Thermal modelling of extrusion based additive manufacturing of composite materials

DEFF Research Database (Denmark)

Jensen, Mathias Laustsen; Sonne, Mads Rostgaard; Hattel, Jesper Henri

One of the hottest topics regarding manufacturing these years is additive manufacturing (AM). AM is a young branch of manufacturing techniques, which by nature is disruptive due to its completely different manufacturing approach, wherein material is added instead of removed. By adding material...... layer by layer, mould and customised tooling requirements from the conventional manufacturing are reduced or removed, which leads to increased customisation options and enables new part complexities without increasing the manufacturing cost. AM hence enables customised small volume productions...... of composite parts not feasible by conventional manufacturing techniques. This sets up new requirements to the part verification and validation, while conventional destructive tests become too expensive. This initial study aims to investigate alternative options to this destructive testing by increasing...

Advances in High Temperature Materials for Additive Manufacturing

Science.gov (United States)

Nordin, Nurul Amira Binti; Johar, Muhammad Akmal Bin; Ibrahim, Mohd Halim Irwan Bin; Marwah, Omar Mohd Faizan bin

2017-08-01

In today’s technology, additive manufacturing has evolved over the year that commonly known as 3D printing. Currently, additive manufacturing have been applied for many industries such as for automotive, aerospace, medical and other commercial product. The technologies are supported by materials for the manufacturing process to produce high quality product. Plus, additive manufacturing technologies has been growth from the lowest to moderate and high technology to fulfil manufacturing industries obligation. Initially from simple 3D printing such as fused deposition modelling (FDM), poly-jet, inkjet printing, to selective laser sintering (SLS), and electron beam melting (EBM). However, the high technology of additive manufacturing nowadays really needs high investment to carry out the process for fine products. There are three foremost type of material which is polymer, metal and ceramic used for additive manufacturing application, and mostly they were in the form of wire feedstock or powder. In circumstance, it is crucial to recognize the characteristics of each type of materials used in order to understand the behaviours of the materials on high temperature application via additive manufacturing. Therefore, this review aims to provide excessive inquiry and gather the necessary information for further research on additive material materials for high temperature application. This paper also proposed a new material based on powder glass, which comes from recycled tempered glass from automotive industry, having a huge potential to be applied for high temperature application. The technique proposed for additive manufacturing will minimize some cost of modelling with same quality of products compare to the others advanced technology used for high temperature application.

Wood lens design philosophy based on a binary additive manufacturing technique

Science.gov (United States)

Marasco, Peter L.; Bailey, Christopher

2016-04-01

Using additive manufacturing techniques in optical engineering to construct a gradient index (GRIN) optic may overcome a number of limitations of GRIN technology. Such techniques are maturing quickly, yielding additional design degrees of freedom for the engineer. How best to employ these degrees of freedom is not completely clear at this time. This paper describes a preliminary design philosophy, including assumptions, pertaining to a particular printing technique for GRIN optics. It includes an analysis based on simulation and initial component measurement.

Additive Manufacturing Design Considerations for Liquid Engine Components

Science.gov (United States)

Whitten, Dave; Hissam, Andy; Baker, Kevin; Rice, Darron

2014-01-01

The Marshall Space Flight Center's Propulsion Systems Department has gained significant experience in the last year designing, building, and testing liquid engine components using additive manufacturing. The department has developed valve, duct, turbo-machinery, and combustion device components using this technology. Many valuable lessons were learned during this process. These lessons will be the focus of this presentation. We will present criteria for selecting part candidates for additive manufacturing. Some part characteristics are 'tailor made' for this process. Selecting the right parts for the process is the first step to maximizing productivity gains. We will also present specific lessons we learned about feature geometry that can and cannot be produced using additive manufacturing machines. Most liquid engine components were made using a two-step process. The base part was made using additive manufacturing and then traditional machining processes were used to produce the final part. The presentation will describe design accommodations needed to make the base part and lessons we learned about which features could be built directly and which require the final machine process. Tolerance capabilities, surface finish, and material thickness allowances will also be covered. Additive Manufacturing can produce internal passages that cannot be made using traditional approaches. It can also eliminate a significant amount of manpower by reducing part count and leveraging model-based design and analysis techniques. Information will be shared about performance enhancements and design efficiencies we experienced for certain categories of engine parts.

Topology Optimization for Additive Manufacturing

DEFF Research Database (Denmark)

Clausen, Anders

This PhD thesis deals with the combination of topology optimization and additive man-ufacturing (AM, also known as 3D-printing). In addition to my own works, the thesis contains a broader review and assessment of the literature within the field. The thesis first presents a classification...... of the various AM technologies, a review of relevant manufacturing materials, the properties of these materials in the additively manufactured part, as well as manufacturing constraints with a potential for design optimization. Subsequently, specific topology optimization formulations relevant for the most im...... for scalable manufacturing. In relation to interface problems it is shown how a flexible void area may be included into a standard minimum compliance problem by employing an additional design variable field and a sensitivity filter. Furthermore, it is shown how the design of coated structures may be modeled...

Characterization of Ti and Co based biomaterials processed via laser based additive manufacturing

Science.gov (United States)

Sahasrabudhe, Himanshu

Titanium and Cobalt based metallic materials are currently the most ideal materials for load-bearing metallic bio medical applications. However, the long term tribological degradation of these materials still remains a problem that needs a solution. To improve the tribological performance of these two metallic systems, three different research approaches were adapted, stemming out four different research projects. First, the simplicity of laser gas nitriding was utilized with a modern LENS(TM) technology to form an in situ nitride rich later in titanium substrate material. This nitride rich composite coating improved the hardness by as much as fifteen times and reduced the wear rate by more than a magnitude. The leaching of metallic ions during wear was also reduced by four times. In the second research project, a mixture of titanium and silicon were processed on a titanium substrate in a nitrogen rich environment. The results of this reactive, in situ additive manufacturing process were Ti-Si-Nitride coatings that were harder than the titanium substrate by more than twenty times. These coatings also reduced the wear rate by more than two magnitudes. In the third research approach, composites of CoCrMo alloy and Calcium phosphate (CaP) bio ceramic were processed using LENS(TM) based additive manufacturing. These composites were effective in reducing the wear in the CoCrMo alloy by more than three times as well as reduce the leaching of cobalt and chromium ions during wear. The novel composite materials were found to develop a tribofilm during wear. In the final project, a combination of hard nitride coating and addition of CaP bioceramic was investigated by processing a mixture of Ti6Al4V alloy and CaP in a nitrogen rich environment using the LENS(TM) technology. The resultant Ti64-CaP-Nitride coatings significantly reduced the wear damage on the substrate. There was also a drastic reduction in the metal ions leached during wear. The results indicate that the three

Adding functionality with additive manufacturing: Fabrication of titanium-based antibiotic eluting implants.

Science.gov (United States)

Cox, Sophie C; Jamshidi, Parastoo; Eisenstein, Neil M; Webber, Mark A; Hassanin, Hany; Attallah, Moataz M; Shepherd, Duncan E T; Addison, Owen; Grover, Liam M

2016-07-01

Additive manufacturing technologies have been utilised in healthcare to create patient-specific implants. This study demonstrates the potential to add new implant functionality by further exploiting the design flexibility of these technologies. Selective laser melting was used to manufacture titanium-based (Ti-6Al-4V) implants containing a reservoir. Pore channels, connecting the implant surface to the reservoir, were incorporated to facilitate antibiotic delivery. An injectable brushite, calcium phosphate cement, was formulated as a carrier vehicle for gentamicin. Incorporation of the antibiotic significantly (p=0.01) improved the compressive strength (5.8±0.7MPa) of the cement compared to non-antibiotic samples. The controlled release of gentamicin sulphate from the calcium phosphate cement injected into the implant reservoir was demonstrated in short term elution studies using ultraviolet-visible spectroscopy. Orientation of the implant pore channels were shown, using micro-computed tomography, to impact design reproducibility and the back-pressure generated during cement injection which ultimately altered porosity. The amount of antibiotic released from all implant designs over a 6hour period (additively manufacture a titanium-based antibiotic eluting implant, which is an attractive alternative to current treatment strategies of periprosthetic infections. Copyright © 2016 Elsevier B.V. All rights reserved.

Numerical modeling of the strand deposition flow in extrusion-based additive manufacturing

DEFF Research Database (Denmark)

Comminal, Raphaël; Serdeczny, Marcin P.; Pedersen, David B.

2018-01-01

-based additive manufacturing, as well as the surface roughness of the fabricated part. Under the assumptions of an isothermal Newtonian fluid and a creeping laminar flow, the deposition flow is controlled by two parameters: the gap distance between the extrusion nozzle and the substrate, and the velocity ratio...

Dropwise additive manufacturing of pharmaceutical products for melt-based dosage forms.

Science.gov (United States)

Içten, Elçin; Giridhar, Arun; Taylor, Lynne S; Nagy, Zoltan K; Reklaitis, Gintaras V

2015-05-01

The US Food and Drug Administration introduced the quality by design approach and process analytical technology guidance to encourage innovation and efficiency in pharmaceutical development, manufacturing, and quality assurance. As part of this renewed emphasis on the improvement of manufacturing, the pharmaceutical industry has begun to develop more efficient production processes with more intensive use of online measurement and sensing, real-time quality control, and process control tools. Here, we present dropwise additive manufacturing of pharmaceutical products (DAMPP) as an alternative to conventional pharmaceutical manufacturing methods. This mini-manufacturing process for the production of pharmaceuticals utilizes drop on demand printing technology for automated and controlled deposition of melt-based formulations onto edible substrates. The advantages of drop-on-demand technology, including reproducible production of small droplets, adjustable drop sizing, high placement accuracy, and flexible use of different formulations, enable production of individualized dosing even for low-dose and high-potency drugs. In this work, DAMPP is used to produce solid oral dosage forms from hot melts of an active pharmaceutical ingredient and a polymer. The dosage forms are analyzed to show the reproducibility of dosing and the dissolution behavior of different formulations. © 2015 Wiley Periodicals, Inc. and the American Pharmacists Association.

Additive manufacturing of tunable lenses

Science.gov (United States)

Schlichting, Katja; Novak, Tobias; Heinrich, Andreas

2017-02-01

Individual additive manufacturing of optical systems based on 3D Printing offers varied possibilities in design and usage. In addition to the additive manufacturing procedure, the usage of tunable lenses allows further advantages for intelligent optical systems. Our goal is to bring the advantages of additive manufacturing together with the huge potential of tunable lenses. We produced tunable lenses as a bundle without any further processing steps, like polishing. The lenses were designed and directly printed with a 3D Printer as a package. The design contains the membrane as an optical part as well as the mechanical parts of the lens, like the attachments for the sleeves which contain the oil. The dynamic optical lenses were filled with an oil. The focal length of the lenses changes due to a change of the radius of curvature. This change is caused by changing the pressure in the inside of the lens. In addition to that, we designed lenses with special structures to obtain different areas with an individual optical power. We want to discuss the huge potential of this technology for several applications. Further, an appropriate controlling system is needed. Wéll show the possibilities to control and regulate the optical power of the lenses. The lenses could be used for illumination tasks, and in the future, for individual measurement tasks. The main advantage is the individuality and the possibility to create an individual design which completely fulfills the requirements for any specific application.

Wide and High Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Post, Brian K. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Roschli, Alex C. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2017-03-01

The goal of this project is to develop and demonstrate the enabling technologies for Wide and High Additive Manufacturing (WHAM). WHAM will open up new areas of U.S. manufacturing for very large tooling in support of the transportation and energy industries, significantly reducing cost and lead time. As with Big Area Additive Manufacturing (BAAM), the initial focus is on the deposition of composite materials.

2015 Summer Design Challenge: Team A&E (2241) Additively Manufactured Discriminator.

Energy Technology Data Exchange (ETDEWEB)

Miller, Sarah E. [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States); Moore, Brandon James [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)

2016-11-01

Current discriminator designs are based on historical designs and traditional manufacturing methods. The goal of this project was to form non-traditional groups to create novel discriminator designs by taking advantage of additive manufacturing. These designs would expand current discriminator designs and provide insight on the applicability of additive manufacturing for future projects. Our design stretched the current abilities of additive manufacturing and noted desired improvements for the future. Through collaboration with NSC, we noted several additional technologies which work well with additive manufacturing such as topology optimization and CT scanning and determined how these technologies could be improved to better combine with additive manufacturing.

Robot-based additive manufacturing for flexible die-modelling in incremental sheet forming

Science.gov (United States)

Rieger, Michael; Störkle, Denis Daniel; Thyssen, Lars; Kuhlenkötter, Bernd

2017-10-01

The paper describes the application concept of additive manufactured dies to support the robot-based incremental sheet metal forming process (`Roboforming') for the production of sheet metal components in small batch sizes. Compared to the dieless kinematic-based generation of a shape by means of two cooperating industrial robots, the supporting robot models a die on the back of the metal sheet by using the robot-based fused layer manufacturing process (FLM). This tool chain is software-defined and preserves the high geometrical form flexibility of Roboforming while flexibly generating support structures adapted to the final part's geometry. Test series serve to confirm the feasibility of the concept by investigating the process challenges of the adhesion to the sheet surface and the general stability as well as the influence on the geometric accuracy compared to the well-known forming strategies.

Cleaning Process Development for Metallic Additively Manufactured Parts

Science.gov (United States)

Tramel, Terri L.; Welker, Roger; Lowery, Niki; Mitchell, Mark

2014-01-01

Additive Manufacturing of metallic components for aerospace applications offers many advantages over traditional manufacturing techniques. As a new technology, many aspects of its widespread utilization remain open to investigation. Among these are the cleaning processes that can be used for post finishing of parts and measurements to verify effectiveness of the cleaning processes. Many cleaning and drying processes and measurement methods that have been used for parts manufactured using conventional techniques are candidates that may be considered for cleaning and verification of additively manufactured parts. Among these are vapor degreasing, ultrasonic immersion and spray cleaning, followed by hot air drying, vacuum baking and solvent displacement drying. Differences in porosity, density, and surface finish of additively manufactured versus conventionally manufactured parts may introduce new considerations in the selection of cleaning and drying processes or the method used to verify their effectiveness. This presentation will review the relative strengths and weaknesses of different candidate cleaning and drying processes as they may apply to additively manufactured metal parts for aerospace applications. An ultrasonic cleaning technique for exploring the cleanability of parts will be presented along with an example using additively manufactured Inconel 718 test specimens to illustrate its use. The data analysis shows that this ultrasonic cleaning approach results in a well-behaved ultrasonic cleaning/extraction behavior. That is, it does not show signs of accelerated cavitation erosion of the base material, which was later confirmed by neutron imaging. In addition, the analysis indicated that complete cleaning would be achieved by ultrasonic immersion cleaning at approximately 5 minutes, which was verified by subsequent cleaning of additional parts.

Advanced Process Chains for Prototyping and Pilot Production based on Additive Manufacturing

DEFF Research Database (Denmark)

Mischkot, Michael

2015-01-01

For many years, Additive Manufacturing (AM) has been a well-established production technology used mainly for rapid prototyping. But the need for increased flexibility and economic low volume production led to the discovery of Additive Manufacturing as a suitable fabrication technique (Mellor 2013...

Adding functionality with additive manufacturing: Fabrication of titanium-based antibiotic eluting implants

Energy Technology Data Exchange (ETDEWEB)

Cox, Sophie C. [School of Chemical Engineering, University of Birmingham, Edgbaston B15 2TT (United Kingdom); Jamshidi, Parastoo [School of Materials and Metallurgy, University of Birmingham, Edgbaston B15 2TT (United Kingdom); Eisenstein, Neil M. [School of Chemical Engineering, University of Birmingham, Edgbaston B15 2TT (United Kingdom); Royal Centre for Defence Medicine, Birmingham Research Park, Vincent Drive, Edgbaston B15 2SQ (United Kingdom); Webber, Mark A. [School of Biosciences, University of Birmingham, Edgbaston B15 2TT (United Kingdom); Hassanin, Hany [School of Materials and Metallurgy, University of Birmingham, Edgbaston B15 2TT (United Kingdom); School of Mechanical and Automotive Engineering, Kingston University, London SW15 3DW (United Kingdom); Attallah, Moataz M. [School of Materials and Metallurgy, University of Birmingham, Edgbaston B15 2TT (United Kingdom); Shepherd, Duncan E.T. [Department of Mechanical Engineering, School of Engineering, University of Birmingham, Edgbaston B15 2TT (United Kingdom); Addison, Owen [School of Dentistry, University of Birmingham, Edgbaston B15 2TT (United Kingdom); Grover, Liam M. [School of Chemical Engineering, University of Birmingham, Edgbaston B15 2TT (United Kingdom)

2016-07-01

Additive manufacturing technologies have been utilised in healthcare to create patient-specific implants. This study demonstrates the potential to add new implant functionality by further exploiting the design flexibility of these technologies. Selective laser melting was used to manufacture titanium-based (Ti-6Al-4V) implants containing a reservoir. Pore channels, connecting the implant surface to the reservoir, were incorporated to facilitate antibiotic delivery. An injectable brushite, calcium phosphate cement, was formulated as a carrier vehicle for gentamicin. Incorporation of the antibiotic significantly (p = 0.01) improved the compressive strength (5.8 ± 0.7 MPa) of the cement compared to non-antibiotic samples. The controlled release of gentamicin sulphate from the calcium phosphate cement injected into the implant reservoir was demonstrated in short term elution studies using ultraviolet-visible spectroscopy. Orientation of the implant pore channels were shown, using micro-computed tomography, to impact design reproducibility and the back-pressure generated during cement injection which ultimately altered porosity. The amount of antibiotic released from all implant designs over a 6 hour period (< 28% of the total amount) were found to exceed the minimum inhibitory concentrations of Staphylococcus aureus (16 μg/mL) and Staphylococcus epidermidis (1 μg/mL); two bacterial species commonly associated with periprosthetic infections. Antibacterial efficacy was confirmed against both bacterial cultures using an agar diffusion assay. Interestingly, pore channel orientation was shown to influence the directionality of inhibition zones. Promisingly, this work demonstrates the potential to additively manufacture a titanium-based antibiotic eluting implant, which is an attractive alternative to current treatment strategies of periprosthetic infections. - Highlights: • Titanium implants were additively manufactured with surface connected reservoirs. • Implants

Adding functionality with additive manufacturing: Fabrication of titanium-based antibiotic eluting implants

International Nuclear Information System (INIS)

Cox, Sophie C.; Jamshidi, Parastoo; Eisenstein, Neil M.; Webber, Mark A.; Hassanin, Hany; Attallah, Moataz M.; Shepherd, Duncan E.T.; Addison, Owen; Grover, Liam M.

2016-01-01

Additive manufacturing technologies have been utilised in healthcare to create patient-specific implants. This study demonstrates the potential to add new implant functionality by further exploiting the design flexibility of these technologies. Selective laser melting was used to manufacture titanium-based (Ti-6Al-4V) implants containing a reservoir. Pore channels, connecting the implant surface to the reservoir, were incorporated to facilitate antibiotic delivery. An injectable brushite, calcium phosphate cement, was formulated as a carrier vehicle for gentamicin. Incorporation of the antibiotic significantly (p = 0.01) improved the compressive strength (5.8 ± 0.7 MPa) of the cement compared to non-antibiotic samples. The controlled release of gentamicin sulphate from the calcium phosphate cement injected into the implant reservoir was demonstrated in short term elution studies using ultraviolet-visible spectroscopy. Orientation of the implant pore channels were shown, using micro-computed tomography, to impact design reproducibility and the back-pressure generated during cement injection which ultimately altered porosity. The amount of antibiotic released from all implant designs over a 6 hour period (< 28% of the total amount) were found to exceed the minimum inhibitory concentrations of Staphylococcus aureus (16 μg/mL) and Staphylococcus epidermidis (1 μg/mL); two bacterial species commonly associated with periprosthetic infections. Antibacterial efficacy was confirmed against both bacterial cultures using an agar diffusion assay. Interestingly, pore channel orientation was shown to influence the directionality of inhibition zones. Promisingly, this work demonstrates the potential to additively manufacture a titanium-based antibiotic eluting implant, which is an attractive alternative to current treatment strategies of periprosthetic infections. - Highlights: • Titanium implants were additively manufactured with surface connected reservoirs. • Implants

Additive manufactured serialization

Science.gov (United States)

Bobbitt, III, John T.

2017-04-18

Methods for forming an identifying mark in a structure are described. The method is used in conjunction with an additive manufacturing method and includes the alteration of a process parameter during the manufacturing process. The method can form in a unique identifying mark within or on the surface of a structure that is virtually impossible to be replicated. Methods can provide a high level of confidence that the identifying mark will remain unaltered on the formed structure.

Harnessing the Potential of Additive Manufacturing

Science.gov (United States)

2016-12-01

31 Defense AT&L: November-December 2016 Harnessing the Potential of Additive Manufacturing Bill Decker Decker is director of Technology...achieve its goal of competition throughout the acquisition life cycle. When we look at additive manufacturing , we have a much different environment. To...Titanium-6 Aluminum-4 Vanadium with Powder Bed Fusion. This specification covers additively manufactured titanium-6 aluminum-4 vanadium (Ti-6Al-4V

Qualification of laser based additive production for manufacturing of forging Tools

Directory of Open Access Journals (Sweden)

Junker Daniel

2015-01-01

Full Text Available Mass customization leads to very short product life cycles, so the costs of a tool have to be amortized with a low number of workpieces. Especially for highly loaded tools, like those for forging, that leads to expensive products. Therefore more economical production processes for tool manufacturing have to be investigated. As laser additive manufacturing is already used for the production of moulds for injection moulding, this technology maybe could also improve the forging tool production. Within this paper laser metal deposition, which is industrially used for tool repair, will be investigated for the use in tool manufacturing. Therefore a mechanical characterization of parts built with different laser process parameters out of the hot work tool steel 1.2709 is made by upsetting tests and hardness measurements. So the influence of the additive manufacturing process on the hardness distribution is analysed.

Additive manufacturing of three-dimensional (3D) microfluidic-based microelectromechanical systems (MEMS) for acoustofluidic applications.

Science.gov (United States)

Cesewski, Ellen; Haring, Alexander P; Tong, Yuxin; Singh, Manjot; Thakur, Rajan; Laheri, Sahil; Read, Kaitlin A; Powell, Michael D; Oestreich, Kenneth J; Johnson, Blake N

2018-06-13

Three-dimensional (3D) printing now enables the fabrication of 3D structural electronics and microfluidics. Further, conventional subtractive manufacturing processes for microelectromechanical systems (MEMS) relatively limit device structure to two dimensions and require post-processing steps for interface with microfluidics. Thus, the objective of this work is to create an additive manufacturing approach for fabrication of 3D microfluidic-based MEMS devices that enables 3D configurations of electromechanical systems and simultaneous integration of microfluidics. Here, we demonstrate the ability to fabricate microfluidic-based acoustofluidic devices that contain orthogonal out-of-plane piezoelectric sensors and actuators using additive manufacturing. The devices were fabricated using a microextrusion 3D printing system that contained integrated pick-and-place functionality. Additively assembled materials and components included 3D printed epoxy, polydimethylsiloxane (PDMS), silver nanoparticles, and eutectic gallium-indium as well as robotically embedded piezoelectric chips (lead zirconate titanate (PZT)). Electrical impedance spectroscopy and finite element modeling studies showed the embedded PZT chips exhibited multiple resonant modes of varying mode shape over the 0-20 MHz frequency range. Flow visualization studies using neutrally buoyant particles (diameter = 0.8-70 μm) confirmed the 3D printed devices generated bulk acoustic waves (BAWs) capable of size-selective manipulation, trapping, and separation of suspended particles in droplets and microchannels. Flow visualization studies in a continuous flow format showed suspended particles could be moved toward or away from the walls of microfluidic channels based on selective actuation of in-plane or out-of-plane PZT chips. This work suggests additive manufacturing potentially provides new opportunities for the design and fabrication of acoustofluidic and microfluidic devices.

Implementing the South African additive manufacturing technology roadmap - the role of an additive manufacturing centre of competence

Directory of Open Access Journals (Sweden)

Du Preez, Willie Bouwer

2015-08-01

Full Text Available The Rapid Product Development Association of South Africa (RAPDASA expressed the need for a national Additive Manufacturing Roadmap. Consequentially, the South African Department of Science and Technology commissioned the development of a South African Additive Manufacturing Technology Roadmap. This was intended to guide role-players in identifying business opportunities, addressing technology gaps, focusing development programmes, and informing investment decisions that would enable local companies and industry sectors to become global leaders in selected areas of additive manufacturing. The challenge remains now for South Africa to decide on an implementation approach that will maximize the impact in the shortest possible time. This article introduces the concept of a national Additive Manufacturing Centre of Competence (AMCoC as a primary implementation vehicle for the roadmap. The support of the current leading players in additive manufacturing in South Africa for such a centre of competence is shared and their key roles are indicated. A summary of the investments that the leading players have already made in the focus areas of the AMCoC over the past two decades is given as confirmation of their commitment towards the advancement of the additive manufacturing technology. An exposition is given of how the AMCoC could indeed become the primary initiative for achieving the agreed national goals on additive manufacturing. The conclusion is that investment by public and private institutions in an AMCoC would be the next step towards ensuring South Africa’s continued progress in the field.

Evolution of solidification texture during additive manufacturing

Science.gov (United States)

Wei, H. L.; Mazumder, J.; DebRoy, T.

2015-01-01

Striking differences in the solidification textures of a nickel based alloy owing to changes in laser scanning pattern during additive manufacturing are examined based on theory and experimental data. Understanding and controlling texture are important because it affects mechanical and chemical properties. Solidification texture depends on the local heat flow directions and competitive grain growth in one of the six preferred growth directions in face centered cubic alloys. Therefore, the heat flow directions are examined for various laser beam scanning patterns based on numerical modeling of heat transfer and fluid flow in three dimensions. Here we show that numerical modeling can not only provide a deeper understanding of the solidification growth patterns during the additive manufacturing, it also serves as a basis for customizing solidification textures which are important for properties and performance of components. PMID:26553246

Applications of Metal Additive Manufacturing in Veterinary Orthopedic Surgery

Science.gov (United States)

Harrysson, Ola L. A.; Marcellin-Little, Denis J.; Horn, Timothy J.

2015-03-01

Veterinary medicine has undergone a rapid increase in specialization over the last three decades. Veterinarians now routinely perform joint replacement, neurosurgery, limb-sparing surgery, interventional radiology, radiation therapy, and other complex medical procedures. Many procedures involve advanced imaging and surgical planning. Evidence-based medicine has also become part of the modus operandi of veterinary clinicians. Modeling and additive manufacturing can provide individualized or customized therapeutic solutions to support the management of companion animals with complex medical problems. The use of metal additive manufacturing is increasing in veterinary orthopedic surgery. This review describes and discusses current and potential applications of metal additive manufacturing in veterinary orthopedic surgery.

Repurposing mainstream CNC machine tools for laser-based additive manufacturing

Science.gov (United States)

Jones, Jason B.

2016-04-01

The advent of laser technology has been a key enabler for industrial 3D printing, known as Additive Manufacturing (AM). Despite its commercial success and unique technical capabilities, laser-based AM systems are not yet able to produce parts with the same accuracy and surface finish as CNC machining. To enable the geometry and material freedoms afforded by AM, yet achieve the precision and productivity of CNC machining, hybrid combinations of these two processes have started to gain traction. To achieve the benefits of combined processing, laser technology has been integrated into mainstream CNC machines - effectively repurposing them as hybrid manufacturing platforms. This paper reviews how this engineering challenge has prompted beam delivery innovations to allow automated changeover between laser processing and machining, using standard CNC tool changers. Handling laser-processing heads using the tool changer also enables automated change over between different types of laser processing heads, further expanding the breadth of laser processing flexibility in a hybrid CNC. This paper highlights the development, challenges and future impact of hybrid CNCs on laser processing.

Sustainability Characterization for Additive Manufacturing.

Science.gov (United States)

Mani, Mahesh; Lyons, Kevin W; Gupta, S K

2014-01-01

Additive manufacturing (AM) has the potential to create geometrically complex parts that require a high degree of customization, using less material and producing less waste. Recent studies have shown that AM can be an economically viable option for use by the industry, yet there are some inherent challenges associated with AM for wider acceptance. The lack of standards in AM impedes its use for parts production since industries primarily depend on established standards in processes and material selection to ensure the consistency and quality. Inability to compare AM performance against traditional manufacturing methods can be a barrier for implementing AM processes. AM process sustainability has become a driver due to growing environmental concerns for manufacturing. This has reinforced the importance to understand and characterize AM processes for sustainability. Process characterization for sustainability will help close the gaps for comparing AM performance to traditional manufacturing methods. Based on a literature review, this paper first examines the potential environmental impacts of AM. A methodology for sustainability characterization of AM is then proposed to serve as a resource for the community to benchmark AM processes for sustainability. Next, research perspectives are discussed along with relevant standardization efforts.

Characterization of Metal Powders Used for Additive Manufacturing.

Science.gov (United States)

Slotwinski, J A; Garboczi, E J; Stutzman, P E; Ferraris, C F; Watson, S S; Peltz, M A

2014-01-01

Additive manufacturing (AM) techniques can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process.

Characterization of Metal Powders Used for Additive Manufacturing

Science.gov (United States)

Slotwinski, JA; Garboczi, EJ; Stutzman, PE; Ferraris, CF; Watson, SS; Peltz, MA

2014-01-01

Additive manufacturing (AM) techniques1 can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process. PMID:26601040

Additive Manufacturing of Aerospace Propulsion Components

Science.gov (United States)

Misra, Ajay K.; Grady, Joseph E.; Carter, Robert

2015-01-01

The presentation will provide an overview of ongoing activities on additive manufacturing of aerospace propulsion components, which included rocket propulsion and gas turbine engines. Future opportunities on additive manufacturing of hybrid electric propulsion components will be discussed.

Additive Manufacturing of Nickel-Base Superalloy IN100 Through Scanning Laser Epitaxy

Science.gov (United States)

Basak, Amrita; Das, Suman

2018-01-01

Scanning laser epitaxy (SLE) is a laser powder bed fusion (LPBF)-based additive manufacturing process that uses a high-power laser to consolidate metal powders facilitating the fabrication of three-dimensional objects. In the present study, SLE is used to produce samples of IN100, a high-γ' non-weldable nickel-base superalloy on similar chemistry substrates. A thorough analysis is performed using various advanced material characterization techniques such as high-resolution optical microscopy, scanning electron microscopy, energy dispersive x-ray spectroscopy, and Vickers microhardness measurements to characterize and compare the quality of the SLE-fabricated IN100 deposits with the investment cast IN100 substrates. The results show that the IN100 deposits have a finer γ/γ' microstructure, weaker elemental segregation, and higher microhardness compared with the substrate. Through this study, it is demonstrated that the SLE process has tremendous potential in the repair and manufacture of gas turbine hot-section components.

Bio-reinforced composite development for additive manufacturing: Nanocellulose-PLA

Energy Technology Data Exchange (ETDEWEB)

Tekinalp, Halil L. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lu, Yuan [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Kunc, Vlastimil [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Duty, Chad E. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Love, Lonnie J. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Peter, William H. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Ozcan, Soydan [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2016-07-01

Additive manufacturing (AM) is transitioning from being only a prototyping method towards becoming a manufacturing technique for the quick production of parts with complex geometries. For the complete realization of this transition, the mechanical properties of the printed parts have to meet the requirements of actual load-bearing structural components. Integration of a reinforcing second phase into a polymer is a viable approach for the improvement of resins mechanical performance. Addition of carbon fibers into acrylonitrile-butadiene-styrene (ABS) has already been shown to improve its mechanical properties compared to the neat ABS resin (both additively manufactured), and led to the manufacture of world s first 3D-printed car. However, both ABS resin and carbon fibers are petroleum-based products, and there is a continuous search for alternative, bio-sourced, renewable materials as a feedstock for manufacturing. Towards this direction, we have investigated the potential of cellulose nanofibril-reinforced polylactic acid (PLA) resin systems as an alternative. CNF-PLA composite systems with up to 40 wt% CNF loadings were prepared via compression molding technique and tested. Significant improvements in both tensile strength (80%) and elastic modulus (128%) were observed. Filaments prepared from the same compositions were also successfully 3D-printed into tensile testing specimens with up to 30% CNF concentrations, and showed similar improvements in mechanical performance. Although CNFs were not individually dispersed in PLA matrix, they were observed to be well blended with the polymer based on SEM micrographs. In summary, preparation and 3D-printing of a 100% bio-based feedstock material with the mechanical properties comparable to the carbon fiber-ABS system was successfully demonstrated that it can open up new window of opportunities in the additive manufacturing industry. Acknowledgement Research sponsored by the U.S. Department of Energy, Office of Energy

Online measurement of bead geometry in GMAW-based additive manufacturing using passive vision

International Nuclear Information System (INIS)

Xiong, Jun; Zhang, Guangjun

2013-01-01

Additive manufacturing based on gas metal arc welding is an advanced technique for depositing fully dense components with low cost. Despite this fact, techniques to achieve accurate control and automation of the process have not yet been perfectly developed. The online measurement of the deposited bead geometry is a key problem for reliable control. In this work a passive vision-sensing system, comprising two cameras and composite filtering techniques, was proposed for real-time detection of the bead height and width through deposition of thin walls. The nozzle to the top surface distance was monitored for eliminating accumulated height errors during the multi-layer deposition process. Various image processing algorithms were applied and discussed for extracting feature parameters. A calibration procedure was presented for the monitoring system. Validation experiments confirmed the effectiveness of the online measurement system for bead geometry in layered additive manufacturing. (paper)

Additive manufacturing of reflective optics: evaluating finishing methods

Science.gov (United States)

Leuteritz, G.; Lachmayer, R.

2018-02-01

Individually shaped light distributions become more and more important in lighting technologies and thus the importance of additively manufactured reflectors increases significantly. The vast field of applications ranges from automotive lighting to medical imaging and bolsters the statement. However, the surfaces of additively manufactured reflectors suffer from insufficient optical properties even when manufactured using optimized process parameters for the Selective Laser Melting (SLM) process. Therefore post-process treatments of reflectors are necessary in order to further enhance their optical quality. This work concentrates on the effectiveness of post-process procedures for reflective optics. Based on already optimized aluminum reflectors, which are manufactured with a SLM machine, the parts are differently machined after the SLM process. Selected finishing methods like laser polishing, sputtering or sand blasting are applied and their effects quantified and compared. The post-process procedures are investigated on their impact on surface roughness and reflectance as well as geometrical precision. For each finishing method a demonstrator will be created and compared to a fully milled sample and among themselves. Ultimately, guidelines are developed in order to figure out the optimal treatment of additively manufactured reflectors regarding their optical and geometrical properties. Simulations of the light distributions will be validated with the developed demonstrators.

Advanced Material Strategies for Next-Generation Additive Manufacturing.

Science.gov (United States)

Chang, Jinke; He, Jiankang; Mao, Mao; Zhou, Wenxing; Lei, Qi; Li, Xiao; Li, Dichen; Chua, Chee-Kai; Zhao, Xin

2018-01-22

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing.

Advanced Material Strategies for Next-Generation Additive Manufacturing

Directory of Open Access Journals (Sweden)

Jinke Chang

2018-01-01

Full Text Available Additive manufacturing (AM has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing.

Advanced Material Strategies for Next-Generation Additive Manufacturing

Science.gov (United States)

Chang, Jinke; He, Jiankang; Zhou, Wenxing; Lei, Qi; Li, Xiao; Li, Dichen

2018-01-01

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing. PMID:29361754

Additive manufacturing in production: challenges and opportunities

Science.gov (United States)

Ahuja, Bhrigu; Karg, Michael; Schmidt, Michael

2015-03-01

Additive manufacturing, characterized by its inherent layer by layer fabrication methodology has been coined by many as the latest revolution in the manufacturing industry. Due to its diversification of Materials, processes, system technology and applications, Additive Manufacturing has been synonymized with terminology such as Rapid prototyping, 3D printing, free-form fabrication, Additive Layer Manufacturing, etc. A huge media and public interest in the technology has led to an innovative attempt of exploring the technology for applications beyond the scope of the traditional engineering industry. Nevertheless, it is believed that a critical factor for the long-term success of Additive Manufacturing would be its ability to fulfill the requirements defined by the traditional manufacturing industry. A parallel development in market trends and product requirements has also lead to a wider scope of opportunities for Additive Manufacturing. The presented paper discusses some of the key challenges which are critical to ensure that Additive Manufacturing is truly accepted as a mainstream production technology in the industry. These challenges would highlight on various aspects of production such as product requirements, process management, data management, intellectual property, work flow management, quality assurance, resource planning, etc. In Addition, changing market trends such as product life cycle, mass customization, sustainability, environmental impact and localized production will form the foundation for the follow up discussion on the current limitations and the corresponding research opportunities. A discussion on ongoing research to address these challenges would include topics like process monitoring, design complexity, process standardization, multi-material and hybrid fabrication, new material development, etc.

Design and additive manufacture for flow chemistry.

Science.gov (United States)

Capel, Andrew J; Edmondson, Steve; Christie, Steven D R; Goodridge, Ruth D; Bibb, Richard J; Thurstans, Matthew

2013-12-07

We review the use of additive manufacturing (AM) as a novel manufacturing technique for the production of milli-scale reactor systems. Five well-developed additive manufacturing techniques: stereolithography (SL), multi-jet modelling (MJM), selective laser melting (SLM), laser sintering (LS) and fused deposition modelling (FDM) were used to manufacture a number of miniaturised reactors which were tested using a range of organic and inorganic reactions.

An implementation framework for additive manufacturing in supply chains

Directory of Open Access Journals (Sweden)

Raed Handal

2017-12-01

Full Text Available Additive manufacturing has become one of the most important technologies in the manufacturing field. Full implementation of additive manufacturing will change many well-known management practices in the production sector. However, theoretical development in the field of additive manufacturing with regard to its impact on supply chain management is rare. While additive manufacturing is believed to revolutionize and enhance traditional manufacturing, there is no comprehensive toolset developed in the manufacturing field to assess the impact of additive manufacturing and determine the best production method that suits the applied supply chain strategy. A significant portion of the existing supply chain methods and frameworks were adopted in this study to examine the implementation of additive manufacturing in supply chain management. The aim of this study is to develop a framework to explain when additive manufacturing impacts supply chain management efficiently.

Low-cost Electromagnetic Heating Technology for Polymer Extrusion-based Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Carter, William G. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Rios, Orlando [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Akers, Ronald R. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Morrison, William A. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2016-01-07

To improve the flow of materials used in in polymer additive manufacturing, ORNL and Ajax Tocco created an induction system for heating fused deposition modeling (FDM) nozzles used in polymer additive manufacturing. The system is capable of reaching a temperature of 230 C, a typical nozzle temperature for extruding ABS polymers, in 17 seconds. A prototype system was built at ORNL and sent to Ajax Tocco who analyzed the system and created a finalized power supply. The induction system was mounted to a PrintSpace Altair desktop printer and used to create several test parts similar in quality to those created using a resistive heated nozzle.

Additive Manufacturing: Unlocking the Evolution of Energy Materials.

Science.gov (United States)

Zhakeyev, Adilet; Wang, Panfeng; Zhang, Li; Shu, Wenmiao; Wang, Huizhi; Xuan, Jin

2017-10-01

The global energy infrastructure is undergoing a drastic transformation towards renewable energy, posing huge challenges on the energy materials research, development and manufacturing. Additive manufacturing has shown its promise to change the way how future energy system can be designed and delivered. It offers capability in manufacturing complex 3D structures, with near-complete design freedom and high sustainability due to minimal use of materials and toxic chemicals. Recent literatures have reported that additive manufacturing could unlock the evolution of energy materials and chemistries with unprecedented performance in the way that could never be achieved by conventional manufacturing techniques. This comprehensive review will fill the gap in communicating on recent breakthroughs in additive manufacturing for energy material and device applications. It will underpin the discoveries on what 3D functional energy structures can be created without design constraints, which bespoke energy materials could be additively manufactured with customised solutions, and how the additively manufactured devices could be integrated into energy systems. This review will also highlight emerging and important applications in energy additive manufacturing, including fuel cells, batteries, hydrogen, solar cell as well as carbon capture and storage.

Challenges in Additive Manufacturing of Alumina

OpenAIRE

Gonzalez, Hugo

2016-01-01

Additive manufacturing is seen by many as the holy grail of manufacturing, the ability to produce parts nearly autonomously. Adding material rather than removing it would eliminate the need for expensive resources and machining. The recent expiration of key 3D printing patents has led to many advances in the field and has dramatically lowered the prices of 3D printers, making them accessible to the average individual. The one area where additive manufacturing is still in its infancy is in cer...

Additive manufacturing of RF absorbers

Science.gov (United States)

Mills, Matthew S.

The ability of additive manufacturing techniques to fabricate integrated electromagnetic absorbers tuned for specific radio frequency bands within structural composites allows for unique combinations of mechanical and electromagnetic properties. These composites and films can be used for RF shielding of sensitive electromagnetic components through in-plane and out-of-plane RF absorption. Structural composites are a common building block of many commercial platforms. These platforms may be placed in situations in which there is a need for embedded RF absorbing properties along with structural properties. Instead of adding radar absorbing treatments to the external surface of existing structures, which adds increased size, weight and cost; it could prove to be advantageous to integrate the microwave absorbing properties directly into the composite during the fabrication process. In this thesis, a method based on additive manufacturing techniques of composites structures with prescribed electromagnetic loss, within the frequency range 1 to 26GHz, is presented. This method utilizes screen printing and nScrypt micro dispensing to pattern a carbon based ink onto low loss substrates. The materials chosen for this study will be presented, and the fabrication technique that these materials went through to create RF absorbing structures will be described. The calibration methods used, the modeling of the RF structures, and the applications in which this technology can be utilized will also be presented.

Effusion plate using additive manufacturing methods

Science.gov (United States)

Johnson, Thomas Edward; Keener, Christopher Paul; Ostebee, Heath Michael; Wegerif, Daniel Gerritt

2016-04-12

Additive manufacturing techniques may be utilized to construct effusion plates. Such additive manufacturing techniques may include defining a configuration for an effusion plate having one or more internal cooling channels. The manufacturing techniques may further include depositing a powder into a chamber, applying an energy source to the deposited powder, and consolidating the powder into a cross-sectional shape corresponding to the defined configuration. Such methods may be implemented to construct an effusion plate having one or more channels with a curved cross-sectional geometry.

Enhancing Surface Finish of Additively Manufactured Titanium and Cobalt Chrome Elements Using Laser Based Finishing

Science.gov (United States)

Gora, Wojciech S.; Tian, Yingtao; Cabo, Aldara Pan; Ardron, Marcus; Maier, Robert R. J.; Prangnell, Philip; Weston, Nicholas J.; Hand, Duncan P.

Additive manufacturing (AM) offers the possibility of creating a complex free form object as a single element, which is not possible using traditional mechanical machining. Unfortunately the typically rough surface finish of additively manufactured parts is unsuitable for many applications. As a result AM parts must be post-processed; typically mechanically machined and/or and polished using either chemical or mechanical techniques (both of which have their limitations). Laser based polishing is based on remelting of a very thin surface layer and it offers potential as a highly repeatable, higher speed process capable of selective area polishing, and without any waste problems (no abrasives or liquids). In this paper an in-depth investigation of CW laser polishing of titanium and cobalt chrome AM elements is presented. The impact of different scanning strategies, laser parameters and initial surface condition on the achieved surface finish is evaluated.

