur Rahman

Electronic Theses and Dissertations

The use of metal-oxide nanoparticles adsorbents is limited to fixed-bed columns in industrial-scale water treatment applications. This limitation is commonly attributed to the tendency of nanoparticles to aggregate, the use of non-sustainable and inefficient polymeric resins as supporting materials, or a lack of adsorption capacity. Foams and aerogels derived from cellulose nanomaterials have unique characteristics, such as high porosity and low density, which enables their use in a variety of environmental applications, including water treatment. However, the overall use of cellulose nanomaterial-based foams in various environmental sectors is limited due to the high cost of production associated with time- and …

Investigating The Effect Of Bead Geometry On Fiber Orientation And Thermomechanical Properties For Large-Format Extrusion-Based Additive Manufacturing, Joanna F. Keaton

Electronic Theses and Dissertations

In large-format extrusion-based additive manufacturing of polymer composites, the relationship between material properties and processing parameters requires further investigation. This thesis focuses on the relationship between fiber orientation and thermomechanical properties for short fiber-filled thermoplastic polymer systems manufactured by extrusion-based additive manufacturing. Fiber orientation is particularly important in determining the thermomechanical properties of the composite material as properties in the direction of deposition are expected to be higher for highly aligned fibers than randomly aligned fibers. Fiber orientation distribution, which is related to processing parameters and deposition conditions, can be efficiently represented by the orientation tensor. The orientation tensor can …

Mechanical Characterization Of Automated Fiber Placement And Additive Manufacturing Hybrid Composites, Lucan Haviland

Electronic Theses and Dissertations

This thesis presents the optimization of processing parameters based on the mechanical properties of Continuous Fiber-Reinforced Thermoplastic (CFRTP) Unidirectional (UD) consolidated tapes. The UD tapes were consolidated using an AFP head and a thermoforming press for comparison. The adhesive strength of hybrid parts consisting of CFRTP UD tape bonded to a 3D-printed substrate with the same matrix system were investigated. Large Area Additive Manufacturing (LAAM) was utilized for the 3D-printed parts. Different types of thermoplastic composite materials were explored, including Glass Fiber reinforced Polyethylene Terephthalate Glycol (GF/PETG), Carbon Fiber reinforced Polyethylene Terephthalate Glycol (CF/PETG), Carbon Fiber reinforced Polycarbonate (CF/PC), and …

Efficient Sintering Of Lunar Soil Using Concentrated Sunlight, Diprajit Biswas

Electronic Theses and Dissertations

Construction material is one crucial need for long-term habitation on the moon. When concentrated for high heat flux, solar radiation can heat lunar soil or regolith until it sinters at temperatures above 900°C. The solid, sintered soil simulant can be used as construction material. This work explores the conditions leading to effective lunar soil sintering for both direct and indirect irradiated sintering. Lunar soil simulants were sintered using concentrated light from a xenon-arc lamp with varying heat flux intensity. During direct sintering of LHS-1, a sintering range of 860°C-1140°C corresponding to a peak heat flux of 105-120 kW/m2 was identified …

Application Of Particle Transfer By Dipping Using Polymer Binder, Md Ibrahim Khalil

Electronic Theses and Dissertations

The demand for particle transfer is increasing in various industries, such as manufacturing, metal joining, microfluidics, roller lubrication process, fuel cells, super-capacitors, hybrid coating, and protective layer applications. As a result, the importance of efficient transfer of solid micron-size particles is becoming more crucial. Submicron-sized particles can easily adhere to solid substrates due to negligible gravitational force, while micron-sized or larger particles require a binder to overcome the gravitational effects. This thesis aims to investigate the interactions between microparticles and polymer thin film on cylindrical substrates using particle transfer methods. The process parameters are optimized and demonstrated two applications of …

Feasibility Of Thermoplastic Extrusion Welding As A Joining Method For Vacuum-Assisted Additively Manufactured Tooling, Chase C. Flaherty

Electronic Theses and Dissertations

In recent years, additive manufacturing (AM) has been successfully utilized for the production of large-scale composite tooling. Within these endeavors, however, limited research has focused on joining methods between printed sections. This work evaluates the feasibility of thermoplastic extrusion welding as a joining method for additively manufactured tooling structures. This joining method was assessed based on industry specifications of conventional thermoset tooling for wind blade manufacturing utilizing the vacuum-assisted resin transfer molding (VARTM) process. The specifications include requirements for the mechanical strength, vacuum integrity, roughness, and hardness of the tool surface. The feasibility of this welded polymer joint was demonstrated …

Additively Manufactured Polymer And Metal Lattice Structures With Eulerian Path, Adeeb Ibne Alam

Electronic Theses and Dissertations

Lattice structure manufacturing with polymers and metals can benefit from the use of Eulerian paths. In this research, two types of lattice fabrication methods are studied where the Eulerian path can be applicable. Polymer lattice is improved by using a new assembly design, while a new way of metal lattice fabrication is discussed.