Rapid production of hollow SS316 profiles by extrusion based additive manufacturing

Science.gov (United States)

Rane, Kedarnath; Cataldo, Salvatore; Parenti, Paolo; Sbaglia, Luca; Mussi, Valerio; Annoni, Massimiliano; Giberti, Hermes; Strano, Matteo

2018-05-01

Complex shaped stainless steel tubes are often required for special purpose biomedical equipment. Nevertheless, traditional manufacturing technologies, such as extrusion, lack the ability to compete in a market of customized complex components because of associated expenses towards tooling and extrusion presses. To rapid manufacture few of such components with low cost and high precision, a new Extrusion based Additive Manufacturing (EAM) process, is proposed in this paper, and as an example, short stainless steel 316L complex shaped and sectioned tubes were prepared by EAM. Several sample parts were produced using this process; the dimensional stability, surface roughness and chemical composition of sintered samples were investigated to prove process competence. The results indicate that feedstock with a 316L particle content of 92.5 wt. % can be prepared with a sigma blade mixing, whose rheological behavior is fit for EAM. The green samples have sufficient strength to handle them for subsequent treatments. The sintered samples considerably shrunk to designed dimensions and have a homogeneous microstructure to impart mechanical strength. Whereas, maintaining comparable dimensional accuracy and chemical composition which are required for biomedical equipment still need iterations, a kinematic correction and modification in debinding cycle was proposed.

The design of impact absorbing structures for additive manufacture

International Nuclear Information System (INIS)

Brennan-Craddock, J; Brackett, D; Wildman, R; Hague, R

2012-01-01

Additive manufacturing (AM) is increasingly becoming a viable manufacturing process due to dramatic advantages that it facilitates in the area of design complexity. This paper investigates the potential of additively manufactured lattice structures for the application of tailored impact absorption specifically for conformal body protection. It explores lattice cell types based on foam microstructures and assesses their suitability for impact absorption. The effect of varying the cell strut edge design is also investigated. The implications of scaling these cells up for AM are discussed as well as the design issues regarding the handling of geometric complexity and the requirement for body conformity. The suitability of AM materials for this application is also discussed.

Advances in 3D printing & additive manufacturing technologies

CERN Document Server

Pandey, Pulak; Kumar, L

2017-01-01

This edited volume comprises select chapters on advanced technologies for 3D printing and additive manufacturing and how these technologies have changed the face of direct, digital technologies for rapid production of models, prototypes and patterns. Because of its wide applications, 3D printing and additive manufacturing technology has become a powerful new industrial revolution in the field of manufacturing. The evolution of 3D printing and additive manufacturing technologies has changed design, engineering and manufacturing processes across industries such as consumer products, aerospace, medical devices and automotives. The objective of this book is to help designers, R&D personnel, and practicing engineers understand the state-of-the-art developments in the field of 3D Printing and Additive Manufacturing. .

Applications of Fiber-Reinforced Polymers in Additive Manufacturing

DEFF Research Database (Denmark)

Hofstätter, Thomas; Pedersen, David Bue; Tosello, Guido

2017-01-01

Additive manufacturing technologies are these years entering the market of functional final parts. Initial research has been performed targeting the integration of fibers into additive manufactured plastic composites. Major advantages, among others, are for example increased tensile strength...... and Young's modulus. Key challenges in the field, as of now, are proper fiber placement, fiber seizing, an increased knowledge in the used materials and how they are applied into engineering solutions through proper control of the additive manufacturing process. The aim of this research is the improved...... understanding of fiber-reinforcement in additive manufacturing in terms of production and application. Vat polymerization and material extrusion techniques for composite additive manufacturing were investigated with respect of increasing adhesion between the matrix material and the fibers. Process optimization...

USABILITY OF ADDITIVE MANUFACTURING (THREEDIMENSIONAL PRINTING) TECHNOLOGIES IN EDUCATION

OpenAIRE

ÖZSOY, KORAY; DUMAN, BURHAN

2017-01-01

Additive manufacturing technologies which are emerge in 1980’s years, they are using for prototip production in first time for that reason their denomination rapid prototyping . Nowadays it called additive manufacturing because of it using for end use functional part’s production. In additive manufacturing, the basic rationales the same, but many different technologies have been developed to manufacture with different approaches. The most common additive manufacturing technologies are stereol...

Laser additive manufacturing of multimaterial tool inserts: a simulation-based optimization study

DEFF Research Database (Denmark)

Mohanty, Sankhya; Hattel, Jesper Henri

2017-01-01

laser additive manufacturing. The physical handling of multi-material in a SLM setup continues to be a primary challenge along with the selection of process parameters/plan to achieve the desired results – both challenges requiring considerable experimental undertakings. Consequently, numerical process...... which a layer of steel has been deposited using cold-spraying technique, such as to protect the microstructure of Ni during selective laser melting. The process modelled thus entails additively manufacturing a steel tool insert around the multi-material specimen with a goal of achieving a dense product......Selective laser melting is fast evolving into an industrially applicable manufacturing process. While components produced from high-value materials, such as Ti6Al4V and Inconel 718 alloys, are already being produced, the processing of multi-material components still remains to be achieved by using...

Mechanical properties of sheet metal components with local reinforcement produced by additive manufacturing

Science.gov (United States)

Ünsal, Ismail; Hama-Saleh, R.; Sviridov, Alexander; Bambach, Markus; Weisheit, A.; Schleifenbaum, J. H.

2018-05-01

New technological challenges like electro-mobility pose an increasing demand for cost-efficient processes for the production of product variants. This demand opens the possibility to combine established die-based manufacturing methods and innovative, dieless technologies like additive manufacturing [1, 2]. In this context, additive manufacturing technologies allow for the weight-efficient local reinforcement of parts before and after forming, enabling manufacturers to produce product variants from series parts [3]. Previous work by the authors shows that the optimal shape of the reinforcing structure can be determined using sizing optimization. Sheet metal parts can then be reinforced using laser metal deposition. The material used is a pearlite-reduced, micro-alloyed steel (ZE 630). The aim of this paper is to determine the effect of the additive manufacturing process on the material behavior and the mechanical properties of the base material and the resulting composite material. The parameters of the AM process are optimized to reach similar material properties in the base material and the build-up volume. A metallographic analysis of the parts is presented, where the additive layers, the base material and also the bonding between the additive layers and the base material are analyzed. The paper shows the feasibility of the approach and details the resulting mechanical properties and performance.

Solid-State Additive Manufacturing for Heat Exchangers

Science.gov (United States)

Norfolk, Mark; Johnson, Hilary

2015-03-01

Energy densities in devices are increasing across many industries including power generation, high power electronics, manufacturing, and automotive. Increasingly, there is a need for very high efficiency thermal management devices that can pull heat out of a small area at higher and higher rates. Metal additive manufacturing (AM) technologies have the promise of creating parts with complex internal geometries required for integral thermal management. However, this goal has not been met due to constraints in fusion-based metal 3D printers. This work presents a new strategy for metal AM of heat exchangers using an ultrasonic sheet lamination approach.

Process Modeling and Validation for Metal Big Area Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Simunovic, Srdjan [ORNL; Nycz, Andrzej [ORNL; Noakes, Mark W. [ORNL; Chin, Charlie [Dassault Systemes; Oancea, Victor [Dassault Systemes

2017-05-01

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to accelerate the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Business models for additive manufacturing

DEFF Research Database (Denmark)

Hadar, Ronen; Bilberg, Arne; Bogers, Marcel

2015-01-01

Digital fabrication — including additive manufacturing (AM), rapid prototyping and 3D printing — has the potential to revolutionize the way in which products are produced and delivered to the customer. Therefore, it challenges companies to reinvent their business model — describing the logic...... of creating and capturing value. In this paper, we explore the implications that AM technologies have for manufacturing systems in the new business models that they enable. In particular, we consider how a consumer goods manufacturer can organize the operations of a more open business model when moving from...... a manufacturer-centric to a consumer-centric value logic. A major shift includes a move from centralized to decentralized supply chains, where consumer goods manufacturers can implement a “hybrid” approach with a focus on localization and accessibility or develop a fully personalized model where the consumer...

Economic trade-offs of additive manufacturing integration in injection moulding process chain

DEFF Research Database (Denmark)

Charalambis, Alessandro; Kerbache, Laoucine; Tosello, Guido

2017-01-01

Additive Manufacturing has emerged as an innovative set of novel technologies capable of replacing established manufacturing processes due to fabrication of highly complex parts and its continuous improvements of efficiency and cost effectiveness. This study is based on the idea that through...... the creation of synergies between additive and conventional manufacturing technologies it is possible to achieve greater cost advantages and operational benefits than by substituting injection moulding with additive manufacturing. The analysis presented explores the cost advantages that can be secured when...... additive manufacturing is used to support the fabrication of mould inserts for the product development phase of the injection moulding process chain. This study shows that fabrication of soft tooling by mean of AM is economically convenient with a cost reduction between 80% and 90%. Break-even points...

Additive Manufacturing Cloud via Peer-Robot Collaboration

Directory of Open Access Journals (Sweden)

Yuan Yao

2016-05-01

Full Text Available When building a 3D printing cloud manufacturing platform, self-sensing and collaboration on manufacturing resources present challenging problems. This paper proposes a peer-robot collaboration framework to deal with these issues. Each robot combines heterogeneous additive manufacturing hardware and software, acting as an intelligent agent. Through collaboration with other robots, it forms a dynamic and scalable integration manufacturing system. The entire distributed system is managed by rules that employ an internal rule engine, which supports rule conversion and conflict resolution. Two additive manufacturing service scenarios are designed to analyse the efficiency and scalability of the framework. Experiments show that the presented method performs well in tasks requiring large-scale access to resources and collaboration.

Material Database for Additive Manufacturing Techniques

Science.gov (United States)

2017-12-01

components in the field. II. BACKGROUND Additive manufacturing is a rapidly maturing process by which digital 3-D design data are used to build up...improves readiness by offering on-demand low-rate production [8, 9]. 3-D printing also enables rapid design iterations and complexity, which improve...abundant in additive manufacturing , allowing design freedom that is only limited by the material strength requirements. A set of eight conductive

Additive Manufacturing of Shape Memory Alloys

Science.gov (United States)

Van Humbeeck, Jan

2018-04-01

Selective Laser Melting (SLM) is an additive manufacturing production process, also called 3D printing, in which functional, complex parts are produced by selectively melting patterns in consecutive layers of powder with a laser beam. The pattern the laser beam is following is controlled by software that calculates the pattern by slicing a 3D CAD model of the part to be constructed. Apart from SLM, also other additive manufacturing techniques such as EBM (Electron Beam Melting), FDM (Fused Deposition Modelling), WAAM (Wire Arc Additive Manufacturing), LENS (Laser Engineered Net Shaping such as Laser Cladding) and binder jetting allow to construct complete parts layer upon layer. But since more experience of AM of shape memory alloys is collected by SLM, this paper will overview the potentials, limits and problems of producing NiTi parts by SLM.

Additive manufacturing of metals

International Nuclear Information System (INIS)

Herzog, Dirk; Seyda, Vanessa; Wycisk, Eric; Emmelmann, Claus

2016-01-01

Additive Manufacturing (AM), the layer-by layer build-up of parts, has lately become an option for serial production. Today, several metallic materials including the important engineering materials steel, aluminium and titanium may be processed to full dense parts with outstanding properties. In this context, the present overview article describes the complex relationship between AM processes, microstructure and resulting properties for metals. It explains the fundamentals of Laser Beam Melting, Electron Beam Melting and Laser Metal Deposition, and introduces the commercially available materials for the different processes. Thereafter, typical microstructures for additively manufactured steel, aluminium and titanium are presented. Special attention is paid to AM specific grain structures, resulting from the complex thermal cycle and high cooling rates. The properties evolving as a consequence of the microstructure are elaborated under static and dynamic loading. According to these properties, typical applications are presented for the materials and methods for conclusion.

Initiatives to Improve Quality of Additively Manufactured Parts

Science.gov (United States)

Waller, Jess; Nichols, Charles

2017-01-01

NASA is providing leadership in an international effort linking government and industry resources to speed adoption of additive manufactured (AM) parts. Participants include government agencies (NASA, USAF, NIST, FAA), industry (commercial aerospace, NDE manufacturers, AM equipment manufacturers), standards organizations and academia. NASA is also partnering with its international space exploration organizations such as ESA and JAXA. NDT is identified as a universal need for all aspects of additive manufacturing.

Additive Manufacturing: Multi Material Processing and Part Quality Control

DEFF Research Database (Denmark)

Pedersen, David Bue

This Ph.D dissertation,ffAdditive Manufacturing: Multi Material Processing and Part Quality Controlff, deal with Additive Manufacturing technologies which is a common name for a series of processes that are recognized by being computer controlled, highly automated, and manufacture objects...... by a layered deposition of material. Two areas of particular interest is addressed. They are rooted in two very different areas, yet is intended to fuel the same goal. To help Additive Manufacturing technologies one step closer to becoming the autonomous, digital manufacturing method of tomorrow. Vision...... systems A paradox exist in the field of Additive Manufacturing. The technologies allow for close-to unrestrained and integral geometrical freedom. Almost any geometry can be manufactured fast, e"ciently and cheap. Something that has been missing fundamental capability since the entering of the industrial...

Additive manufacturing: From implants to organs

African Journals Online (AJOL)

Additive manufacturing (AM) constructs 3D objects layer by layer under computer control from 3D models. 3D printing is one ... anatomical models for surgery planning, and design and construction ... production of implants, particularly to replace bony structures, is ... Manufactured organs are, however, an elusive goal.

Additive Manufacturing Materials Study for Gaseous Radiation Detection

Energy Technology Data Exchange (ETDEWEB)

Steer, C.A.; Durose, A.; Boakes, J. [AWE Aldermaston, Reading, Berkshire, RG7 4PR (United Kingdom)

2015-07-01

Additive manufacturing (AM) techniques may lead to improvements in many areas of radiation detector construction; notably the rapid manufacturing time allows for a reduced time between prototype iterations. The additive nature of the technique results in a granular microstructure which may be permeable to ingress by atmospheric gases and make it unsuitable for gaseous radiation detector development. In this study we consider the application of AM to the construction of enclosures and frames for wire-based gaseous radiation tracking detectors. We have focussed on oxygen impurity ingress as a measure of the permeability of the enclosure, and the gas charging and discharging curves of several simplistic enclosure shapes are reported. A prototype wire-frame is also presented to examine structural strength and positional accuracy of an AM produced frame. We lastly discuss the implications of this study for AM based radiation detection technology as a diagnostic tool for incident response scenarios, such as the interrogation of a suspect radiation-emitting package. (authors)

Additive Manufacturing Materials Study for Gaseous Radiation Detection

International Nuclear Information System (INIS)

Steer, C.A.; Durose, A.; Boakes, J.

2015-01-01

Additive manufacturing (AM) techniques may lead to improvements in many areas of radiation detector construction; notably the rapid manufacturing time allows for a reduced time between prototype iterations. The additive nature of the technique results in a granular microstructure which may be permeable to ingress by atmospheric gases and make it unsuitable for gaseous radiation detector development. In this study we consider the application of AM to the construction of enclosures and frames for wire-based gaseous radiation tracking detectors. We have focussed on oxygen impurity ingress as a measure of the permeability of the enclosure, and the gas charging and discharging curves of several simplistic enclosure shapes are reported. A prototype wire-frame is also presented to examine structural strength and positional accuracy of an AM produced frame. We lastly discuss the implications of this study for AM based radiation detection technology as a diagnostic tool for incident response scenarios, such as the interrogation of a suspect radiation-emitting package. (authors)

Feasibility and Testing of Additive Manufactured Components

Energy Technology Data Exchange (ETDEWEB)

Dehoff, Ryan R [ORNL; Hummelt, Ed [Eaton Corporation; Solovyeva, Lyudmila [Eaton Corporation

2016-09-01

This project focused on demonstrating the ability to fabricate two parts with different geometry: an arc flash interrupter and a hydraulic manifold. Eaton Corporation provided ORNL solid models, information related to tolerances and sensitive parameters of the parts and provided testing and evaluation. ORNL successfully manufactured both components, provided cost models of the manufacturing (materials, labor, time and post processing) and delivered test components for Eaton evaluation. The arc flash suppressor was fabricated using the Renishaw laser powder bed technology in CoCrMo while the manifold was produced from Ti-6Al-4V using the Arcam electron beam melting technology. These manufacturing techniques were selected based on the design and geometrical tolerances required. A full-scale manifold was produced on the Arcam A2 system (nearly 12 inches tall). A portion of the manifold was also produced in the Arcam Q10 system. Although a full scale manifold could not be produced in the system, a full scale manifold is expected to have similar material properties, geometric accuracy, and surface finish as could be fabricated on an Arcam Q20 system that is capable of producing four full scale manifolds in a production environment. In addition to the manifold, mechanical test specimens, geometric tolerance artifacts, and microstructure samples were produced alongside the manifold. The development and demonstration of these two key components helped Eaton understand the impact additive manufacturing can have on many of their existing products. By working within the MDF and leveraging ORNL’s manufacturing and characterization capabilities, the work will ensure the rapid insertion and commercialization of this technology.

Topology optimization of structures and infill for additive manufacturing

DEFF Research Database (Denmark)

Sigmund, Ole; Clausen, Anders; Groen, Jeroen Peter

Topology optimization (TO) [1] is a widely used tool for generating optimal structures for subsequent realization by additive manufacturing (AM) methods. TO is a numerical method that, based on iterated finite element analyses, gradient-based optimization algorithms and design parameterizations...... described by point clouds, delivers optimal but often rather complex topologies. As such, TO is a design method that takes full advantage of the large design freedom offered by AM technologies. Much recent effortin the TO community has been devoted to the development of algorithms that take manufacturing...... as a design gimmick to illustrate the capabilities of AM to mimic natural creations like honeycombs and bonestructure. Partly for manufacturing reasons, infill microstructure is often built as open-walled foam structures. However, as maybe unknown by many, open-walled microstructures are not optimal...

Lightweight custom composite prosthetic components using an additive manufacturing-based molding technique.

Science.gov (United States)

Leddy, Michael T; Belter, Joseph T; Gemmell, Kevin D; Dollar, Aaron M

2015-01-01

Additive manufacturing techniques are becoming more prominent and cost-effective as 3D printing becomes higher quality and more inexpensive. The idea of 3D printed prosthetics components promises affordable, customizable devices, but these systems currently have major shortcomings in durability and function. In this paper, we propose a fabrication method for custom composite prostheses utilizing additive manufacturing, allowing for customizability, as well the durability of professional prosthetics. The manufacturing process is completed using 3D printed molds in a multi-stage molding system, which creates a custom finger or palm with a lightweight epoxy foam core, a durable composite outer shell, and soft urethane gripping surfaces. The composite material was compared to 3D printed and aluminum materials using a three-point bending test to compare stiffness, as well as gravimetric measurements to compare weight. The composite finger demonstrates the largest stiffness with the lowest weight compared to other tested fingers, as well as having customizability and lower cost, proving to potentially be a substantial benefit to the development of upper-limb prostheses.

Emerging technologies in arthroplasty: additive manufacturing.

Science.gov (United States)

Banerjee, Samik; Kulesha, Gene; Kester, Mark; Mont, Michael A

2014-06-01

Additive manufacturing is an industrial technology whereby three-dimensional visual computer models are fabricated into physical components by selectively curing, depositing, or consolidating various materials in consecutive layers. Although initially developed for production of simulated models, the technology has undergone vast improvements and is currently increasingly being used for the production of end-use components in various aerospace, automotive, and biomedical specialties. The ability of this technology to be used for the manufacture of solid-mesh-foam monolithic and coated components of complex geometries previously considered unmanufacturable has attracted the attention of implant manufacturers, bioengineers, and orthopedic surgeons. Currently, there is a paucity of reports describing this fabrication method in the orthopedic literature. Therefore, we aimed to briefly describe this technology, some of the applications in other orthopedic subspecialties, its present use in hip and knee arthroplasty, and concerns with the present form of the technology. As there are few reports of clinical trials presently available, the true benefits of this technology can only be realized when studies evaluating the clinical and radiographic outcomes of cementless implants manufactured with additive manufacturing report durable fixation, less stress shielding, and better implant survivorship. Nevertheless, the authors believe that this technology holds great promise and may potentially change the conventional methods of casting, machining, and tooling for implant manufacturing in the future. Thieme Medical Publishers 333 Seventh Avenue, New York, NY 10001, USA.

The Frontiers of Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Grote, Christopher John [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

2016-03-03

Additive manufacturing, more commonly known as 3-D printing, has become a ubiquitous tool in science for its precise control over mechanical design. For additive manufacturing to work, a 3-D structure is split into thin 2D slices, and then different physical properties, such as photo-polymerization or melting, are used to grow the sequential layers. The level of control allows not only for devices to be made with a variety of materials: e.g. plastics, metals, and quantum dots, but to also have finely controlled structures leading to other novel properties. While 3-D printing is widely used by hobbyists for making models, it also has industrial applications in structural engineering, biological tissue scaffolding, customized electric circuitry, fuel cells, security, and more.

Additive Manufacturing of Porous Metal

Energy Technology Data Exchange (ETDEWEB)

Dehoff, Ryan R. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Kirka, Michael M. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2017-06-01

Currently, helium is obtained through separation from natural gas. The current industrial process incurs significant costs and requires large energy resources to successfully achieve separation. Through utilizing Additive Manufacturing (AM) technologies it is possible to reduce both of these burdens when refining helium gas. The ability to engineer porosity levels within Inconel 718 discs for controlled separation of helium from natural gas was investigated. Arrays of samples fabricated using the electron beam melting process were analyzed for their relative porosity density. Based upon the measurements, full scale discs were fabricated, and subsequently tested to determine their effectiveness in separating helium from liquefied natural gas.

PicPrint: Embedding pictures in additive manufacturing

DEFF Research Database (Denmark)

Nielsen, Jannik Boll; Eiríksson, Eyþór Rúnar; Lyngby, Rasmus Ahrenkiel

2017-01-01

Here  we  present  PicPrint,  a  method  and  tool  for  producing  an  additively  manufactured  lithophane,  enabling  transferring  and embedding  2D  information  into  additively  manufactured  3D  objects.  The  method  takes  an  input  image  and  converts  it  to  a......, after which  the mesh is  ready  for either  direct  print  on an additive manufacturing system, or transfer to other geometries via Boolean mesh operations. ...

A review on powder-based additive manufacturing for tissue engineering: selective laser sintering and inkjet 3D printing.

Science.gov (United States)

Shirazi, Seyed Farid Seyed; Gharehkhani, Samira; Mehrali, Mehdi; Yarmand, Hooman; Metselaar, Hendrik Simon Cornelis; Adib Kadri, Nahrizul; Osman, Noor Azuan Abu

2015-06-01

Since most starting materials for tissue engineering are in powder form, using powder-based additive manufacturing methods is attractive and practical. The principal point of employing additive manufacturing (AM) systems is to fabricate parts with arbitrary geometrical complexity with relatively minimal tooling cost and time. Selective laser sintering (SLS) and inkjet 3D printing (3DP) are two powerful and versatile AM techniques which are applicable to powder-based material systems. Hence, the latest state of knowledge available on the use of AM powder-based techniques in tissue engineering and their effect on mechanical and biological properties of fabricated tissues and scaffolds must be updated. Determining the effective setup of parameters, developing improved biocompatible/bioactive materials, and improving the mechanical/biological properties of laser sintered and 3D printed tissues are the three main concerns which have been investigated in this article.

Dendritic microstructure and hot cracking of laser additive manufactured Inconel 718 under improved base cooling

Energy Technology Data Exchange (ETDEWEB)

Chen, Yuan; Lu, Fenggui; Zhang, Ke; Nie, Pulin; Elmi Hosseini, Seyed Reza; Feng, Kai, E-mail: fengkai@sjtu.edu.cn; Li, Zhuguo, E-mail: lizg@sjtu.edu.cn

2016-06-15

The base cooling effect was improved by imposing the continuous water flow on the back of the substrate during the laser additive manufacturing of Inconel 718 (IN718). The dendritic microstructure, crystal orientation and hot cracking behavior were studied by using optical microscopy (OM), scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) techniques. The results showed that the crystal orientation was increased by increasing the base cooling effect during the deposition. Also, highly ordered columnar dendrites were established, and mono-crystalline texture was constructed in the final clad. It was fund that the effect of solidification cracking on the properties of final clad was negligible since it was only generated at the top region of the deposit, while liquation cracking was produced and remained in the heat affected zone (HAZ) and needed to be carefully controlled. The susceptibility to the liquation cracking showed a high dependence on the grain boundary misorientation, which was considered to be attributed to the stability of interdendritic liquation films, as well as the magnitude of local stress concentration in the last stage of solidification. - Highlights: • The base cooling effect was increased during laser additive manufacturing. • Highly ordered dendrites were established under improved base cooling. • The crystal orientation was increased by improving the base cooling effect. • Liquation cracking tendency was reduced due to the increase of base cooling. • Liquation cracking increased with the increase of grain boundary misorientation.

Dendritic microstructure and hot cracking of laser additive manufactured Inconel 718 under improved base cooling

International Nuclear Information System (INIS)

Chen, Yuan; Lu, Fenggui; Zhang, Ke; Nie, Pulin; Elmi Hosseini, Seyed Reza; Feng, Kai; Li, Zhuguo

2016-01-01

The base cooling effect was improved by imposing the continuous water flow on the back of the substrate during the laser additive manufacturing of Inconel 718 (IN718). The dendritic microstructure, crystal orientation and hot cracking behavior were studied by using optical microscopy (OM), scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) techniques. The results showed that the crystal orientation was increased by increasing the base cooling effect during the deposition. Also, highly ordered columnar dendrites were established, and mono-crystalline texture was constructed in the final clad. It was fund that the effect of solidification cracking on the properties of final clad was negligible since it was only generated at the top region of the deposit, while liquation cracking was produced and remained in the heat affected zone (HAZ) and needed to be carefully controlled. The susceptibility to the liquation cracking showed a high dependence on the grain boundary misorientation, which was considered to be attributed to the stability of interdendritic liquation films, as well as the magnitude of local stress concentration in the last stage of solidification. - Highlights: • The base cooling effect was increased during laser additive manufacturing. • Highly ordered dendrites were established under improved base cooling. • The crystal orientation was increased by improving the base cooling effect. • Liquation cracking tendency was reduced due to the increase of base cooling. • Liquation cracking increased with the increase of grain boundary misorientation.

Feature based Weld-Deposition for Additive Manufacturing of Complex Shapes

Science.gov (United States)

Panchagnula, Jayaprakash Sharma; Simhambhatla, Suryakumar

2018-06-01

Fabricating functional metal parts using Additive Manufacturing (AM) is a leading trend. However, realizing overhanging features has been a challenge due to the lack of support mechanism for metals. Powder-bed fusion techniques like, Selective Laser Sintering (SLS) employ easily-breakable-scaffolds made of the same material to realize the overhangs. However, the same approach is not extendible to deposition processes like laser or arc based direct energy deposition processes. Although it is possible to realize small overhangs by exploiting the inherent overhanging capability of the process or by blinding some small features like holes, the same cannot be extended for more complex geometries. The current work presents a novel approach for realizing complex overhanging features without the need of support structures. This is possible by using higher order kinematics and suitably aligning the overhang with the deposition direction. Feature based non-uniform slicing and non-uniform area-filling are some vital concepts required in realizing the same and are briefly discussed here. This method can be used to fabricate and/or repair fully dense and functional components for various engineering applications. Although this approach has been implemented for weld-deposition based system, the same can be extended to any other direct energy deposition processes also.

Advanced Manufacturing Technologies (AMT): Additive Manufactured Hot Fire Planning and Testing in GRC Cell 32 Project

Science.gov (United States)

Fikes, John C.

2014-01-01

The objective of this project is to hot fire test an additively manufactured thrust chamber assembly TCA (injector and thrust chamber). GRC will install the additively manufactured Inconel 625 injector, two additively manufactured (SLM) water cooled Cu-Cr thrust chamber barrels and one additively manufactured (SLM) water cooled Cu-Cr thrust chamber nozzle on the test stand in Cell 32 and perform hot fire testing of the integrated TCA.

Process chain modeling and selection in an additive manufacturing context

DEFF Research Database (Denmark)

Thompson, Mary Kathryn; Stolfi, Alessandro; Mischkot, Michael

2016-01-01

This paper introduces a new two-dimensional approach to modeling manufacturing process chains. This approach is used to consider the role of additive manufacturing technologies in process chains for a part with micro scale features and no internal geometry. It is shown that additive manufacturing...... evolving fields like additive manufacturing....

Laser-based additive manufacturing: where it has been, where it needs to go

Science.gov (United States)

Cooper, Khershed P.

2014-03-01

It is no secret that the laser was the driver for additive manufacturing (AM) of 3D objects since such objects were first demonstrated in the mid-1980s. A myriad of techniques utilizing the directed energy of lasers were invented. Lasers are used to selectively sinter or fuse incremental layers in powder-beds, melt streaming powder following a programmed path, and polymerize photopolymers in a liquid vat layer-by-layer. The laser is an energy source of choice for repair of damaged components, for manufacture of new or replacement parts, and for rapid prototyping of concept designs. Lasers enable microstructure gradients and heterogeneous structures designed to exhibit unique properties and behavior. Laserbased additive manufacturing has been successful in producing relatively simple near net-shape metallic parts saving material and cost, but requiring finish-machining and in repair and refurbishment of worn components. It has been routinely used to produce polymer parts. These capabilities have been widely recognized as evidenced by the explosion in interest in AM technology, nationally. These successes are, however, tempered by challenges facing practitioners such as process and part qualification and verification, which are needed to bring AM as a true manufacturing technology. The ONR manufacturing science program, in collaboration with other agencies, invested in basic R&D in AM since its beginnings. It continues to invest, currently focusing on developing cyber-enabled manufacturing systems for AM. It is believed that such computation, communication and control approaches will help in validating AM and moving it to the factory floor along side CNC machines.

Additive manufacturing: state-of-the-art and application framework

Directory of Open Access Journals (Sweden)

Vinícius Picanço Rodrigues

2017-09-01

Full Text Available Additive manufacturing encompasses a class of production processes with increasing applications in different areas and supply chains. Due to its flexibility for production in small batches and the versatility of materials and geometries, this technology is recognized as being capable of revolutionizing the production processes as well as changing production strategies that are currently employed. However, there are different technologies under the generic label of additive manufacturing, materials and application areas with different requirements. Given the growing importance of additive manufacturing as a production process, and also considering the need to have a better insight into the potential applications for driving research and development efforts, this article presents a proposal of organization for additive manufacturing applications in seven areas. Additionally, the article provides a panorama of the current development stage of this technology, with a review of its major technological variants. The results presented aim to serve as a basis to support driving initiatives in additive manufacturing in companies, development agencies and research institutions.

Self-supporting rhombic infill structures for additive manufacturing

DEFF Research Database (Denmark)

Wu, Jun; Wang, Charlie C.L.; Zhang, Xiaoting

2016-01-01

Recent work has demonstrated that the interior material layout of a 3D model can be designed to make a fabricated replica satisfy application-specific demands on its physical properties, such as resistance to external loads. A widely used practice to fabricate such models is by layer-based additive...... manufacturing (AM), which however suffers from the problem of adding and removing interior supporting structures. In this paper, we present a novel method for generating application-specific infill structures on rhombic cells so that the resultant structures can automatically satisfy manufacturing requirements...... on overhang-angle and wall-thickness. Additional supporting structures can be avoided entirely in our framework. To achieve this, we introduce the usage of an adaptive rhombic grid, which is built from an input surface model. Starting from the initial sparse set of rhombic cells, via numerical optimization...

Certification of Additive Manufacturing Processing Parameters through Physics-Based Predictive Simulation of Process-Defects-Microstructure

Data.gov (United States)

National Aeronautics and Space Administration — Additive manufacturing (AM), also known as 3D printing, is a next generation technology for cost-effective and accelerated way of manufacturing complex-shaped...

Mechanical properties of open-cell metallic biomaterials manufactured using additive manufacturing

International Nuclear Information System (INIS)

Campoli, G.; Borleffs, M.S.; Amin Yavari, S.; Wauthle, R.; Weinans, H.; Zadpoor, A.A.

2013-01-01

Highlights: ► Finite element (FE) models were used to predict the mechanical properties of porous biomaterials. ► Porous materials were produced using additive manufacturing techniques. ► Manufacturing irregularities need to be implemented in FE models. ► FE models are more accurate than analytical models in predicting mechanical properties. - Abstract: An important practical problem in application of open-cell porous biomaterials is the prediction of the mechanical properties of the material given its micro-architecture and the properties of its matrix material. Although analytical methods can be used for this purpose, these models are often based on several simplifying assumptions with respect to the complex architecture and cannot provide accurate prediction results. The aim of the current study is to present finite element (FE) models that can predict the mechanical properties of porous titanium produced using selective laser melting or selective electron beam melting. The irregularities caused by the manufacturing process including structural variations of the architecture are implemented in the FE models using statistical models. The predictions of FE models are compared with those of analytical models and are tested against experimental data. It is shown that, as opposed to analytical models, the predictions of FE models are in agreement with experimental observations. It is concluded that manufacturing irregularities significantly affect the mechanical properties of porous biomaterials

Photogrammetry for Repositioning in Additive Manufacturing

DEFF Research Database (Denmark)

Jensen, Janus Nørtoft; Lyngby, Rasmus Ahrenkiel; Aanæs, Henrik

2017-01-01

In this preliminary work, we present our current status on how to use single camera photogrammetry to determine the orientation of an additively manufactured partly finished object that has been repositioned in the printing chamber, from a single image taken with a calibrated camera, and comparing...... this to the CAD model of the object. We describe how this knowledge can be used to update the machine code of the printer such that printing of the object can be resumed in the new location. This opens possibilities for embedding and assembling foreign parts into the additive manufacturing pipeline, adding...

Utility of Big Area Additive Manufacturing (BAAM) For The Rapid Manufacture of Customized Electric Vehicles

Energy Technology Data Exchange (ETDEWEB)

Love, Lonnie J [ORNL

2015-08-01

This Oak Ridge National Laboratory (ORNL) Manufacturing Development Facility (MDF) technical collaboration project was conducted in two phases as a CRADA with Local Motors Inc. Phase 1 was previously reported as Advanced Manufacturing of Complex Cyber Mechanical Devices through Community Engagement and Micro-manufacturing and demonstrated the integration of components onto a prototype body part for a vehicle. Phase 2 was reported as Utility of Big Area Additive Manufacturing (BAAM) for the Rapid Manufacture of Customized Electric Vehicles and demonstrated the high profile live printing of an all-electric vehicle using ONRL s Big Area Additive Manufacturing (BAAM) technology. This demonstration generated considerable national attention and successfully demonstrated the capabilities of the BAAM system as developed by ORNL and Cincinnati, Inc. and the feasibility of additive manufacturing of a full scale electric vehicle as envisioned by the CRADA partner Local Motors, Inc.

Surface-specific additive manufacturing test artefacts

Science.gov (United States)

Townsend, Andrew; Racasan, Radu; Blunt, Liam

2018-06-01

Many test artefact designs have been proposed for use with additive manufacturing (AM) systems. These test artefacts have primarily been designed for the evaluation of AM form and dimensional performance. A series of surface-specific measurement test artefacts designed for use in the verification of AM manufacturing processes are proposed here. Surface-specific test artefacts can be made more compact because they do not require the large dimensions needed for accurate dimensional and form measurements. The series of three test artefacts are designed to provide comprehensive information pertaining to the manufactured surface. Measurement possibilities include deviation analysis, surface texture parameter data generation, sub-surface analysis, layer step analysis and build resolution comparison. The test artefacts are designed to provide easy access for measurement using conventional surface measurement techniques, for example, focus variation microscopy, stylus profilometry, confocal microscopy and scanning electron microscopy. Additionally, the test artefacts may be simply visually inspected as a comparative tool, giving a fast indication of process variation between builds. The three test artefacts are small enough to be included in every build and include built-in manufacturing traceability information, making them a convenient physical record of the build.

Life Cycle Assessment of Fiber-Reinforced Additive Manufacturing for Injection Molding Insert Production

DEFF Research Database (Denmark)

Hofstätter, Thomas; Stotz, Philippe Maurice; Bey, Niki

2017-01-01

Additively manufactured (AM) injection molding (IM) inserts have proved to be capable to substitute conventionally manufactured metal inserts with polymer-based insert enforced with short, virgin, unseized carbon fibers (CFs). It has been shown that the implementation of AM technology resulted......, this contribution provides a comparison of environmental performance of conventionally vs. additively manufactured inserts in a full life cycle perspective indicated in Figure 1, including materials, production, use and end-of-life (EoL) stages....

Rheology of high melt strength polypropylene for additive manufacturing

DEFF Research Database (Denmark)

Jagenteufel, Ralf; Hofstätter, Thomas; Kamleitner, Florian

2017-01-01

stability, whereas HMS-PP showed a more stable behavior at the investigated temperatures. Hereafter, the material was used in a fused deposition modeling additive manufacturing process, focusing on the investigation of possible improvements of HMS-PP over ABS. Based on the extrusion parameters for ABS...

State-of-the-art laser additive manufacturing for hot-work tool steels

OpenAIRE

Klocke, Fritz; Arntz, Kristian; Teli, Mahesh; Winands, Kai; Wegener, Maximilian; Oliari, Stella

2017-01-01

Additive manufacturing (AM) processes are based on the controlled selective deposition of material by which a part is manufactured or remanufactured (repaired), layer by layer. Research in AM is drastically on the increase in the last several years owing to the benefits that AM provides over conventional manufacturing i.e. reduction in material usage, time-to-market reduction, improved functionality, increased ability to customize and near-net shape manufacturing. There has been a number of A...

Additive Manufacturing for Affordable Rocket Engines

Science.gov (United States)

West, Brian; Robertson, Elizabeth; Osborne, Robin; Calvert, Marty

2016-01-01

Additive manufacturing (also known as 3D printing) technology has the potential to drastically reduce costs and lead times associated with the development of complex liquid rocket engine systems. NASA is using 3D printing to manufacture rocket engine components including augmented spark igniters, injectors, turbopumps, and valves. NASA is advancing the process to certify these components for flight. Success Story: MSFC has been developing rocket 3D-printing technology using the Selective Laser Melting (SLM) process. Over the last several years, NASA has built and tested several injectors and combustion chambers. Recently, MSFC has 3D printed an augmented spark igniter for potential use the RS-25 engines that will be used on the Space Launch System. The new design is expected to reduce the cost of the igniter by a factor of four. MSFC has also 3D printed and tested a liquid hydrogen turbopump for potential use on an Upper Stage Engine. Additive manufacturing of the turbopump resulted in a 45% part count reduction. To understanding how the 3D printed parts perform and to certify them for flight, MSFC built a breadboard liquid rocket engine using additive manufactured components including injectors, turbomachinery, and valves. The liquid rocket engine was tested seven times in 2016 using liquid oxygen and liquid hydrogen. In addition to exposing the hardware to harsh environments, engineers learned to design for the new manufacturing technique, taking advantage of its capabilities and gaining awareness of its limitations. Benefit: The 3D-printing technology promises reduced cost and schedule for rocket engines. Cost is a function of complexity, and the most complicated features provide the largest opportunities for cost reductions. This is especially true where brazes or welds can be eliminated. The drastic reduction in part count achievable with 3D printing creates a waterfall effect that reduces the number of processes and drawings, decreases the amount of touch

Additive Manufacturing of Biomaterials, Tissues, and Organs

NARCIS (Netherlands)

Zadpoor, Amir A; Malda, Jos|info:eu-repo/dai/nl/412461099

The introduction of additive manufacturing (AM), often referred to as three-dimensional (3D) printing, has initiated what some believe to be a manufacturing revolution, and has expedited the development of the field of biofabrication. Moreover, recent advances in AM have facilitated further

Additively manufactured porous tantalum implants

NARCIS (Netherlands)

Wauthle, Ruben; Van Der Stok, Johan; Yavari, Saber Amin; Van Humbeeck, Jan; Kruth, Jean Pierre; Zadpoor, Amir Abbas; Weinans, Harrie; Mulier, Michiel; Schrooten, Jan

2015-01-01

The medical device industry's interest in open porous, metallic biomaterials has increased in response to additive manufacturing techniques enabling the production of complex shapes that cannot be produced with conventional techniques. Tantalum is an important metal for medical devices because of

Rapid prototyping of multi-scale biomedical microdevices by combining additive manufacturing technologies.

Science.gov (United States)

Hengsbach, Stefan; Lantada, Andrés Díaz

2014-08-01

The possibility of designing and manufacturing biomedical microdevices with multiple length-scale geometries can help to promote special interactions both with their environment and with surrounding biological systems. These interactions aim to enhance biocompatibility and overall performance by using biomimetic approaches. In this paper, we present a design and manufacturing procedure for obtaining multi-scale biomedical microsystems based on the combination of two additive manufacturing processes: a conventional laser writer to manufacture the overall device structure, and a direct-laser writer based on two-photon polymerization to yield finer details. The process excels for its versatility, accuracy and manufacturing speed and allows for the manufacture of microsystems and implants with overall sizes up to several millimeters and with details down to sub-micrometric structures. As an application example we have focused on manufacturing a biomedical microsystem to analyze the impact of microtextured surfaces on cell motility. This process yielded a relevant increase in precision and manufacturing speed when compared with more conventional rapid prototyping procedures.

Designing an in-situ ultrasonic nondestructive evaluation system for ultrasonic additive manufacturing

Science.gov (United States)

Nadimpalli, Venkata K.; Nagy, Peter B.

2018-04-01

Ultrasonic Additive Manufacturing (UAM) is a solid-state layer by layer manufacturing process that utilizes vibration induced plastic deformation to form a metallurgical bond between a thin layer and an existing base structure. Due to the vibration based bonding mechanism, the quality of components at each layer depends on the geometry of the structure. In-situ monitoring during and between UAM manufacturing steps offers the potential for closed-loop control to optimize process parameters and to repair existing defects. One interface that is most prone to delamination is the base/build interface and often UAM component height and quality are limited by failure at the base/build interface. Low manufacturing temperatures and favorable orientation of typical interface defects in UAM make ultrasonic NDE an attractive candidate for online monitoring. Two approaches for in-situ NDE are discussed and the design of the monitoring system optimized so that the quality of UAM components is not affected by the addition of the NDE setup. Preliminary results from in-situ ultrasonic NDE indicate the potential to be utilized for online qualification, closed-loop control and offline certification of UAM components.

Additive Manufacturing of Biomaterials, Tissues, and Organs

NARCIS (Netherlands)

Zadpoor, Amir A; Malda, Jos

2017-01-01

The introduction of additive manufacturing (AM), often referred to as three-dimensional (3D) printing, has initiated what some believe to be a manufacturing revolution, and has expedited the development of the field of biofabrication. Moreover, recent advances in AM have facilitated further

Deposition Time and Thermal Cycles of Fabricating Thin-wall Steel Parts by Double Electrode GMAW Based Additive Manufacturing

Directory of Open Access Journals (Sweden)

Yang Dongqing

2017-01-01

Full Text Available The deposition time for fabricating the thin-wall part as well as the peak temperature of the substrate during the process was analyzed in the double electrode gas metal arc welding (DE-GMAW based additive manufacturing (AM. The total deposition time and the interlayer idle time of the manufacturing process decreased with the increasing of the bypass current under the same interlayer temperature and the same deposition rate. The thermal cycling curves illustrated that the peak temperature of the substrate was lower in the DE-GMAW base AM under the same conditions. When depositing the thin-wall parts, the DE-GMAW based AM can reduce the heat input to the substrate and improve the fabrication efficiency, compared with the GMAW based AM.

Feasibility of using Big Area Additive Manufacturing to Directly Manufacture Boat Molds

Energy Technology Data Exchange (ETDEWEB)

Post, Brian K. [ORNL; Chesser, Phillip C. [ORNL; Lind, Randall F. [ORNL; Sallas, Matthew R. [ORNL; Love, Lonnie J. [ORNL

2018-01-01

The goal of this project was to explore the feasibility of using Big Area Additive Manufacturing (BAAM) to directly manufacture a boat mold without the need for coatings. All prior tooling projects with BAAM required the use to thick coatings to overcome the surface finish limitations of the BAAM process. While the BAAM process significantly lowers the cost of building the mold, the high cost element rapidly became the coatings (cost of the material, labor on coating, and finishing). As an example, the time and cost to manufacture the molds for the Wind Turbine project with TPI Composites Inc. and the molds for the submarine project with Carderock Naval Warfare Systems was a fraction of the time and cost of the coatings. For this project, a catamaran boat hull mold was designed, manufactured, and assembled with an additional 0.15” thickness of material on all mold surfaces. After printing, the mold was immediately machined and assembled. Alliance MG, LLC (AMG), the industry partner of this project, experimented with mold release agents on the carbon-fiber reinforced acrylonitrile butadiene styrene (CF ABS) to verify that the material can be directly used as a mold (rather than needing a coating). In addition, for large molds (such as the wind turbine mold with TPI Composites Inc.), the mold only provided the target surface. A steel subframe had to be manufactured to provide structural integrity. If successful, this will significantly reduce the time and cost necessary for manufacturing large resin infusion molds using the BAAM process.

Additive Manufacturing and Business Models: Current Knowledge and Missing Perspectives

Directory of Open Access Journals (Sweden)

Christina Öberg

2018-06-01

Full Text Available Additive manufacturing, that is 3D printing technology, may change the way companies operate their businesses. This article adopts a business model perspective to create an understanding of what we know about these changes. It summarizes current knowledge on additive manufacturing within management and business research, and it discusses future research directions in relation to business models for additive manufacturing. Using the scientific database Web of Science, 116 journal articles were identified. The literature review reveals that most research concerns manufacturing optimization. A more holistic view of the changes that additive manufacturing may bring about for firms is needed, as is more research on changed value propositions, and customer/sales-related issues. The article contributes to previous research by systematically summarizing additive manufacturing research in the business and management literature, and by highlighting areas for further investigation related to the business models of individual firms.

Minimum Compliance Topology Optimization of Shell-Infill Composites for Additive Manufacturing

DEFF Research Database (Denmark)

Wu, Jun; Clausen, Anders; Sigmund, Ole

2017-01-01

Additively manufactured parts are often composed of two sub-structures, a solid shell forming their exterior and a porous infill occupying the interior. To account for this feature this paper presents a novel method for generating simultaneously optimized shell and infill in the context of minimum...... interpolation model into a physical density field, upon which the compliance is minimized. Enhanced by an adapted robust formulation for controlling the minimum length scale of the base, our method generates optimized shell-infill composites suitable for additive manufacturing. We demonstrate the effectiveness...

NASA OSMA NDE Program Additive Manufacturing Foundational Effort

Science.gov (United States)

Waller, Jess; Walker, James; Burke, Eric; Wells, Douglas; Nichols, Charles

2016-01-01

NASA is providing key leadership in an international effort linking NASA and non-NASA resources to speed adoption of additive manufacturing (AM) to meet NASA's mission goals. Participants include industry, NASA's space partners, other government agencies, standards organizations and academia. Nondestructive Evaluation (NDE) is identified as a universal need for all aspects of additive manufacturing.

Consolidation & Factors Influencing Sintering Process in Polymer Powder Based Additive Manufacturing

Science.gov (United States)

Sagar, M. B.; Elangovan, K.

2017-08-01

Additive Manufacturing (AM) is two decade old technology; where parts are build layer manufacturing method directly from a CAD template. Over the years, AM techniques changes the future way of part fabrication with enhanced intricacy and custom-made features are aimed. Commercially polymers, metals, ceramic and metal-polymer composites are in practice where polymers enhanced the expectations in AM and are considered as a kind of next industrial revolution. Growing trend in polymer application motivated to study their feasibility and properties. Laser sintering, Heat sintering and Inhibition sintering are the most successful AM techniques for polymers but having least application. The presentation gives up selective sintering of powder polymers and listed commercially available polymer materials. Important significant factors for effective processing and analytical approaches to access them are discussed.

An In-Depth Review on Direct Additive Manufacturing of Metals

Science.gov (United States)

Azam, Farooq I.; Rani, Ahmad Majdi Abdul; Altaf, Khurram; Rao, T. V. V. L. N.; Aimi Zaharin, Haizum

2018-03-01

Additive manufacturing (AM), also known as 3D Printing, is a revolutionary manufacturing technique which has been developing rapidly in the last 30 years. The evolution of this precision manufacturing process from rapid prototyping to ready-to-use parts has significantly alleviated manufacturing constraints and design freedom has been outstandingly widened. AM is a non-conventional manufacturing technique which utilizes a 3D CAD model data to build parts by adding one material layer at a time, rather than removing it and fulfills the demand for manufacturing parts with complex geometric shapes, great dimensional accuracy, and easy to assemble parts. Additive manufacturing of metals has become the area of extensive research, progressing towards the production of final products and replacing conventional manufacturing methods. This paper provides an insight to the available metal additive manufacturing technologies that can be used to produce end user products without using conventional manufacturing methods. The paper also includes the comparison of mechanical and physical properties of parts produced by AM with the parts manufactured using conventional processes.

Laser additive manufacturing bulk graphene-copper nanocomposites.

Science.gov (United States)

Hu, Zengrong; Chen, Feng; Lin, Dong; Nian, Qiong; Parandoush, Pedram; Zhu, Xing; Shao, Zhuqiang; Cheng, Gary J

2017-11-03

The exceptional mechanical properties of graphene make it an ideal nanofiller for reinforcing metal matrix composites (MMCs). In this work, graphene-copper (Gr-Cu) nanocomposites have been fabricated by a laser additive manufacturing process. Transmission electron microscopy (TEM), x-ray diffraction (XRD) and Raman spectroscopy were utilized to characterize the fabricated nanocomposites. The XRD, Raman spectroscopy, energy dispersive spectroscopy and TEM results demonstrated the feasibility of laser additive manufacturing of Gr-Cu nanocomposites. The microstructures were characterized by high resolution TEM and the results further revealed the interface between the copper matrix and graphene. With the addition of graphene, the mechanical properties of the composites were enhanced significantly. Nanoindentation tests showed that the average modulus value and hardness of the composites were 118.9 GPa and 3 GPa respectively; 17.6% and 50% increases were achieved compared with pure copper, respectively. This work demonstrates a new way to manufacture graphene copper nanocomposites with ultra-strong mechanical properties and provides alternatives for applications in electrical and thermal conductors.

Evaluation of Advanced Polymers for Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Rios, Orlando [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Carter, William G. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Kutchko, Cindy [PPG Industries, Pittsburgh, PA (United States); Fenn, David [PPG Industries, Pittsburgh, PA (United States); Olson, Kurt [PPG Industries, Pittsburgh, PA (United States)

2017-09-08

The goal of this Manufacturing Demonstration Facility (MDF) technical collaboration project between Oak Ridge National Laboratory (ORNL) and PPG Industries, Inc. (PPG) was to evaluate the feasibility of using conventional coatings chemistry and technology to build up material layer-by-layer. The PPG-ORNL study successfully demonstrated that polymeric coatings formulations may overcome many limitations of common thermoplastics used in additive manufacturing (AM), allow lightweight nozzle design for material deposition, and increase build rate. The materials effort focused on layer-by-layer deposition of coatings with each layer fusing together. The combination of materials and deposition results in an additively manufactured build that has sufficient mechanical properties to bear the load of additional layers, yet is capable of bonding across the z-layers to improve build direction strength. The formulation properties were tuned to enable a novel, high-throughput deposition method that is highly scalable, compatible with high loading of reinforcing fillers, and inherently low-cost.

Development of Cranial Bone Surrogate Structures Using Stereolithographic Additive Manufacturing

Science.gov (United States)

2017-09-29

Additive Manufacturing by Jared M Gardner and Thomas A Plaisted Approved for public release; distribution is unlimited...Laboratory Development of Cranial Bone Surrogate Structures Using Stereolithographic Additive Manufacturing by Thomas A Plaisted Weapons...Structures Using Stereolithographic Additive Manufacturing 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) Jared

System and method for high power diode based additive manufacturing

Science.gov (United States)

El-Dasher, Bassem S.; Bayramian, Andrew; Demuth, James A.; Farmer, Joseph C.; Torres, Sharon G.

2016-04-12

A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

System and method for high power diode based additive manufacturing

Energy Technology Data Exchange (ETDEWEB)

El-Dasher, Bassem S.; Bayramian, Andrew; Demuth, James A.; Farmer, Joseph C.; Torres, Sharon G.

2018-01-02

A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

Finding phosphorus containing additives in manufactured foods

Directory of Open Access Journals (Sweden)

Lyn Lloyd

2012-06-01

This reflects manufactured foods in NZ and it is likely that these results could be generalized to countries with similar food patterns and supplies. Quantitative data in manufactured foods is unlikely to be available to guide patient choice so qualitative information of where to find P additives can be helpful.

Additive Manufacturing of Biomaterials, Tissues, and Organs.

Science.gov (United States)

Zadpoor, Amir A; Malda, Jos

2017-01-01

The introduction of additive manufacturing (AM), often referred to as three-dimensional (3D) printing, has initiated what some believe to be a manufacturing revolution, and has expedited the development of the field of biofabrication. Moreover, recent advances in AM have facilitated further development of patient-specific healthcare solutions. Customization of many healthcare products and services, such as implants, drug delivery devices, medical instruments, prosthetics, and in vitro models, would have been extremely challenging-if not impossible-without AM technologies. The current special issue of the Annals of Biomedical Engineering presents the latest trends in application of AM techniques to healthcare-related areas of research. As a prelude to this special issue, we review here the most important areas of biomedical research and clinical practice that have benefited from recent developments in additive manufacturing techniques. This editorial, therefore, aims to sketch the research landscape within which the other contributions of the special issue can be better understood and positioned. In what follows, we briefly review the application of additive manufacturing techniques in studies addressing biomaterials, (re)generation of tissues and organs, disease models, drug delivery systems, implants, medical instruments, prosthetics, orthotics, and AM objects used for medical visualization and communication.

A study on the applications of AI in finishing of additive manufacturing parts

Science.gov (United States)

Fathima Patham, K.

2017-06-01

Artificial intelligent and computer simulation are the technological powerful tools for solving complex problems in the manufacturing industries. Additive Manufacturing is one of the powerful manufacturing techniques that provide design flexibilities to the products. The products with complex shapes are directly manufactured without the need of any machining and tooling using Additive Manufacturing. However, the main drawback of the components produced using the Additive Manufacturing processes is the quality of the surfaces. This study aims to minimize the defects caused during Additive Manufacturing with the aid of Artificial Intelligence. The developed AI system has three layers, each layer is trying to eliminate or minimize the production errors. The first layer of the AI system optimizes the digitization of the 3D CAD model of the product and hence reduces the stair case errors. The second layer of the AI system optimizes the 3D printing machine parameters in order to eliminate the warping effect. The third layer of AI system helps to choose the surface finishing technique suitable for the printed component based on the Degree of Complexity of the product and the material. The efficiency of the developed AI system was examined on the functional parts such as gears.

Monitoring system for the quality assessment in additive manufacturing

Energy Technology Data Exchange (ETDEWEB)

Carl, Volker, E-mail: carl@t-zfp.de [Carl Messtechnik, Thyssenstrasse 183a, 46535 Dinslaken (Germany)

2015-03-31

Additive Manufacturing (AM) refers to a process by which a set of digital data -representing a certain complex 3dim design - is used to grow the respective 3dim real structure equal to the corresponding design. For the powder-based EOS manufacturing process a variety of plastic and metal materials can be used. Thereby, AM is in many aspects a very powerful tool as it can help to overcome particular limitations in conventional manufacturing. AM enables more freedom of design, complex, hollow and/or lightweight structures as well as product individualisation and functional integration. As such it is a promising approach with respect to the future design and manufacturing of complex 3dim structures. On the other hand, it certainly calls for new methods and standards in view of quality assessment. In particular, when utilizing AM for the design of complex parts used in aviation and aerospace technologies, appropriate monitoring systems are mandatory. In this respect, recently, sustainable progress has been accomplished by joining the common efforts and concerns of a manufacturer Additive Manufacturing systems and respective materials (EOS), along with those of an operator of such systems (MTU Aero Engines) and experienced application engineers (Carl Metrology), using decent know how in the field of optical and infrared methods regarding non-destructive-examination (NDE). The newly developed technology is best described by a high-resolution layer by layer inspection technique, which allows for a 3D tomography-analysis of the complex part at any time during the manufacturing process. Thereby, inspection costs are kept rather low by using smart image-processing methods as well as CMOS sensors instead of infrared detectors. Moreover, results from conventional physical metallurgy may easily be correlated with the predictive results of the monitoring system which not only allows for improvements of the AM monitoring system, but finally leads to an optimisation of the quality

Additive manufacturing: state-of-the-art and application framework

DEFF Research Database (Denmark)

Rodrigues, Vinicius Picanco; de Senzi Zancul, Eduardo; Gonçalves Mançanares, Cauê

2017-01-01

Additive manufacturing encompasses a class of production processes with increasing applications indifferent areas and supply chains. Due to its flexibility for production in small batches and the versatilityof materials and geometries, this technology is recognized as being capable...... of revolutionizing theproduction processes as well as changing production strategies that are currently employed. However,there are different technologies under the generic label of additive manufacturing, materials and applicationareas with different requirements. Given the growing importance of additive...... manufacturingas a production process, and also considering the need to have a better insight into the potential applicationsfor driving research and development efforts, this article presents a proposal of organizationfor additive manufacturing applications in seven areas. Additionally, the article provides...

Utilization of curve offsets in additive manufacturing

Science.gov (United States)

Haseltalab, Vahid; Yaman, Ulas; Dolen, Melik

2018-05-01

Curve offsets are utilized in different fields of engineering and science. Additive manufacturing, which lately becomes an explicit requirement in manufacturing industry, utilizes curve offsets widely. One of the necessities of offsetting is for scaling which is required if there is shrinkage after the fabrication or if the surface quality of the resulting part is unacceptable. Therefore, some post-processing is indispensable. But the major application of curve offsets in additive manufacturing processes is for generating head trajectories. In a point-wise AM process, a correct tool-path in each layer can reduce lots of costs and increase the surface quality of the fabricated parts. In this study, different curve offset generation algorithms are analyzed to show their capabilities and disadvantages through some test cases and improvements on their drawbacks are suggested.

Topology Optimization for Reducing Additive Manufacturing Processing Distortions

Science.gov (United States)

2017-12-01

distribution is unlimited. 1. Introduction Additive manufacturing (AM) is a production method that involves gradual, layer- by-layer building of material... design space—allowing the production of pre- viously unmanufacturable topologically optimized structures—constraints remain. One constraint, for...ARL-TR-8242•DEC 2017 US Army Research Laboratory Topology Optimization for ReducingAdditive Manufacturing ProcessingDistortions by Raymond A Wildman

Additively Manufactured Ceramic Rocket Engine Components

Data.gov (United States)

National Aeronautics and Space Administration — HRL Laboratories, LLC, with Vector Space Systems (VSS) as subcontractor, has a 24-month effort to develop additive manufacturing technology for reinforced ceramic...

Current use and potential of additive manufacturing for optical applications

Science.gov (United States)

Brunelle, Matthew; Ferralli, Ian; Whitsitt, Rebecca; Medicus, Kate

2017-10-01

Additive manufacturing, or 3D printing, has become widely used in recent years for the creation of both prototype and end-use parts. Because the parts are created in a layer-by-layer manner, the flexibility of additive manufacturing is unparalleled and has opened the design space to enable features like undercuts and internal channels which cannot exist on traditional, subtractively manufactured parts. This flexibility can also be leveraged for optical applications. This paper outlines some of the current uses of 3D printing in the optical manufacturing process at Optimax. Several materials and additive technologies are utilized, including polymer printing through fused deposition modeling, which creates parts by depositing a softened thermoplastic filament in a layerwise fashion. Stereolithography, which uses light to cure layers of a photopolymer resin, will also be discussed. These technologies are used to manufacture functional prototypes, fixtures, sealed housings, and other components. Additionally, metal printing through selective laser melting, which uses a laser to melt metal powder layers into a dense solid, will be discussed due to the potential to manufacture thermally stable opticalmechanical assembly frameworks and functional optics. Examples of several additively manufactured optical components will be shown.

Impact of additive manufacturing on aircraft supply chain performance

DEFF Research Database (Denmark)

Ghadge, Abhijeet; Karantoni, Georgia; Chaudhuri, Atanu

2018-01-01

Purpose – The purpose of this paper is to assess the impact of additive manufacturing (AM) implementation on aircraft supply chain (SC) networks. Additive and conventional manufacturing spare part inventory control systems are studied and compared, revealing insights into SC performance. Design....... Originality/value – The study provides robust evidence for making critical managerial decisions on SC re-design driven by a new and disruptive technology. Next-generation SC and logistics will replace the current demand for fulfilling material products by AM machines. Keywords Performance measurement......, Simulation, Additive manufacturing, Supply chains, Aerospace industry...

The Crucial Role of Additive Manufacturing at NASA

Science.gov (United States)

Vickers, John

2016-01-01

At NASA, the first steps of the Journey to Mars are well underway with the development of NASA's next generation launch system and investments in research and technologies that should increase the affordability, capability, and safety of exploration activities. Additive Manufacturing presents a disruptive opportunity for NASA to design and manufacture hardware with new materials at dramatically reduced cost and schedule. Opportunities to incorporate additive manufacturing align very well with NASA missions and with most NASA programs related to space, science, and aeronautics. The Agency also relies on many partnerships with other government agencies, industry and academia.

Improvements in Operational Readiness by Distributing Manufacturing Capability in the Supply Chain through Additive Manufacturing

Science.gov (United States)

2017-12-01

Second, the report presents the results of laboratory tests designed to evaluate additive manufacturing time of four repair parts. C. RESEARCH...since the production repeatability and reliability of the parts are not well understood (Merritt 2015, 9). The Army’s Additive Manufacturing ...that has a single factory that produces all of their products . This definition is expanded to include a network of manufacturing facilities where each

Additive manufacturing of magnetic shielding and ultra-high vacuum flange for cold atom sensors.

Science.gov (United States)

Vovrosh, Jamie; Voulazeris, Georgios; Petrov, Plamen G; Zou, Ji; Gaber, Youssef; Benn, Laura; Woolger, David; Attallah, Moataz M; Boyer, Vincent; Bongs, Kai; Holynski, Michael

2018-01-31

Recent advances in the understanding and control of quantum technologies, such as those based on cold atoms, have resulted in devices with extraordinary metrological performance. To realise this potential outside of a lab environment the size, weight and power consumption need to be reduced. Here we demonstrate the use of laser powder bed fusion, an additive manufacturing technique, as a production technique relevant to the manufacture of quantum sensors. As a demonstration we have constructed two key components using additive manufacturing, namely magnetic shielding and vacuum chambers. The initial prototypes for magnetic shields show shielding factors within a factor of 3 of conventional approaches. The vacuum demonstrator device shows that 3D-printed titanium structures are suitable for use as vacuum chambers, with the test system reaching base pressures of 5 ± 0.5 × 10 -10 mbar. These demonstrations show considerable promise for the use of additive manufacturing for cold atom based quantum technologies, in future enabling improved integrated structures, allowing for the reduction in size, weight and assembly complexity.

Surface texture measurement for additive manufacturing

International Nuclear Information System (INIS)

Triantaphyllou, Andrew; Tomita, Ben; Milne, Katherine A; Giusca, Claudiu L; Macaulay, Gavin D; Roerig, Felix; Hoebel, Matthias; Leach, Richard K

2015-01-01

The surface texture of additively manufactured metallic surfaces made by powder bed methods is affected by a number of factors, including the powder’s particle size distribution, the effect of the heat source, the thickness of the printed layers, the angle of the surface relative to the horizontal build bed and the effect of any post processing/finishing. The aim of the research reported here is to understand the way these surfaces should be measured in order to characterise them. In published research to date, the surface texture is generally reported as an Ra value, measured across the lay. The appropriateness of this method for such surfaces is investigated here. A preliminary investigation was carried out on two additive manufacturing processes—selective laser melting (SLM) and electron beam melting (EBM)—focusing on the effect of build angle and post processing. The surfaces were measured using both tactile and optical methods and a range of profile and areal parameters were reported. Test coupons were manufactured at four angles relative to the horizontal plane of the powder bed using both SLM and EBM. The effect of lay—caused by the layered nature of the manufacturing process—was investigated, as was the required sample area for optical measurements. The surfaces were also measured before and after grit blasting. (paper)

Surface texture measurement for additive manufacturing

Science.gov (United States)

Triantaphyllou, Andrew; Giusca, Claudiu L.; Macaulay, Gavin D.; Roerig, Felix; Hoebel, Matthias; Leach, Richard K.; Tomita, Ben; Milne, Katherine A.

2015-06-01

The surface texture of additively manufactured metallic surfaces made by powder bed methods is affected by a number of factors, including the powder’s particle size distribution, the effect of the heat source, the thickness of the printed layers, the angle of the surface relative to the horizontal build bed and the effect of any post processing/finishing. The aim of the research reported here is to understand the way these surfaces should be measured in order to characterise them. In published research to date, the surface texture is generally reported as an Ra value, measured across the lay. The appropriateness of this method for such surfaces is investigated here. A preliminary investigation was carried out on two additive manufacturing processes—selective laser melting (SLM) and electron beam melting (EBM)—focusing on the effect of build angle and post processing. The surfaces were measured using both tactile and optical methods and a range of profile and areal parameters were reported. Test coupons were manufactured at four angles relative to the horizontal plane of the powder bed using both SLM and EBM. The effect of lay—caused by the layered nature of the manufacturing process—was investigated, as was the required sample area for optical measurements. The surfaces were also measured before and after grit blasting.

Additive Manufacturing of Composites and Complex Materials

Science.gov (United States)

Spowart, Jonathan E.; Gupta, Nikhil; Lehmhus, Dirk

2018-03-01

Advanced composite materials form an important class of high-performance industrial materials used in weight-sensitive applications such as aerospace structures, automotive structures and sports equipment. In many of these applications, parts are made in small production runs, are highly customized and involve long process development times. Developments in additive manufacturing (AM) methods have helped in overcoming many of these limitations. The special topic of Additive Manufacturing of Composites and Complex Materials captures the state of the art in this area by collecting nine papers that present much novel advancement in this field. The studies under this topic show advancement in the area of AM of carbon fiber and graphene-reinforced composites with high thermal and electrical conductivities, development of new hollow glass particle-filled syntactic foam filaments for printing lightweight structures and integration of sensors or actuators during AM of metallic parts. Some of the studies are focused on process optimization or modification to increase the manufacturing speed or tuning manufacturing techniques to enable AM of new materials.

Additive Manufacturing of Magnesium (Mg) Alloys

Data.gov (United States)

National Aeronautics and Space Administration — The proposed work is to investigate additive manufacturing techniques for Mg alloys.  It will leverage off research being conducted at University of Florida and...

Economic Analysis of Additive Manufacturing Integration in Injection Molding Process Chain

DEFF Research Database (Denmark)

Charalambis, Alessandro; Kerbache, Laoucine; Tosello, Guido

The purpose of this research is to analyze how additive manufacturing can create value when it is utilized as a supportive technology to injection molding by quantifying the cost advantages that can be obtained. Tooling for the product development phase is investigated as pilot integration area...... of additive manufacturing with injection molding. Cost considerations are discussed through the development of a cost estimation model. The study shows that integration of additive manufacturing in the product development phase for fabrication of soft tooling is economically convenient with a cost reduction...... of 79,8% and 89,9%. The cost models on additive manufacturing have been built so far on the idea of substituting injection molding with additive manufacturing. In response to this literature gap, this research addresses the advantages of additive manufacturing utilized in a synergistic rather than...

Feasibility Study on 3-D Printing of Metallic Structural Materials with Robotized Laser-Based Metal Additive Manufacturing

Science.gov (United States)

Ding, Yaoyu; Kovacevic, Radovan

2016-07-01

Metallic structural materials continue to open new avenues in achieving exotic mechanical properties that are naturally unavailable. They hold great potential in developing novel products in diverse industries such as the automotive, aerospace, biomedical, oil and gas, and defense. Currently, the use of metallic structural materials in industry is still limited because of difficulties in their manufacturing. This article studied the feasibility of printing metallic structural materials with robotized laser-based metal additive manufacturing (RLMAM). In this study, two metallic structural materials characterized by an enlarged positive Poisson's ratio and a negative Poisson's ratio were designed and simulated, respectively. An RLMAM system developed at the Research Center for Advanced Manufacturing of Southern Methodist University was used to print them. The results of the tensile tests indicated that the printed samples successfully achieved the corresponding mechanical properties.

Design of an Orthopedic Product by Using Additive Manufacturing Technology: The Arm Splint.

Science.gov (United States)

Blaya, Fernando; Pedro, Pilar San; Silva, Julia López; D'Amato, Roberto; Heras, Enrique Soriano; Juanes, Juan Antonio

2018-02-05

The traditional fabrication process of custom-made splints has hardly undergone any progress since the beginning of its use at the end of the eighteenth century. New manufacturing techniques and the new materials can help to modernize this treatment method of fractures. The use of Additive Manufacturing has been proposed in recent years as an alternative process for the manufacture of splints and there has been an increase in public awareness and exploration. For this reason, in this study a splint model printed in 3D, that replaces the deficiencies of the cast maintaining its virtues, has been proposed. The proposed methodology is based on three-dimensional digitalization techniques and 3D modeling with reverse engineering software. The work integrates different scientific disciplines to achieve its main goal: to improve life quality of the patient. In addition, the splint has been designed based on the principles of sustainable development. The design of splint is made of Polycarbonate by technique of Additive Manufacturing with fused deposition manufacturing, and conceived with organic shapes, customizing openings and closing buttons with rubber. In this preliminary study the final result is a prototype of the 3D printed arm splint in a reduced scale by using PLA as material.

Large-scale Manufacturing of Nanoparticulate-based Lubrication Additives for Improved Energy Efficiency and Reduced Emissions

Energy Technology Data Exchange (ETDEWEB)

Erdemir, Ali [Argonne National Laboratory

2013-09-26

This project was funded under the Department of Energy (DOE) Lab Call on Nanomanufacturing for Energy Efficiency and was directed toward the development of novel boron-based nanocolloidal lubrication additives for improving the friction and wear performance of machine components in a wide range of industrial and transportation applications. Argonne's research team concentrated on the scientific and technical aspects of the project, using a range of state-of-the art analytical and tribological test facilities. Argonne has extensive past experience and expertise in working with boron-based solid and liquid lubrication additives, and has intellectual property ownership of several. There were two industrial collaborators in this project: Ashland Oil (represented by its Valvoline subsidiary) and Primet Precision Materials, Inc. (a leading nanomaterials company). There was also a sub-contract with the University of Arkansas. The major objectives of the project were to develop novel boron-based nanocolloidal lubrication additives and to optimize and verify their performance under boundary-lubricated sliding conditions. The project also tackled problems related to colloidal dispersion, larger-scale manufacturing and blending of nano-additives with base carrier oils. Other important issues dealt with in the project were determination of the optimum size and concentration of the particles and compatibility with various base fluids and/or additives. Boron-based particulate additives considered in this project included boric acid (H{sub 3}BO{sub 3}), hexagonal boron nitride (h-BN), boron oxide, and borax. As part of this project, we also explored a hybrid MoS{sub 2} + boric acid formulation approach for more effective lubrication and reported the results. The major motivation behind this work was to reduce energy losses related to friction and wear in a wide spectrum of mechanical systems and thereby reduce our dependence on imported oil. Growing concern over greenhouse

Biocompatibility of photopolymers for additive manufacturing

OpenAIRE

Leonhardt Stefan; Klare Martin; Scheer Maurice; Fischer Theresa; Cordes Burghard; Eblenkamp Markus

2016-01-01

To establish photopolymers for the production of class II or class III medical products by additive manufacturing it is essential to know which components of photopolymeric systems, consisting of monomers, photoinitiators and additives, are the determining factors on their biocompatible properties. In this study the leachable substances of a cured photopolymeric system were eluted and identified by HPLC-MS detection. In addition the cured photopolymer was testes for cytotoxicity and genotoxic...

Overview of Additive Manufacturing Initiatives at NASA Marshall Space Flight Center

Science.gov (United States)

Clinton, R. G., Jr.

2018-01-01

NASA's In Space Manufacturing Initiative (ISM) includes: The case for ISM - why; ISM path to exploration - results from the 3D Printing In Zero-G Technology Demonstration - ISM challenges; In space Robotic Manufacturing and Assembly (IRMA); Additive construction. Additively Manufacturing (AM) development for liquid rocket engine space flight hardware. MSFC standard and specification for additively manufactured space flight hardware. Summary.

Printed Proliferation: The Implications of Additive Manufacturing and Nuclear Weapons Proliferation

Energy Technology Data Exchange (ETDEWEB)

Lindsey, Nicholas C. [Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

2016-01-26

The growth of additive manufacturing as a disruptive technology poses nuclear proliferation concerns worthy of serious consideration. Additive manufacturing began in the early 1980s with technological advances in polymer manipulation, computer capabilities, and computer-aided design (CAD) modeling. It was originally limited to rapid prototyping; however, it eventually developed into a complete means of production that has slowly penetrated the consumer market. Today, additive manufacturing machines can produce complex and unique items in a vast array of materials including plastics, metals, and ceramics. These capabilities have democratized the manufacturing industry, allowing almost anyone to produce items as simple as cup holders or as complex as jet fuel nozzles. Additive manufacturing, or three-dimensional (3D) printing as it is commonly called, relies on CAD files created or shared by individuals with additive manufacturing machines to produce a 3D object from a digital model. This sharing of files means that a 3D object can be scanned or rendered as a CAD model in one country, and then downloaded and printed in another country, allowing items to be shared globally without physically crossing borders. The sharing of CAD files online has been a challenging task for the export controls regime to manage over the years, and additive manufacturing could make these transfers more common. In this sense, additive manufacturing is a disruptive technology not only within the manufacturing industry but also within the nuclear nonproliferation world. This paper provides an overview of additive manufacturing concerns of proliferation.

Nano-Magnets and Additive Manufacturing for Electric Motors

Science.gov (United States)

Misra, Ajay K.

2014-01-01

High power density is required for application of electric motors in hybrid electric propulsion. Potential path to achieve high power density in electric motors include advanced materials, lightweight thermal management, lightweight structural concepts, high power density power electronics, and advanced manufacturing. This presentation will focus on two key technologies for achieving high power density, advanced magnets and additive manufacturing. The maximum energy product in current magnets is reaching their theoretical limits as a result of material and process improvements. Future improvements in the maximum energy product for magnets can be achieved through development of nanocomposite magnets combining the hard magnetic phase and soft magnetic phase at the nanoscale level. The presentation will provide an overview of the current state of development for nanocomposite magnets and the future path for doubling the maximum energy product. The other part of the presentation will focus on the role of additive manufacturing in fabrication of high power density electric motors. The presentation will highlight the potential opportunities for applying additive manufacturing to fabricate electric motors.

Ceramic-Based 4D Components: Additive Manufacturing (AM) of Ceramic-Based Functionally Graded Materials (FGM) by Thermoplastic 3D Printing (T3DP).

Science.gov (United States)

Scheithauer, Uwe; Weingarten, Steven; Johne, Robert; Schwarzer, Eric; Abel, Johannes; Richter, Hans-Jürgen; Moritz, Tassilo; Michaelis, Alexander

2017-11-28

In our study, we investigated the additive manufacturing (AM) of ceramic-based functionally graded materials (FGM) by the direct AM technology thermoplastic 3D printing (T3DP). Zirconia components with varying microstructures were additively manufactured by using thermoplastic suspensions with different contents of pore-forming agents (PFA), which were co-sintered defect-free. Different materials were investigated concerning their suitability as PFA for the T3DP process. Diverse zirconia-based suspensions were prepared and used for the AM of single- and multi-material test components. All of the samples were sintered defect-free, and in the end, we could realize a brick wall-like component consisting of dense (<1% porosity) and porous (approx. 5% porosity) zirconia areas to combine different properties in one component. T3DP opens the door to the AM of further ceramic-based 4D components, such as multi-color, multi-material, or especially, multi-functional components.

Additive manufacturing for consumer-centric business models

DEFF Research Database (Denmark)

Bogers, Marcel; Hadar, Ronen; Bilberg, Arne

2016-01-01

Digital fabrication—including additive manufacturing (AM), rapid prototyping and 3D printing—has the potential to revolutionize the way in which products are produced and delivered to the customer. Therefore, it challenges companies to reinvent their business model—describing the logic of creating...... and capturing value. In this paper, we explore the implications that AM technologies have for manufacturing systems in the new business models that they enable. In particular, we consider how a consumer goods manufacturer can organize the operations of a more open business model when moving from a manufacturer......-centric to a consumer-centric value logic. A major shift includes a move from centralized to decentralized supply chains, where consumer goods manufacturers can implement a “hybrid” approach with a focus on localization and accessibility or develop a fully personalized model where the consumer effectively takes over...

Additive manufacturing of polymer-derived ceramics

Science.gov (United States)

Eckel, Zak C.; Zhou, Chaoyin; Martin, John H.; Jacobsen, Alan J.; Carter, William B.; Schaedler, Tobias A.

2016-01-01

The extremely high melting point of many ceramics adds challenges to additive manufacturing as compared with metals and polymers. Because ceramics cannot be cast or machined easily, three-dimensional (3D) printing enables a big leap in geometrical flexibility. We report preceramic monomers that are cured with ultraviolet light in a stereolithography 3D printer or through a patterned mask, forming 3D polymer structures that can have complex shape and cellular architecture. These polymer structures can be pyrolyzed to a ceramic with uniform shrinkage and virtually no porosity. Silicon oxycarbide microlattice and honeycomb cellular materials fabricated with this approach exhibit higher strength than ceramic foams of similar density. Additive manufacturing of such materials is of interest for propulsion components, thermal protection systems, porous burners, microelectromechanical systems, and electronic device packaging.

Application of Additive Manufacturing in Oral and Maxillofacial Surgery.

Science.gov (United States)

Farré-Guasch, Elisabet; Wolff, Jan; Helder, Marco N; Schulten, Engelbert A J M; Forouzanfar, Tim; Klein-Nulend, Jenneke

2015-12-01

Additive manufacturing is the process of joining materials to create objects from digital 3-dimensional (3D) model data, which is a promising technology in oral and maxillofacial surgery. The management of lost craniofacial tissues owing to congenital abnormalities, trauma, or cancer treatment poses a challenge to oral and maxillofacial surgeons. Many strategies have been proposed for the management of such defects, but autogenous bone grafts remain the gold standard for reconstructive bone surgery. Nevertheless, cell-based treatments using adipose stem cells combined with osteoconductive biomaterials or scaffolds have become a promising alternative to autogenous bone grafts. Such treatment protocols often require customized 3D scaffolds that fulfill functional and esthetic requirements, provide adequate blood supply, and meet the load-bearing requirements of the head. Currently, such customized 3D scaffolds are being manufactured using additive manufacturing technology. In this review, 2 of the current and emerging modalities for reconstruction of oral and maxillofacial bone defects are highlighted and discussed, namely human maxillary sinus floor elevation as a valid model to test bone tissue-engineering approaches enabling the application of 1-step surgical procedures and seeding of Good Manufacturing Practice-level adipose stem cells on computer-aided manufactured scaffolds to reconstruct large bone defects in a 2-step surgical procedure, in which cells are expanded ex vivo and seeded on resorbable scaffolds before implantation. Furthermore, imaging-guided tissue-engineering technologies to predetermine the surgical location and to facilitate the manufacturing of custom-made implants that meet the specific patient's demands are discussed. The potential of tissue-engineered constructs designed for the repair of large oral and maxillofacial bone defects in load-bearing situations in a 1-step surgical procedure combining these 2 innovative approaches is

Additive manufacturing techniques for the production of tissue engineering constructs.

Science.gov (United States)

Mota, Carlos; Puppi, Dario; Chiellini, Federica; Chiellini, Emo

2015-03-01

'Additive manufacturing' (AM) refers to a class of manufacturing processes based on the building of a solid object from three-dimensional (3D) model data by joining materials, usually layer upon layer. Among the vast array of techniques developed for the production of tissue-engineering (TE) scaffolds, AM techniques are gaining great interest for their suitability in achieving complex shapes and microstructures with a high degree of automation, good accuracy and reproducibility. In addition, the possibility of rapidly producing tissue-engineered constructs meeting patient's specific requirements, in terms of tissue defect size and geometry as well as autologous biological features, makes them a powerful way of enhancing clinical routine procedures. This paper gives an extensive overview of different AM techniques classes (i.e. stereolithography, selective laser sintering, 3D printing, melt-extrusion-based techniques, solution/slurry extrusion-based techniques, and tissue and organ printing) employed for the development of tissue-engineered constructs made of different materials (i.e. polymeric, ceramic and composite, alone or in combination with bioactive agents), by highlighting their principles and technological solutions. Copyright © 2012 John Wiley & Sons, Ltd.

CT image segmentation methods for bone used in medical additive manufacturing.

Science.gov (United States)

van Eijnatten, Maureen; van Dijk, Roelof; Dobbe, Johannes; Streekstra, Geert; Koivisto, Juha; Wolff, Jan

2018-01-01

The accuracy of additive manufactured medical constructs is limited by errors introduced during image segmentation. The aim of this study was to review the existing literature on different image segmentation methods used in medical additive manufacturing. Thirty-two publications that reported on the accuracy of bone segmentation based on computed tomography images were identified using PubMed, ScienceDirect, Scopus, and Google Scholar. The advantages and disadvantages of the different segmentation methods used in these studies were evaluated and reported accuracies were compared. The spread between the reported accuracies was large (0.04 mm - 1.9 mm). Global thresholding was the most commonly used segmentation method with accuracies under 0.6 mm. The disadvantage of this method is the extensive manual post-processing required. Advanced thresholding methods could improve the accuracy to under 0.38 mm. However, such methods are currently not included in commercial software packages. Statistical shape model methods resulted in accuracies from 0.25 mm to 1.9 mm but are only suitable for anatomical structures with moderate anatomical variations. Thresholding remains the most widely used segmentation method in medical additive manufacturing. To improve the accuracy and reduce the costs of patient-specific additive manufactured constructs, more advanced segmentation methods are required. Copyright © 2017 IPEM. Published by Elsevier Ltd. All rights reserved.

Review of Shape Deviation Modeling for Additive Manufacturing

OpenAIRE

Zhu , Zuowei; Keimasi , Safa; ANWER , Nabil; Mathieu , Luc; Qiao , Lihong

2016-01-01

International audience; Additive Manufacturing (AM) is becoming a promising technology capable of building complex customized parts with internal geometries and graded material by stacking up thin individual layers. However, a comprehensive geometric model for Additive Manufacturing is not mature yet. Dimensional and form accuracy and surface finish are still a bottleneck for AM regarding quality control. In this paper, an up-to-date review is drawn on methods and approaches that have been de...

Additive Manufacturing in the Marine Corps

Science.gov (United States)

2015-06-01

TERMS additive manufacturing, 3D printing, improving logistics 15. NUMBER OF PAGES 123 16. PRICE CODE 17. SECURITY CLASSIFICATION OF REPORT...One such method is ultrasonic agglomeration. The process produces compact snack items that are nutrient-dense and shelf-stable. Currently Army...possess outdated technology. Additionally, prices for the printers are dropping significantly.202 Therefore, the Marine Corps will not only have outdated

Post Processing Methods used to Improve Surface Finish of Products which are Manufactured by Additive Manufacturing Technologies: A Review

Science.gov (United States)

Kumbhar, N. N.; Mulay, A. V.

2016-08-01

The Additive Manufacturing (AM) processes open the possibility to go directly from Computer-Aided Design (CAD) to a physical prototype. These prototypes are used as test models before it is finalized as well as sometimes as a final product. Additive Manufacturing has many advantages over the traditional process used to develop a product such as allowing early customer involvement in product development, complex shape generation and also save time as well as money. Additive manufacturing also possess some special challenges that are usually worth overcoming such as Poor Surface quality, Physical Properties and use of specific raw material for manufacturing. To improve the surface quality several attempts had been made by controlling various process parameters of Additive manufacturing and also applying different post processing techniques on components manufactured by Additive manufacturing. The main objective of this work is to document an extensive literature review in the general area of post processing techniques which are used in Additive manufacturing.

Anomaly Detection In Additively Manufactured Parts Using Laser Doppler Vibrometery

Energy Technology Data Exchange (ETDEWEB)

Hernandez, Carlos A. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

2015-09-29

Additively manufactured parts are susceptible to non-uniform structure caused by the unique manufacturing process. This can lead to structural weakness or catastrophic failure. Using laser Doppler vibrometry and frequency response analysis, non-contact detection of anomalies in additively manufactured parts may be possible. Preliminary tests show promise for small scale detection, but more future work is necessary.

Additively manufactured metallic porous biomaterials based on minimal surfaces : A unique combination of topological, mechanical, and mass transport properties

NARCIS (Netherlands)

Bobbert, F S L; Lietaert, K; Eftekhari, A A; Pouran, B; Ahmadi, S M; Weinans, H; Zadpoor, A A

2017-01-01

Porous biomaterials that simultaneously mimic the topological, mechanical, and mass transport properties of bone are in great demand but are rarely found in the literature. In this study, we rationally designed and additively manufactured (AM) porous metallic biomaterials based on four different

Comparison of prosthetic models produced by traditional and additive manufacturing methods.

Science.gov (United States)

Park, Jin-Young; Kim, Hae-Young; Kim, Ji-Hwan; Kim, Jae-Hong; Kim, Woong-Chul

2015-08-01

The purpose of this study was to verify the clinical-feasibility of additive manufacturing by comparing the accuracy of four different manufacturing methods for metal coping: the conventional lost wax technique (CLWT); subtractive methods with wax blank milling (WBM); and two additive methods, multi jet modeling (MJM), and micro-stereolithography (Micro-SLA). Thirty study models were created using an acrylic model with the maxillary upper right canine, first premolar, and first molar teeth. Based on the scan files from a non-contact blue light scanner (Identica; Medit Co. Ltd., Seoul, Korea), thirty cores were produced using the WBM, MJM, and Micro-SLA methods, respectively, and another thirty frameworks were produced using the CLWT method. To measure the marginal and internal gap, the silicone replica method was adopted, and the silicone images obtained were evaluated using a digital microscope (KH-7700; Hirox, Tokyo, Japan) at 140X magnification. Analyses were performed using two-way analysis of variance (ANOVA) and Tukey post hoc test (α=.05). The mean marginal gaps and internal gaps showed significant differences according to tooth type (Pmanufacturing method (Pmanufacturing methods were within a clinically allowable range, and, thus, the clinical use of additive manufacturing methods is acceptable as an alternative to the traditional lost wax-technique and subtractive manufacturing.