For the fused filament fabrication process, a new interlocking design and assemble-based lattice structure building approach is investigated by increasing continuity in layers and avoiding support structures. To minimize contour plurality, Eulerian paths between the edges were enforced. Two configurations in the form of cubic and octet …

Development And Evaluation Of Modeling Approaches For Extrusion-Based Additive Manufacturing Of Thermoplastics, Christopher C. Bock

Electronic Theses and Dissertations

This work focuses on evaluating different modeling approaches and model parameters for thermoplastic AM, with the goal of informing more efficient and effective modeling approaches. First, different modeling approaches were tested and compared to experiments. From this it was found that all three of the modeling approaches provide comparable results and provide similar results to experiments. Then one of the modeling approaches was tested on large scale geometries, and it was found that the model results matched experiments closely. Then the effect of different material properties was evaluated, this was done by performing a fractional factorial design of experiments where …

Development And Testing Of A 1:70 Scale Model Wind Turbine Of The Iea Reference 15 Mw Floating Offshore System, Amber Parker

Electronic Theses and Dissertations

This thesis presents the development of a 1/70th scale performance-matched wind turbine intended for wind and wave basin model testing of commercially viable floating wind turbine structures based off of the International Energy Agency (IEA) Wind 15 MW design. The focus of this demonstration is to test active blade pitch response controls and to provide an experimental dataset for use by modelers and industry for future turbine improvements. Future research is planned to test the turbine in conjunction with an actively damping hull to test the interactions between the two control systems.

Outlined in this thesis are the methods of …

Development Of Thermoplastic Composite External Reinforcing Of Concrete Decking System, Jackman A. Mickiewicz

Electronic Theses and Dissertations

The use of reinforced concrete is very common in the construction of a wide variety of structures. In buildings it is used for floors, beams, columns, and walls. It can also be used in infrastructure as parts of bridges, dams, pavements, etc. Typically, concrete is reinforced with steel, primarily rebar, to carry tensile stresses.

Like every other industry, construction is always looking at ways to advance its technology. The work outlined in this thesis looks to assist in that goal, primarily by looking at options for using a different material than the traditional steel reinforcements to create a reinforced concrete …

Thermal And Mechanical Numerical Modeling Of Extrusion-Based 3d Printed Reinforced Polymers For Selecting Manufacturing Process Parameters, Sunil Bhandari

Electronic Theses and Dissertations

Extrusion-based 3D printing of thermoplastic polymer composites manufactures parts that have nonhomogenous, orthotropic, and process-dependent macro-scale material properties. As a part of the dissertation, research works were carried out to: • improve the interlayer mechanical properties and reduce the orthotropy, • use experimentally homogenized orthotropic material properties to numerically model the mechanical behavior of the non-homogenous orthotropic 3D printed parts, • create an efficient numerical thermal model to predict the process-dependent thermal history of the 3D printed part, and • aid the manufacturing process by selecting a suitable set of processing parameters based on a simplified sequentially coupled thermomechanical model. …

Modeling And Simulation Of The Thermoforming Process In Thermoplastic-Matrix Composite Materials, Philip M. Bean

Electronic Theses and Dissertations

Thermoplastic-matrix composite materials have unique advantages over traditional thermosets including faster processing, improved fracture toughness, and recyclability. These and other benefits have caused increasing interest in the use of these materials in both aerospace and automotive industries. Due to the differences in behavior, these materials require a different type of manufacturing process to thermoset matrix composites. This manufacturing process generally involves using pre manufactured tape-layers. These layers, containing both thermoplastic-matrix and fiber-reinforcement, are aligned to the desired orientation, and stacked up into a “tailored blank” using an automated tape layup machine. They are then heated to the thermoplastic melting temperature …

Feasibility Of Hybrid Thermoplastic Composite-Concrete Load Bearing System, Camerin M. Seigars

Electronic Theses and Dissertations

Thermoplastic composites have many advantages over thermoset composites such as being recyclable, rapidly manufacturable, and more impact resistant. The goal of this thesis is to assess the feasibility of using thermoplastic composites in structural applications through literature review, mechanical testing, design of a load-bearing hybrid composite-concrete structures, and the implementation of thermoplastic composites for tensile reinforcement of concrete. The study had four objectives covering the stated goal.

1. Conduct a literature review to direct thermoplastic material selection
2. Characterize thermoplastic material mechanical properties using standardized mechanical testing
3. Design a hybrid composite-reinforced concrete beam, and
4. Develop thermoplastic shear connectors to develop composite action …

Feasibility Of Using 3d Printed Molds For Thermoforming Thermoplastic Composites, Sunil Bhandari

Electronic Theses and Dissertations

This thesis presents a novel combined experimental and numerical mechanics approach for characterizing 3D printed thermoplastic materials by the fused deposition modeling process for thermoforming thermoplastic composites. The implications of this work are:

1. a methodology for model-based performance evaluation of 3D printed structural parts, and
2. an improved design of 3D printed molds for composites manufacturing, which has potential for material innovations and scaled-up applications in additive manufacturing.

The thesis formulates basic criteria for selection of thermoplastic polymer used for the 3D printed mold based on forming temperatures. The thesis creates a lattice and shell finite element model of the 3D …

Integration Of Process Parameter Control And Digital Image Correlation Methods In An Investigation Of The Variability Of Marine Polymer Matrix Composite Material Properties, Keith Andrew Berube

Electronic Theses and Dissertations

The very nature of continuous fiber composite materials, with their heterogeneous structure of layered and interwoven fibers bound together by a polymer resin matrix, lead to an inevitable variability in mechanical properties. This is especially true if the fabrication process is not well controlled. Unlike fabricating components with metals, where the properties of the material are known beforehand, the final properties of the composite material are determined during the process of fabricating the composite part. The research described herein was undertaken to better enable the use of polymer matrix composites in the marine construction industry by developing a knowledge base …