Workshop Report on Additive Manufacturing for Large-Scale Metal Components - Development and Deployment of Metal Big-Area-Additive-Manufacturing (Large-Scale Metals AM) System

Energy Technology Data Exchange (ETDEWEB)

Babu, Sudarsanam Suresh [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility; Love, Lonnie J. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility; Peter, William H. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility; Dehoff, Ryan [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility

2016-05-01

Additive manufacturing (AM) is considered an emerging technology that is expected to transform the way industry can make low-volume, high value complex structures. This disruptive technology promises to replace legacy manufacturing methods for the fabrication of existing components in addition to bringing new innovation for new components with increased functional and mechanical properties. This report outlines the outcome of a workshop on large-scale metal additive manufacturing held at Oak Ridge National Laboratory (ORNL) on March 11, 2016. The charter for the workshop was outlined by the Department of Energy (DOE) Advanced Manufacturing Office program manager. The status and impact of the Big Area Additive Manufacturing (BAAM) for polymer matrix composites was presented as the background motivation for the workshop. Following, the extension of underlying technology to low-cost metals was proposed with the following goals: (i) High deposition rates (approaching 100 lbs/h); (ii) Low cost (<$10/lbs) for steel, iron, aluminum, nickel, as well as, higher cost titanium, (iii) large components (major axis greater than 6 ft) and (iv) compliance of property requirements. The above concept was discussed in depth by representatives from different industrial sectors including welding, metal fabrication machinery, energy, construction, aerospace and heavy manufacturing. In addition, DOE’s newly launched High Performance Computing for Manufacturing (HPC4MFG) program was reviewed. This program will apply thermo-mechanical models to elucidate deeper understanding of the interactions between design, process, and materials during additive manufacturing. Following these presentations, all the attendees took part in a brainstorming session where everyone identified the top 10 challenges in large-scale metal AM from their own perspective. The feedback was analyzed and grouped in different categories including, (i) CAD to PART software, (ii) selection of energy source, (iii

The Future of Additive Manufacturing in Air Force Acquisition

Science.gov (United States)

2017-03-22

heal, if not cure, the acquisition woes and financial death spiral . 7 Additive Manufacturing as a Partial Solution to Acquisition Woes “As we... methodologies .”7 Additive manufacturing starts with a 3D model, derived either from a 3D scanner or created via software such as a Computer Aided Design (CAD

Additive manufacturing technology in reconstructive surgery.

Science.gov (United States)

Fuller, Scott C; Moore, Michael G

2016-10-01

Technological advances have been part and parcel of modern reconstructive surgery, in that practitioners of this discipline are continually looking for innovative ways to perfect their craft and improve patient outcomes. We are currently in a technological climate wherein advances in computers, imaging, and science have coalesced with resulting innovative breakthroughs that are not merely limited to improved outcomes and enhanced patient care, but may provide novel approaches to training the next generation of reconstructive surgeons. New developments in software and modeling platforms, imaging modalities, tissue engineering, additive manufacturing, and customization of implants are poised to revolutionize the field of reconstructive surgery. The interface between technological advances and reconstructive surgery continues to expand. Additive manufacturing techniques continue to evolve in an effort to improve patient outcomes, decrease operative time, and serve as instructional tools for the training of reconstructive surgeons.

Additive Manufacturing of SiC Based Ceramics and Ceramic Matrix Composites

Science.gov (United States)

Halbig, Michael Charles; Singh, Mrityunjay

2015-01-01

Silicon carbide (SiC) ceramics and SiC fiber reinforcedSiC ceramic matrix composites (SiCSiC CMCs) offer high payoff as replacements for metals in turbine engine applications due to their lighter weight, higher temperature capability, and lower cooling requirements. Additive manufacturing approaches can offer game changing technologies for the quick and low cost fabrication of parts with much greater design freedom and geometric complexity. Four approaches for developing these materials are presented. The first two utilize low cost 3D printers. The first uses pre-ceramic pastes developed as feed materials which are converted to SiC after firing. The second uses wood containing filament to print a carbonaceous preform which is infiltrated with a pre-ceramic polymer and converted to SiC. The other two approaches pursue the AM of CMCs. The first is binder jet SiC powder processing in collaboration with rp+m (Rapid Prototyping+Manufacturing). Processing optimization was pursued through SiC powder blending, infiltration with and without SiC nano powder loading, and integration of nanofibers into the powder bed. The second approach was laminated object manufacturing (LOM) in which fiber prepregs and laminates are cut to shape by a laser and stacked to form the desired part. Scanning electron microscopy was conducted on materials from all approaches with select approaches also characterized with XRD, TGA, and bend testing.

Inspection of additive manufactured parts using laser ultrasonics

Science.gov (United States)

Lévesque, D.; Bescond, C.; Lord, M.; Cao, X.; Wanjara, P.; Monchalin, J.-P.

2016-02-01

Additive manufacturing is a novel technology of high importance for global sustainability of resources. As additive manufacturing involves typically layer-by-layer fusion of the feedstock (wire or powder), an important characteristic of the fabricated metallic structural parts, such as those used in aero-engines, is the performance, which is highly related to the presence of defects, such as cracks, lack of fusion or bonding between layers, and porosity. For this purpose, laser ultrasonics is very attractive due to its non-contact nature and is especially suited for the analysis of parts of complex geometries. In addition, the technique is well adapted to online implementation and real-time measurement during the manufacturing process. The inspection can be performed from either the top deposited layer or the underside of the substrate and the defects can be visualized using laser ultrasonics combined with the synthetic aperture focusing technique (SAFT). In this work, a variety of results obtained off-line on INCONEL® 718 and Ti-6Al-4V coupons that were manufactured using laser powder, laser wire, or electron beam wire deposition are reported and most defects detected were further confirmed by X-ray micro-computed tomography.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing Part I: System Analysis, Component Identification, Additive Manufacturing, and Testing of Polymer Composites

Science.gov (United States)

Grady, Joseph E.; Haller, William J.; Poinsatte, Philip E.; Halbig, Michael C.; Schnulo, Sydney L.; Singh, Mrityunjay; Weir, Don; Wali, Natalie; Vinup, Michael; Jones, Michael G.;

Cost, resources, and energy efficiency of additive manufacturing

OpenAIRE

Dudek Piotr; Zagórski Krzysztof

2017-01-01

Additive manufacturing (AM) is the process of joining materials to make objects from Computer Aided Design (CAD) model data, usually layer upon layer, as opposed to using subtractive manufacturing methods. The use of rapid prototyping technologies has increased significantly in recent years. These new techniques, while still evolving, are projected to exert a profound impact on manufacturing. They can reduce energy use and time to market and offer industry new design flexibility. We include a...

Metal Additive Manufacturing: A Review of Mechanical Properties

Science.gov (United States)

Lewandowski, John J.; Seifi, Mohsen

2016-07-01

This article reviews published data on the mechanical properties of additively manufactured metallic materials. The additive manufacturing techniques utilized to generate samples covered in this review include powder bed fusion (e.g., EBM, SLM, DMLS) and directed energy deposition (e.g., LENS, EBF3). Although only a limited number of metallic alloy systems are currently available for additive manufacturing (e.g., Ti-6Al-4V, TiAl, stainless steel, Inconel 625/718, and Al-Si-10Mg), the bulk of the published mechanical properties information has been generated on Ti-6Al-4V. However, summary tables for published mechanical properties and/or key figures are included for each of the alloys listed above, grouped by the additive technique used to generate the data. Published values for mechanical properties obtained from hardness, tension/compression, fracture toughness, fatigue crack growth, and high cycle fatigue are included for as-built, heat-treated, and/or HIP conditions, when available. The effects of test orientation/build direction on properties, when available, are also provided, along with discussion of the potential source(s) (e.g., texture, microstructure changes, defects) of anisotropy in properties. Recommendations for additional work are also provided.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

Science.gov (United States)

Grady, Joseph E.; Halbig, Michael C.; Singh, Mrityunjay

2015-01-01

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing", evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Mechanical properties of additively manufactured octagonal honeycombs

Energy Technology Data Exchange (ETDEWEB)

Hedayati, R., E-mail: rezahedayati@gmail.com [Department of Mechanical Engineering, Amirkabir University of Technology (Tehran Polytechnic), Hafez Ave, Tehran (Iran, Islamic Republic of); Department of Biomechanical Engineering, Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Mekelweg 2, 2628 CD Delft (Netherlands); Sadighi, M.; Mohammadi-Aghdam, M. [Department of Mechanical Engineering, Amirkabir University of Technology (Tehran Polytechnic), Hafez Ave, Tehran (Iran, Islamic Republic of); Zadpoor, A.A. [Department of Biomechanical Engineering, Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Mekelweg 2, 2628 CD Delft (Netherlands)

2016-12-01

Honeycomb structures have found numerous applications as structural and biomedical materials due to their favourable properties such as low weight, high stiffness, and porosity. Application of additive manufacturing and 3D printing techniques allows for manufacturing of honeycombs with arbitrary shape and wall thickness, opening the way for optimizing the mechanical and physical properties for specific applications. In this study, the mechanical properties of honeycomb structures with a new geometry, called octagonal honeycomb, were investigated using analytical, numerical, and experimental approaches. An additive manufacturing technique, namely fused deposition modelling, was used to fabricate the honeycomb from polylactic acid (PLA). The honeycombs structures were then mechanically tested under compression and the mechanical properties of the structures were determined. In addition, the Euler-Bernoulli and Timoshenko beam theories were used for deriving analytical relationships for elastic modulus, yield stress, Poisson's ratio, and buckling stress of this new design of honeycomb structures. Finite element models were also created to analyse the mechanical behaviour of the honeycombs computationally. The analytical solutions obtained using Timoshenko beam theory were close to computational results in terms of elastic modulus, Poisson's ratio and yield stress, especially for relative densities smaller than 25%. The analytical solutions based on the Timoshenko analytical solution and the computational results were in good agreement with experimental observations. Finally, the elastic properties of the proposed honeycomb structure were compared to those of other honeycomb structures such as square, triangular, hexagonal, mixed, diamond, and Kagome. The octagonal honeycomb showed yield stress and elastic modulus values very close to those of regular hexagonal honeycombs and lower than the other considered honeycombs. - Highlights: • The octagonal

Electron beam additive manufacturing with wire - Analysis of the process

Science.gov (United States)

Weglowski, Marek St.; Błacha, Sylwester; Pilarczyk, Jan; Dutkiewicz, Jan; Rogal, Łukasz

2018-05-01

The electron beam additive manufacturing process with wire is a part of global trend to find fast and efficient methods for producing complex shapes elements from costly metal alloys such as stainless steels, nickel alloys, titanium alloys etc. whose production by other conventional technologies is unprofitable or technically impossible. Demand for additive manufacturing is linked to the development of new technologies in the automotive, aerospace and machinery industries. The aim of the presented work was to carried out research on electron beam additive manufacturing with a wire as a deposited (filler) material. The scope of the work was to investigate the influence of selected technological parameters such as: wire feed rate, beam current, travelling speed, acceleration voltage on stability of the deposition process and geometric dimensions of the padding welds. The research revealed that, at low beam currents, the deposition process is unstable. The padding weld reinforcement is non-uniform. Irregularity of the width, height and straightness of the padding welds can be observed. At too high acceleration voltage and beam current, burn-through of plate and excess penetration weld can be revealed. The achieved results and gained knowledge allowed to produce, based on EBAM with wire process, whole structure from stainless steel.

Analysis of Additive Manufacturing for Sustainment of Naval Aviation Systems

Science.gov (United States)

2017-09-01

decline and allow manufacturers to explore alternative product designs and supply processes at lower risk. If the aerospace and defense industry...C. SYSTEMS ENGINEERING AND ADDITIVE MANUFACTURING During the design and development of new products or systems, engineers must consider the...Bradford L., and Vhance V. Valencia. 2017. “3D-Printing Design Using Systems Engineering.” In Additive Manufacturing Handbook: Product Development for the

Prototyping of Individual Ankle Orthosis Using Additive Manufacturing Technologies

Directory of Open Access Journals (Sweden)

Natalia Wierzbicka

2017-09-01

Full Text Available The paper presents design and manufacturing process of an individualized ankle orthosis using additive manufacturing technologies and reverse engineering. Conventional processes of manufacturing of orthosesareexpensive and time consuming -an alternative method was proposed. The patient’s leg was 3D scanned and the orthosis was designed using a CAD system. It was then manufactured using the Fused Deposition Modelling technology, assembled and fully tested. Positive results were obtained.

Additive Design and Manufacturing of Jet Engine Parts

Directory of Open Access Journals (Sweden)

Pinlian Han

2017-10-01

Full Text Available The additive design (AD and additive manufacturing (AM of jet engine parts will revolutionize the traditional aerospace industry. The unique characteristics of AM, such as gradient materials and micro-structures, have opened up a new direction in jet engine design and manufacturing. Engineers have been liberated from many constraints associated with traditional methodologies and technologies. One of the most significant features of the AM process is that it can ensure the consistency of parts because it starts from point(s, continues to line(s and layer(s, and ends with the competed part. Collaboration between design and manufacturing is the key to success in fields including aerodynamics, thermodynamics, structural integration, heat transfer, material development, and machining. Engineers must change the way they design a part, as they shift from the traditional method of “subtracting material” to the new method of “adding material” in order to manufacture a part. AD is not the same as designing for AM. A new method and new tools are required to assist with this new way of designing and manufacturing. This paper discusses in detail what is required in AD and AM, and how current problems can be solved.

Mechanics of additively manufactured biomaterials.

Science.gov (United States)

Zadpoor, Amir A

2017-06-01

Additive manufacturing (3D printing) has found many applications in healthcare including fabrication of biomaterials as well as bioprinting of tissues and organs. Additively manufactured (AM) biomaterials may possess arbitrarily complex micro-architectures that give rise to novel mechanical, physical, and biological properties. The mechanical behavior of such porous biomaterials including their quasi-static mechanical properties and fatigue resistance is not yet well understood. It is particularly important to understand the relationship between the designed micro-architecture (topology) and the resulting mechanical properties. The current special issue is dedicated to understanding the mechanical behavior of AM biomaterials. Although various types of AM biomaterials are represented in the special issue, the primary focus is on AM porous metallic biomaterials. As a prelude to this special issue, this editorial reviews some of the latest findings in the mechanical behavior of AM porous metallic biomaterials so as to describe the current state-of-the-art and set the stage for the other studies appearing in the issue. Some areas that are important for future research are also briefly mentioned. Copyright © 2017 Elsevier Ltd. All rights reserved.

Grain Structure Control of Additively Manufactured Metallic Materials

Directory of Open Access Journals (Sweden)

Fuyao Yan

2017-11-01

Full Text Available Grain structure control is challenging for metal additive manufacturing (AM. Grain structure optimization requires the control of grain morphology with grain size refinement, which can improve the mechanical properties of additive manufactured components. This work summarizes methods to promote fine equiaxed grains in both the additive manufacturing process and subsequent heat treatment. Influences of temperature gradient, solidification velocity and alloy composition on grain morphology are discussed. Equiaxed solidification is greatly promoted by introducing a high density of heterogeneous nucleation sites via powder rate control in the direct energy deposition (DED technique or powder surface treatment for powder-bed techniques. Grain growth/coarsening during post-processing heat treatment can be restricted by presence of nano-scale oxide particles formed in-situ during AM. Grain refinement of martensitic steels can also be achieved by cyclic austenitizing in post-processing heat treatment. Evidently, new alloy powder design is another sustainable method enhancing the capability of AM for high-performance components with desirable microstructures.

Additive Manufacturing for Highly Efficient Window Inserts CRADA Report

Energy Technology Data Exchange (ETDEWEB)

Roschli, Alex C. [ORNL; Chesser, Phillip C. [ORNL; Love, Lonnie J. [ORNL

2018-04-01

ORNL partnered with the Mackinac Technology Company to demonstrate how additive manufacturing can be used to create highly energy efficient window inserts for retrofit in pre-existing buildings. Many early iterations of the window inserts were fabricated using carbon fiber reinforced thermoplastics and polycarbonate films as a stand in for the low-e coated films produced by the Mackinac Technology Company. After demonstration of the proof of concept, i.e. custom window inserts with tensioned film, the materials used for the manufacture of the frames was more closely examined. Hollow particle-filled syntactic foam and low-density polymer composites formed by expandable microspheres were explored as the materials used to additively manufacture the frames of the inserts. It was concluded that low-cost retrofit window inserts in custom sizes could be easily fabricated using large scale additive manufacturing. Furthermore, the syntactic and expanded foams developed and tested satisfy the mechanical performance requirements for the application.

Five-Axis Ultrasonic Additive Manufacturing for Nuclear Component Manufacture

Science.gov (United States)

Hehr, Adam; Wenning, Justin; Terrani, Kurt; Babu, Sudarsanam Suresh; Norfolk, Mark

2017-03-01

Ultrasonic additive manufacturing (UAM) is a three-dimensional metal printing technology which uses high-frequency vibrations to scrub and weld together both similar and dissimilar metal foils. There is no melting in the process and no special atmosphere requirements are needed. Consequently, dissimilar metals can be joined with little to no intermetallic compound formation, and large components can be manufactured. These attributes have the potential to transform manufacturing of nuclear reactor core components such as control elements for the High Flux Isotope Reactor at Oak Ridge National Laboratory. These components are hybrid structures consisting of an outer cladding layer in contact with the coolant with neutron-absorbing materials inside, such as neutron poisons for reactor control purposes. UAM systems are built into a computer numerical control (CNC) framework to utilize intermittent subtractive processes. These subtractive processes are used to introduce internal features as the component is being built and for net shaping. The CNC framework is also used for controlling the motion of the welding operation. It is demonstrated here that curved components with embedded features can be produced using a five-axis code for the welder for the first time.

A study on the mechanical properties of additive manufactured polymer materials

Energy Technology Data Exchange (ETDEWEB)

Kim, Dong Bum; Lee, In Hwan; Cho, Hae Yong [Dept. of Mechanical Engineering, Chungbuk National University, Cheongju (Korea, Republic of)

2015-08-15

Traditionally, additive manufacturing (AM) technology has been used to fabricate prototypes in the early development phase of a product. This technology is being applied to release manufacturing of a product because of its low cost and fast fabrication. AM technology is a process of joining materials to fabricate a product from the 3D CAD data in a layer-by-layer manner. The orientation of a layer during manufacturing can affect the mechanical properties of the product because of its anisotropy. In this paper, tensile testing of polymer-based specimens were built with a typical AM process (FDM, PolyJet and SLA) to study the mechanical properties of the AM materials. The ASTM D 638 tensile testing standard was followed for building the specimens. The mechanical properties of the specimens were determined on the basis of stress-strain curves formed by tensile tests. In addition, the fracture surfaces of the specimens were observed by SEM to analyze the results.

An Additively Manufactured Torch Igniter for Liquid Propellants

Data.gov (United States)

National Aeronautics and Space Administration — Consistent and reliable rocket engine ignition has yet to be proven through an additively manufactured torch igniter for liquid propellants. The coupling of additive...

Social aspects in additive manufacturing of pharmaceutical products

DEFF Research Database (Denmark)

Lind, Johanna Lena Maria; Kälvemark Sporrong, Sofia; Kaae, Susanne

2016-01-01

INTRODUCTION: Additive manufacturing (AM) techniques, such as drug printing, represent a new engineering approach that can implement the concept of personalized medicine via on-demand manufacturing of dosage forms with individually adjusted doses. Implementation of AM principles...... will be used for production of on-demand medicine. The impact of such changes in the distribution chain on regulation, healthcare professionals and patients are highlighted. Expert opinion: Drug manufacturing by traditional methods is well-established, but it lacks the possibility for on-demand personalized...

Electric poling-assisted additive manufacturing process for PVDF polymer-based piezoelectric device applications

International Nuclear Information System (INIS)

Lee, ChaBum; Tarbutton, Joshua A

2014-01-01

This paper presents a new additive manufacturing (AM) process to directly and continuously print piezoelectric devices from polyvinylidene fluoride (PVDF) polymeric filament rods under a strong electric field. This process, called ‘electric poling-assisted additive manufacturing or EPAM, combines AM and electric poling processes and is able to fabricate free-form shape piezoelectric devices continuously. In this process, the PVDF polymer dipoles remain well-aligned and uniform over a large area in a single design, production and fabrication step. During EPAM process, molten PVDF polymer is simultaneously mechanically stresses in-situ by the leading nozzle and electrically poled by applying high electric field under high temperature. The EPAM system was constructed to directly print piezoelectric structures from PVDF polymeric filament while applying high electric field between nozzle tip and printing bed in AM machine. Piezoelectric devices were successfully fabricated using the EPAM process. The crystalline phase transitions that occurred from the process were identified by using the Fourier transform infrared spectroscope. The results indicate that devices printed under a strong electric field become piezoelectric during the EPAM process and that stronger electric fields result in greater piezoelectricity as marked by the electrical response and the formation of sharper peaks at the polar β crystalline wavenumber of the PVDF polymer. Performing this process in the absence of an electric field does not result in dipole alignment of PVDF polymer. The EPAM process is expected to lead to the widespread use of AM to fabricate a variety of piezoelectric PVDF polymer-based devices for sensing, actuation and energy harvesting applications with simple, low cost, single processing and fabrication step. (paper)

Augmented Reality Interfaces for Additive Manufacturing

DEFF Research Database (Denmark)

Eiríksson, Eyþór Rúnar; Pedersen, David Bue; Frisvad, Jeppe Revall

2017-01-01

This paper explores potential use cases for using augmented reality (AR) as a tool to operate industrial machines. As a baseline we use an additive manufacturing system, more commonly known as a 3D printer. We implement novel augmented interfaces and controls using readily available open source...

Designing for Color in Additive Manufacturing

DEFF Research Database (Denmark)

Eiríksson, Eyþór Rúnar; Luongo, Andrea; Frisvad, Jeppe Revall

2016-01-01

In this paper we present a color design pipeline for 3D printed or additively manufactured parts. We demonstrate how to characterize and calibrate a commercial printer and how to obtain its forward and backward color transformation models. We present results from our assistive color design tool...

Additive Manufacturing of Low Cost Upper Stage Propulsion Components

Science.gov (United States)

Protz, Christopher; Bowman, Randy; Cooper, Ken; Fikes, John; Taminger, Karen; Wright, Belinda

2014-01-01

NASA is currently developing Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. These Low Cost Upper Stage Propulsion (LCUSP) tasks are funded through NASA's Game Changing Development Program in the Space Technology Mission Directorate. The LCUSP project will develop a copper alloy additive manufacturing design process and develop and optimize the Electron Beam Freeform Fabrication (EBF3) manufacturing process to direct deposit a nickel alloy structural jacket and manifolds onto an SLM manufactured GRCop chamber and Ni-alloy nozzle. In order to develop these processes, the project will characterize both the microstructural and mechanical properties of the SLMproduced GRCop-84, and will explore and document novel design techniques specific to AM combustion devices components. These manufacturing technologies will be used to build a 25K-class regenerative chamber and nozzle (to be used with tested DMLS injectors) that will be tested individually and as a system in hot fire tests to demonstrate the applicability of the technologies. These tasks are expected to bring costs and manufacturing time down as spacecraft propulsion systems typically comprise more than 70% of the total vehicle cost and account for a significant portion of the development schedule. Additionally, high pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design to be time consuming and costly to build. LCUSP presents an opportunity to develop and demonstrate a process that can infuse these technologies into industry, build competition, and drive down costs of future engines.

Additive Manufacturing: Which DLA-Managed Legacy Parts are Potential AM Candidates

Science.gov (United States)

2016-07-01

R G ADDITIVE MANUFACTURING : WHICH DLA-MANAGED LEGACY PARTS ARE POTENTIAL AM CANDIDATES? REPORT DL501T1 J UL Y 2016...L Y 2 0 1 6 ADDITIVE MANUFACTURING : WHICH DLA-MANAGED LEGACY PARTS ARE POTENTIAL AM CANDIDATES? REPORT DL501T1 Thomas K . Pa rk s...DESIGNATED BY OTHER OFFICIAL DOCUMENTATION. LMI © 2016. ALL RIGHTS RESERVED. iii Additive Manufacturing : Which DLA-Managed Legacy Parts Are

Investigation of microstructure in additive manufactured Inconel 625 by spatially resolved neutron transmission spectroscopy

Science.gov (United States)

Tremsin, Anton S.; Gao, Yan; Dial, Laura C.; Grazzi, Francesco; Shinohara, Takenao

2016-01-01

Non-destructive testing techniques based on neutron imaging and diffraction can provide information on the internal structure of relatively thick metal samples (up to several cm), which are opaque to other conventional non-destructive methods. Spatially resolved neutron transmission spectroscopy is an extension of traditional neutron radiography, where multiple images are acquired simultaneously, each corresponding to a narrow range of energy. The analysis of transmission spectra enables studies of bulk microstructures at the spatial resolution comparable to the detector pixel. In this study we demonstrate the possibility of imaging (with 100 μm resolution) distribution of some microstructure properties, such as residual strain, texture, voids and impurities in Inconel 625 samples manufactured with an additive manufacturing method called direct metal laser melting (DMLM). Although this imaging technique can be implemented only in a few large-scale facilities, it can be a valuable tool for optimization of additive manufacturing techniques and materials and for correlating bulk microstructure properties to manufacturing process parameters. In addition, the experimental strain distribution can help validate finite element models which many industries use to predict the residual stress distributions in additive manufactured components.

Additively Manufactured Multi-Material Insert, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — Parabilis Space Technologies is pleased to propose development of a novel additive manufacturing method which enables the use of multiple dissimilar materials in an...

Thermoelectric Cooling-Aided Bead Geometry Regulation in Wire and Arc-Based Additive Manufacturing of Thin-Walled Structures

Directory of Open Access Journals (Sweden)

Fang Li

2018-01-01

Full Text Available Wire and arc-based additive manufacturing (WAAM is a rapidly developing technology which employs a welding arc to melt metal wire for additive manufacturing purposes. During WAAM of thin-walled structures, as the wall height increases, the heat dissipation to the substrate is slowed down gradually and so is the solidification of the molten pool, leading to variation of the bead geometry. Though gradually reducing the heat input via adjusting the process parameters can alleviate this issue, as suggested by previous studies, it relies on experience to a large extent and inevitably sacrifices the deposition rate because the wire feed rate is directly coupled with the heat input. This study introduces for the first time an in-process active cooling system based on thermoelectric cooling technology into WAAM, which aims to eliminate the difference in heat dissipation between upper and lower layers. The case study shows that, with the aid of thermoelectric cooling, the bead width error is reduced by 56.8%, the total fabrication time is reduced by 60.9%, and the average grain size is refined by 25%. The proposed technique provides new insight into bead geometry regulation during WAAM with various benefits in terms of geometric accuracy, productivity, and microstructure.

Characterizations of additive manufactured porous titanium implants.

Science.gov (United States)

Basalah, Ahmad; Shanjani, Yaser; Esmaeili, Shahrzad; Toyserkani, Ehsan

2012-10-01

This article describes physical, chemical, and mechanical characterizations of porous titanium implants made by an additive manufacturing method to gain insight into the correlation of process parameters and final physical properties of implants used in orthopedics. For the manufacturing chain, the powder metallurgy technology was combined with the additive manufacturing to fabricate the porous structure from the pure tanium powder. A 3D printing machine was employed in this study to produce porous bar samples. A number of physical parameters such as titanium powder size, polyvinyl alcohol (PVA) amount, sintering temperature and time were investigated to control the mechanical properties and porosity of the structures. The produced samples were characterized through porosity and shrinkage measurements, mechanical compression test and scanning electron microscopy (SEM). The results showed a level of porosity in the samples in the range of 31-43%, which is within the range of the porosity of the cancelluous bone and approaches the range of the porosity of the cortical bone. The results of the mechanical test showed that the compressive strength is in the wide range of 56-509 MPa implying the effect of the process parameters on the mechanical strengths. This technique of manufacturing of Ti porous structures demonstrated a low level of shrinkage with the shrinkage percentage ranging from 1.5 to 5%. Copyright © 2012 Wiley Periodicals, Inc.

Additive Manufacturing of Wind Turbine Molds

Energy Technology Data Exchange (ETDEWEB)

Post, Brian [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Richardson, Bradley [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lloyd, Peter [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Love, Lonnie [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Nolet, Stephen [TPI Composites, Scottsdale, AZ (United States); Hannan, James [TPI Composites, Scottsdale, AZ (United States)

2017-07-01

The objective of this project was to explore the utility of Big Area Additive Manufacturing (BAAM) for low cost manufacturing of wind turbine molds. Engineers at Oak Ridge National Laboratory (ORNL) and TPI Composites (TPI) collaborated to design and manufacture a printed mold that can be used for resin infusion of wind turbine components. Specific focus was on required material properties (operating temperatures and pressures, coefficient of thermal expansion (CTE), thermal conductivity), surface finish (accuracy and coatings) and system integration (integrated vacuum ports, and heating element). The project began with a simple proof of principle components, targeting surface coatings and material properties for printing a small section (approximately 4’ x 4’ x 2’) of a mold. Next, the second phase scaled up and integrated with the objective of capturing all of the necessary components (integrated heating to accelerate cure time, and vacuum, sealing) for resin infusion on a mold of significant size (8’ x 20’ x 6’).

Additive Manufacturing Technology for Biomedical Components: A review

Science.gov (United States)

Aimi Zaharin, Haizum; Rani, Ahmad Majdi Abdul; Lenggo Ginta, Turnad; Azam, Farooq I.

2018-03-01

Over the last decades, additive manufacturing has shown potential application in ranging fields. No longer a prototyping technology, it is now being utilised as a manufacturing technology for giant industries such as the automotive, aircraft and recently in the medical industry. It is a very successful method that provides health-care solution in biomedical sectors by producing patient-specific prosthetics, improve tissues engineering and facilitate pre-operating session. This paper thus presents a brief overview of the most commercially important additive manufacturing technologies, which is currently available for fabricating biomedical components such as Stereolithography (SLA), Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Fused Deposition Modelling (FDM) and Electron Beam Melting (EBM). It introduces the basic principles of the main process, highlights some of the beneficial applications in medical industry and the current limitation of applied technology.

Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

Science.gov (United States)

MacDonald, D.; Fernández, R.; Delloro, F.; Jodoin, B.

2017-04-01

Titanium parts are ideally suited for aerospace applications due to their unique combination of high specific strength and excellent corrosion resistance. However, titanium as bulk material is expensive and challenging/costly to machine. Production of complex titanium parts through additive manufacturing looks promising, but there are still many barriers to overcome before reaching mainstream commercialization. The cold gas dynamic spraying process offers the potential for additive manufacturing of large titanium parts due to its reduced reactive environment, its simplicity to operate, and the high deposition rates it offers. A few challenges are to be addressed before the additive manufacturing potential of titanium by cold gas dynamic spraying can be reached. In particular, it is known that titanium is easy to deposit by cold gas dynamic spraying, but the deposits produced are usually porous when nitrogen is used as the carrier gas. In this work, a method to manufacture low-porosity titanium components at high deposition efficiencies is revealed. The components are produced by combining low-pressure cold spray using nitrogen as the carrier gas with low-cost titanium powder produced using the Armstrong process. The microstructure and mechanical properties of additive manufactured titanium components are investigated.

Additively Manufactured IN718 Components with Wirelessly Powered and Interrogated Embedded Sensing

Energy Technology Data Exchange (ETDEWEB)

Attridge, Paul [United Technologies Research Center, East Hartford, CT (United States); Bajekal, Sanjay [United Technologies Research Center, East Hartford, CT (United States); Klecka, Michael [United Technologies Research Center, East Hartford, CT (United States); Wu, Xin [United Technologies Research Center, East Hartford, CT (United States); Savulak, Steve [United Technologies Research Center, East Hartford, CT (United States); Viens, Dan [United Technologies Research Center, East Hartford, CT (United States); Carey, Michael [United Technologies Research Center, East Hartford, CT (United States); Miano, John [United Technologies Research Center, East Hartford, CT (United States); Rioux, William [United Technologies Research Center, East Hartford, CT (United States); Zacchio, Joseph [United Technologies Research Center, East Hartford, CT (United States); Dunst, Richard [National Energy Technology Lab. (NETL), Pittsburgh, PA, (United States); Straub, Doug [National Energy Technology Lab. (NETL), Pittsburgh, PA, (United States); Mantese, Joseph [United Technologies Research Center, East Hartford, CT (United States)

2017-07-14

A methodology is described for embedding commercial-off-the-shelf sensors together with wireless communication and power circuit elements using direct laser metal sintered additively manufactured components. Physics based models of the additive manufacturing processes and sensor/wireless level performance models guided the design and embedment processes. A combination of cold spray deposition and laser engineered net shaping was used to fashion the transmitter/receiving elements and embed the sensors, thereby providing environmental protection and component robustness/survivability for harsh conditions. By design, this complement of analog and digital sensors were wirelessly powered and interrogated using a health and utilization monitoring system; enabling real-time, in situ prognostics and diagnostics.

Simple additive manufacturing of an osteoconductive ceramic using suspension melt extrusion

DEFF Research Database (Denmark)

Slots, Casper; Bonde Jensen, Martin; Ditzel, Nicholas

2017-01-01

/calcium phosphate suspension melt for simple additive manufacturing of ceramic tricalcium phosphate implants. METHODS: A wide variety of non-aqueous liquids were tested to determine the formulation of a storable 3D printable tricalcium phosphate suspension ink, and only fatty acid-based inks were found to work...

In-situ acoustic signature monitoring in additive manufacturing processes

Science.gov (United States)

Koester, Lucas W.; Taheri, Hossein; Bigelow, Timothy A.; Bond, Leonard J.; Faierson, Eric J.

2018-04-01

Additive manufacturing is a rapidly maturing process for the production of complex metallic, ceramic, polymeric, and composite components. The processes used are numerous, and with the complex geometries involved this can make quality control and standardization of the process and inspection difficult. Acoustic emission measurements have been used previously to monitor a number of processes including machining and welding. The authors have identified acoustic signature measurement as a potential means of monitoring metal additive manufacturing processes using process noise characteristics and those discrete acoustic emission events characteristic of defect growth, including cracks and delamination. Results of acoustic monitoring for a metal additive manufacturing process (directed energy deposition) are reported. The work investigated correlations between acoustic emissions and process noise with variations in machine state and deposition parameters, and provided proof of concept data that such correlations do exist.

Additive manufacturing for steels: a review

Science.gov (United States)

Zadi-Maad, A.; Rohib, R.; Irawan, A.

2018-01-01

Additive manufacturing (AM) of steels involves the layer by layer consolidation of powder or wire feedstock using a heating beam to form near net shape products. For the past decades, the AM technique reaches the maturation of both research grade and commercial production due to significant research work from academic, government and industrial research organization worldwide. AM process has been implemented to replace the conventional process of steel fabrication due to its potentially lower cost and flexibility manufacturing. This paper provides a review of previous research related to the AM methods followed by current challenges issues. The relationship between microstructure, mechanical properties, and process parameters will be discussed. Future trends and recommendation for further works are also provided.

Circular Economy: Questions for Responsible Minerals, Additive Manufacturing and Recycling of Metals

Directory of Open Access Journals (Sweden)

Damien Giurco

2014-05-01

Full Text Available The concept of the circular economy proposes new patterns of production, consumption and use, based on circular flows of resources. Under a scenario where there is a global shift towards the circular economy, this paper discusses the advent of two parallel and yet-to-be-connected trends for Australia, namely: (i responsible minerals supply chains and (ii additive manufacturing, also known as 3D production systems. Acknowledging the current context for waste management, the paper explores future interlinked questions which arise in the circular economy for responsible supply chains, additive manufacturing, and metals recycling. For example, where do mined and recycled resources fit in responsible supply chains as inputs to responsible production? What is required to ensure 3D production systems are resource efficient? How could more distributed models of production, enabled by additive manufacturing, change the geographical scale at which it is economic or desirable to close the loop? Examples are given to highlight the need for an integrated research agenda to address these questions and to foster Australian opportunities in the circular economy.

Considerations on the Construction of a Powder Bed Fusion Platform for Additive Manufacturing

DEFF Research Database (Denmark)

Andersen, Sebastian Aagaard; Nielsen, Karl-Emil; Pedersen, David Bue

2017-01-01

As the demand for moulds and other tools becomes increasingly specific and complex, an additive manufacturing approach to production is making its way to the industry through laser based consolidation of metal powder particles by a method known as powder bed fusion. This paper concerns a variety...... of design choices facilitating the development of an experimental powder bed fusion machine tool, capable of manufacturing metal parts with strength matching that of conventional manufactured parts and a complexity surpassing that of subtractive processes. To understand the different mechanisms acting...

Additive Manufacturing of Dense Hexagonal Boron Nitride Objects

Energy Technology Data Exchange (ETDEWEB)

Marquez Rossy, Andres E [ORNL; Armstrong, Beth L [ORNL; Elliott, Amy M [ORNL; Lara-Curzio, Edgar [ORNL

2017-05-12

The feasibility of manufacturing hexagonal boron nitride objects via additive manufacturing techniques was investigated. It was demonstrated that it is possible to hot-extrude thermoplastic filaments containing uniformly distributed boron nitride particles with a volume concentration as high as 60% and that these thermoplastic filaments can be used as feedstock for 3D-printing objects using a fused deposition system. Objects 3D-printed by fused deposition were subsequently sintered at high temperature to obtain dense ceramic products. In a parallel study the behavior of hexagonal boron nitride in aqueous solutions was investigated. It was shown that the addition of a cationic dispersant to an azeotrope enabled the formulation of slurries with a volume concentration of boron nitride as high as 33%. Although these slurries exhibited complex rheological behavior, the results from this study are encouraging and provide a pathway for manufacturing hexagonal boron nitride objects via robocasting.

3D Printing, Additive Manufacturing, and Solid Freeform Fabrication: The Technologies of the Past, Present and Future

Science.gov (United States)

Beaman, Joseph

2015-03-01

Starting in the late 1980's, several new technologies were created that have the potential to revolutionize manufacturing. These technologies are, for the most part, additive processes that build up parts layer by layer. In addition, the processes that are being touted for hard-core manufacturing are primarily laser or e-beam based processes. This presentation gives a brief history of Additive Manufacturing and gives an assessment for these technologies. These technologies initially grew out of a commercial need for rapid prototyping. This market has a different requirement for process and quality control than traditional manufacturing. The relatively poor process control of the existing commercial Additive Manufacturing equipment is a vestige of this history. This presentation discusses this history and improvements in quality over time. The emphasis will be on Additive Manufacturing processes that are being considered for direct manufacturing, which is a different market than the 3D Printing ``Makerbot'' market. Topics discussed include past and present machine sensors, materials, and operational methods that were used in the past and those that are used today to create manufactured parts. Finally, a discussion of new methods and future directions of AM is presented.

Characterizing Polymer Powders used in Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Bajric, Sendin [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

2017-11-16

These are a set of slides that give the personal background of the author, information about his LANL organization, and information about his internship project at LANL about additive manufacturing and selective laser sintering (SLS).

Fatigue crack propagation in additively manufactured porous biomaterials

NARCIS (Netherlands)

Hedayati, R.; Amin Yavari, S.; Zadpoor, A.A.

2017-01-01

Additively manufactured porous titanium implants, in addition to preserving the excellent biocompatible properties of titanium, have very small stiffness values comparable to those of natural bones. Although usually loaded in compression, biomedical implants can also be under tensional, shear,

SLM processing-microstructure-mechanical property correlation in an aluminum alloy produced by additive manufacturing

Science.gov (United States)

Alejos, Martin Fernando

Additive manufacturing has become a highly researched topic in recent years all over the world. The current research evaluates the merits of additive manufacturing based on the mechanical, microstructural, and fracture properties of additive manufactured AlSi10Mg test specimens. The additive manufactured build plates consisted of tensile and fatigue test specimens. They were printed in the 0°, 30°, 60°, and 90° orientations relative to the build platform. Tensile and dynamic fatigue tests were conducted followed by microstructural characterization and fracture analysis. A wrought 6061 T6 aluminum alloy was also tested for comparison. Tensile tests revealed similar ultimate tensile strengths for all aluminum tensile specimens (350-380 MPa). Fatigue strength was greatest for wrought 6061 T6 aluminum (175 MPa). The fatigue behavior was a strong function of build orientation for the additive manufactured specimens. The 0°, 30°, and 60° orientations had fatigue strengths close to 104 MPa while the 90° orientation had a fatigue strength of 125 MPa. All test specimens failed primarily in a ductile manner. The effect of laser power, hatch spacing, and scan speed were also studied using microstructural analysis. Increasing laser power decreased grain size and void size. Increasing scan speed led to the formation of columnar grains. Increasing hatch spacing decreased grain size and the amount of voids present in the microstructure.

Mechanical and Fatigue Properties of Additively Manufactured Metallic Materials

Science.gov (United States)

Yadollahi, Aref

This study aims to investigate the mechanical and fatigue behavior of additively manufactured metallic materials. Several challenges associated with different metal additive manufacturing (AM) techniques (i.e. laser-powder bed fusion and direct laser deposition) have been addressed experimentally and numerically. Experiments have been carried out to study the effects of process inter-layer time interval--i.e. either building the samples one-at-a-time or multi-at-a-time (in-parallel)--on the microstructural features and mechanical properties of 316L stainless steel samples, fabricated via a direct laser deposition (DLD). Next, the effect of building orientation--i.e. the orientation in which AM parts are built--on microstructure, tensile, and fatigue behaviors of 17-4 PH stainless steel, fabricated via a laser-powder bed fusion (L-PBF) method was investigated. Afterwards, the effect of surface finishing--here, as-built versus machined--on uniaxial fatigue behavior and failure mechanisms of Inconel 718 fabricated via a laser-powder bed fusion technique was sought. The numerical studies, as part of this dissertation, aimed to model the mechanical behavior of AM materials, under monotonic and cyclic loading, based on the observations and findings from the experiments. Despite significant research efforts for optimizing process parameters, achieving a homogenous, defect-free AM product--immediately after fabrication--has not yet been fully demonstrated. Thus, one solution for ensuring the adoption of AM materials for application should center on predicting the variations in mechanical behavior of AM parts based on their resultant microstructure. In this regard, an internal state variable (ISV) plasticity-damage model was employed to quantify the damage evolution in DLD 316L SS, under tensile loading, using the microstructural features associated with the manufacturing process. Finally, fatigue behavior of AM parts has been modeled based on the crack-growth concept

Fundamental Aspects of Selective Melting Additive Manufacturing Processes

Energy Technology Data Exchange (ETDEWEB)

van Swol, Frank B. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Miller, James E. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

2014-12-01

Certain details of the additive manufacturing process known as selective laser melting (SLM) affect the performance of the final metal part. To unleash the full potential of SLM it is crucial that the process engineer in the field receives guidance about how to select values for a multitude of process variables employed in the building process. These include, for example, the type of powder (e.g., size distribution, shape, type of alloy), orientation of the build axis, the beam scan rate, the beam power density, the scan pattern and scan rate. The science-based selection of these settings con- stitutes an intrinsically challenging multi-physics problem involving heating and melting a metal alloy, reactive, dynamic wetting followed by re-solidification. In addition, inherent to the process is its considerable variability that stems from the powder packing. Each time a limited number of powder particles are placed, the stacking is intrinsically different from the previous, possessing a different geometry, and having a different set of contact areas with the surrounding particles. As a result, even if all other process parameters (scan rate, etc) are exactly the same, the shape and contact geometry and area of the final melt pool will be unique to that particular configuration. This report identifies the most important issues facing SLM, discusses the fundamental physics associated with it and points out how modeling can support the additive manufacturing efforts.

Additively manufactured custom load-bearing implantable devices: grounds for caution

Directory of Open Access Journals (Sweden)

Elisabetta M Zanetti

2017-08-01

Full Text Available Background Additive manufacturing technologies are being enthusiastically adopted by the orthopaedic community since they are providing new perspectives and new possibilities. First applications were finalised for educational purposes, pre-operative planning, and design of surgical guides; recent applications also encompass the production of implantable devices where 3D printing can bring substantial benefits such as customization, optimization, and manufacturing of very complex geometries. The conceptual smoothness of the whole process may lead to the idea that any medical practitioner can use a 3D printer and her/his imagination to design and produce novel products for personal or commercial use. Aims Outlining how the whole process presents more than one critical aspects, still demanding further research in order to allow a safe application of this technology for fully-custom design, in particular confining attention to orthopaedic/orthodontic prostheses defined as components responding mainly to a structural function. Methods Current knowledge of mechanical properties of additively manufactured components has been examined along with reasons why the behaviour of these components might differ from traditionally manufactured components. The structural information still missing for mechanical design is outlined. Results Mechanical properties of additively manufactured components are not completely known, and especially fatigue limit needs to be examined further. Conclusion At the present stage, with reference to load-bearing implants subjected to many loading cycles, the indication of custom-made additively manufactured medical devices should be restricted to the cases with no viable alternative.

Damage evolution and failure mechanisms in additively manufactured stainless steel

Energy Technology Data Exchange (ETDEWEB)

Carlton, Holly D., E-mail: carlton4@llnl.gov [Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Avenue, Livermore, CA 94550 (United States); Haboub, Abdel [Lincoln University, Life and Physical Sciences Department, 820 Chestnut St, Jefferson City, MO 65101 (United States); Gallegos, Gilbert F. [Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Avenue, Livermore, CA 94550 (United States); Parkinson, Dilworth Y.; MacDowell, Alastair A. [Advanced Light Source, Lawrence Berkeley National Laboratory, 1 Cyclotron Road, Berkeley, CA 94720 (United States)

2016-01-10

In situ tensile tests were performed on additively manufactured austenitic stainless steel to track damage evolution within the material. For these experiments Synchrotron Radiation micro-Tomography was used to measure three-dimensional pore volume, distribution, and morphology in stainless steel at the micrometer length-scale while tensile loading was applied. The results showed that porosity distribution played a larger role in affecting the fracture mechanisms than measured bulk density. Specifically, additively manufactured stainless steel specimens with large inhomogeneous void distributions displayed a flaw-dominated failure where cracks were shown to initiate at pre-existing voids, while annealed additively manufactured stainless steel specimens, which contained low porosity and randomly distributed pores, displayed fracture mechanisms that closely resembled wrought metal.

Microstructures and Grain Refinement of Additive-Manufactured Ti- xW Alloys

Science.gov (United States)

Mendoza, Michael Y.; Samimi, Peyman; Brice, David A.; Martin, Brian W.; Rolchigo, Matt R.; LeSar, Richard; Collins, Peter C.

2017-07-01

It is necessary to better understand the composition-processing-microstructure relationships that exist for materials produced by additive manufacturing. To this end, Laser Engineered Net Shaping (LENS™), a type of additive manufacturing, was used to produce a compositionally graded titanium binary model alloy system (Ti- xW specimen (0 ≤ x ≤ 30 wt pct), so that relationships could be made between composition, processing, and the prior beta grain size. Importantly, the thermophysical properties of the Ti- xW, specifically its supercooling parameter ( P) and growth restriction factor ( Q), are such that grain refinement is expected and was observed. The systematic, combinatorial study of this binary system provides an opportunity to assess the mechanisms by which grain refinement occurs in Ti-based alloys in general, and for additive manufacturing in particular. The operating mechanisms that govern the relationship between composition and grain size are interpreted using a model originally developed for aluminum and magnesium alloys and subsequently applied for titanium alloys. The prior beta grain factor observed and the interpretations of their correlations indicate that tungsten is a good grain refiner and such models are valid to explain the grain-refinement process. By extension, other binary elements or higher order alloy systems with similar thermophysical properties should exhibit similar grain refinement.

Biological features produced by additive manufacturing processes using vat photopolymerization method

DEFF Research Database (Denmark)

Davoudinejad, Ali; Mendez Ribo, Macarena; Pedersen, David Bue

2017-01-01

of micro biological features by Additive Manufacturing (AM) processes. The study characterizes the additive manufacturing processes for polymeric micro part productions using the vat photopolymerization method. A specifically designed vat photopolymerization AM machine suitable for precision printing...

Additive manufacturing of short and mixed fibre-reinforced polymer

Science.gov (United States)

Lewicki, James; Duoss, Eric B.; Rodriguez, Jennifer Nicole; Worsley, Marcus A.; King, Michael J.

2018-01-09

Additive manufacturing of a fiber-reinforced polymer (FRP) product using an additive manufacturing print head; a reservoir in the additive manufacturing print head; short carbon fibers in the reservoir, wherein the short carbon fibers are randomly aligned in the reservoir; an acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin in the reservoir, wherein the short carbon fibers are dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin; a tapered nozzle in the additive manufacturing print head operatively connected to the reservoir, the tapered nozzle produces an extruded material that forms the fiber-reinforced polymer product; baffles in the tapered nozzle that receive the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin with the short carbon fibers dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin; and a system for driving the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin with the short carbon fibers dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin from the reservoir through the tapered nozzle wherein the randomly aligned short carbon fibers in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin are aligned by the baffles and wherein the extruded material has the short carbon fibers aligned in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin that forms the fiber-reinforced polymer product.

Additive Manufacturing (AM) in Expeditionary Operations: Current Needs, Technical Challenges, and Opportunities

Science.gov (United States)

2016-06-01

REPORT TYPE AND DATES COVERED Master’s Thesis 06-30-2014 to 06-17-2016 4. TITLE AND SUBTITLE ADDITIVE MANUFACTURING (AM) IN EXPEDITIONARY OPERATIONS: CUR...CODE 13. ABSTRACT (maximum 200 words) Additive manufacturing (AM), or 3D printing, is poised to change the world of military expeditionary operations...unlimited ADDITIVE MANUFACTURING (AM) IN EXPEDITIONARY OPERATIONS: CURRENT NEEDS, TECHNICAL CHALLENGES, AND OPPORTUNITIES Matthew Daniel Friedell Captain

3D Machine Vision and Additive Manufacturing: Concurrent Product and Process Development

International Nuclear Information System (INIS)

Ilyas, Ismet P

2013-01-01

The manufacturing environment rapidly changes in turbulence fashion. Digital manufacturing (DM) plays a significant role and one of the key strategies in setting up vision and strategic planning toward the knowledge based manufacturing. An approach of combining 3D machine vision (3D-MV) and an Additive Manufacturing (AM) may finally be finding its niche in manufacturing. This paper briefly overviews the integration of the 3D machine vision and AM in concurrent product and process development, the challenges and opportunities, the implementation of the 3D-MV and AM at POLMAN Bandung in accelerating product design and process development, and discusses a direct deployment of this approach on a real case from our industrial partners that have placed this as one of the very important and strategic approach in research as well as product/prototype development. The strategic aspects and needs of this combination approach in research, design and development are main concerns of the presentation.

Education packed in technology to promote innovations: Teaching Additive Manufacturing based on a rolling Lab

Directory of Open Access Journals (Sweden)

Thurn Laura Katharina

2017-01-01

Full Text Available 3D Printing is about to revolutionize the way we design and produce future products. This causes not just immense research and development activities worldwide but requires intensive education and training efforts. As 3D Printing is an ideal tool to set up a decentralized production, it is one key to integrate even rural and under-industrialized parts of the country into high tech education and professional training needed. But how to reach the relevant groups - pupils from schools as well as professional staff of preferably companies? Remembered the old proverb: “If the mountain won’t come to the prophet, the prophet must go to the mountain” the plan of a mobile 3D printing lab was born. Based on our experiences, we designed the technical infrastructure and the educational approach to adopt Additive Manufacturing courses to a short term comprehensive teaching. To create a fully equipped workplace for every participant, we redesigned a double-decker bus. The paper addresses the strategy behind the bus, the infrastructure in detail, the developed courses taught and the resonance on this project. Looking forward, the paper gives a sneak preview on the further development in terms of specialized courses to be given in the bus as well as in the frame of accompanying activities such as engineering design of parts, application of new materials for Additive Manufacturing such as metals and follow-up production like plastic injection molding.

Using Additive Manufacturing to Reduce the Cost of Instrument Development

Data.gov (United States)

National Aeronautics and Space Administration — Additive Manufacturing (AM), commonly known as 3D printing, is widely used in the commercial sector for the manufacture of consumer goods, high performance parts for...

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

DEFF Research Database (Denmark)

Thompson, Mary Kathryn; Moroni, Giovanni; Vaneker, Tom

2016-01-01

The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology...... has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future...

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

DEFF Research Database (Denmark)

Thompson, Mary Kathryn; Moroni, Giovanni; Vaneker, Tom

2016-01-01

has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future......The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology...

Evaluation of Additive Manufacturing for Composite Part Molds

Energy Technology Data Exchange (ETDEWEB)

Duty, Chad E. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Springfield, Robert M. [Tru Design, LLC, Knoxville, TN (United States)

2015-02-01

The ORNL Manufacturing Demonstration Facility (MDF) collaborated with Tru-Design to test the quality and durability of molds used for making fiber reinforced composites using additive manufacturing. The partners developed surface treatment techniques including epoxy coatings and machining to improve the quality of the surface finish. Test samples made using the printed and surface finished molds demonstrated life spans suitable for one-of-a-kind and low-volume applications, meeting the project objective.

Predicting Color Output of Additive Manufactured Parts

DEFF Research Database (Denmark)

Eiríksson, Eyþór Rúnar; Pedersen, David Bue; Aanæs, Henrik

2015-01-01

In this paper we address the colorimetric performance of a multicolor additive manufacturing process. A method on how to measure and characterize color performance of said process is presented. Furthermore, a method on predicting the color output is demonstrated, allowing for previsualization...

IR-laser assisted additive freeform optics manufacturing.

Science.gov (United States)

Hong, Zhihan; Liang, Rongguang

2017-08-02

Computer-controlled additive manufacturing (AM) processes, also known as three-dimensional (3D) printing, create 3D objects by the successive adding of a material or materials. While there have been tremendous developments in AM, the 3D printing of optics is lagging due to the limits in materials and tight requirements for optical applicaitons. We propose a new precision additive freeform optics manufacturing (AFOM) method using an pulsed infrared (IR) laser. Compared to ultraviolet (UV) curable materials, thermally curable optical silicones have a number of advantages, such as strong UV stability, non-yellowing, and high transmission, making it particularly suitable for optical applications. Pulsed IR laser radiation offers a distinct advantage in processing optical silicones, as the high peak intensity achieved in the focal region allows for curing the material quickly, while the brief duration of the laser-material interaction creates a negligible heat-affected zone.

Evolution of Additively Manufactured Injection Molding Inserts Investigated by Thermal Simulations

DEFF Research Database (Denmark)

Hofstätter, Thomas; Pedersen, David B.; Tosello, Guido

Injection molding using inserts from vat polymerization, an additive manufacturing technology, has been investigated for pilot production and rapid prototyping purposes throughout the past years. A standard mold is equipped with additively manufactured inserts in a rectangular shape of (20 x 20 x 2...

Biocompatibility of photopolymers for additive manufacturing

Directory of Open Access Journals (Sweden)

Leonhardt Stefan

2016-09-01

Full Text Available To establish photopolymers for the production of class II or class III medical products by additive manufacturing it is essential to know which components of photopolymeric systems, consisting of monomers, photoinitiators and additives, are the determining factors on their biocompatible properties. In this study the leachable substances of a cured photopolymeric system were eluted and identified by HPLC-MS detection. In addition the cured photopolymer was testes for cytotoxicity and genotoxicity according to DIN EN ISO 10993 for long time applications. The results showed that uncured residual monomers are the determining factor on the biocompatible properties of the photopolymeric system. Strategies to reduce these residual monomers in the cured photopolymer are presented.

3D metal droplet printing development and advanced materials additive manufacturing

Directory of Open Access Journals (Sweden)

Lawrence E. Murr

2017-01-01

Full Text Available While commercial additive manufacturing processes involving direct metal wire or powder deposition along with powder bed fusion technologies using laser and electron beam melting have proliferated over the past decade, inkjet printing using molten metal droplets for direct, 3D printing has been elusive. In this paper we review the more than three decades of development of metal droplet generation for precision additive manufacturing applications utilizing advanced, high-temperature metals and alloys. Issues concerning process optimization, including product structure and properties affected by oxidation are discussed and some comparisons of related additive manufactured microstructures are presented.

Additive Manufacturing of Fuel Injectors

Energy Technology Data Exchange (ETDEWEB)

Sadek Tadros, Dr. Alber Alphonse [Edison Welding Institute, Inc., Columbus, OH (United States); Ritter, Dr. George W. [Edison Welding Institute, Inc., Columbus, OH (United States); Drews, Charles Donald [Edison Welding Institute, Inc., Columbus, OH (United States); Ryan, Daniel [Solar Turbines Inc., San Diego, CA (United States)

2017-10-24

Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventional manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the project

Powder bed charging during electron-beam additive manufacturing

International Nuclear Information System (INIS)

Cordero, Zachary C.; Meyer, Harry M.; Nandwana, Peeyush; Dehoff, Ryan R.

2017-01-01

Electrons injected into the build envelope during powder bed electron-beam additive manufacturing can accumulate on the irradiated particles and cause them to repel each other. Under certain conditions, these electrostatic forces can grow so large that they drive the particles out of the build envelope in a process known as “smoking”. In the present work, we investigate the causes of powder bed charging and smoking during electron-beam additive manufacturing. In the first part of the paper, we characterize the surface chemistry of a common feedstock material—gas-atomized Ti-6Al-4V powder—and find that a thick, electrically insulating oxide overlayer encapsulates the particles. Based on these experimental results, we then formulate an analytical model of powder bed charging in which each particle is approximated as a capacitor, where the particle and its substrate are the electrodes and the oxide overlayer is the dielectric. Using this model, we estimate the charge distribution in the powder bed, the electrostatic forces acting on the particles, and the conditions under which the powder bed will smoke. It is found that the electrical resistivity of the oxide overlayer strongly influences the charging behavior of the powder bed and that a high resistivity promotes charge accumulation and consequent smoking. This analysis suggests new quality control and process design measures that can help suppress smoking.

Additive manufacturing method for SRF components of various geometries

Science.gov (United States)

Rimmer, Robert; Frigola, Pedro E; Murokh, Alex Y

2015-05-05

An additive manufacturing method for forming nearly monolithic SRF niobium cavities and end group components of arbitrary shape with features such as optimized wall thickness and integral stiffeners, greatly reducing the cost and technical variability of conventional cavity construction. The additive manufacturing method for forming an SRF cavity, includes atomizing niobium to form a niobium powder, feeding the niobium powder into an electron beam melter under a vacuum, melting the niobium powder under a vacuum in the electron beam melter to form an SRF cavity; and polishing the inside surface of the SRF cavity.

Powder Characterization and Optimization for Additive Manufacturing

NARCIS (Netherlands)

Cordova, Laura; Campos, Mónica; Tinga, Tiedo

2017-01-01

Achieving the optimal quality for Additive Manufactured (AM) parts does not only depend on setting the right process parameters. Material feedstock also plays an important role when aiming for high performance products. The metal AM processes that are most applicable to industry, Powder Bed Fusion

Additive Manufacturing of Metastable Beta Titanium Alloys

Science.gov (United States)

Yannetta, Christopher J.

Additive manufacturing processes of many alloys are known to develop texture during the deposition process due to the rapid reheating and the directionality of the dissipation of heat. Titanium alloys and with respect to this study beta titanium alloys are especially susceptible to these effects. This work examines Ti-20wt%V and Ti-12wt%Mo deposited under normal additive manufacturing process parameters to examine the texture of these beta-stabilized alloys. Both microstructures contained columnar prior beta grains 1-2 mm in length beginning at the substrate with no visible equiaxed grains. This microstructure remained constant in the vanadium system throughout the build. The microstructure of the alloy containing molybdenum changed from a columnar to an equiaxed structure as the build height increased. Eighteen additional samples of the Ti-Mo system were created under different processing parameters to identify what role laser power and travel speed have on the microstructure. There appears to be a correlation in alpha lath size and power density. The two binary alloys were again deposited under the same conditions with the addition of 0.5wt% boron to investigate the effects an insoluble interstitial alloying element would have on the microstructure. The size of the prior beta grains in these two alloys were reduced with the addition of boron by approximately 50 (V) and 100 (Mo) times.

The scope of additive manufacturing in cryogenics, component design, and applications

Science.gov (United States)

Stautner, W.; Vanapalli, S.; Weiss, K.-P.; Chen, R.; Amm, K.; Budesheim, E.; Ricci, J.

2017-12-01

Additive manufacturing techniques using composites or metals are rapidly gaining momentum in cryogenic applications. Small or large, complex structural components are now no longer limited to mere design studies but can now move into the production stream thanks to new machines on the market that allow for light-weight, cost optimized designs with short turnaround times. The potential for cost reductions from bulk materials machined to tight tolerances has become obvious. Furthermore, additive manufacturing opens doors and design space for cryogenic components that to date did not exist or were not possible in the past, using bulk materials along with elaborate and expensive machining processes, e.g. micromachining. The cryogenic engineer now faces the challenge to design toward those new additive manufacturing capabilities. Additionally, re-thinking designs toward cost optimization and fast implementation also requires detailed knowledge of mechanical and thermal properties at cryogenic temperatures. In the following we compile the information available to date and show a possible roadmap for additive manufacturing applications of parts and components typically used in cryogenic engineering designs.

Metalorganic solution deposition of lead zirconate titanate films onto an additively manufactured Ni-based superalloy

International Nuclear Information System (INIS)

Patel, T.; Khassaf, H.; Vijayan, S.; Bassiri-Gharb, N.; Aindow, M.; Alpay, S.P.; Hebert, R.J.

2017-01-01

Recent advances in additive manufacturing of high-temperature alloys for structural aerospace applications has led to interest in integrating additional functionality into such parts. Lead zirconate titanate (PZT) is a prototypical ferroelectric ceramic used as the electro-active material in many piezoelectric sensors and actuators. In this study, 300 nm thick PbZr_0_._2Ti_0_._8O_3 (PZT 20/80) films were grown using metalorganic solution deposition onto additively manufactured substrates of Inconel 718. The microstructures of the films and the nature of the film/substrate interfaces were characterized using a combination of X-ray diffraction and electron microscopy techniques. Electrical measurements were performed to determine the ferroelectric, dielectric, and conductive responses of the PZT films. Our findings show that the PZT films exhibit robust ferroelectricity characterized by well-defined polarization-applied electric field (P-E) hysteresis loops. The samples display internal bias of up to ∼40 kV/cm. The room temperature remnant polarization and the small signal dielectric permittivity are ∼70 μC/cm"2 and 205, respectively. The dielectric loss (tan δ) and the leakage current at 1 kHz are 9% and 1 nA at 1 V, respectively. We attribute the internal bias observed in the hysteresis loops and the overall large dielectric losses to the presence of an intermediate oxide layer at the PZT/Inconel interface, which forms during the high temperature crystallization of the ferroelectric film. These results show that it is possible to grow functional oxides with promising electrical properties onto additively manufactured metallic substrates.

Cost estimation of a specifically designed direct light processing (DLP) additive manufacturing machine for precision printing

DEFF Research Database (Denmark)

Charalambis, Alessandro; Davoudinejad, Ali; Tosello, Guido

2017-01-01

creating new opportunities for manufacturers in a variety of industrial sectors. AM is an essentialprototyping technique for product design and development that is used in many different fields. However, the suitability of AMapplications in actual production in an industrial context needs to be determined......Additive Manufacturing (AM) refers to a portfolio of novel manufacturing technologies based on a layer-by-layer fabrication method.The market and industrial application of additive manufacturing technologies as an established manufacturing process have increasedexponentially in the last years....... This study, presents a cost estimation model forprecision printing with a specifically designed Digital Light Processing (DLP) AM machine built and validated at the Technical Universityof Denmark. The model presented in this study can be easily adapted and applied to estimate within a high level...

Laser beam welding of titanium additive manufactured parts

OpenAIRE

Wits, Wessel Willems; Jauregui Becker, Juan Manuel

2015-01-01

In this paper the joinability of titanium Additive Manufactured (AM) parts is explored. Keyhole welding, using a pulsed laser beam, of conventionally produced parts is compared to AM parts. Metal AM parts are notorious for having remaining porosities and other non-isotropic properties due to the layered manufacturing process. This study shows that due to these deficiencies more energy per unit weld length is required to obtain a similar keyhole geometry for titanium AM parts. It is also demon...

SURFACE ENGINEERING FOR PARTS MADE BY ADDITIVE MANUFACTURING

OpenAIRE

Nutal, Nicolas; Rochus, Pierre; Collette, Jean-Paul; Crahay, Jean; Larnicol, Maiween; Jochem, Helen; Magnien, Julien; Masse, Christian; Rigo, Olivier; Vanhumbeeck, Jean-François; Pambaguian, Laurent

2015-01-01

the surface preparation of metal parts made by additive manufacturing (AM). AM is a technology of choice for manufacturing of parts with complex shapes (heat exchangers, RF supports, optical parts…) and integrated functions such as conformal cooling channels, clips, hinges, etc. This opens the door for lightweight parts which are of prime importance for space applications. The potential of the AM technologies is however impeded by the quite rough surface finish that is observed on the as-m...

Evaporation model for beam based additive manufacturing using free surface lattice Boltzmann methods

International Nuclear Information System (INIS)

Klassen, Alexander; Scharowsky, Thorsten; Körner, Carolin

2014-01-01

Evaporation plays an important role in many technical applications including beam-based additive manufacturing processes, such as selective electron beam or selective laser melting (SEBM/SLM). In this paper, we describe an evaporation model which we employ within the framework of a two-dimensional free surface lattice Boltzmann method. With this method, we solve the hydrodynamics as well as thermodynamics of the molten material taking into account the mass and energy losses due to evaporation and the recoil pressure acting on the melt pool. Validation of the numerical model is performed by measuring maximum melt depths and evaporative losses in samples of pure titanium and Ti–6Al–4V molten by an electron beam. Finally, the model is applied to create processing maps for an SEBM process. The results predict that the penetration depth of the electron beam, which is a function of the acceleration voltage, has a significant influence on evaporation effects. (paper)

In-Process Monitoring of Additive Manufacturing, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — The key innovation in this project is the implementation of an Imaging Fourier Transform Spectrometer (IFTS) for in situ metal additive manufacturing process...

Internal Fiber Structure of a High-Performing, Additively Manufactured Injection Molding Insert

DEFF Research Database (Denmark)

Hofstätter, Thomas; Baier, Sina; Trinderup, Camilla H.

A standard mold is equipped with additively manufactured inserts in a rectangular shape produced with vat photo polymerization. While the lifetime compared to conventional materials such as brass, steel, and aluminum is reduced, the prototyping and design phase can be shortened significantly...... by using flexible and cost-effective additive manufacturing technologies. Higher production volumes still exceed the capability of additively manufactured inserts, which are overruled by the stronger performance of less-flexible but mechanically advanced materials. In this contribution, the internal...... structure of a high-performing, fiber-reinforced injection molding insert has been analyzed. The insert reached a statistically proven and reproducible lifetime of 4,500 shots, which significantly outperforms any other previously published additively manufactured inserts. Computer tomography, tensile tests...

Metrological assurance and traceability for Industry 4.0 and additive manufacturing in Ukraine

Science.gov (United States)

Skliarov, Volodymyr; Neyezhmakov, Pavel; Prokopov, Alexander

2018-03-01

The national measurement standards from the point of view of traceability of the results of measurement in additive manufacturing in Ukraine are considered in the paper. The metrological characteristics of the national primary measurement standards in the field of geometric, temperature, optical-physical and time-frequency measurements, which took part in international comparisons within COOMET projects, are presented. The accurate geometric, temperature, optical-physical and time-frequency measurements are the key ones in controlling the quality of additive manufacturing. The use of advanced CAD/CAE/CAM systems allows to simulate the process of additive manufacturing at each stage. In accordance with the areas of the technology of additive manufacturing, the ways of improving the national measurement standards of Ukraine for the growing needs of metrology of additive manufacturing are considered.

Standardization of rate of sugar addition for the manufacture of Thabdi.

Science.gov (United States)

Hirpara, Krupa B; Patel, H G; Prajapati, J P

2015-02-01

Traditional Indian Dairy Products are manufactured in India using an age old practice which varies from place to place. For manufacture of these products industrially, a standard formulation is required. Thabdi, a region specific, very popular heat desiccated milk product is one of such products which has not been studied scientifically. Sugar plays an important role in physico-chemical, sensory, textural characteristics and also the shelf life of any milk sweet. Hence for process standardization of Thabdi manufacture, different levels of sugar i.e. 4, 6, 8 and 10 (percent of milk) were studied so that an optimum level yielding best organoleptic characteristics in final product can be selected. The product was made from milk standardized to 0.66 Fat:SNF level and added with ghee @ 1.2 % of milk at the time of colour and texture development stage as selected from the earlier phase of study. Based on the results obtained, a level of 8 % sugar addition on the milk basis at the time of manufacture has been selected to have full taste and sensory attributes.

In-situ alloyed LENS additively manufactured TiAl-Nb structure

CSIR Research Space (South Africa)

Tlotleng, Monnamme

2017-11-01

Full Text Available corporates are interested in developments that will lead to cost effective manufacturing technologies that are able to produce homogenous, defect free TiAl structures. Additive manufacturing is one promising technology hence it was explored here in studying...

Additive Manufacturing: From Rapid Prototyping to Flight

Science.gov (United States)

Prater, Tracie

2015-01-01

Additive manufacturing (AM) offers tremendous promise for the rocket propulsion community. Foundational work must be performed to ensure the safe performance of AM parts. Government, industry, and academia must collaborate in the characterization, design, modeling, and process control to accelerate the certification of AM parts for human-rated flight.

Additive-manufactured sandwich lattice structures: A numerical and experimental investigation

Science.gov (United States)

Fergani, Omar; Tronvoll, Sigmund; Brøtan, Vegard; Welo, Torgeir; Sørby, Knut

2017-10-01

The utilization of additive-manufactured lattice structures in engineered products is becoming more and more common as the competitiveness of AM as a production technology has increased during the past several years. Lattice structures may enable important weight reductions as well as open opportunities to build products with customized functional properties, thanks to the flexibility of AM for producing complex geometrical configurations. One of the most critical aspects related to taking AM into new application areas—such as safety critical products—is currently the limited understanding of the mechanical behavior of sandwich-based lattice structure mechanical under static and dynamic loading. In this study, we evaluate manufacturability of lattice structures and the impact of AM processing parameters on the structural behavior of this type of sandwich structures. For this purpose, we conducted static compression testing for a variety of geometry and manufacturing parameters. Further, the study discusses a numerical model capable of predicting the behavior of different lattice structure. A reasonably good correlation between the experimental and numerical results was observed.

Exploiting Additive Manufacturing Infill in Topology Optimization for Improved Buckling Load

DEFF Research Database (Denmark)

Clausen, Anders; Aage, Niels; Sigmund, Ole

2016-01-01

Additive manufacturing (AM) permits the fabrication of functionally optimized components with high geometrical complexity. The opportunity of using porous infill as an integrated part of the manufacturing process is an example of a unique AM feature. Automated design methods are still incapable...... the standard and coating approaches to topology optimization for the MBB beam benchmark case. The optimized structures are additively manufactured using a filamentary technique. This experimental study validates the numerical model used in the coating approach. Depending on the properties of the infill...

Analytical relationships for prediction of the mechanical properties of additively manufactured porous biomaterials

NARCIS (Netherlands)

Zadpoor, A.A.; Hedayati, R.

2016-01-01

Recent developments in additive manufacturing techniques have motivated an increasing number of researchers to study regular porous biomaterials that are based on repeating unit cells. The physical and mechanical properties of such porous biomaterials have therefore received increasing attention

Real-time interferometric monitoring and measuring of photopolymerization based stereolithographic additive manufacturing process: sensor model and algorithm

International Nuclear Information System (INIS)

Zhao, X; Rosen, D W

2017-01-01

As additive manufacturing is poised for growth and innovations, it faces barriers of lack of in-process metrology and control to advance into wider industry applications. The exposure controlled projection lithography (ECPL) is a layerless mask-projection stereolithographic additive manufacturing process, in which parts are fabricated from photopolymers on a stationary transparent substrate. To improve the process accuracy with closed-loop control for ECPL, this paper develops an interferometric curing monitoring and measuring (ICM and M) method which addresses the sensor modeling and algorithms issues. A physical sensor model for ICM and M is derived based on interference optics utilizing the concept of instantaneous frequency. The associated calibration procedure is outlined for ICM and M measurement accuracy. To solve the sensor model, particularly in real time, an online evolutionary parameter estimation algorithm is developed adopting moving horizon exponentially weighted Fourier curve fitting and numerical integration. As a preliminary validation, simulated real-time measurement by offline analysis of a video of interferograms acquired in the ECPL process is presented. The agreement between the cured height estimated by ICM and M and that measured by microscope indicates that the measurement principle is promising as real-time metrology for global measurement and control of the ECPL process. (paper)

Additive manufacturing of scaffolds with dexamethasone controlled release for enhanced bone regeneration.

Science.gov (United States)

Costa, Pedro F; Puga, Ana M; Díaz-Gomez, Luis; Concheiro, Angel; Busch, Dirk H; Alvarez-Lorenzo, Carmen

2015-12-30

The adoption of additive manufacturing in tissue engineering and regenerative medicine (TERM) strategies greatly relies on the development of novel 3D printable materials with advanced properties. In this work we have developed a material for bone TERM applications with tunable bioerosion rate and dexamethasone release profile which can be further employed in fused deposition modelling (the most common and accessible 3D printing technology in the market). The developed material consisted of a blend of poly-ϵ-caprolactone (PCL) and poloxamine (Tetronic®) and was processed into a ready-to-use filament form by means of a simplified melt-based methodology, therefore eliminating the utilization of solvents. 3D scaffolds composed of various blend formulations were additively manufactured and analyzed revealing blend ratio-specific degradation rates and dexamethasone release profiles. Furthermore, in vitro culture studies revealed a similar blend ratio-specific trend concerning the osteoinductive activity of the fabricated scaffolds when these were seeded and cultured with human mesenchymal stem cells. The developed material enables to specifically address different regenerative requirements found in various tissue defects. The versatility of such strategy is further increased by the ability of additive manufacturing to accurately fabricate implants matching any given defect geometry. Copyright © 2015 Elsevier B.V. All rights reserved.

Measurement of fracture toughness of metallic materials produced by additive manufacturing

Science.gov (United States)

Quénard, O.; Dorival, O.; Guy, Ph.; Votié, A.; Brethome, K.

2018-04-01

This study focuses on the microstructure and mechanical properties of metallic materials produced by additive layer manufacturing (ALM), especially the laser beam melting process. The influence of the specimen orientation during the ALM process and that of two post-build thermal treatments were investigated. The identified metal powder is Ti-6Al-4V (titanium base). Metallographic analysis shows their effects on the microstructure of the metals. Mechanical experiments involving tensile tests as well as toughness tests were performed according to ASTM (American Society for Testing and Materials) norms. The results show that the main influence is that of the thermal treatments; however the manufacturing stacking direction may lead to some anisotropy in the mechanical properties.

Additive Manufactured Coronagraph Bench for Detection of Exoplanets

Data.gov (United States)

National Aeronautics and Space Administration — We propose to use additive manufacturing (AM) to build a Coronagraph Bench engineering test unit.  The versatility inherent in the 3D-printing process allows for a...

New Nomenclatures for Heat Treatments of Additively Manufactured Titanium Alloys

Science.gov (United States)

Baker, Andrew H.; Collins, Peter C.; Williams, James C.

2017-07-01

The heat-treatment designations and microstructure nomenclatures for many structural metallic alloys were established for traditional metals processing, such as casting, hot rolling or forging. These terms do not necessarily apply for additively manufactured (i.e., three-dimensionally printed or "3D printed") metallic structures. The heat-treatment terminology for titanium alloys generally implies the heat-treatment temperatures and their sequence relative to a thermomechanical processing step (e.g., forging, rolling). These designations include: β-processing, α + β-processing, β-annealing, duplex annealing and mill annealing. Owing to the absence of a thermomechanical processing step, these traditional designations can pose a problem when titanium alloys are first produced via additive manufacturing, and then heat-treated. This communication proposes new nomenclatures for heat treatments of additively manufactured titanium alloys, and uses the distinct microstructural features to provide a correlation between traditional nomenclature and the proposed nomenclature.

Ultrasonic assessment of additive manufactured Ti-6Al-4V

Science.gov (United States)

Schehl, Norman; Kramb, Vicki; Dierken, Josiah; Aldrin, John; Schwalbach, Edwin; John, Reji

2018-04-01

Additive Manufacturing (AM) processes offer the potential for manufacturing cost savings and rapid insertion into service through production of near net shape components for complicated structures. Use of these parts in high reliability applications such as those in the aerospace industry will require nondestructive characterization methods to ensure post-process material quality in as-built condition. Ultrasonic methods can be used for this quality verification. Depending on the application, the service life of AM components can be sensitive to the part surface condition. The surface roughness and layered structure inherent to the electron-beam powder-bed fusion process necessitates new approaches to evaluate subsurface material integrity in its presence. Experimental methods and data analytics may improve the evaluation of as-built additively manufactured materials. This paper discusses the assessment of additively manufactured EBM Ti-6Al-4V panels using ultrasonic methods and the data analytics applied to evaluate material integrity. The assessment was done as an exploratory study as the discontinuities of interest in these test samples were not known when the measurements were performed. Water immersion ultrasonic techniques, including pulse-echo and through transmission with 10 MHz focused transducers, were used to explore the material integrity of as-built plates. Subsequent destructive mechanical tests of specimens extracted from the plates provided fracture locations indicating critical flaws. To further understand the effect of surface-roughness, an evaluation of ultrasonic response in the presence of as-built surfaces and with the surface removed was performed. The assessment of additive manufactured EBM Ti-6Al-4V panels with ultrasonic techniques indicated that ultrasonic energy was attenuated by the as-built surface roughness. In addition, feature detection was shown to be sensitive to experimental ultrasonic parameters and flaw morphology.

A comparative study of additive and subtractive manufacturing for dental restorations.

Science.gov (United States)

Bae, Eun-Jeong; Jeong, Il-Do; Kim, Woong-Chul; Kim, Ji-Hwan

2017-08-01

Digital systems have recently found widespread application in the fabrication of dental restorations. For the clinical assessment of dental restorations fabricated digitally, it is necessary to evaluate their accuracy. However, studies of the accuracy of inlay restorations fabricated with additive manufacturing are lacking. The purpose of this in vitro study was to evaluate and compare the accuracy of inlay restorations fabricated by using recently introduced additive manufacturing with the accuracy of subtractive methods. The inlay (distal occlusal cavity) shape was fabricated using 3-dimensional image (reference data) software. Specimens were fabricated using 4 different methods (each n=10, total N=40), including 2 additive manufacturing methods, stereolithography apparatus and selective laser sintering; and 2 subtractive methods, wax and zirconia milling. Fabricated specimens were scanned using a dental scanner and then compared by overlapping reference data. The results were statistically analyzed using a 1-way analysis of variance (α=.05). Additionally, the surface morphology of 1 randomly (the first of each specimen) selected specimen from each group was evaluated using a digital microscope. The results of the overlap analysis of the dental restorations indicated that the root mean square (RMS) deviation observed in the restorations fabricated using the additive manufacturing methods were significantly different from those fabricated using the subtractive methods (Padditive manufacturing methods (P=.466). Similarly, no significant differences were found between wax and zirconia, the subtractive methods (P=.986). The observed RMS values were 106 μm for stereolithography apparatus, 113 μm for selective laser sintering, 116 μm for wax, and 119 μm for zirconia. Microscopic evaluation of the surface revealed a fine linear gap between the layers of restorations fabricated using stereolithography apparatus and a grooved hole with inconsistent weak scratches

Finite element simulation and experimental verification of ultrasonic non-destructive inspection of defects in additively manufactured materials

Science.gov (United States)

Taheri, H.; Koester, L.; Bigelow, T.; Bond, L. J.

2018-04-01

Industrial applications of additively manufactured components are increasing quickly. Adequate quality control of the parts is necessary in ensuring safety when using these materials. Base material properties, surface conditions, as well as location and size of defects are some of the main targets for nondestructive evaluation of additively manufactured parts, and the problem of adequate characterization is compounded given the challenges of complex part geometry. Numerical modeling can allow the interplay of the various factors to be studied, which can lead to improved measurement design. This paper presents a finite element simulation verified by experimental results of ultrasonic waves scattering from flat bottom holes (FBH) in additive manufacturing materials. A focused beam immersion ultrasound transducer was used for both the modeling and simulations in the additive manufactured samples. The samples were SS17 4 PH steel samples made by laser sintering in a powder bed.

PDC Journeys to Product Analysis Development and Additive Manufacturing?

International Nuclear Information System (INIS)

Shalina Sheik Muhamad

2015-01-01

The technology for product development and manufacturing has gone through many advancements. It is widely recognised that it would provide competitive advantage for engineering organization in term of product development cycle, productivity, sustainability and efficiency. We begin by describing the general characteristic of design process that will need to be integrated in product life cycle management. In Nuclear Malaysia, especially in engineering design activities the majority have been using 3D modelling. This paper discusses on the current product design practiced in Nuclear Malaysia, new product development process and new manufacturing technique which is additive manufacturing. (author)

Low-Cost Nanocellulose-Reinforced High-Temperature Polymer Composites for Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Ozcan, Soydan [ORNL; Tekinalp, Halil L [ORNL; Love, Lonnie J [ORNL; Kunc, Vlastimil [ORNL; Nelson, Kim [American Process Inc.

2016-07-13

ORNL worked with American Process Inc. to demonstrate the potential use of bio-based BioPlus^® lignin-coated cellulose nanofibrils (L-CNF) as a reinforcing agent in the development of polymer feedstock suitable for additive manufacturing. L-CNF-reinforced polylactic acid (PLA) testing coupons were prepared and up to 69% increase in tensile strength and 133% increase in elastic modulus were demonstrated.

APPLICATION OF ADDITIVELY MANUFACTURED POLYMER COMPOSITE PROTOTYPES IN FOUNDRY

Directory of Open Access Journals (Sweden)

Wiesław Kuczko

2015-05-01

Full Text Available The paper presents a method, developed by the authors, for manufacturing polymer composites with the matrix manufactured in a layered manner (via 3D printing – Fused Deposition Modeling out of a thermoplastic material. As an example of practical application of this method, functional prototypes are presented, which were used as elements of foundry tooling – patterns for sand molding. In case of manufacturing prototype castings or short series of products, foundries usually cooperate with modeling studios, which produce patterns by conventional, subtractive manufacturing technologies. If patterns have complex shapes, this results in high manufacturing costs and significantly longer time of tooling preparation. The method proposed by the authors allows manufacturing functional prototypes in a short time thanks to utilizing capabilities of additive manufacturing (3D printing technology. Thanks to using two types of materials simultaneously (ABS combined with chemically hardened resins, the produced prototypes are capable of carrying increased loads. Moreover, the method developed by the authors is characterized by manufacturing costs lower than in the basic technology of Fused Deposition Modeling. During the presented studies, the pattern was produced as a polymer composite and it was used to prepare a mold and a set of metal castings.

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets

NARCIS (Netherlands)

Li, L; Tirado, A.; Nlebedim, I.C.; Rios, O.; Post, B.; Kunc, V.; Lowden, R.R.; Lara-Curzio, E.; Fredette, R.; Ormerod, J.; Lograsso, T.A.; Paranthaman, M.P.

2016-01-01

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing

Validation of Reverse-Engineered and Additive-Manufactured Microsurgical Instrument Prototype.

Science.gov (United States)

Singh, Ramandeep; Suri, Ashish; Anand, Sneh; Baby, Britty

2016-12-01

With advancements in imaging techniques, neurosurgical procedures are becoming highly precise and minimally invasive, thus demanding development of new ergonomically aesthetic instruments. Conventionally, neurosurgical instruments are manufactured using subtractive manufacturing methods. Such a process is complex, time-consuming, and impractical for prototype development and validation of new designs. Therefore, an alternative design process has been used utilizing blue light scanning, computer-aided designing, and additive manufacturing direct metal laser sintering (DMLS) for microsurgical instrument prototype development. Deviations of DMLS-fabricated instrument were studied by superimposing scan data of fabricated instrument with the computer-aided designing model. Content and concurrent validity of the fabricated prototypes was done by a group of 15 neurosurgeons by performing sciatic nerve anastomosis in small laboratory animals. Comparative scoring was obtained for the control and study instrument. T test was applied to the individual parameters and P values for force (P direct application of these additive-manufactured instruments in the operating room requires further validation. © The Author(s) 2016.

Build platform that provides mechanical engagement with additive manufacturing prints

Science.gov (United States)

Elliott, Amelia M.

2018-03-06

A build platform and methods of fabricating an article with such a platform in an extrusion-type additive manufacturing machine are provided. A platform body 202 includes features 204 that extend outward from the body 202. The features 204 define protrusive areas 206 and recessive areas 208 that cooperate to mechanically engage the extruded material that forms the initial layers 220 of an article when the article is being fabricated by a nozzle 12 of the additive manufacturing machine 10.

Multi-orifice deposition nozzle for additive manufacturing

Science.gov (United States)

Lind, Randall F.; Post, Brian K.; Cini, Colin L.

2017-11-21

An additive manufacturing extrusion head includes a nozzle for accepting and depositing a heated material onto a work surface and/or part. The nozzle includes a valve body and an internal poppet body moveable between positions to permit deposition of at least two bead sizes of heated material onto a work surface and/or part.

Development and fabrication of patient-specific knee implant using additive manufacturing techniques

Science.gov (United States)

Zammit, Robert; Rochman, Arif

2017-10-01

Total knee replacement is the most effective treatment to relief pain and restore normal function in a diseased knee joint. The aim of this research was to develop a patient-specific knee implant which can be fabricated using additive manufacturing techniques and has reduced wear rates using a highly wear resistant materials. The proposed design was chosen based on implant requirements, such as reduction in wear rates as well as strong fixation. The patient-specific knee implant improves on conventional knee implants by modifying the articulating surfaces and bone-implant interfaces. Moreover, tribological tests of different polymeric wear couples were carried out to determine the optimal materials to use for the articulating surfaces. Finite element analysis was utilized to evaluate the stresses sustained by the proposed design. Finally, the patient-specific knee implant was successfully built using additive manufacturing techniques.

Progress toward Topology Optimization (TO) for Additive Manufacturing (AM) and Fatigue

Science.gov (United States)

2017-06-15

ARL-CR-0815 ● JUNE 2017 US Army Research Laboratory Progress toward Topology Optimization (TO) for Additive Manufacturing (AM...needed. Do not return it to the originator. ARL-CR-0815 ● JUNE 2017 US Army Research Laboratory Progress toward Topology ...Report 3. DATES COVERED (From - To) May 2015–May 2017 4. TITLE AND SUBTITLE Progress toward Topology Optimization (TO) for Additive Manufacturing

Mechanical Properties of a Newly Additive Manufactured Implant Material Based on Ti-42Nb.

Science.gov (United States)

Schulze, Christian; Weinmann, Markus; Schweigel, Christoph; Keßler, Olaf; Bader, Rainer

2018-01-13

The application of Ti-6Al-4V alloy or commercially pure titanium for additive manufacturing enables the fabrication of complex structural implants and patient-specific implant geometries. However, the difference in Young's modulus of α + β-phase Ti alloys compared to the human bone promotes stress-shielding effects in the implant-bone interphase. The aim of the present study is the mechanical characterization of a new pre-alloyed β-phase Ti-42Nb alloy for application in additive manufacturing. The present investigation focuses on the mechanical properties of SLM-printed Ti-42Nb alloy in tensile and compression tests. In addition, the raw Ti-42Nb powder, the microstructure of the specimens prior to and after compression tests, as well as the fracture occurring in tensile tests are characterized by means of the SEM/EDX analysis. The Ti-42Nb raw powder exhibits a dendrite-like Ti-structure, which is melted layer-by-layer into a microstructure with a very homogeneous distribution of Nb and Ti during the SLM process. Tensile tests display Young's modulus of 60.51 ± 3.92 GPa and an ultimate tensile strength of 683.17 ± 16.67 MPa, whereas, under a compressive load, a compressive strength of 1330.74 ± 53.45 MPa is observed. The combination of high mechanical strength and low elastic modulus makes Ti-42Nb an interesting material for orthopedic and dental implants. The spherical shape of the pre-alloyed material additionally allows for application in metal 3D printing, enabling the fabrication of patient-specific structural implants.

Polymers for 3D Printing and Customized Additive Manufacturing.

Science.gov (United States)

Ligon, Samuel Clark; Liska, Robert; Stampfl, Jürgen; Gurr, Matthias; Mülhaupt, Rolf

2017-08-09

Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer by layer without the need for molds or machining. AM enables decentralized fabrication of customized objects on demand by exploiting digital information storage and retrieval via the Internet. The ongoing transition from rapid prototyping to rapid manufacturing prompts new challenges for mechanical engineers and materials scientists alike. Because polymers are by far the most utilized class of materials for AM, this Review focuses on polymer processing and the development of polymers and advanced polymer systems specifically for AM. AM techniques covered include vat photopolymerization (stereolithography), powder bed fusion (SLS), material and binder jetting (inkjet and aerosol 3D printing), sheet lamination (LOM), extrusion (FDM, 3D dispensing, 3D fiber deposition, and 3D plotting), and 3D bioprinting. The range of polymers used in AM encompasses thermoplastics, thermosets, elastomers, hydrogels, functional polymers, polymer blends, composites, and biological systems. Aspects of polymer design, additives, and processing parameters as they relate to enhancing build speed and improving accuracy, functionality, surface finish, stability, mechanical properties, and porosity are addressed. Selected applications demonstrate how polymer-based AM is being exploited in lightweight engineering, architecture, food processing, optics, energy technology, dentistry, drug delivery, and personalized medicine. Unparalleled by metals and ceramics, polymer-based AM plays a key role in the emerging AM of advanced multifunctional and multimaterial systems including living biological systems as well as life-like synthetic systems.

Polymers for 3D Printing and Customized Additive Manufacturing

Science.gov (United States)

2017-01-01

Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer by layer without the need for molds or machining. AM enables decentralized fabrication of customized objects on demand by exploiting digital information storage and retrieval via the Internet. The ongoing transition from rapid prototyping to rapid manufacturing prompts new challenges for mechanical engineers and materials scientists alike. Because polymers are by far the most utilized class of materials for AM, this Review focuses on polymer processing and the development of polymers and advanced polymer systems specifically for AM. AM techniques covered include vat photopolymerization (stereolithography), powder bed fusion (SLS), material and binder jetting (inkjet and aerosol 3D printing), sheet lamination (LOM), extrusion (FDM, 3D dispensing, 3D fiber deposition, and 3D plotting), and 3D bioprinting. The range of polymers used in AM encompasses thermoplastics, thermosets, elastomers, hydrogels, functional polymers, polymer blends, composites, and biological systems. Aspects of polymer design, additives, and processing parameters as they relate to enhancing build speed and improving accuracy, functionality, surface finish, stability, mechanical properties, and porosity are addressed. Selected applications demonstrate how polymer-based AM is being exploited in lightweight engineering, architecture, food processing, optics, energy technology, dentistry, drug delivery, and personalized medicine. Unparalleled by metals and ceramics, polymer-based AM plays a key role in the emerging AM of advanced multifunctional and multimaterial systems including living biological systems as well as life-like synthetic systems. PMID:28756658

Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers

Science.gov (United States)

Gradl, Paul; Barnett, Greg; Brandsmeier, Will; Greene, Sandy Elam; Protz, Chris

2016-01-01

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, evaluate bimetallic deposition and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.

Additively manufactured hierarchical stainless steels with high strength and ductility

Science.gov (United States)

Wang, Y. Morris; Voisin, Thomas; McKeown, Joseph T.; Ye, Jianchao; Calta, Nicholas P.; Li, Zan; Zeng, Zhi; Zhang, Yin; Chen, Wen; Roehling, Tien Tran; Ott, Ryan T.; Santala, Melissa K.; Depond, Philip J.; Matthews, Manyalibo J.; Hamza, Alex V.; Zhu, Ting

2018-01-01

Many traditional approaches for strengthening steels typically come at the expense of useful ductility, a dilemma known as strength-ductility trade-off. New metallurgical processing might offer the possibility of overcoming this. Here we report that austenitic 316L stainless steels additively manufactured via a laser powder-bed-fusion technique exhibit a combination of yield strength and tensile ductility that surpasses that of conventional 316L steels. High strength is attributed to solidification-enabled cellular structures, low-angle grain boundaries, and dislocations formed during manufacturing, while high uniform elongation correlates to a steady and progressive work-hardening mechanism regulated by a hierarchically heterogeneous microstructure, with length scales spanning nearly six orders of magnitude. In addition, solute segregation along cellular walls and low-angle grain boundaries can enhance dislocation pinning and promote twinning. This work demonstrates the potential of additive manufacturing to create alloys with unique microstructures and high performance for structural applications.

Additive manufacturing of titanium alloys state of the art, challenges and opportunities

CERN Document Server

Dutta, Bhaskar

2016-01-01

Additive Manufacturing of Titanium Alloys: State of the Art, Challenges and Opportunities provides alternative methods to the conventional approach for the fabrication of the majority of titanium components produced via the cast and wrought technique, a process which involves a considerable amount of expensive machining. In contrast, the Additive Manufacturing (AM) approach allows very close to final part configuration to be directly fabricated minimizing machining cost, while achieving mechanical properties at least at cast and wrought levels. In addition, the book offers the benefit of significant savings through better material utilization for parts with high buy-to-fly ratios (ratio of initial stock mass to final part mass before and after manufacturing). As titanium additive manufacturing has attracted considerable attention from both academicians and technologists, and has already led to many applications in aerospace and terrestrial systems, as well as in the medical industry, this book explores the un...

Femtosecond laser additive manufacturing of YSZ

Energy Technology Data Exchange (ETDEWEB)

Liu, Jian; Bai, Shuang [PolarOnyx, Inc., San Jose, CA (United States)

2017-04-15

Laser additive manufacturing (LAM) of Yttria-Stabilized Zirconia (YSZ) is investigated using femtosecond (fs) fiber lasers. Various processing conditions are studied, which leads to desired characteristics in terms of morphology, porosity, hardness, microstructural and mechanical properties of the processed components. High-density (>99%) YSZ part with refined grain and increased hardness was obtained. Microstructure features of fabricated specimens were studied with SEM, EDX, the measured micro hardness is achieved as high as 18.84 GPa. (orig.)

Compliance and control characteristics of an additive manufactured-flexure stage

Energy Technology Data Exchange (ETDEWEB)

Lee, ChaBum; Tarbutton, Joshua A. [Department of Mechanical Engineering, University of South Carolina, 300 Main St., Columbia, South Carolina 29208 (United States)

2015-04-15

This paper presents a compliance and positioning control characteristics of additive manufactured-nanopositioning system consisted of the flexure mechanism and voice coil motor (VCM). The double compound notch type flexure stage was designed to utilize the elastic deformation of two symmetrical four-bar mechanisms to provide a millimeter-level working range. Additive manufacturing (AM) process, stereolithography, was used to fabricate the flexure stage. The AM stage was inspected by using 3D X-ray computerized tomography scanner: air-voids and shape irregularity. The compliance, open-loop resonance peak, and damping ratio of the AM stage were measured 0.317 mm/N, 80 Hz, and 0.19, respectively. The AM stage was proportional-integral-derivative positioning feedback-controlled and the capacitive type sensor was used to measure the displacement. As a result, the AM flexure mechanism was successfully 25 nm positioning controlled within 500 μm range. The resonance peak was found approximately at 280 Hz in closed-loop. This research showed that the AM flexure mechanism and the VCM can provide millimeter range with high precision and can be a good alternative to an expensive metal-based flexure mechanism and piezoelectric transducer.

Using Additive Manufacturing to Print a CubeSat Propulsion System

Science.gov (United States)

Marshall, William M.

2015-01-01

CubeSats are increasingly being utilized for missions traditionally ascribed to larger satellites CubeSat unit (1U) defined as 10 cm x 10 cm x 11 cm. Have been built up to 6U sizes. CubeSats are typically built up from commercially available off-the-shelf components, but have limited capabilities. By using additive manufacturing, mission specific capabilities (such as propulsion), can be built into a system. This effort is part of STMD Small Satellite program Printing the Complete CubeSat. Interest in propulsion concepts for CubeSats is rapidly gaining interest-Numerous concepts exist for CubeSat scale propulsion concepts. The focus of this effort is how to incorporate into structure using additive manufacturing. End-use of propulsion system dictates which type of system to develop-Pulse-mode RCS would require different system than a delta-V orbital maneuvering system. Team chose an RCS system based on available propulsion systems and feasibility of printing using a materials extrusion process. Initially investigated a cold-gas propulsion system for RCS applications-Materials extrusion process did not permit adequate sealing of part to make this a functional approach.

Compliance and control characteristics of an additive manufactured-flexure stage

International Nuclear Information System (INIS)

Lee, ChaBum; Tarbutton, Joshua A.

2015-01-01

This paper presents a compliance and positioning control characteristics of additive manufactured-nanopositioning system consisted of the flexure mechanism and voice coil motor (VCM). The double compound notch type flexure stage was designed to utilize the elastic deformation of two symmetrical four-bar mechanisms to provide a millimeter-level working range. Additive manufacturing (AM) process, stereolithography, was used to fabricate the flexure stage. The AM stage was inspected by using 3D X-ray computerized tomography scanner: air-voids and shape irregularity. The compliance, open-loop resonance peak, and damping ratio of the AM stage were measured 0.317 mm/N, 80 Hz, and 0.19, respectively. The AM stage was proportional-integral-derivative positioning feedback-controlled and the capacitive type sensor was used to measure the displacement. As a result, the AM flexure mechanism was successfully 25 nm positioning controlled within 500 μm range. The resonance peak was found approximately at 280 Hz in closed-loop. This research showed that the AM flexure mechanism and the VCM can provide millimeter range with high precision and can be a good alternative to an expensive metal-based flexure mechanism and piezoelectric transducer

Additive Manufacturing of Cranial Simulants for Blast Induced Traumatic Brain Injury

Science.gov (United States)

2017-08-28

REPORT TYPE 08/28/2017 Poster 4. TITLE AND SUBTITLE Additive Manufacturing of Cranial Sin1ulants for Blast Induced Traumatic Brain Injut’y 6... manufacturing techniques: Fused deposition modeling: ca sling molds Casting: white and gray matter Polymerization of injected solution...Sandia National Laboratories Conclusion MICHIGAN STAT[ l- I’ll I \\ I R <, I r \\ Additive manufacturrng provrdes a cost effective fabrration

Performance Simulation and Verification of Vat Photopolymerization Based, Additively Manufactured Injection Molding Inserts with Micro-Features

DEFF Research Database (Denmark)

Mischkot, Michael; Hofstätter, Thomas; Michailidou, Ifigeneia

2017-01-01

Injection molding soft tooling inserts manufactured additively with vat photopolymerization represent a valid technology for prototyping and pilot production of polymer parts. However, a significant drawback is the low heat conductivity of photopolymers influencing cycletime and part quality...

Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

Science.gov (United States)

Babu, S. S.; Raghavan, N.; Raplee, J.; Foster, S. J.; Frederick, C.; Haines, M.; Dinwiddie, R.; Kirka, M. K.; Plotkowski, A.; Lee, Y.; Dehoff, R. R.

2018-06-01

Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can be used for repair and reclamation of nickel alloy components. The current paper explores opportunities for innovation and qualification challenges with respect to deployment of AM as a disruptive manufacturing technology. In the first part of the paper, fundamental correlations of processing parameters to defect tendency and microstructure evolution will be explored using DED process. In the second part of the paper, opportunities for innovation in terms of site-specific control of microstructure during processing will be discussed. In the third part of the paper, challenges in qualification of AM parts for service will be discussed and potential methods to alleviate these issues through in situ process monitoring, and big data analytics are proposed.

Laser assisted hybrid additive manufacturing of thermoelectric modules

Science.gov (United States)

Zhang, Tao; Tewolde, Mahder; Longtin, Jon P.; Hwang, David J.

2017-02-01

Thermoelectric generators (TEGs) are an attractive means to produce electricity, particular from waste heat applications. However, TEGs are almost exclusively manufactured as flat, rigid modules of limited size and shape, and therefore an appropriate mounting for intimate contact of TEGs modules onto arbitrary surfaces represents a significant challenge. In this study, we introduce laser assisted additive manufacturing method to produce multi-layered thermoelectric generator device directly on flat and non-flat surfaces for waste heat recovery. The laser assisted processing spans from laser scribing of thermal sprayed thin films, curing of dispensed thermoelectric inks and selective laser sintering to functionalize thermoelectric materials.

Characterization of plastic and boron carbide additive manufactured neutron collimators

Science.gov (United States)

Stone, M. B.; Siddel, D. H.; Elliott, A. M.; Anderson, D.; Abernathy, D. L.

2017-12-01

Additive manufacturing techniques allow for the production of materials with complicated geometries with reduced costs and production time over traditional methods. We have applied this technique to the production of neutron collimators for use in thermal and cold neutron scattering instrumentation directly out of boron carbide. We discuss the design and generation of these collimators. We also provide measurements at neutron scattering beamlines which serve to characterize the performance of these collimators. Additive manufacturing of parts using neutron absorbing material may also find applications in radiography and neutron moderation.

Additive manufacturing technology in spare parts supply chain

DEFF Research Database (Denmark)

Li, Yao; Jia, Guozhu; Yang, Cheng

2017-01-01

Additive Manufacturing (AM) technology has the potential to significantly improve supply chain dynamics. The purpose of this paper is to investigate the impact of AM on spare parts supply chain. Three supply chain scenarios are investigated in this paper, namely conventional supply chain...

Design and development of a layer-based additive manufacturing process for the realization of metal parts of designed mesostructure

Science.gov (United States)

Williams, Christopher Bryant

Low-density cellular materials, metallic bodies with gaseous voids, are a unique class of materials that are characterized by their high strength, low mass, good energy absorption characteristics, and good thermal and acoustic insulation properties. In an effort to take advantage of this entire suite of positive mechanical traits, designers are tailoring the cellular mesostructure for multiple design objectives. Unfortunately, existing cellular material manufacturing technologies limit the design space as they are limited to certain part mesostructure, material type, and macrostructure. The opportunity that exists to improve the design of existing products, and the ability to reap the benefits of cellular materials in new applications is the driving force behind this research. As such, the primary research goal of this work is to design, embody, and analyze a manufacturing process that provides a designer the ability to specify the material type, material composition, void morphology, and mesostructure topology for any conceivable part geometry. The accomplishment of this goal is achieved in three phases of research: (1) Design---Following a systematic design process and a rigorous selection exercise, a layer-based additive manufacturing process is designed that is capable of meeting the unique requirements of fabricating cellular material geometry. Specifically, metal parts of designed mesostructure are fabricated via three-dimensional printing of metal oxide ceramic powder followed by post-processing in a reducing atmosphere. (2) Embodiment ---The primary research hypothesis is verified through the use of the designed manufacturing process chain to successfully realize metal parts of designed mesostructure. (3) Modeling & Evaluation ---The designed manufacturing process is modeled in this final research phase so as to increase understanding of experimental results and to establish a foundation for future analytical modeling research. In addition to an analysis of

Mechanical Properties of a Newly Additive Manufactured Implant Material Based on Ti-42Nb

Directory of Open Access Journals (Sweden)

Christian Schulze

2018-01-01

Full Text Available The application of Ti-6Al-4V alloy or commercially pure titanium for additive manufacturing enables the fabrication of complex structural implants and patient-specific implant geometries. However, the difference in Young’s modulus of α + β-phase Ti alloys compared to the human bone promotes stress-shielding effects in the implant–bone interphase. The aim of the present study is the mechanical characterization of a new pre-alloyed β-phase Ti-42Nb alloy for application in additive manufacturing. The present investigation focuses on the mechanical properties of SLM-printed Ti-42Nb alloy in tensile and compression tests. In addition, the raw Ti-42Nb powder, the microstructure of the specimens prior to and after compression tests, as well as the fracture occurring in tensile tests are characterized by means of the SEM/EDX analysis. The Ti-42Nb raw powder exhibits a dendrite-like Ti-structure, which is melted layer-by-layer into a microstructure with a very homogeneous distribution of Nb and Ti during the SLM process. Tensile tests display Young’s modulus of 60.51 ± 3.92 GPa and an ultimate tensile strength of 683.17 ± 16.67 MPa, whereas, under a compressive load, a compressive strength of 1330.74 ± 53.45 MPa is observed. The combination of high mechanical strength and low elastic modulus makes Ti-42Nb an interesting material for orthopedic and dental implants. The spherical shape of the pre-alloyed material additionally allows for application in metal 3D printing, enabling the fabrication of patient-specific structural implants.

Electrostatic Levitation for Studies of Additive Manufactured Materials

Science.gov (United States)

SanSoucie, Michael P.; Rogers, Jan R.; Tramel, Terri

2014-01-01

The electrostatic levitation (ESL) laboratory at NASA's Marshall Space Flight Center is a unique facility for investigators studying high temperature materials. The laboratory boasts two levitators in which samples can be levitated, heated, melted, undercooled, and resolidified. Electrostatic levitation minimizes gravitational effects and allows materials to be studied without contact with a container or instrumentation. The lab also has a high temperature emissivity measurement system, which provides normal spectral and normal total emissivity measurements at use temperature. The ESL lab has been instrumental in many pioneering materials investigations of thermophysical properties, e.g., creep measurements, solidification, triggered nucleation, and emissivity at high temperatures. Research in the ESL lab has already led to the development of advanced high temperature materials for aerospace applications, coatings for rocket nozzles, improved medical and industrial optics, metallic glasses, ablatives for reentry vehicles, and materials with memory. Modeling of additive manufacturing materials processing is necessary for the study of their resulting materials properties. In addition, the modeling of the selective laser melting processes and its materials property predictions are also underway. Unfortunately, there is very little data for the properties of these materials, especially of the materials in the liquid state. Some method to measure thermophysical properties of additive manufacturing materials is necessary. The ESL lab is ideal for these studies. The lab can provide surface tension and viscosity of molten materials, density measurements, emissivity measurements, and even creep strength measurements. The ESL lab can also determine melting temperature, surface temperatures, and phase transition temperatures of additive manufactured materials. This presentation will provide background on the ESL lab and its capabilities, provide an approach to using the ESL

Additive manufacturing techniques and their biomedical applications

Directory of Open Access Journals (Sweden)

Yujing Liu

2017-12-01

Full Text Available Additive manufacturing (AM, also known as three-dimensional (3D printing, is gaining increasing attention in medical fields, especially in dental and implant areas. Because AM technologies have many advantages in comparison with traditional technologies, such as the ability to manufacture patient-specific complex components, high material utilization, support of tissue growth, and a unique customized service for individual patients, AM is considered to have a large potential market in medical fields. This brief review presents the recent progress of 3D-printed biomedical materials for bone applications, mainly for metallic materials, including multifunctional alloys with high strength and low Young’s modulus, shape memory alloys, and their 3D fabrication by AM technologies. It describes the potential of 3D printing techniques in precision medicine and community health.

On the dynamic response of additively manufactured 316L

Science.gov (United States)

Smith, Liam; Eakins, Daniel; Chapman, David; Hooper, Paul

2017-06-01

Understanding the dynamic performance of Additively Manufactured (AM) materials is important when designing components for real-world applications. A series of Taylor tests were carried out on AM and conventionally manufactured 316L Stainless Steel. AM specimens were produced with a Renishaw AM250 selective laser melting machine. Taylor tests were conducted in a reverse anvil-on-rod configuration with soft capture and post loading measurements used to corroborate high speed deformation imaging. The influence of microstructure orientation and surface roughness was investigated by manufacturing samples parallel and perpendicular to build direction and with both as-built and machined finishes. Results were compared with optimised Johnson-Cook and Zerilli-Armstrong constitutive models within AUTODYN FE software.

Porous composite with negative thermal expansion obtained by photopolymer additive manufacturing

OpenAIRE

Akihiro Takezawa; Makoto Kobashi; Mitsuru Kitamura

2015-01-01

Additive manufacturing (AM) could be a novel method of fabricating composite and porous materials having various effective performances based on mechanisms of their internal geometries. Materials fabricated by AM could rapidly be used in industrial application since they could easily be embedded in the target part employing the same AM process used for the bulk material. Furthermore, multi-material AM has greater potential than usual single-material AM in producing materials with effective pr...

Additively Manufactured, Thermally Stable Telescope Mirror Substrates, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — This proposal is to demonstrate the feasibility of using selective laser melting (SLM) to develop the material composition and the additive manufacturing fabrication...

Real-Time Geometric Analysis of Additive Manufacturing, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — Current selective laser melting additive manufacturing (AM) systems do not have adequate process control features for wide-spread adoption across NASA. In this...

Biomedical applications of additive manufacturing: present and future

NARCIS (Netherlands)

Singh, Sunpreet; Ramakrishna, Seeram; Bouten, Carlijn V.C.; Narayan, Roger

2017-01-01

Three dimensional printing (3DP) or additive manufacturing (AM) of medical devices and scaffolds for tissue engineering, regenerative medicine, ex-vivo tissues and drug delivery is of intense interest in recent years. A few medical devices namely, ZipDose ® , Pharmacoprinting, powder bed fusion,

DIMENSIONAL VERIFICATION AND QUALITY CONTROL OF IMPLANTS PRODUCED BY ADDITIVE MANUFACTURING

Directory of Open Access Journals (Sweden)

Teodor Toth

2015-07-01

Full Text Available Purpose: Development of computer technology and alternative manufacturing methods in form of additive manufacturing leads to the manufacture of products with complex shapes. In the field of medicine they include, inter alia, custom-made implants manufactured for a particular patient, such as cranial implants, maxillofacial implants, etc. With regard to the fact that such implants are inserted into a patient’s body, it is necessary to perform the verification, including the shape and dimensional verification. The article deals with the application of the industrial computer tomography within the process of inspection and verification of selected custom-made implant types.Methodology/Approach: The Department of Biomedical Engineering and Measurement performs the verification of medicinal products manufactured by the additive manufacturing technologies from the Ti-6Al-4V (Grade 5 titanium alloy, using the coordinate measuring machine Carl Zeiss Contura G2 and the industrial computed tomography machine Carl Zeiss Metrotom 1500. These equipment fulfil the requirements for the identification and evaluation of dimensions of both, the external and the internal structures. Findings: The article presents the possibilities of the computed tomography utilisation in the inspection of individual implant manufacture using the additive manufacturing technologies. The results indicate that with the adjustment of appropriate input parameters (alignment, this technology is appropriate for the analysis of shape deviations, when compared with the CAD model.Research Limitation/implication: With the increasing distance of measured object from X-ray source, the machine’s resolution function decreases. Decreasing of resolution has a minor impact on the measured dimensions (relatively high tolerances, but has a significant impact on the evaluation of porosity and inclusions. Originality/Value of paper: Currently, the verification of a manufactured implant  can be

Additive Manufacturing of Hierarchical Porous Structures

Energy Technology Data Exchange (ETDEWEB)

Grote, Christopher John [Los Alamos National Lab. (LANL), Los Alamos, NM (United States). Materials Science and Technology Division. Polymers and Coatings

2016-08-30

Additive manufacturing has become a tool of choice for the development of customizable components. Developments in this technology have led to a powerful array of printers that t serve a variety of needs. However, resin development plays a crucial role in leading the technology forward. This paper addresses the development and application of printing hierarchical porous structures. Beginning with the development of a porous scaffold, which can be functionalized with a variety of materials, and concluding with customized resins for metal, ceramic, and carbon structures.

Surface modification of biomaterials and biomedical devices using additive manufacturing.

Science.gov (United States)

Bose, Susmita; Robertson, Samuel Ford; Bandyopadhyay, Amit

2018-01-15

The demand for synthetic biomaterials in medical devices, pharmaceutical products and, tissue replacement applications are growing steadily due to aging population worldwide. The use for patient matched devices is also increasing due to availability and integration of new technologies. Applications of additive manufacturing (AM) or 3D printing (3DP) in biomaterials have also increased significantly over the past decade towards traditional as well as innovative next generation Class I, II and III devices. In this review, we have focused our attention towards the use of AM in surface modified biomaterials to enhance their in vitro and in vivo performances. Specifically, we have discussed the use of AM to deliberately modify the surfaces of different classes of biomaterials with spatial specificity in a single manufacturing process as well as commented on the future outlook towards surface modification using AM. It is widely understood that the success of implanted medical devices depends largely on favorable material-tissue interactions. Additive manufacturing has gained traction as a viable and unique approach to engineered biomaterials, for both bulk and surface properties that improve implant outcomes. This review explores how additive manufacturing techniques have been and can be used to augment the surfaces of biomedical devices for direct clinical applications. Copyright © 2017 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

AM Envelope. The potential of Additive Manufacturing for facade constructions

Directory of Open Access Journals (Sweden)

Holger Strauss

2017-11-01

Full Text Available This dissertation shows the potential of Additive Manufacturing (AM for the development of building envelopes: AM will change the way of designing facades, how we engineer and produce them. To achieve today’s demands from those future envelopes, we have to find new solutions. New technologies offer one possible way to do so. They open new approaches in designing, producing and processing building construction and facades. Finding the one capable of having big impact is difficult – Additive Manufacturing is one possible answer. The term ‘AM Envelope’ (Additive Manufacturing Envelope describes the transfer of this technology to the building envelope. Additive Fabrication is a building block that aids in developing the building envelope from a mere space enclosure to a dynamic building envelope. First beginnings of AM facade construction show up when dealing with relevant aspects like material consumption, mounting or part’s performance. From those starting points several parts of an existing post-and-beam façade system were optimized, aiming toward the implementation of AM into the production chain. Enhancements on all different levels of production were achieved: storing, producing, mounting and performance. AM offers the opportunity to manufacture facades ‘just in time’. It is no longer necessary to store or produce large numbers of parts in advance. Initial investment for tooling can be avoided, as design improvements can be realized within the dataset of the AM part. AM is based on ‘tool-less’ production, all parts can be further developed with every new generation. Producing tool-less also allows for new shapes and functional parts in small batch sizes – down to batch size one. The parts performance can be re-interpreted based on the demands within the system, not based on the limitations of conventional manufacturing. AM offers new ways of materializing the physical part around its function. It leads toward customized

Advantages of utilizing DMD based rapid manufacturing systems in mass customization applications

Science.gov (United States)

El-Siblani, A.

2010-02-01

The Use of DMD based Rapid Manufacturing Systems has proven to be very advantageous in the production of highly accurate plastic based components for use in mass customization market such as hearing aids, and dental markets. The voxelization process currently afforded with the DLP technology eliminates any layering effect associated with all existing additive Rapid Manufacturing technologies. The smooth accurate surfaces produced in an additive process utilizing DLP technology, through the voxelization approach, allow for the production of custom finished products. The implementation of DLP technology in rapid prototyping and rapid manufacturing systems allow for the usage of highly viscous photopolymer based liquid and paste composites for rapid manufacturing that could not be used in any other additive process prior to implementation of DLP technology in RP and RM systems. It also allowed for the greater throughput in production without sacrificing quality and accuracy.

Laser beam welding of titanium additive manufactured parts

NARCIS (Netherlands)

Wits, Wessel Willems; Jauregui Becker, Juan Manuel

2015-01-01

In this paper the joinability of titanium Additive Manufactured (AM) parts is explored. Keyhole welding, using a pulsed laser beam, of conventionally produced parts is compared to AM parts. Metal AM parts are notorious for having remaining porosities and other non-isotropic properties due to the

Selecting parts for additive manufacturing in service logistics

NARCIS (Netherlands)

Knofius, Nils; van der Heijden, Matthijs C.; Zijm, Willem H.M.

2016-01-01

Purpose For more than ten years, the value of additive manufacturing (AM) for after-sales service logistics has been propagated. Today, however, only few applications are observed in practice. In this paper, possible reasons for this discrepancy are discussed and a method is developed to simplify

Selecting parts for additive manufacturing in service logistics

NARCIS (Netherlands)

Knofius, Nils; van der Heijden, Matthijs C.; Zijm, Willem H.M.

2016-01-01

Purpose – For more than ten years, the value of additive manufacturing (AM) for after-sales service logistics has been propagated. Today, however, only few applications are observed in practice. In this paper, possible reasons for this discrepancy are discussed and a method is developed to simplify

Design for Additive Bio-Manufacturing: From Patient-Specific Medical Devices to Rationally Designed Meta-Biomaterials.

Science.gov (United States)

Zadpoor, Amir A

2017-07-25

Recent advances in additive manufacturing (AM) techniques in terms of accuracy, reliability, the range of processable materials, and commercial availability have made them promising candidates for production of functional parts including those used in the biomedical industry. The complexity-for-free feature offered by AM means that very complex designs become feasible to manufacture, while batch-size-indifference enables fabrication of fully patient-specific medical devices. Design for AM (DfAM) approaches aim to fully utilize those features for development of medical devices with substantially enhanced performance and biomaterials with unprecedented combinations of favorable properties that originate from complex geometrical designs at the micro-scale. This paper reviews the most important approaches in DfAM particularly those applicable to additive bio-manufacturing including image-based design pipelines, parametric and non-parametric designs, metamaterials, rational and computationally enabled design, topology optimization, and bio-inspired design. Areas with limited research have been identified and suggestions have been made for future research. The paper concludes with a brief discussion on the practical aspects of DfAM and the potential of combining AM with subtractive and formative manufacturing processes in so-called hybrid manufacturing processes.

Design for Additive Bio-Manufacturing: From Patient-Specific Medical Devices to Rationally Designed Meta-Biomaterials

Directory of Open Access Journals (Sweden)

Amir A. Zadpoor

2017-07-01

Full Text Available Recent advances in additive manufacturing (AM techniques in terms of accuracy, reliability, the range of processable materials, and commercial availability have made them promising candidates for production of functional parts including those used in the biomedical industry. The complexity-for-free feature offered by AM means that very complex designs become feasible to manufacture, while batch-size-indifference enables fabrication of fully patient-specific medical devices. Design for AM (DfAM approaches aim to fully utilize those features for development of medical devices with substantially enhanced performance and biomaterials with unprecedented combinations of favorable properties that originate from complex geometrical designs at the micro-scale. This paper reviews the most important approaches in DfAM particularly those applicable to additive bio-manufacturing including image-based design pipelines, parametric and non-parametric designs, metamaterials, rational and computationally enabled design, topology optimization, and bio-inspired design. Areas with limited research have been identified and suggestions have been made for future research. The paper concludes with a brief discussion on the practical aspects of DfAM and the potential of combining AM with subtractive and formative manufacturing processes in so-called hybrid manufacturing processes.

Design of Test Parts to Characterize Micro Additive Manufacturing Processes

DEFF Research Database (Denmark)

Thompson, Mary Kathryn; Mischkot, Michael

2015-01-01

The minimum feature size and obtainable tolerances of additive manufacturing processes are linked to the smallest volumetric elements (voxels) that can be created. This work presents the iterative design of a test part to investigate the resolution of AM processes with voxel sizes at the micro...... scale. Each design iteration reduces the test part size, increases the number of test features, improves functionality, and decreases coupling in the part. The final design is a set of three test parts that are easy to orient and measure, and that provide useful information about micro additive...... manufacturing processes....

Neutron Characterization of Additively Manufactured Components. Workshop Report

Energy Technology Data Exchange (ETDEWEB)

Watkins, Thomas R. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Payzant, E. Andrew [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Babu, Sudarsanam Suresh [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2015-09-01

Additive manufacturing (AM) is a collection of promising manufacturing methods that industry is beginning to explore and adopt. Macroscopically complicated and near net shape components are being built using AM, but how the material behaves in service is a big question for industry. Consequently, AM components/materials need further research into exactly what is made and how it will behave in service. This one and a half day workshop included a series of invited presentations from academia, industry and national laboratories (see Appendix A for the workshop agenda and list of talks). The workshop was welcomed by Alan Tennant, Chief Scientist, Neutron Sciences Directorate, ORNL, and opened remotely by Rob Ivestor, Deputy Director, Advanced Manufacturing Office-DOE, who declared AM adoptees as titans who will be able to create customized 3-D structures with 1 million to 1 billion micro welds with locally tailored microstructures. Further he stated that characterization with neutrons is key to be able to bring critical insight/information into the AM process/property/behavior relationship. Subsequently, the presentations spanned a slice of the current state of the art AM techniques and many of the most relevant characterization techniques using neutrons. After the talks, a panel discussion was held; workshop participants (see Appendix B for a list of attendees) providing questions and the panel answers. The main purpose of the panel discussion was to build consensus regarding the critical research needs in AM that can be addressed with neutrons. These needs were placed into three categories: modes of access for neutrons, new capabilities needed, new AM material issues and neutrons. Recommendations from the workshop were determined based on the panel discussion.

Laser additive manufacturing of 3D meshes for optical applications.

Science.gov (United States)

Essa, Khamis; Sabouri, Aydin; Butt, Haider; Basuny, Fawzia Hamed; Ghazy, Mootaz; El-Sayed, Mahmoud Ahmed

2018-01-01

Selective laser melting (SLM) is a widely used additive manufacturing process that can be used for printing of intricate three dimensional (3D) metallic structures. Here we demonstrate the fabrication of titanium alloy Ti-6Al-4V alloy based 3D meshes with nodally-connected diamond like unit cells, with lattice spacing varying from 400 to 1000 microns. A Concept Laser M2 system equipped with laser that has a wavelength of 1075 nm, a constant beam spot size of 50μm and maximum power of 400W was used to manufacture the 3D meshes. These meshes act as optical shutters / directional transmitters and display interesting optical properties. A detailed optical characterisation was carried out and it was found that these structures can be optimised to act as scalable rotational shutters with high efficiencies and as angle selective transmission screens for protection against unwanted and dangerous radiations. The efficiency of fabricated lattice structures can be increased by enlarging the meshing size.

Laser additive manufacturing of 3D meshes for optical applications.

Directory of Open Access Journals (Sweden)

Khamis Essa

Full Text Available Selective laser melting (SLM is a widely used additive manufacturing process that can be used for printing of intricate three dimensional (3D metallic structures. Here we demonstrate the fabrication of titanium alloy Ti-6Al-4V alloy based 3D meshes with nodally-connected diamond like unit cells, with lattice spacing varying from 400 to 1000 microns. A Concept Laser M2 system equipped with laser that has a wavelength of 1075 nm, a constant beam spot size of 50μm and maximum power of 400W was used to manufacture the 3D meshes. These meshes act as optical shutters / directional transmitters and display interesting optical properties. A detailed optical characterisation was carried out and it was found that these structures can be optimised to act as scalable rotational shutters with high efficiencies and as angle selective transmission screens for protection against unwanted and dangerous radiations. The efficiency of fabricated lattice structures can be increased by enlarging the meshing size.

The Effect of Ultrasonic Additive Manufacturing on Integrated Printed Electronic Conductors

Science.gov (United States)

Bournias-Varotsis, Alkaios; Wang, Shanda; Hutt, David; Engstrøm, Daniel S.

2018-07-01

Ultrasonic additive manufacturing (UAM) is a low temperature manufacturing method capable of embedding printed electronics in metal components. The effect of UAM processing on the resistivity of conductive tracks printed with five different conductive pastes based on silver, copper or carbon flakes/particles in either a thermoplastic or thermoset filler binder are investigated. For all but the carbon-based paste, the resistivity changed linearly with the UAM energy input. After UAM processing, a resistivity increase of more than 150 times was recorded for the copper based thermoset paste. The silver based pastes showed a resistivity increase of between 1.1 and 50 times from their initial values. The carbon-based paste showed no change in resistivity after UAM processing. Focussed ion beam microstructure analysis of the printed conductive tracks before and after UAM processing showed that the silver particles and flakes in at least one of the pastes partly dislodged from their thermoset filler creating voids, thereby increasing the resistivity, whereas the silver flakes in a thermoplastic filler did not dislodge due to material flow of the polymer binder. The lowest resistivity (8 × 10-5 Ω cm) after UAM processing was achieved for a thermoplastic paste with silver flakes at low UAM processing energy.

The Effect of Ultrasonic Additive Manufacturing on Integrated Printed Electronic Conductors

Science.gov (United States)

Bournias-Varotsis, Alkaios; Wang, Shanda; Hutt, David; Engstrøm, Daniel S.

2018-03-01

Ultrasonic additive manufacturing (UAM) is a low temperature manufacturing method capable of embedding printed electronics in metal components. The effect of UAM processing on the resistivity of conductive tracks printed with five different conductive pastes based on silver, copper or carbon flakes/particles in either a thermoplastic or thermoset filler binder are investigated. For all but the carbon-based paste, the resistivity changed linearly with the UAM energy input. After UAM processing, a resistivity increase of more than 150 times was recorded for the copper based thermoset paste. The silver based pastes showed a resistivity increase of between 1.1 and 50 times from their initial values. The carbon-based paste showed no change in resistivity after UAM processing. Focussed ion beam microstructure analysis of the printed conductive tracks before and after UAM processing showed that the silver particles and flakes in at least one of the pastes partly dislodged from their thermoset filler creating voids, thereby increasing the resistivity, whereas the silver flakes in a thermoplastic filler did not dislodge due to material flow of the polymer binder. The lowest resistivity (8 × 10-5 Ω cm) after UAM processing was achieved for a thermoplastic paste with silver flakes at low UAM processing energy.

Large-scale additive manufacturing with bioinspired cellulosic materials.

Science.gov (United States)

Sanandiya, Naresh D; Vijay, Yadunund; Dimopoulou, Marina; Dritsas, Stylianos; Fernandez, Javier G

2018-06-05

Cellulose is the most abundant and broadly distributed organic compound and industrial by-product on Earth. However, despite decades of extensive research, the bottom-up use of cellulose to fabricate 3D objects is still plagued with problems that restrict its practical applications: derivatives with vast polluting effects, use in combination with plastics, lack of scalability and high production cost. Here we demonstrate the general use of cellulose to manufacture large 3D objects. Our approach diverges from the common association of cellulose with green plants and it is inspired by the wall of the fungus-like oomycetes, which is reproduced introducing small amounts of chitin between cellulose fibers. The resulting fungal-like adhesive material(s) (FLAM) are strong, lightweight and inexpensive, and can be molded or processed using woodworking techniques. We believe this first large-scale additive manufacture with ubiquitous biological polymers will be the catalyst for the transition to environmentally benign and circular manufacturing models.

Innovative Techniques for Micro-scale Additive Manufacturing for Sensors

Data.gov (United States)

National Aeronautics and Space Administration — The field of additive manufacturing with real materials (such as metals) has evolved from 3D printing of plastics.  The primary approach uses powder bed fusion...

Advanced Manufacturing Technologies (AMT): Additive Manufactured Hot Fire Planning and Testing in GRC Cell 32

Data.gov (United States)

National Aeronautics and Space Administration — The objective of this project is to hot fire test an additively manufactured thrust chamber assembly TCA (injector and thrust chamber). GRC will install the...

Additive manufacturing of Ti-Si-N ceramic coatings on titanium

International Nuclear Information System (INIS)

Zhang, Yanning; Sahasrabudhe, Himanshu; Bandyopadhyay, Amit

2015-01-01

Highlights: • 3D Printing or additive manufacturing of hard Ti-Si-N based ceramics coating on Ti metal substrate. • Understanding of phase transformation as a function of compositional variation. • Evaluation of influence of processing parameters and composition on wear resistance. - Abstract: In this study, Laser Engineered Net Shaping (LENS TM ) was employed towards Additive Manufacturing/3D Printing of Ti-Si-N coatings with three different Ti-Si ratios on commercially pure titanium (cp-Ti) substrate. Microstructural analysis, phase analysis using X-ray diffraction, wear resistance and hardness measurements were done on LENS™ processed 3D printed coatings. Coatings showed graded microstructures and in situ formed phases. Results showed that microstructural variations and phase changes influence coating's hardness and wear resistance directly. High hardness values were obtained from all samples’ top surface where the hardness of coatings can be ranked as 90% Ti-10% Si-N coating (2093.67 ± 144 HV 0.2 ) > 100% Ti-N coating (1846 ± 68.5 HV 0.2 ) > 75% Ti-25% Si-N coating (1375.3 ± 61.4 HV 0.2 ). However, wear resistance was more dependent on inherent Si content, and samples with higher Si content showed better wear resistance

Additive manufacturing of Ti-Si-N ceramic coatings on titanium

Energy Technology Data Exchange (ETDEWEB)

Zhang, Yanning; Sahasrabudhe, Himanshu; Bandyopadhyay, Amit, E-mail: amitband@wsu.edu

2015-08-15

Highlights: • 3D Printing or additive manufacturing of hard Ti-Si-N based ceramics coating on Ti metal substrate. • Understanding of phase transformation as a function of compositional variation. • Evaluation of influence of processing parameters and composition on wear resistance. - Abstract: In this study, Laser Engineered Net Shaping (LENS{sup TM}) was employed towards Additive Manufacturing/3D Printing of Ti-Si-N coatings with three different Ti-Si ratios on commercially pure titanium (cp-Ti) substrate. Microstructural analysis, phase analysis using X-ray diffraction, wear resistance and hardness measurements were done on LENS™ processed 3D printed coatings. Coatings showed graded microstructures and in situ formed phases. Results showed that microstructural variations and phase changes influence coating's hardness and wear resistance directly. High hardness values were obtained from all samples’ top surface where the hardness of coatings can be ranked as 90% Ti-10% Si-N coating (2093.67 ± 144 HV{sub 0.2}) > 100% Ti-N coating (1846 ± 68.5 HV{sub 0.2}) > 75% Ti-25% Si-N coating (1375.3 ± 61.4 HV{sub 0.2}). However, wear resistance was more dependent on inherent Si content, and samples with higher Si content showed better wear resistance.

Defense Additive Manufacturing: DOD Needs to Systematically Track Department-wide 3D Printing Efforts

Science.gov (United States)

2015-10-01

the chair of the group, while the teams each have some level of activity in additive manufacturing , it is not identified as one of the teams. Page...DEFENSE ADDITIVE MANUFACTURING DOD Needs to Systematically Track Department-wide 3D Printing Efforts Report to...2015 to 00-00-2015 4. TITLE AND SUBTITLE Defense Additive Manufacturing : DOD Needs to Systematically Track Department-wide 3D Printing Efforts 5a

NASA/ORNL/AFRL Project Work on EBM LSHR: Additive Manufacturing of High-Temperature Gamma-Prime Strengthened Ni-Based Superalloys

Science.gov (United States)

Sudbrack, Chantal K.; Kirka, Michael M.; Dehoff, Ryan R.; Carter, Robert W.; Semiatin, Sheldon L.; Gabb, Timothy P.

2016-01-01

Powder-bed fabrication of aerospace alloys may revolutionize production by eliminating the need for extensive machining and expensive tooling. Heated-bed electron-beam melting (EBM) offers advantages over non-heated laser additive manufacturing (AM) methods, including lower residual stress, reduced risk of contamination, slower cooling rates, and faster build times. NASA Glenn Research Center has joint project work with Oak Ridge National Lab and the Air Force Research Laboratory to explore the feasibility of fabricating advanced Ni-based gamma-prime superalloys with EBM AM.

Additive manufacturing with polypropylene microfibers.

Science.gov (United States)

Haigh, Jodie N; Dargaville, Tim R; Dalton, Paul D

2017-08-01

The additive manufacturing of small diameter polypropylene microfibers is described, achieved using a technique termed melt electrospinning writing. Sequential fiber layering, which is important for accurate three-dimensional fabrication, was achieved with the smallest fiber diameter of 16.4±0.2μm obtained. The collector speed, temperature and melt flow rate to the nozzle were optimized for quality and minimal fiber pulsing. Of particular importance to the success of this method is appropriate heating of the collector plate, so that the electrostatically drawn filament adheres during the direct-writing process. By demonstrating the direct-writing of polypropylene, new applications exploiting the favorable mechanical, stability and biocompatible properties of this polymer are envisaged. Copyright © 2017. Published by Elsevier B.V.

Microstructures and mechanical behavior of Inconel 625 fabricated by solid-state additive manufacturing

International Nuclear Information System (INIS)

Rivera, O.G.; Allison, P.G.; Jordon, J.B.; Rodriguez, O.L.; Brewer, L.N.; McClelland, Z.; Whittington, W.R.; Francis, D.; Su, J.; Martens, R.L.; Hardwick, N.

2017-01-01

Here we introduce a novel thermo-mechanical Solid State Additive Manufacturing (SSAM) process referred to as Additive Friction Stir (AFS) manufacturing that provides a new and alternative path to fusion-based additive manufacturing processes for developing fully-dense, near-net shape components with a refined-equiaxed grain morphology. This study is the first to investigate the beneficial grain refinement and densification produced by AFS in IN625 that results in advantageous mechanical properties (YS, UTS, εf) at both quasi-static and high strain rate. Electron Backscatter Diffraction (EBSD) observed grain refinement during the layer deposition in the AFS specimens, where the results identified fine equiaxed grain structures with even finer grain structures forming at the layer interfaces. The EBSD quantified grains as fine as 0.27 µm in these interface regions while the average grain size was approximately 1 µm. Additionally, this is the first study to report on the strain rate dependence of AFS IN625 through quasi-static (QS) (0.001/s) and high strain rate (HR) (1500/s) tensile experiments using a servo hydraulic frame and a direct tension-Kolsky bar, respectively, which captured both yield and ultimate tensile strengths increasing as strain rate increased. The HS results exhibited an approximately 200 MPa increase in engineering strength over the QS results, with the fracture surfaces at both strain rates aligned with the maximum shear plane and exhibiting localized microvoids.

Microstructures and mechanical behavior of Inconel 625 fabricated by solid-state additive manufacturing

Energy Technology Data Exchange (ETDEWEB)

Rivera, O.G. [Department of Mechanical Engineering, The University of Alabama, Tuscaloosa, AL (United States); Allison, P.G., E-mail: pallison@eng.ua.edu [Department of Mechanical Engineering, The University of Alabama, Tuscaloosa, AL (United States); Jordon, J.B.; Rodriguez, O.L. [Department of Mechanical Engineering, The University of Alabama, Tuscaloosa, AL (United States); Brewer, L.N. [Department of Metallurgical Engineering, The University of Alabama, Tuscaloosa, AL (United States); McClelland, Z. [US Army Corps of Engineers, Engineer Research and Development Center, Vicksburg, MS (United States); Whittington, W.R.; Francis, D. [Center of Advanced Vehicular Systems, Mississippi State University, Starkville, MS (United States); Su, J. [Aeroprobe Corporation, Christiansburg, VA (United States); Martens, R.L. [Central Analytical Facility, The University of Alabama, Tuscaloosa, AL (United States); Hardwick, N. [Aeroprobe Corporation, Christiansburg, VA (United States)

2017-05-10

Here we introduce a novel thermo-mechanical Solid State Additive Manufacturing (SSAM) process referred to as Additive Friction Stir (AFS) manufacturing that provides a new and alternative path to fusion-based additive manufacturing processes for developing fully-dense, near-net shape components with a refined-equiaxed grain morphology. This study is the first to investigate the beneficial grain refinement and densification produced by AFS in IN625 that results in advantageous mechanical properties (YS, UTS, εf) at both quasi-static and high strain rate. Electron Backscatter Diffraction (EBSD) observed grain refinement during the layer deposition in the AFS specimens, where the results identified fine equiaxed grain structures with even finer grain structures forming at the layer interfaces. The EBSD quantified grains as fine as 0.27 µm in these interface regions while the average grain size was approximately 1 µm. Additionally, this is the first study to report on the strain rate dependence of AFS IN625 through quasi-static (QS) (0.001/s) and high strain rate (HR) (1500/s) tensile experiments using a servo hydraulic frame and a direct tension-Kolsky bar, respectively, which captured both yield and ultimate tensile strengths increasing as strain rate increased. The HS results exhibited an approximately 200 MPa increase in engineering strength over the QS results, with the fracture surfaces at both strain rates aligned with the maximum shear plane and exhibiting localized microvoids.

Additive manufacturing: From implants to organs | Douglas | South ...

African Journals Online (AJOL)

Additive manufacturing (AM) constructs 3D objects layer by layer under computer control from 3D models. 3D printing is one example of this kind of technology. AM offers geometric flexibility in its products and therefore allows customisation to suit individual needs. Clinical success has been shown with models for surgical ...

Titanium-Based Hip Stems with Drug Delivery Functionality through Additive Manufacturing.

Science.gov (United States)

Bezuidenhout, Martin B; Dimitrov, Dimitar M; van Staden, Anton D; Oosthuizen, Gert A; Dicks, Leon M T

2015-01-01

Postoperative infections are a major concern in patients that receive implants. These infections generally occur in areas with poor blood flow and pathogens do not always respond to antibiotic treatment. With the latest developments in nanotechnology, the incorporation of antibiotics into prosthetic implants may soon become a standard procedure. The success will, however, depend on the ability to control the release of antibiotics at concentrations high enough to prevent the development of antibiotic-resistant strains. Through additive manufacturing, antibiotics can be incorporated into cementless femoral stems to produce prosthetic devices with antimicrobial properties. With the emerging increase in resistance to antibiotics, the incorporation of antimicrobial compounds other than antibiotics, preferably drugs with a broader spectrum of antimicrobial activity, will have to be explored. This review highlights the microorganisms associated with total hip arthroplasty (THA), discusses the advantages and disadvantages of the latest materials used in hip implants, compares different antimicrobial agents that could be incorporated, and addresses novel ideas for future research.

Titanium-Based Hip Stems with Drug Delivery Functionality through Additive Manufacturing

Directory of Open Access Journals (Sweden)

Martin B. Bezuidenhout

2015-01-01

Full Text Available Postoperative infections are a major concern in patients that receive implants. These infections generally occur in areas with poor blood flow and pathogens do not always respond to antibiotic treatment. With the latest developments in nanotechnology, the incorporation of antibiotics into prosthetic implants may soon become a standard procedure. The success will, however, depend on the ability to control the release of antibiotics at concentrations high enough to prevent the development of antibiotic-resistant strains. Through additive manufacturing, antibiotics can be incorporated into cementless femoral stems to produce prosthetic devices with antimicrobial properties. With the emerging increase in resistance to antibiotics, the incorporation of antimicrobial compounds other than antibiotics, preferably drugs with a broader spectrum of antimicrobial activity, will have to be explored. This review highlights the microorganisms associated with total hip arthroplasty (THA, discusses the advantages and disadvantages of the latest materials used in hip implants, compares different antimicrobial agents that could be incorporated, and addresses novel ideas for future research.

Design and manufacture of high performance hollow engine valves by Additive Layer Manufacturing

International Nuclear Information System (INIS)

Cooper, D.; Thornby, J.; Blundell, N.; Henrys, R.; Williams, M.A.; Gibbons, G.

2015-01-01

Highlights: • High performance engine valve has been redesigned and optimised for and using ALM. • FEA was utilised to optimise and select a design for manufacture and testing. • Micro computed tomography was used in design and validation as an NDT technique. • Real world test of components was conducted to evaluate their performance. • Has demonstrated the potential for ALM in a high performance engineering context. - Abstract: Additive Layer Manufacture (ALM) of metallic components provides significant opportunities for the reduction of component weight, in order to realise improvements in vehicle fuel efficiency or performance. This paper examines the potential benefits of ALM with regard to reducing the weight of Internal Combustion Engine inlet or exhaust valves. A case study component is presented, for which an improved ALM design has been created, manufactured and evaluated. Micro-Computed Tomography (μ-CT) scanning was utilised to reverse engineer an original component, and to assess the ALM component’s internal geometry and material integrity. The case study valve was re-designed using Finite Element Analysis (FEA) to select a light weighted design which provides a conservative 9.4 g, (20%) weight saving on the Original Equipment Manufacturer (OEM) component. An engine test of over 175,000 cycles at between 2000 and 9500 rpm was conducted, after which μ-CT scanning confirmed no evidence of internal cracking, failure or significant deformation

Investigation on the Accuracy of CT Porosity Analysis of Additive Manufactured Metallic Parts

NARCIS (Netherlands)

Zanini, Filippo; Hermanek, Petr; Rathore, Jitendra; Wits, Wessel W; Carmignato, Simone

2015-01-01

Additive manufacturing (AM) is emerging as an important manufacturing sector, due to its almost unlimited design freedom, the capability to produce personalized parts and the efficient material use. A reliable knowledge about material porosity of manufactured parts is crucial for optimizing AM

Targeted Structural Optimization with Additive Manufacturing of Metals

Science.gov (United States)

Burt, Adam; Hull, Patrick

2015-01-01

The recent advances in additive manufacturing (AM) of metals have now improved the state-of-the-art such that traditionally non-producible parts can be readily produced in a cost-effective way. Because of these advances in manufacturing technology, structural optimization techniques are well positioned to supplement and advance this new technology. The goal of this project is to develop a structural design, analysis, and optimization framework combined with AM to significantly light-weight the interior of metallic structures while maintaining the selected structural properties of the original solid. This is a new state-of-the-art capability to significantly reduce mass, while maintaining the structural integrity of the original design, something that can only be done with AM. In addition, this framework will couple the design, analysis, and fabrication process, meaning that what has been designed directly represents the produced part, thus closing the loop on the design cycle and removing human iteration between design and fabrication. This fundamental concept has applications from light-weighting launch vehicle components to in situ resource fabrication.

An Additive Manufacturing Test Artifact

Science.gov (United States)

Moylan, Shawn; Slotwinski, John; Cooke, April; Jurrens, Kevin; Donmez, M Alkan

2014-01-01

A test artifact, intended for standardization, is proposed for the purpose of evaluating the performance of additive manufacturing (AM) systems. A thorough analysis of previously proposed AM test artifacts as well as experience with machining test artifacts have inspired the design of the proposed test artifact. This new artifact is designed to provide a characterization of the capabilities and limitations of an AM system, as well as to allow system improvement by linking specific errors measured in the test artifact to specific sources in the AM system. The proposed test artifact has been built in multiple materials using multiple AM technologies. The results of several of the builds are discussed, demonstrating how the measurement results can be used to characterize and improve a specific AM system. PMID:26601039

Rheology of High-Melt-Strength Polypropylene for Additive Manufacturing

DEFF Research Database (Denmark)

Hofstätter, Thomas; Kamleitner, Florian; Jagenteufel, Ralf

Acrylonitrile butadiene styrene (ABS) is a widely used material for additive manufacturing (AM) fused deposition modeling (FDM). The rheological properties of high-melt-strength polypropylene (HMS-PP) were compared to commercially available ABS 250 filament to study the possibility of using...

Additive Manufacturing and Casting Technology Comparison: Mechanical Properties, Productivity and Cost Benchmark

Science.gov (United States)

Vevers, A.; Kromanis, A.; Gerins, E.; Ozolins, J.

2018-04-01

The casting technology is one of the oldest production technologies in the world but in the recent years metal additive manufacturing also known as metal 3D printing has been evolving with huge steps. Both technologies have capabilities to produce parts with internal holes and at first glance surface roughness is similar for both technologies, which means that for precise dimensions parts have to be machined in places where precise fit is necessary. Benchmark tests have been made to find out if parts which are produced with metal additive manufacturing can be used to replace parts which are produced with casting technology. Most of the comparative tests have been made with GJS-400-15 grade which is one of the most popular cast iron grades. To compare mechanical properties samples have been produced using additive manufacturing and tested for tensile strength, hardness, surface roughness and microstructure and then the results have been compared with the samples produced with casting technology. In addition, both technologies have been compared in terms of the production time and production costs to see if additive manufacturing is competitive with the casting technology. The original paper has been written in the Latvian language as part of the Master Thesis within the framework of the production technology study programme at Riga Technical University.

Additive Manufactured Superconducting Cavities

Science.gov (United States)

Holland, Eric; Rosen, Yaniv; Woolleet, Nathan; Materise, Nicholas; Voisin, Thomas; Wang, Morris; Mireles, Jorge; Carosi, Gianpaolo; Dubois, Jonathan

Superconducting radio frequency cavities provide an ultra-low dissipative environment, which has enabled fundamental investigations in quantum mechanics, materials properties, and the search for new particles in and beyond the standard model. However, resonator designs are constrained by limitations in conventional machining techniques. For example, current through a seam is a limiting factor in performance for many waveguide cavities. Development of highly reproducible methods for metallic parts through additive manufacturing, referred to colloquially as 3D printing\\x9D, opens the possibility for novel cavity designs which cannot be implemented through conventional methods. We present preliminary investigations of superconducting cavities made through a selective laser melting process, which compacts a granular powder via a high-power laser according to a digitally defined geometry. Initial work suggests that assuming a loss model and numerically optimizing a geometry to minimize dissipation results in modest improvements in device performance. Furthermore, a subset of titanium alloys, particularly, a titanium, aluminum, vanadium alloy (Ti - 6Al - 4V) exhibits properties indicative of a high kinetic inductance material. This work is supported by LDRD 16-SI-004.

Environmental Cracking and Irradiation Resistant Stainless Steels by Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Rebak, Raul B.

2018-03-30

Metal additive manufacturing (AM), or metal 3D printing is an emergent advanced manufacturing method that can create near net shape geometries directly from computer models. This technology can provide the capability to rapidly fabricate complex parts that may be required to enhance the integrity of reactor internals components. Such opportunities may be observed during a plant refueling outage and AM parts can be rapidly custom designed, manufactured and deployed within the outage interval. Additive manufacturing of stainless steel (SS) components can add business benefits on fast delivery on repair hardware, installation tooling, new design prototypes tests, etc. For the nuclear industry, the supply chain is always an issue for reactor service. AM can provide through-life supply chain (40-60 years) for high-value low-volume components. In the meantime, the capability of generating complex geometries and functional gradient materials will improve the performance, reduce the overall component cost, plant asset management cost and increase the plant reliability by the improvement in materials performance in nuclear environments. While extensive work has been conducted regarding additively manufacturing of austenitic SS parts, most efforts focused only on basic attributes such as porosity, residual stress, basic tensile properties, along with components yield and process monitoring. Little work has been done to define and evaluate the material requirements for nuclear applications. Technical gaps exist, which limit this technology adoption in the nuclear industry, which includes high manufacturing cost, unknown risks, limited nuclear related data, lack of specification and qualification methods, and no prior business experience. The main objective of this program was to generate research data to address all these technical gaps and establish a commercial practice to use AM technology in the nuclear power industry. The detailed objectives are listed as follows: (1

Study of flow stress and spall strength of additively manufactured Ti-6-4 alloy

Science.gov (United States)

Cohen, Amitay; Paris, Vitaly; Yosef-Hai, Arnon; Gudinetsky, Eli; Tiferet, Eitan

2017-06-01

The use of additive manufacturing (AM) by Electron Beam Melting (EBM) or Selective Laser Melting (SLM) has extensively grown in the past few years. A major goal in AM is to manufacture materials with mechanical properties at least as good as traditionally manufactured materials. In this work we present results of planar impact tests and Split Hopkinson Pressure Bar tests (SHPB) on Ti-6-4 manufactured by EBM and SLM processes. Results of planar impact tests on SLM samples display slightly higher spall strength compared to EBM while the stress at Hugoniot elastic limit (HEL) is practically the same. Stress strain curves based on SHPB measurements at two different strain rates present similar plastic flow stresses for SLM and EBM processed Ti-6-4 alloy, while the flow stress is about 20% higher than reported for commercial reference material. The strain to failure of both materials shows considerable strain rate sensitivity. The results of post-mortem analysis of spall fracture will also be presented.

On the development of high quality NiTi shape memory and pseudoelastic parts by additive manufacturing

International Nuclear Information System (INIS)

Haberland, Christoph; Elahinia, Mohammad; Walker, Jason M; Meier, Horst; Frenzel, Jan

2014-01-01

Additive manufacturing provides an attractive processing method for nickel–titanium (NiTi) shape memory and pseudoelastic parts. In this paper, we show how the additive manufacturing process affects structural and functional properties of additively manufactured NiTi and how the process parameter set-up can be optimized to produce high quality NiTi parts and components. Comparisons of shape recovery due to shape memory and pseudoelasticity in additively manufactured and commercial NiTi exhibit promising potential for this innovative processing method. (paper)

Operational Cybersecurity Risks and Their Effect on Adoption of Additive Manufacturing in the Naval Domain

Science.gov (United States)

2017-12-01

CYBERSECURITY RISKS AND THEIR EFFECT ON ADOPTION OF ADDITIVE MANUFACTURING IN THE NAVAL DOMAIN by Michael D. Grimshaw December 2017 Thesis...OF ADDITIVE MANUFACTURING IN THE NAVAL DOMAIN 5. FUNDING NUMBERS 6. AUTHOR(S) Michael D. Grimshaw 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES...DISTRIBUTION CODE 13. ABSTRACT (maximum 200 words) Additive manufacturing (AM) has been proven to provide multiple benefits over traditional

Process-Structure Linkages Using a Data Science Approach: Application to Simulated Additive Manufacturing Data

International Nuclear Information System (INIS)

Popova, Evdokia; Rodgers, Theron M.; Gong, Xinyi; Cecen, Ahmet; Madison, Jonathan D.; Kalidindi, Surya R.

2017-01-01

A novel data science workflow is developed and demonstrated to extract process-structure linkages (i.e., reduced-order model) for microstructure evolution problems when the final microstructure depends on (simulation or experimental) processing parameters. Our workflow consists of four main steps: data pre-processing, microstructure quantification, dimensionality reduction, and extraction/validation of process-structure linkages. These methods that can be employed within each step vary based on the type and amount of available data. In this paper, this data-driven workflow is applied to a set of synthetic additive manufacturing microstructures obtained using the Potts-kinetic Monte Carlo (kMC) approach. Additive manufacturing techniques inherently produce complex microstructures that can vary significantly with processing conditions. Using the developed workflow, a low-dimensional data-driven model was established to correlate process parameters with the predicted final microstructure. In addition, the modular workflows developed and presented in this work facilitate easy dissemination and curation by the broader community.

AM Envelope : Potentials of Additive Manufacturing for facade construction

NARCIS (Netherlands)

Strauss, H.; Knaack, U.

2012-01-01

Not only in the medical, aviation and automotive industry, the Additive Manufacturing (AM) processes are being looked upon as increasingly important production processes. But also the construction industiy is realizing more and more the chances and opportunities, that open up with these technologies

Impedance-based structural health monitoring of additive manufactured structures with embedded piezoelectric wafers

Science.gov (United States)

Scheyer, Austin G.; Anton, Steven R.

2017-04-01

Embedding sensors within additive manufactured (AM) structures gives the ability to develop smart structures that are capable of monitoring the mechanical health of a system. AM provides an opportunity to embed sensors within a structure during the manufacturing process. One major limitation of AM technology is the ability to verify the geometric and material properties of fabricated structures. Over the past several years, the electromechanical impedance (EMI) method for structural health monitoring (SHM) has been proven to be an effective method for sensing damage in structurers. The EMI method utilizes the coupling between the electrical and mechanical properties of a piezoelectric transducer to detect a change in the dynamic response of a structure. A piezoelectric device, usually a lead zirconate titanate (PZT) ceramic wafer, is bonded to a structure and the electrical impedance is measured across as range of frequencies. A change in the electrical impedance is directly correlated to changes made to the mechanical condition of the structure. In this work, the EMI method is employed on piezoelectric transducers embedded inside AM parts to evaluate the feasibility of performing SHM on parts fabricated using additive manufacturing. The fused deposition modeling (FDM) method is used to print specimens for this feasibility study. The specimens are printed from polylactic acid (PLA) in the shape of a beam with an embedded monolithic piezoelectric ceramic disc. The specimen is mounted as a cantilever while impedance measurements are taken using an HP 4194A impedance analyzer. Both destructive and nondestructive damage is simulated in the specimens by adding an end mass and drilling a hole near the free end of the cantilever, respectively. The Root Mean Square Deviation (RMSD) method is utilized as a metric for quantifying damage to the system. In an effort to determine a threshold for RMSD, the values are calculated for the variation associated with taking multiple

Research on manufacturing service behavior modeling based on block chain theory

Science.gov (United States)

Zhao, Gang; Zhang, Guangli; Liu, Ming; Yu, Shuqin; Liu, Yali; Zhang, Xu

2018-04-01

According to the attribute characteristics of processing craft, the manufacturing service behavior is divided into service attribute, basic attribute, process attribute, resource attribute. The attribute information model of manufacturing service is established. The manufacturing service behavior information is successfully divided into public and private domain. Additionally, the block chain technology is introduced, and the information model of manufacturing service based on block chain principle is established, which solves the problem of sharing and secreting information of processing behavior, and ensures that data is not tampered with. Based on the key pairing verification relationship, the selective publishing mechanism for manufacturing information is established, achieving the traceability of product data, guarantying the quality of processing quality.

State-of-the-art of fiber-reinforced polymers in additive manufacturing technologies

DEFF Research Database (Denmark)

Hofstätter, Thomas; Pedersen, David Bue; Tosello, Guido

2017-01-01

Additive manufacturing technologies have received a lot of attention in recent years for their use in multiple materials such as metals, ceramics, and polymers. The aim of this review article is to analyze the technology of fiber-reinforced polymers and its implementation with additive...... manufacturing. This article reviews recent developments, ideas, and state-of-the-art technologies in this field. Moreover, it gives an overview of the materials currently available for fiber-reinforced material technology....

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

Science.gov (United States)

O’Neal, T. Derek

2016-01-01

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. This paper discusses the impacts of the DMLS fabrication technique on the design of the turbopump and lessons learned during DMLS hardware fabrication and material testing.

A study of internal structure in components made by additive manufacturing process using 3 D X-ray tomography

Energy Technology Data Exchange (ETDEWEB)

Raguvarun, K., E-mail: prajagopal@iitm.ac.in; Balasubramaniam, Krishnan, E-mail: prajagopal@iitm.ac.in; Rajagopal, Prabhu, E-mail: prajagopal@iitm.ac.in [Centre for NDE, Indian Institute of Technology Madras, Chennai 600036, Tamilnadu (India); Palanisamy, Suresh [Swinburne University of Technology, Faculty of Engineering, Science and Technology, Hawthorn, Victoria 3122 Australia and Defence Materials Technology Centre, Hawthorn, Victoria 3122 (Australia); Nagarajah, Romesh; Kapoor, Ajay [Swinburne University of Technology, Faculty of Engineering, Science and Technology, Hawthorn, Victoria 3122 (Australia); Hoye, Nicholas; Curiri, Dominic [University of Wollongong, Faculty of Engineering, New South Wales 2522, Australia and Defence Materials Technology Centre, Hawthorn, Victoria 3122 (Australia)

2015-03-31

Additive manufacturing methods are gaining increasing popularity for rapidly and efficiently manufacturing parts and components in the industrial context, as well as for domestic applications. However, except when used for prototyping or rapid visualization of components, industries are concerned with the load carrying capacity and strength achievable by additive manufactured parts. In this paper, the wire-arc additive manufacturing (AM) process based on gas tungsten arc welding (GTAW) has been examined for the internal structure and constitution of components generated by the process. High-resolution 3D X-ray tomography is used to gain cut-views through wedge-shaped parts created using this GTAW additive manufacturing process with titanium alloy materials. In this work, two different control conditions for the GTAW process are considered. The studies reveal clusters of porosities, located in periodic spatial intervals along the sample cross-section. Such internal defects can have a detrimental effect on the strength of the resulting AM components, as shown in destructive testing studies. Closer examination of this phenomenon shows that defect clusters are preferentially located at GTAW traversal path intervals. These results highlight the strong need for enhanced control of process parameters in ensuring components with minimal defects and higher strength.

A study of internal structure in components made by additive manufacturing process using 3 D X-ray tomography

International Nuclear Information System (INIS)

Raguvarun, K.; Balasubramaniam, Krishnan; Rajagopal, Prabhu; Palanisamy, Suresh; Nagarajah, Romesh; Kapoor, Ajay; Hoye, Nicholas; Curiri, Dominic

2015-01-01

Additive manufacturing methods are gaining increasing popularity for rapidly and efficiently manufacturing parts and components in the industrial context, as well as for domestic applications. However, except when used for prototyping or rapid visualization of components, industries are concerned with the load carrying capacity and strength achievable by additive manufactured parts. In this paper, the wire-arc additive manufacturing (AM) process based on gas tungsten arc welding (GTAW) has been examined for the internal structure and constitution of components generated by the process. High-resolution 3D X-ray tomography is used to gain cut-views through wedge-shaped parts created using this GTAW additive manufacturing process with titanium alloy materials. In this work, two different control conditions for the GTAW process are considered. The studies reveal clusters of porosities, located in periodic spatial intervals along the sample cross-section. Such internal defects can have a detrimental effect on the strength of the resulting AM components, as shown in destructive testing studies. Closer examination of this phenomenon shows that defect clusters are preferentially located at GTAW traversal path intervals. These results highlight the strong need for enhanced control of process parameters in ensuring components with minimal defects and higher strength

Fatigue crack growth in additive manufactured products

Directory of Open Access Journals (Sweden)

A. Riemer

2015-10-01

Full Text Available Additive Manufacturing (AM is a new innovative technique that allows the direct fabrication of complex, individual, delicate and high-strength products, based on their 3D data. Selective Laser Melting (SLM is one of the AM processes that generates metallic components layer by layer using powder-bed technique. The irradiation and consequent melting of metallic powder is realised by the laser source. Employing SLM, especially complex and individual products, such as implants or aerospace parts, are well suited for economic production in small batches. The first important issue in this work was to analyse the fatigue crack growth (FCG in titanium alloy Ti-6-4 and stainless steel 316L processed by SLM. As a first step, stress intensity range decreasing tests were performed on SLM samples in their “as-built” condition. The next step was to adopt measures for optimisation of fatigue crack growth performance of SLM parts. For this purpose various heat treatments such as stress relief annealing and hot isostatic pressing (HIP were applied to the CT specimens. Finally, the strong impact of heat treatment on the residual lifetime was demonstrated by numerical fatigue crack growth simulations. For this purpose, the hip joint implant consisting of Ti-6-4 and processed by SLM was taken into account. It was found that residual stresses have a strong influence on the crack growth in Ti-6-4, while the influence of the micro-pores on the threshold values remains low. In contrast the results for 316L show that its fracturemechanical behaviour is not affected by residual stresses, whereas the microstructural features lead to modification in the da/dN-K-data. The second fundamental aim of this work was to demonstrate the possibilities of the SLM process. For that reason, the individually tailored bicycle crank was optimised regarding its weight and local stresses and finally manufactured using the SLM system. The iterative optimisation procedure was based on

In-line monitoring and reverse 3D model reconstruction in additive manufacturing

DEFF Research Database (Denmark)

Pedersen, David Bue; Hansen, Hans Nørgaard; Nielsen, Jakob Skov

2010-01-01

Additive manufacturing allows for close-to unrestrained geometrical freedom in part design. The ability to manufacture geometries of such complexity is however limited by the fact that it proves difficult to verify tolerances of these parts. Tolerancs of featuress that are inaccessible...

Application of additive manufacturing in oral and maxillofacial surgery

NARCIS (Netherlands)

Farré-Guasch, E.; Wolff, J.; Helder, M.N.; Schulten, E.A.J.M.; Forouzanfar, T.; Klein-Nulend, J.

2015-01-01

Additive manufacturing is the process of joining materials to create objects from digital 3-dimensional (3D) model data,which is a promising technology in oral andmaxillofacial surgery. The management of lost craniofacial tissues owing to congenital abnormalities, trauma, or cancer treatment poses a

Autonomously Self-Adhesive Hydrogels as Building Blocks for Additive Manufacturing.

Science.gov (United States)

Deng, Xudong; Attalla, Rana; Sadowski, Lukas P; Chen, Mengsu; Majcher, Michael J; Urosev, Ivan; Yin, Da-Chuan; Selvaganapathy, P Ravi; Filipe, Carlos D M; Hoare, Todd

2018-01-08

We report a simple method of preparing autonomous and rapid self-adhesive hydrogels and their use as building blocks for additive manufacturing of functional tissue scaffolds. Dynamic cross-linking between 2-aminophenylboronic acid-functionalized hyaluronic acid and poly(vinyl alcohol) yields hydrogels that recover their mechanical integrity within 1 min after cutting or shear under both neutral and acidic pH conditions. Incorporation of this hydrogel in an interpenetrating calcium-alginate network results in an interfacially stiffer but still rapidly self-adhesive hydrogel that can be assembled into hollow perfusion channels by simple contact additive manufacturing within minutes. Such channels withstand fluid perfusion while retaining their dimensions and support endothelial cell growth and proliferation, providing a simple and modular route to produce customized cell scaffolds.

Design and fabrication of a sleep apnea device using computer-aided design/additive manufacture technologies.

Science.gov (United States)

Al Mortadi, Noor; Eggbeer, Dominic; Lewis, Jeffrey; Williams, Robert J

2013-04-01

The aim of this study was to analyze the latest innovations in additive manufacture techniques and uniquely apply them to dentistry, to build a sleep apnea device requiring rotating hinges. Laser scanning was used to capture the three-dimensional topography of an upper and lower dental cast. The data sets were imported into an appropriate computer-aided design software environment, which was used to design a sleep apnea device. This design was then exported as a stereolithography file and transferred for three-dimensional printing by an additive manufacture machine. The results not only revealed that the novel computer-based technique presented provides new design opportunities but also highlighted limitations that must be addressed before the techniques can become clinically viable.

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing, Part II: Additive Manufacturing and Characterization of Polymer Composites

Science.gov (United States)

Chuang, Kathy C.; Grady, Joseph E.; Arnold, Steven M.; Draper, Robert D.; Shin, Eugene; Patterson, Clark; Santelle, Tom; Lao, Chao; Rhein, Morgan; Mehl, Jeremy

2015-01-01

This publication is the second part of the three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides-Ultem 9085 and experimental Ultem 1000 mixed with 10% chopped carbon fiber. A property comparison between FDM-printed and injection molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25 to 31%. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties. A preliminary modeling was also initiated to predict the mechanical properties of FDM-printed Ultem 9085 coupons in relation to varied raster angles and void contents, using the GRC-developed MAC/GMC program.

Ultrasonic Additive Manufacturing for High Performance Combustion Chambers, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — The objective of this proposal is to demonstrate the feasibility of using ultrasonic additive manufacturing (UAM) to dramatically reduce the cost and lead-time of...

Additive Manufacturing of Catalytically Active Living Materials.

Science.gov (United States)

Saha, Abhijit; Johnston, Trevor G; Shafranek, Ryan T; Goodman, Cassandra J; Zalatan, Jesse G; Storti, Duane W; Ganter, Mark A; Nelson, Alshakim

2018-04-25

Living materials, which are composites of living cells residing in a polymeric matrix, are designed to utilize the innate functionalities of the cells to address a broad range of applications such as fermentation and biosensing. Herein, we demonstrate the additive manufacturing of catalytically active living materials (AMCALM) for continuous fermentation. A multi-stimuli-responsive yeast-laden hydrogel ink, based on F127-dimethacrylate, was developed and printed using a direct-write 3D printer. The reversible stimuli-responsive behaviors of the polymer hydrogel inks to temperature and pressure are critical, as they enabled the facile incorporation of yeast cells and subsequent fabrication of 3D lattice constructs. Subsequent photo-cross-linking of the printed polymer hydrogel afforded a robust elastic material. These yeast-laden living materials were metabolically active in the fermentation of glucose into ethanol for 2 weeks in a continuous batch process without significant reduction in efficiency (∼90% yield of ethanol). This cell immobilization platform may potentially be applicable toward other genetically modified yeast strains to produce other high-value chemicals in a continuous biofermentation process.

Additive Manufacturing of Parts and Tooling in Robotic Systems

Energy Technology Data Exchange (ETDEWEB)

Love, Lonnie J. [ORNL; Hassen, Ahmed A. [ORNL; Chesser, Phillip C. [ORNL; Parsons, Jeremy [Mantaro Networks, Inc.

2018-04-01

ORNL worked with Transcend Robotics, LLC to explore additive manufacturing of the two-piece compression body for their ARTI mobile robot platform. Extrusion compression molding was identified as an effective means of manufacturing these parts. ORNL consulted on modifications to the housing design to accommodate the selected manufacturing process. Parts were printed using ORNL's FDM machines for testing and evaluation of the design as a precursor to molding the parts. The assembly and evaluation of the parts proved favorable and minor design changes to improve assembly and performance were identified.The goal is to develop a light weight and rugged two-part robotic enclosure for an unmanned ground vehicle UGV) that will be used in search and rescue applications. The FDM parts fabricated by ORNL allowed Transcend Robotics to assemble a prototype robot and verify that the new parts will meet the performance requirements. ORNL fabricated enclosure parts out of ABS and Nylon 12 materials such that the design could be tested prior to fabricating tooling for compression molding of Nylon 6 with carbon fiber fill. The robot was performance tested and compared with the previous manufacturing techniques and found to have superior performance.

Additive Manufacturing of Molds for Fabrication of Insulated Concrete Block

Energy Technology Data Exchange (ETDEWEB)

Love, Lonnie J. [ORNL; Lloyd, Peter D. [ORNL

2018-02-01

ORNL worked with concrete block manufacturer, NRG Insulated Block, to demonstrate additive manufacturing of a multi-component block mold for its line of insulated blocks. Solid models of the mold parts were constructed from existing two-dimensional drawings and the parts were fabricated on a Stratasys Fortus 900 using ULTEM 9085. Block mold parts were delivered to NRG and installed on one of their fabrication lines. While form and fit were acceptable, the molds failed to function during NRG’s testing.

Process development for green part printing using binder jetting additive manufacturing

Science.gov (United States)

Miyanaji, Hadi; Orth, Morgan; Akbar, Junaid Muhammad; Yang, Li

2018-05-01

Originally developed decades ago, the binder jetting additive manufacturing (BJ-AM) process possesses various advantages compared to other additive manufacturing (AM) technologies such as broad material compatibility and technological expandability. However, the adoption of BJ-AM has been limited by the lack of knowledge with the fundamental understanding of the process principles and characteristics, as well as the relatively few systematic design guideline that are available. In this work, the process design considerations for BJ-AM in green part fabrication were discussed in detail in order to provide a comprehensive perspective of the design for additive manufacturing for the process. Various process factors, including binder saturation, in-process drying, powder spreading, powder feedstock characteristics, binder characteristics and post-process curing, could significantly affect the printing quality of the green parts such as geometrical accuracy and part integrity. For powder feedstock with low flowability, even though process parameters could be optimized to partially offset the printing feasibility issue, the qualities of the green parts will be intrinsically limited due to the existence of large internal voids that are inaccessible to the binder. In addition, during the process development, the balanced combination between the saturation level and in-process drying is of critical importance in the quality control of the green parts.

Evaluation of Additively Manufactured Metals for Use in Oxygen Systems Project

Science.gov (United States)

Tylka, Jonathan; Cooper, Ken; Peralta, Stephen; Wilcutt, Terrence; Hughitt, Brian; Generazio, Edward

2016-01-01

Space Launch System, Commercial Resupply, and Commercial Crew programs have published intent to use additively manufactured (AM) components in propulsion systems and are likely to include various life support systems in the future. Parts produced by these types of additive manufacturing techniques have not been fully evaluated for use in oxygen systems and the inherent risks have not been fully identified. Some areas of primary concern in the SLS process with respect to oxygen compatibility may be the porosity of the printed parts, fundamental differences in microstructure of an AM part as compared to traditional materials, or increased risk of shed metal particulate into an oxygen system. If an ignition were to occur the printed material could be more flammable than components manufactured from a traditional billet of raw material and/or present a significant hazards if not identified and rigorously studied in advance of implementation into an oxygen system.

Additive Manufacturing of High-Entropy Alloys by Laser Processing

NARCIS (Netherlands)

Ocelik, V.; Janssen, Niels; Smith, Stefan; De Hosson, J. Th M.

This contribution concentrates on the possibilities of additive manufacturing of high-entropy clad layers by laser processing. In particular, the effects of the laser surface processing parameters on the microstructure and hardness of high-entropy alloys (HEAs) were examined. AlCoCrFeNi alloys with

Fluid Mechanics Of Molten Metal Droplets In Additive Manufacturing

Czech Academy of Sciences Publication Activity Database

Tesař, Václav; Šonský, Jiří

2016-01-01

Roč. 4, č. 4 (2016), s. 403-412 ISSN 2046-0546 R&D Projects: GA ČR GA13-23046S Institutional support: RVO:61388998 Keywords : additive manufacturing * droplets * molten metal Subject RIV: BK - Fluid Dynamics http://www.witpress.com/elibrary/cmem-volumes/4/4/1545

Social aspects in additive manufacturing of pharmaceutical products.

Science.gov (United States)

Lind, Johanna; Kälvemark Sporrong, Sofia; Kaae, Susanne; Rantanen, Jukka; Genina, Natalja

2017-08-01

Additive manufacturing (AM) techniques, such as drug printing, represent a new engineering approach that can implement the concept of personalized medicine via on-demand manufacturing of dosage forms with individually adjusted doses. Implementation of AM principles, such as pharmacoprinting, will challenge the entire drug distribution chain and affect the society at different levels. Areas covered: This work summarizes the concept of personalized medicine and gives an overview of possibilities for monitoring patients' health. The most recent activities in the field of printing technologies for fabrication of dosage forms and 'polypills' with flexible doses and tailored release profiles are reviewed. Different scenarios for the drug distribution chain with the required adjustments in drug logistics, quality systems and environmental safety are discussed, as well as whether AM will be used for production of on-demand medicine. The impact of such changes in the distribution chain on regulation, healthcare professionals and patients are highlighted. Expert opinion: Drug manufacturing by traditional methods is well-established, but it lacks the possibility for on-demand personalized drug production. With the recent approval of the first printed medicine, society should be prepared for the changes that will follow the introduction of printed pharmaceuticals.

Microstructure and texture evolution in aluminum and commercially pure titanium dissimilar welds fabricated using ultrasonic additive manufacturing

International Nuclear Information System (INIS)

Sridharan, Niyanth; Wolcott, Paul; Dapino, Marcelo; Babu, S.S.

2016-01-01

Ultrasonic additive manufacturing (UAM) is a solid-state hybrid manufacturing technique. In this work characterization using electron back scatter diffraction was performed on aluminum–titanium dissimilar metal welds made using a 9 kW ultrasonic additive manufacturing system. The results showed that the aluminum texture at the interface after ultrasonic additive manufacturing is similar to aluminum texture observed during accumulative roll bonding of aluminum alloys. It is finally concluded that the underlying mechanism of bond formation in ultrasonic additive manufacturing primarily relies on severe shear deformation at the interface.

The Development of High Temperature Thermoplastic Composite Materials for Additive Manufactured Autoclave Tooling

Energy Technology Data Exchange (ETDEWEB)

Kunc, Vlastimil [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Duty, Chad E. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lindahl, John M. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Hassen, Ahmed A. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2017-08-01

In this work, ORNL and Techmer investigated and screened different high temperature thermoplastic reinforced materials to fabricate composite molds for autoclave processes using Additive Manufacturing (AM) techniques. This project directly led to the development and commercial release of two printable, high temperature composite materials available through Techmer PM. These new materials are targeted for high temperature tooling made via large scale additive manufacturing.

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing of Ceramic Composites. Part III; Additive Manufacturing and Characterization of Ceramic Composites

Science.gov (United States)

Halbig, Michael C.; Grady, Joseph E.; Singh, Mrityunjay; Ramsey, Jack; Patterson, Clark; Santelle, Tom

2015-01-01

This publication is the third part of a three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce ceramic matrix composite materials and aircraft engine components by the binder jet process. Different SiC powders with median sizes ranging from 9.3 to 53.0 microns were investigated solely and in powder blends in order to maximize powder packing. Various infiltration approaches were investigated to include polycarbosilane (SMP-10), phenolic, and liquid silicon. Single infiltrations of SMP-10 and phenolic only slightly filled in the interior. When the SMP-10 was loaded with sub-micron sized SiC powders, the infiltrant gave a much better result of filling in the interior. Silicon carbide fibers were added to the powder bed to make ceramic matrix composite materials. Microscopy showed that the fibers were well distributed with no preferred orientation on the horizontal plane and fibers in the vertical plane were at angles as much as 45deg. Secondary infiltration steps were necessary to further densify the material. Two to three extra infiltration steps of SMP-10 increased the density by 0.20 to 0.55 g/cc. However, the highest densities achieved were 2.10 to 2.15 g/cc. Mechanical tests consisting of 4 point bend tests were conducted. Samples from the two CMC panels had higher strengths and strains to failure than the samples from the two nonfiber reinforced panels. The highest strengths were from Set N with 65 vol% fiber loading which had an average strength of 66 MPa. Analysis of the fracture surfaces did not reveal pullout of the reinforcing fibers. Blunt fiber failure suggested that there was not composite behavior. The binder jet additive manufacturing method was used to also demonstrate the fabrication of turbine engine vane components of two different designs and sizes. The

Enhanced additive manufacturing with a reciprocating platen

Science.gov (United States)

Lind, Randall F.; Blue, Craig A.; Love, Lonnie J.; Post, Brian K.; Lloyd, Peter D.

2018-02-06

An additive manufacturing extrusion head that includes a heated nozzle for accepting a feedstock and extruding the feedstock onto a substrate at a deposition plane, the nozzle having a longitudinal extrusion axis. A reciprocating platen surrounds the nozzle, the platen operable to reciprocate along the extrusion axis at or above the deposition plane as the nozzle extrudes feedstock onto the substrate; and wherein the platen flattens the extruded feedstock such that it does not protrude above the deposition plane as the extrusion head traverses over the substrate.

Mechanical Properties of Austenitic Stainless Steel Made by Additive Manufacturing.

Science.gov (United States)

Luecke, William E; Slotwinski, John A

2014-01-01

Using uniaxial tensile and hardness testing, we evaluated the variability and anisotropy of the mechanical properties of an austenitic stainless steel, UNS S17400, manufactured by an additive process, selective laser melting. Like wrought materials, the mechanical properties depend on the orientation introduced by the processing. The recommended stress-relief heat treatment increases the tensile strength, reduces the yield strength, and decreases the extent of the discontinuous yielding. The mechanical properties, assessed by hardness, are very uniform across the build plate, but the stress-relief heat treatment introduced a small non-uniformity that had no correlation to position on the build plate. Analysis of the mechanical property behavior resulted in four conclusions. (1) The within-build and build-to-build tensile properties of the UNS S17400 stainless steel are less repeatable than mature engineering structural alloys, but similar to other structural alloys made by additive manufacturing. (2) The anisotropy of the mechanical properties of the UNS S17400 material of this study is larger than that of mature structural alloys, but is similar to other structural alloys made by additive manufacturing. (3) The tensile mechanical properties of the UNS S17400 material fabricated by selective laser melting are very different from those of wrought, heat-treated 17-4PH stainless steel. (4) The large discontinuous yielding strain in all tests resulted from the formation and propagation of Lüders bands.

NASA's Additive Manufacturing Development Materials Science to Technology Infusion - Connecting the Digital Dots

Science.gov (United States)

Vickers, John

2017-01-01

At NASA, the first steps of the Journey to Mars are well underway with the development of NASA's next generation launch system and investments in research and technologies that should increase the affordability, capability, and safety of exploration activities. Additive Manufacturing presents a disruptive opportunity for NASA to design and manufacture hardware with new materials at dramatically reduced cost and schedule. Opportunities to incorporate additive manufacturing align very well with NASA missions and with most NASA programs related to space, science, and aeronautics. The Agency also relies on many partnerships with other government agencies, industry and academia.

Generalized requirements and decompositions for the design of test parts for micro additive manufacturing research

DEFF Research Database (Denmark)

Thompson, Mary Kathryn; Clemmensen, Line Katrine Harder

2015-01-01

The design of experimental test parts to characterize micro additive manufacturing (AM) processes is challenging due to the influence of the manufacturing and metrology processes. This work builds on the lessons learned from a case study in the literature to derive generalized requirements and high...... level decompositions for the design of test parts and the design of experiments to characterize micro additive manufacturing processes. While the test parts and the experiments described are still work in progress, the generic requirements derived from them can serve as a starting point for the design...... of other micro additive manufacturing related studies and their decompositions can help structure future work....

Additive manufacturing of tools for lapping glass

Science.gov (United States)

Williams, Wesley B.

2013-09-01

Additive manufacturing technologies have the ability to directly produce parts with complex geometries without the need for secondary processes, tooling or fixtures. This ability was used to produce concave lapping tools with a VFlash 3D printer from 3D Systems. The lapping tools were first designed in Creo Parametric with a defined constant radius and radial groove pattern. The models were converted to stereolithography files which the VFlash used in building the parts, layer by layer, from a UV curable resin. The tools were rotated at 60 rpm and used with 120 grit and 220 grit silicon carbide lapping paste to lap 0.750" diameter fused silica workpieces. The samples developed a matte appearance on the lapped surface that started as a ring at the edge of the workpiece and expanded to the center. This indicated that as material was removed, the workpiece radius was beginning to match the tool radius. The workpieces were then cleaned and lapped on a second tool (with equivalent geometry) using a 3000 grit corundum aluminum oxide lapping paste, until a near specular surface was achieved. By using lapping tools that have been additively manufactured, fused silica workpieces can be lapped to approach a specified convex geometry. This approach may enable more rapid lapping of near net shape workpieces that minimize the material removal required by subsequent polishing. This research may also enable development of new lapping tool geometry and groove patterns for improved loose abrasive finishing.

IN718 Additive Manufacturing Properties and Influences

Science.gov (United States)

Lambert, Dennis M.

2015-01-01

The results of tensile, fracture, and fatigue testing of IN718 coupons produced using the selective laser melting (SLM) additive manufacturing technique are presented. The data has been "generalized" to remove the numerical values, although certain references to material standards are provided. This document provides some knowledge of the effect of variation of controlled build parameters used in the SLM process, a snapshot of the capabilities of SLM in industry at present, and shares some of the lessons learned along the way. For the build parameter characterization, the parameters were varied over a range about the machine manufacturer's recommended value, and in each case they were varied individually, although some co-variance of those parameters would be expected. SLM-produced IN718, tensile, fracture, and high-cycle fatigue properties equivalent to wrought IN718 are achievable. Build and post-build processes need to be determined and then controlled to established limits to accomplish this. It is recommended that a multi-variable evaluation, e.g., design-of-experiment (DOE), of the build parameters be performed to better evaluate the co-variance of the parameters.

Additive manufacture with IN625 superalloy using laser and plasma transferred arc

International Nuclear Information System (INIS)

Cardozo, Eloisa Pereira; D'Oliveira, Ana Sofia C.M.; Ganguly, Supryio; Pardal, Goncalo Rodrigues

2016-01-01

Full text: Additive manufacturing of mechanical components processed with metallic alloys is a growing market due to its full potential over the traditional manufacturing. Material efficiency is a key factor towards the selection of AM procedures, particularly for parts fabricated with high cost alloys such as Ni based alloys. Inspite the advantages of this innovative technique many challenges have to be met before its wide acceptance by industries from different sectors. This study contributes to the current knowledge progress regarding the analysis of AM parts processed by laser and Plasma transferred arc (PTA). IN625 Ni based alloy, layer by- layer parts were processed and analyzed in the as processed condition and after homogenization heat treatment. Characterization was carried out by confocal and scanning electron microscopy, X-ray diffraction and microhardness profile. Results revealed similar hardness although laser AM specimens exhibited a finer structure. Data acquire after the homogenization heat treatment suggests the as processed PTA samples to have a more stable microstructure. Discussion highlights the potential of each technique and their competitiveness. (author)

Additive manufacture with IN625 superalloy using laser and plasma transferred arc

Energy Technology Data Exchange (ETDEWEB)

Cardozo, Eloisa Pereira; D' Oliveira, Ana Sofia C.M., E-mail: elocrdz@gmail.com [Universidade Federal do Parana (UFPR), PR (Brazil); Ganguly, Supryio; Pardal, Goncalo Rodrigues [Cranfield University, Bedford (United Kingdom)

2016-07-01

Full text: Additive manufacturing of mechanical components processed with metallic alloys is a growing market due to its full potential over the traditional manufacturing. Material efficiency is a key factor towards the selection of AM procedures, particularly for parts fabricated with high cost alloys such as Ni based alloys. Inspite the advantages of this innovative technique many challenges have to be met before its wide acceptance by industries from different sectors. This study contributes to the current knowledge progress regarding the analysis of AM parts processed by laser and Plasma transferred arc (PTA). IN625 Ni based alloy, layer by- layer parts were processed and analyzed in the as processed condition and after homogenization heat treatment. Characterization was carried out by confocal and scanning electron microscopy, X-ray diffraction and microhardness profile. Results revealed similar hardness although laser AM specimens exhibited a finer structure. Data acquire after the homogenization heat treatment suggests the as processed PTA samples to have a more stable microstructure. Discussion highlights the potential of each technique and their competitiveness. (author)

An additive manufacturing-based PCL-alginate-chondrocyte bioprinted scaffold for cartilage tissue engineering.

Science.gov (United States)

Kundu, Joydip; Shim, Jin-Hyung; Jang, Jinah; Kim, Sung-Won; Cho, Dong-Woo

2015-11-01

Regenerative medicine is targeted to improve, restore or replace damaged tissues or organs using a combination of cells, materials and growth factors. Both tissue engineering and developmental biology currently deal with the process of tissue self-assembly and extracellular matrix (ECM) deposition. In this investigation, additive manufacturing (AM) with a multihead deposition system (MHDS) was used to fabricate three-dimensional (3D) cell-printed scaffolds using layer-by-layer (LBL) deposition of polycaprolactone (PCL) and chondrocyte cell-encapsulated alginate hydrogel. Appropriate cell dispensing conditions and optimum alginate concentrations for maintaining cell viability were determined. In vitro cell-based biochemical assays were performed to determine glycosaminoglycans (GAGs), DNA and total collagen contents from different PCL-alginate gel constructs. PCL-alginate gels containing transforming growth factor-β (TGFβ) showed higher ECM formation. The 3D cell-printed scaffolds of PCL-alginate gel were implanted in the dorsal subcutaneous spaces of female nude mice. Histochemical [Alcian blue and haematoxylin and eosin (H&E) staining] and immunohistochemical (type II collagen) analyses of the retrieved implants after 4 weeks revealed enhanced cartilage tissue and type II collagen fibril formation in the PCL-alginate gel (+TGFβ) hybrid scaffold. In conclusion, we present an innovative cell-printed scaffold for cartilage regeneration fabricated by an advanced bioprinting technology. Copyright © 2013 John Wiley & Sons, Ltd.

Additive manufacturing for freeform mechatronics design: from concepts to applications

NARCIS (Netherlands)

Baars, G. van; Smeltink, J.; Werff, J. van der; Limpens, M.; Barink, M.; Berg, D. van den; Vreugd, J. de; Witvoet, G.; Galaktionov, O.S.

2015-01-01

This article presents developments of freeform mechatronics concepts, enabled by industrial Additive Manufacturing (AM), aiming at breakthroughs for precision engineering challenges such as lightweight, advanced thermal control, and integrated design. To assess potential impact in future

Additive manufacturing of titanium alloy for aircraft components

OpenAIRE

Uhlmann, E.; Kersting, R.; Klein, T.B.; Cruz, M.F.; Borille, A.V.

2015-01-01

Selective Laser melting (SLM) is an additive manufacturing technology that uses laser as a power source to sinter powdered metals to produce solid structures. The application of SLM permits engineers to develop and implement components with topologically optimized designs and resultant material properties in comparison to conventionally produced casting parts. Current aviation programs as ACARE 2020 (Advisory Council for Aviation Research and Innovation in the EU) and Flightpath 2050 request ...

K-9 training aids made using additive manufacturing

Science.gov (United States)

Reynolds, John G.; Durban, Matthew M.; Gash, Alexander E.; Grapes, Michael D.; Kelley, Ryan S.; Sullivan, Kyle T.

2018-02-20

Additive Manufacturing (AM) is used to make aids that target the training of K-9s to detect explosives. The process uses mixtures of explosives and matrices commonly used in AM. The explosives are formulated into a mixture with the matrix and printed using AM techniques and equipment. The explosive concentrations are kept less than 10% by wt. of the mixture to conform to requirements of shipping and handling.

Additive manufacturing of ceramics: Stereolithography versus binder jetting

OpenAIRE

Nachum, Sarig; Vogt, Joachim; Raether, Friedrich

2016-01-01

Stereolithography and Binder Jetting are two promising Additive Manufacturing techniques for the fabrication of complex ceramics components. The Fraunhofer Center for High Temperature Material and Design HTL/DE has experience in the fabrication and development of ceramic and metallic components with both technologies. This paper describes and compares the respective process setups as well as the advantages and disadvantages of both techniques, and discusses future challenges and developments ...

Additive Manufacturing of Vascular Grafts and Vascularized Tissue Constructs.

Science.gov (United States)

Elomaa, Laura; Yang, Yunzhi Peter

2017-10-01

There is a great need for engineered vascular grafts among patients with cardiovascular diseases who are in need of bypass therapy and lack autologous healthy blood vessels. In addition, because of the severe worldwide shortage of organ donors, there is an increasing need for engineered vascularized tissue constructs as an alternative to organ transplants. Additive manufacturing (AM) offers great advantages and flexibility of fabrication of cell-laden, multimaterial, and anatomically shaped vascular grafts and vascularized tissue constructs. Various inkjet-, extrusion-, and photocrosslinking-based AM techniques have been applied to the fabrication of both self-standing vascular grafts and porous, vascularized tissue constructs. This review discusses the state-of-the-art research on the use of AM for vascular applications and the key criteria for biomaterials in the AM of both acellular and cellular constructs. We envision that new smart printing materials that can adapt to their environment and encourage rapid endothelialization and remodeling will be the key factor in the future for the successful AM of personalized and dynamic vascular tissue applications.

Additive Manufacturing Modeling and Simulation A Literature Review for Electron Beam Free Form Fabrication

Science.gov (United States)

Seufzer, William J.

2014-01-01

Additive manufacturing is coming into industrial use and has several desirable attributes. Control of the deposition remains a complex challenge, and so this literature review was initiated to capture current modeling efforts in the field of additive manufacturing. This paper summarizes about 10 years of modeling and simulation related to both welding and additive manufacturing. The goals were to learn who is doing what in modeling and simulation, to summarize various approaches taken to create models, and to identify research gaps. Later sections in the report summarize implications for closed-loop-control of the process, implications for local research efforts, and implications for local modeling efforts.

Experimental validation of additively manufactured optimized shapes for passive cooling

DEFF Research Database (Denmark)

Lazarov, Boyan S.; Sigmund, Ole; Meyer, Knud E.

2018-01-01

This article confirms the superior performance of topology optimized heat sinks compared to lattice designs and suggests simpler manufacturable pin-fin design interpretations. The development is driven by the wide adoption of light-emitting-diode (LED) lamps for industrial and residential lighting....... The presented heat sink solutions are generated by topology optimization, a computational morphogenesis approach with ultimate design freedom, relying on high-performance computing and simulation. Optimized devices exhibit complex and organic-looking topologies which are realized with the help of additive...... manufacturing. To reduce manufacturing cost, a simplified interpretation of the optimized design is produced and validated as well. Numerical and experimental results agree well and indicate that the obtained designs outperform lattice geometries by more than 21%, resulting in a doubling of life expectancy and...

Hopper design for metallic powders used in additive manufacturing processes

CSIR Research Space (South Africa)

Visagie, N

2013-10-01

Full Text Available The influence of hopper geometry on the flow behaviour of typical metallic powders used in additive manufacturing processes is investigated. Bulk hopper theory provides a method of determining critical hopper parameters for bulk amounts...

Towards Additive Manufacture of Functional, Spline-Based Morphometric Models of Healthy and Diseased Coronary Arteries: In Vitro Proof-of-Concept Using a Porcine Template

Directory of Open Access Journals (Sweden)

Rachel Jewkes

2018-02-01

Full Text Available The aim of this study is to assess the additive manufacture of morphometric models of healthy and diseased coronary arteries. Using a dissected porcine coronary artery, a model was developed with the use of computer aided engineering, with splines used to design arteries in health and disease. The model was altered to demonstrate four cases of stenosis displaying varying severity, based on published morphometric data available. Both an Objet Eden 250 printer and a Solidscape 3Z Pro printer were used in this analysis. A wax printed model was set into a flexible thermoplastic and was valuable for experimental testing with helical flow patterns observed in healthy models, dominating the distal LAD (left anterior descending and left circumflex arteries. Recirculation zones were detected in all models, but were visibly larger in the stenosed cases. Resin models provide useful analytical tools for understanding the spatial relationships of blood vessels, and could be applied to preoperative planning techniques, but were not suitable for physical testing. In conclusion, it is feasible to develop blood vessel models enabling experimental work; further, through additive manufacture of bio-compatible materials, there is the possibility of manufacturing customized replacement arteries.

Towards Additive Manufacture of Functional, Spline-Based Morphometric Models of Healthy and Diseased Coronary Arteries: In Vitro Proof-of-Concept Using a Porcine Template.

Science.gov (United States)

Jewkes, Rachel; Burton, Hanna E; Espino, Daniel M

2018-02-02

The aim of this study is to assess the additive manufacture of morphometric models of healthy and diseased coronary arteries. Using a dissected porcine coronary artery, a model was developed with the use of computer aided engineering, with splines used to design arteries in health and disease. The model was altered to demonstrate four cases of stenosis displaying varying severity, based on published morphometric data available. Both an Objet Eden 250 printer and a Solidscape 3Z Pro printer were used in this analysis. A wax printed model was set into a flexible thermoplastic and was valuable for experimental testing with helical flow patterns observed in healthy models, dominating the distal LAD (left anterior descending) and left circumflex arteries. Recirculation zones were detected in all models, but were visibly larger in the stenosed cases. Resin models provide useful analytical tools for understanding the spatial relationships of blood vessels, and could be applied to preoperative planning techniques, but were not suitable for physical testing. In conclusion, it is feasible to develop blood vessel models enabling experimental work; further, through additive manufacture of bio-compatible materials, there is the possibility of manufacturing customized replacement arteries.

Make disruptive technological change happen - The case of additive manufacturing

DEFF Research Database (Denmark)

Maresch, Daniela; Gartner, Johannes

2018-01-01

Disruptive technological change can contribute to a more abundant world. However, potentially disruptive technologies often struggle to significantly influence practice. One prominent example is additive manufacturing (AM). Although AM is often regarded as the next great technological revolution...

Machinability of Al 6061 Deposited with Cold Spray Additive Manufacturing

Science.gov (United States)

Aldwell, Barry; Kelly, Elaine; Wall, Ronan; Amaldi, Andrea; O'Donnell, Garret E.; Lupoi, Rocco

2017-10-01

Additive manufacturing techniques such as cold spray are translating from research laboratories into more mainstream high-end production systems. Similar to many additive processes, finishing still depends on removal processes. This research presents the results from investigations into aspects of the machinability of aluminum 6061 tubes manufactured with cold spray. Through the analysis of cutting forces and observations on chip formation and surface morphology, the effect of cutting speed, feed rate, and heat treatment was quantified, for both cold-sprayed and bulk aluminum 6061. High-speed video of chip formation shows changes in chip form for varying material and heat treatment, which is supported by the force data and quantitative imaging of the machined surface. The results shown in this paper demonstrate that parameters involved in cold spray directly impact on machinability and therefore have implications for machining parameters and strategy.

Numerical and experimental study of Ti6Al4V components manufactured using powder bed fusion additive manufacturing

OpenAIRE

Zielinski, J.; Mindt, H.-W.; Düchting, J.; Schleifenbaum, J.H.; Megahed, M.

2017-01-01

Powder bed fusion additive manufacturing of titanium alloys is an interesting manufacturing route for many applications requiring high material strength combined with geometric complexity. Managing powder bed fusion challenges, including porosity, surface finish, distortions and residual stresses of as-built material, is the key to bringing the advantages of this process to production main stream. This paper discusses the application of experimental and numerical analysis towards optimizing t...

Data-Driven Modeling for Minimizing the Side-Channel Information Leakage in Additive Manufacturing

OpenAIRE

Faezi, Sina

2017-01-01

Cyber-physical additive manufacturing systems consists of tight integration of cyber and physical domains. This results in new cross-domain vulnerabilities that poses unique security challenges. One of the challenges is preventing confidentiality breach due to physical-to-cyber domain attacks, where attackers can use physical analog emissions to steal the cyber-domain information. This information theft is based on the idea that an attacker can accurately estimate the relation between the ana...

Design of novel materials for additive manufacturing - Isotropic microstructure and high defect tolerance.

Science.gov (United States)

Günther, J; Brenne, F; Droste, M; Wendler, M; Volkova, O; Biermann, H; Niendorf, T

2018-01-22

Electron Beam Melting (EBM) is a powder-bed additive manufacturing technology enabling the production of complex metallic parts with generally good mechanical properties. However, the performance of powder-bed based additively manufactured materials is governed by multiple factors that are difficult to control. Alloys that solidify in cubic crystal structures are usually affected by strong anisotropy due to the formation of columnar grains of preferred orientation. Moreover, processing induced defects and porosity detrimentally influence static and cyclic mechanical properties. The current study presents results on processing of a metastable austenitic CrMnNi steel by EBM. Due to multiple phase transformations induced by intrinsic heat-treatment in the layer-wise EBM process the material develops a fine-grained microstructure almost without a preferred crystallographic grain orientation. The deformation-induced phase transformation yields high damage tolerance and, thus, excellent mechanical properties less sensitive to process-induced inhomogeneities. Various scan strategies were applied to evaluate the width of an appropriate process window in terms of microstructure evolution, porosity and change of chemical composition.

Additive Manufacturing in Offsite Repair of Consumer Electronics

Science.gov (United States)

Chekurov, Sergei; Salmi, Mika

Spare parts for products that are at the end of their life cycles, but still under warranty, are logistically difficult because they are commonly not stored in the central warehouse. These uncommon spare parts occupy valuable space in smaller inventories and take a long time to be transported to the point of need, thus delaying the repair process. This paper proposes that storing the spare parts on a server and producing them with additive manufacturing (AM) on demand can shorten the repair cycle by simplifying the logistics. Introducing AM in the repair supply chain lowers the number of products that need to be reimbursed to the customer due to lengthy repairs, improves the repair statistics of the repair shops, and reduces the number of items that are held in stock. For this paper, the functionality of the concept was verified by reverse engineering a memory cover of a portable computer and laser sintering it from polyamide 12. The additively manufactured component fit well and the computer operated normally after the replacement. The current spare part supply chain model and models with AM machinery located at the repair shop, the centralized spare part provider, and the original equipment manufacturer were provided. The durations of the repair process in the models were compared by simulating two scenarios with the Monte Carlo method. As the biggest improvement, the model with the AM machine in the repair shop reduced the duration of the repair process from 14 days to three days. The result points to the conclusion that placing the machine as close to the need as possible is the best option, if there is enough demand. The spare parts currently compatible with AM are plastic components without strict surface roughness requirements, but more spare parts will become compatible with the development of AM.

The Adoption of Additive Manufacturing Technology in Sweden

OpenAIRE

Kianian, Babak; Tavassoli, Sam; Larsson, Tobias; Diegel, Olaf

2015-01-01

This article analyzes the adoption of additive manufacturing (AM) technologies in Sweden. The data set consists of a recent and representative sample of Swedish AM users (companies, universities, and research institutes). The authors investigate two questions. First, what are the current applications of AM in Sweden (e.g., rapid prototyping [RP], production)? Second, what are the factors that can explain the variation in AM adoption among the users? Using a regression analysis technique, the ...

Review on Advances of Functional Material for Additive Manufacturing

Science.gov (United States)

Zulkifli, Nur Amalina Binti; Akmal Johar, Muhammad; Faizan Marwah, Omar Mohd; Irwan Ibrahim, Mohd Halim

2017-08-01

The attempt of finding and making new materials in improving products that are already in the market are widely done by researchers nowadays. This project is focusing on making new materials for functional material through additive manufacturing application. The idea of this project came from the ability limitation of capacitor in market nowadays in storing higher charges but smaller in size. Powder glass is the new material that could to be used as a dielectric material for capacitor with the help of palm kernel oil as the binder. This paper reviews on applications done through additive manufacturing method and also types of functional materials used in this method previously. Structure of a capacitor, dielectric properties and measurement techniques that are trying to be carried out are also explains in this paper. Last part of this paper brief on the material proposal and reasons those materials are chosen. New dielectric material for capacitor which are able to store more charges but still small in size are expected to be produced as the outcome of this research.

Additive Manufacturing Processes: Selective Laser Melting, Electron Beam Melting and Binder Jetting-Selection Guidelines.

Science.gov (United States)

Gokuldoss, Prashanth Konda; Kolla, Sri; Eckert, Jürgen

2017-06-19

Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties.

Additive Manufacturing Processes: Selective Laser Melting, Electron Beam Melting and Binder Jetting—Selection Guidelines

Science.gov (United States)

Konda Gokuldoss, Prashanth; Kolla, Sri; Eckert, Jürgen

2017-01-01

Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties. PMID:28773031

Challenges and opportunities of fibre-reinforced polymers in additive manufacturing with focus on industrial applications

DEFF Research Database (Denmark)

Hofstätter, Thomas; Pedersen, David Bue; Tosello, Guido

2017-01-01

Functional parts made by additive manufacturing of polymers have entered the area of industrial applications in recent years providing a wide range of materials with various mechanical, thermal, and electrical properties. These additive manufacturing processes can be combined with known fibre...

Mechanical Properties of Additively Manufactured Thick Honeycombs

Directory of Open Access Journals (Sweden)

Reza Hedayati

2016-07-01

Full Text Available Honeycombs resemble the structure of a number of natural and biological materials such as cancellous bone, wood, and cork. Thick honeycomb could be also used for energy absorption applications. Moreover, studying the mechanical behavior of honeycombs under in-plane loading could help understanding the mechanical behavior of more complex 3D tessellated structures such as porous biomaterials. In this paper, we study the mechanical behavior of thick honeycombs made using additive manufacturing techniques that allow for fabrication of honeycombs with arbitrary and precisely controlled thickness. Thick honeycombs with different wall thicknesses were produced from polylactic acid (PLA using fused deposition modelling, i.e., an additive manufacturing technique. The samples were mechanically tested in-plane under compression to determine their mechanical properties. We also obtained exact analytical solutions for the stiffness matrix of thick hexagonal honeycombs using both Euler-Bernoulli and Timoshenko beam theories. The stiffness matrix was then used to derive analytical relationships that describe the elastic modulus, yield stress, and Poisson’s ratio of thick honeycombs. Finite element models were also built for computational analysis of the mechanical behavior of thick honeycombs under compression. The mechanical properties obtained using our analytical relationships were compared with experimental observations and computational results as well as with analytical solutions available in the literature. It was found that the analytical solutions presented here are in good agreement with experimental and computational results even for very thick honeycombs, whereas the analytical solutions available in the literature show a large deviation from experimental observation, computational results, and our analytical solutions.

A novel classification and online platform for planning and documentation of medical applications of additive manufacturing.

Science.gov (United States)

Tuomi, Jukka; Paloheimo, Kaija-Stiina; Vehviläinen, Juho; Björkstrand, Roy; Salmi, Mika; Huotilainen, Eero; Kontio, Risto; Rouse, Stephen; Gibson, Ian; Mäkitie, Antti A

2014-12-01

Additive manufacturing technologies are widely used in industrial settings and now increasingly also in several areas of medicine. Various techniques and numerous types of materials are used for these applications. There is a clear need to unify and harmonize the patterns of their use worldwide. We present a 5-class system to aid planning of these applications and related scientific work as well as communication between various actors involved in this field. An online, matrix-based platform and a database were developed for planning and documentation of various solutions. This platform will help the medical community to structurally develop both research innovations and clinical applications of additive manufacturing. The online platform can be accessed through http://www.medicalam.info. © The Author(s) 2014.

A synopsis of the Defense Advanced Research Projects Agency (DARPA) investment in additive manufacture and what challenges remain

Science.gov (United States)

Maher, Michael; Smith, Adrien; Margiotta, Jesse

2014-03-01

DARPA's interest in additive manufacture dates back to the mid-80s with seedling programs that developed the foundational knowledge and equipment that led to the Solid Freeform Fabrication program in 1990. The drivers for this program included reducing development times by enabling "tool-less" manufacturing as well as integration of design and fabrication tools. DARPA consistently pushed the boundaries of additive manufacture with follow-on programs that expanded the material suite available for 3-D printing as well as new processes that expanded the technology's capability base. Programs such as the Mesoscopic Integrated Conformal Electronics (MICE) program incorporated functionality to the manufacturing processes through direct write of electronics. DARPA's investment in additive manufacture continues to this day but the focus has changed. DARPA's early investments were focused on developing and demonstrating the technology's capabilities. Now that the technology has been demonstrated, there is serious interest in taking advantage of the attributes unique to the processing methodology (such as customization and new design possibilities) for producing production parts. Accordingly, today's investment at DARPA addresses the systematic barriers to implementation rather than the technology itself. The Open Manufacturing program is enabling rapid qualification of new technologies for the manufacturing environment through the development of new modeling and informatics tools. While the technology is becoming more mainstream, there are plenty of challenges that need to be addressed. And as the technology continues to mature, the agency will continue to look for those "DARPA-hard" challenges that enable revolutionary changes in capability and performance for the Department of Defense.

Development of contour scanning parameters to improve surface finishing of additive manufactured parts

CSIR Research Space (South Africa)

Hoosain, Shaik

2017-10-01

Full Text Available Additive manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire or sheets in a process that proceeds layer by layer. Many techniques have been developed to accomplish this via melting...

Lithography-based ceramic manufacture (LCM) of auxetic structures: present capabilities and challenges

International Nuclear Information System (INIS)

Lantada, Andrés Díaz; De Blas Romero, Adrián; Schwentenwein, Martin; Jellinek, Christopher; Homa, Johannes

2016-01-01

Auxetic metamaterials are known for having a negative Poisson’s ratio (NPR) and for displaying the unexpected properties of lateral expansion when stretched and densification when compressed. Even though a wide set of micro-manufacturing resources have been used for the development of auxetic metamaterials and related devices, additional precision and an extension to other families of materials is needed for their industrial expansion. In addition, their manufacture using ceramic materials is still challenging. In this study we present a very promising approach for the development of auxetic metamaterials and devices based on the use of lithography-based ceramic manufacturing. The process stands out for its precision and complex three-dimensional geometries attainable, without the need of supporting structures, and for enabling the manufacture of ceramic auxetics with their geometry controlled from the design stage with micrometric precision. To our knowledge it represents the first example of application of this technology to the manufacture of auxetic geometries using ceramic materials. We have used a special three-dimensional auxetic design whose remarkable NPR has been previously highlighted. (paper)

Structural Color for Additive Manufacturing: 3D-Printed Photonic Crystals from Block Copolymers.

Science.gov (United States)

Boyle, Bret M; French, Tracy A; Pearson, Ryan M; McCarthy, Blaine G; Miyake, Garret M

2017-03-28

The incorporation of structural color into 3D printed parts is reported, presenting an alternative to the need for pigments or dyes for colored parts produced through additive manufacturing. Thermoplastic build materials composed of dendritic block copolymers were designed, synthesized, and used to additively manufacture plastic parts exhibiting structural color. The reflection properties of the photonic crystals arise from the periodic nanostructure formed through block copolymer self-assembly during polymer processing. The wavelength of reflected light could be tuned across the visible spectrum by synthetically controlling the block copolymer molecular weight and manufacture parts that reflected violet, green, or orange light with the capacity to serve as selective optical filters and light guides.

Additively Manufactured Bimetallic Combustion Chambers for Small Launch Vehicles, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — Arctic Slope Technical Services, Inc. (ASTS) is pleased to present this proposal for demonstrating feasibility of an additive manufacturing (AM) approach for...

IN718 Additive Manufacturing Properties and Influences

Science.gov (United States)

Lambert, Dennis M.

2015-01-01

The results of tensile, fracture, and fatigue testing of IN718 coupons produced using the selective laser melting (SLM) additive manufacturing technique are presented. The data have been "sanitized" to remove the numerical values, although certain references to material standards are provided. This document provides some knowledge of the effect of variation of controlled build parameters used in the SLM process, a snapshot of the capabilities of SLM in industry at present, and shares some of the lessons learned along the way. For the build parameter characterization, the parameters were varied over a range that was centered about the machine manufacturer's recommended value, and in each case they were varied individually, although some co-variance of those parameters would be expected. Tensile, fracture, and high-cycle fatigue properties equivalent to wrought IN718 are achievable with SLM-produced IN718. Build and post-build processes need to be determined and then controlled to established limits to accomplish this. It is recommended that a multi-variable evaluation, e.g., design-of experiment (DOE), of the build parameters be performed to better evaluate the co-variance of the parameters.

Computational Process Modeling for Additive Manufacturing (OSU)

Science.gov (United States)

Bagg, Stacey; Zhang, Wei

2015-01-01

Powder-Bed Additive Manufacturing (AM) through Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) is being used by NASA and the Aerospace industry to "print" parts that traditionally are very complex, high cost, or long schedule lead items. The process spreads a thin layer of metal powder over a build platform, then melts the powder in a series of welds in a desired shape. The next layer of powder is applied, and the process is repeated until layer-by-layer, a very complex part can be built. This reduces cost and schedule by eliminating very complex tooling and processes traditionally used in aerospace component manufacturing. To use the process to print end-use items, NASA seeks to understand SLM material well enough to develop a method of qualifying parts for space flight operation. Traditionally, a new material process takes many years and high investment to generate statistical databases and experiential knowledge, but computational modeling can truncate the schedule and cost -many experiments can be run quickly in a model, which would take years and a high material cost to run empirically. This project seeks to optimize material build parameters with reduced time and cost through modeling.

Study of additive manufactured microwave cavities for pulsed optically pumped atomic clock applications

Science.gov (United States)

Affolderbach, C.; Moreno, W.; Ivanov, A. E.; Debogovic, T.; Pellaton, M.; Skrivervik, A. K.; de Rijk, E.; Mileti, G.

2018-03-01

Additive manufacturing (AM) of passive microwave components is of high interest for the cost-effective and rapid prototyping or manufacture of devices with complex geometries. Here, we present an experimental study on the properties of recently demonstrated microwave resonator cavities manufactured by AM, in view of their applications to high-performance compact atomic clocks. The microwave cavities employ a loop-gap geometry using six electrodes. The critical electrode structures were manufactured monolithically using two different approaches: Stereolithography (SLA) of a polymer followed by metal coating and Selective Laser Melting (SLM) of aluminum. The tested microwave cavities show the desired TE011-like resonant mode at the Rb clock frequency of ≈6.835 GHz, with a microwave magnetic field highly parallel to the quantization axis across the vapor cell. When operated in an atomic clock setup, the measured atomic Rabi oscillations are comparable to those observed for conventionally manufactured cavities and indicate a good uniformity of the field amplitude across the vapor cell. Employing a time-domain Ramsey scheme on one of the SLA cavities, high-contrast (34%) Ramsey fringes are observed for the Rb clock transition, along with a narrow (166 Hz linewidth) central fringe. The measured clock stability of 2.2 × 10-13 τ-1/2 up to the integration time of 30 s is comparable to the current state-of-the-art stabilities of compact vapor-cell clocks based on conventional microwave cavities and thus demonstrates the feasibility of the approach.

Microstructure of rapidly solidified Nb-based pre-alloyed powders for additive manufacturing

Energy Technology Data Exchange (ETDEWEB)

Guo, Yueling; Jia, Lina, E-mail: jialina@buaa.edu.cn; Kong, Bin; Zhang, Shengnan; Zhang, Fengxiang; Zhang, Hu

2017-07-01

Highlights: • Sphere shaped Nb-37Ti-13Cr-2Al-1Si pre-alloyed powders were prepared by PREP. • An oxide layer with a thickness of 9.39 nm was generated on the powder surface. • The main phases of the pre-alloyed powders were Nbss and Cr{sub 2}Nb. • SDAS increased and microhardness decreased with the increase of powder size. • Microstructure of powders evolved into large grains from dendrite structures after HT. - Abstract: For powder-based additive manufacturing, sphere-shaped Nb-37Ti-13Cr-2Al-1Si pre-alloyed powders were prepared by plasma rotating electrode processing (PREP). The microstructure, surface oxidation and microhardness of the pre-alloyed powders were systematically investigated. Results showed that the main phases were Nb solid solution (Nbss) and Cr{sub 2}Nb. The Cr{sub 2}Nb phases were further determined using transmission electron microscopy (TEM). Fine dendrite structures were observed in the as-fabricated pre-alloyed powders, which transformed to large grains after heat treatment (HT) at 1450 °C for 3 h. With the increase of powder size, the secondary dendrite arm spacing (SDAS) increased and the microhardness (HV) decreased. A clean powder surface free of oxide particles was obtained by PREP and an oxide layer with 9.39 nm in thickness was generated on the powder surface. Compared with Cr- and Nb-oxides, more Ti-oxides were formed on outmost powder surface with a higher content of Ti (up to 47.86 at.%). The differences upon the microstructure and microhardness of the pre-alloyed powders with different sizes were discussed.

Infill Optimization for Additive Manufacturing - Approaching Bone-like Porous Structures

DEFF Research Database (Denmark)

Wu, Jun; Aage, Niels; Westermann, Ruediger

2018-01-01

Porous structures such as trabecular bone are widely seen in nature. These structures exhibit superior mechanical properties whilst being lightweight. In this paper, we present a method to generate bone-like porous structures asl ightweight infill for additive manufacturing. Our method builds upon...

Sensing and controlling resin-layer thickness in additive manufacturing processes

NARCIS (Netherlands)

Kozhevnikov, A.

2017-01-01

This AM-TKI project in collaboration with TNO focusses on the sensing and control of resin-layer thickness in AM applications. Industrial Additive Manufacturing is considered to be a potential breakthrough production technology for many applications. A specific AM implementation is VAT photo

Nondestructive Testing of Additive Manufactured Metal Parts Used in Aerospace Applications

Science.gov (United States)

Waller, Jess M.

2018-01-01

NDE inspectors, QA/QE professionals, and program managers responsible for the out-sourcing, procurement, fabrication, finishing, inspection, and qualification and certification of additively manufactured (AM) parts should attend this course.

Additively Manufactured, Net Shape Powder Metallurgy Cans for Valves Used in Energy Production

Energy Technology Data Exchange (ETDEWEB)

Peter, William H. [ORNL; Gandy, David [Electric Power Research Institute (EPRI); Lannom, Robert [Oak Ridge National Laboratory (ORNL)

2018-01-01

This CRADA NFE-14-05241 was conducted as a Technical Collaboration project within the Oak Ridge National Laboratory (ORNL) Manufacturing Demonstration Facility (MDF) sponsored by the US Department of Energy Advanced Manufacturing Office (CPS Agreement Number 24761). Opportunities for MDF technical collaborations are listed in the announcement “Manufacturing Demonstration Facility Technology Collaborations for US Manufacturers in Advanced Manufacturing and Materials Technologies” posted at http://web.ornl.gov/sci/manufacturing/docs/FBO-ORNL-MDF-2013-2.pdf. The goal of technical collaborations is to engage industry partners to participate in short-term, collaborative projects within the Manufacturing Demonstration Facility (MDF) to assess applicability and of new energy efficient manufacturing technologies. Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC.ORNL would like to acknowledge the leadership of EPRI in pulling together the extensive team and managing the execution of the project. In addition, ORNL would like to acknowledge the other contributions of the team members associated with this project. Quintus provided time, access, expertise, and labor of their hydro forming capabilities to evaluate both conventional and additively manufactured tools through this process. Crane ChemPharma Energy provided guidance and information on valve geometries. Carpenter Powder Products was involved with the team providing information on powder processing as it pertains to the canning and hot isostatic pressing of powder. on providing powder and knowledge as it pertains to powder supply for hot isostatic pressing; they also provided powder for the test trials by the industrial team. Bodycote provided guidance on hot isostatic pressing and can requirements. They were also responsible for the hot isostatic pressing of the test valve

Controlling the microstructure and properties of wire arc additive manufactured Ti–6Al–4V with trace boron additions

International Nuclear Information System (INIS)

Bermingham, M.J.; Kent, D.; Zhan, H.; StJohn, D.H.; Dargusch, M.S.

2015-01-01

This study demonstrates that trace boron addition to Ti–6Al–4V coupons produced by additive layer manufacturing is an effective way to eliminate the deleterious anisotropic microstructures often encountered with this manufacturing technique. Trace boron additions (up to 0.13 wt.%) to this alloy eliminate grain boundary-α and colony-α, and instead produce a homogeneous α-microstructure consisting of fine equiaxed α-grains in both as-deposited and heat treated coupons. Prior-β grains remain columnar with boron addition but become narrower due to the wider solidification range and growth restricting effect of the boron solute. Compared to unmodified Ti–6Al–4V alloy, Ti–6Al–4V modified with trace boron additions showed up to 40% improvement in plasticity with no loss in strength under uniaxial compression at room temperature. Boron additions were found to inhibit twinning transmission that causes sudden large load drops during deformation of the unmodified Ti–6Al–4V alloy in the heat treated condition

Expanding the Design Space: Forging the Transition from 3D Printing to Additive Manufacturing

Science.gov (United States)

Amend, Matthew

The synergy of Additive Manufacturing and Computational Geometry has the potential to radically expand the "design space" of solutions available to designers. Additive Manufacturing (AM) is capable of fabricating objects that are highly complex both in geometry and material properties. However, the introduction of any new technology can have a disruptive effect on established design practices and organizations. Before "Design for Additive Manufacturing" (DFAM) is a commonplace means of producing objects employed in "real world" products, appropriate design knowledge must be sufficiently integrated within industry. First, materials suited to additive manufacturing methods must be developed to satisfy existing industry standards and specifications, or new standards must be developed. Second, a new class of design representation (CAD) tools will need to be developed. Third, designers and design organizations will need to develop strategies for employing such tools. This thesis describes three DFAM exercises intended to demonstrate the potential for innovative design when using advanced additive materials, tools, and printers. These design exercises included 1) a light-weight composite layup mold developed with topology optimization, 2) a low-pressure fluid duct enhanced with an external lattice structure, and 3) an airline seat tray designed using a non-uniform lattice structure optimized with topology optimization.

Additive manufacturing technologies of porous metal implants

Directory of Open Access Journals (Sweden)

Yang Quanzhan

2014-06-01

Full Text Available Biomedical metal materials with good corrosion resistance and mechanical properties are widely used in orthopedic surgery and dental implant materials, but they can easily cause stress shielding due to the significant difference in elastic modulus between the implant and human bones. The elastic modulus of porous metals is lower than that of dense metals. Therefore, it is possible to adjust the pore parameters to make the elastic modulus of porous metals match or be comparable with that of the bone tissue. At the same time, the open porous metals with pores connected to each other could provide the structural condition for bone ingrowth, which is helpful in strengthening the biological combination of bone tissue with the implants. Therefore, the preparation technologies of porous metal implants and related research have been drawing more and more attention due to the excellent features of porous metals. Selective laser melting (SLM and electron beam melting technology (EBM are important research fields of additive manufacturing. They have the advantages of directly forming arbitrarily complex shaped metal parts which are suitable for the preparation of porous metal implants with complex shape and fine structure. As new manufacturing technologies, the applications of SLM and EBM for porous metal implants have just begun. This paper aims to understand the technology status of SLM and EBM, the research progress of porous metal implants preparation by using SLM and EBM, and the biological compatibility of the materials, individual design and manufacturing requirements. The existing problems and future research directions for porous metal implants prepared by SLM and EBM methods are discussed in the last paragraph.

Additive Manufactured Very Light Weight Diamond Turned Aspheric Mirror, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — Selective laser melting, referred to as "Direct Metal Laser Sintering"(DMLS), "Metal Powder Bed Fusion" or "3D Printing" is an additive manufacturing process which...

Spray-Dried Cellulose Nanofibril-Reinforced Polypropylene Composites for Extrusion-Based Additive Manufacturing: Nonisothermal Crystallization Kinetics and Thermal Expansion

Directory of Open Access Journals (Sweden)

Lu Wang

2018-02-01

Full Text Available Isotactic polypropylene (iPP is a versatile polymer. It accounts for the second-largest polymer consumption worldwide. However, iPP is difficult to 3D print via extrusion-based processing. This is attributable to its rapid crystallization rate. In this study, spray-dried cellulose nanofibrils (SDCNF and maleic anhydride polypropylene (MAPP were investigated to reveal their effects on the nonisothermal crystallization kinetics and thermal expansion of iPP. SDCNF at 3 wt % and 30 wt % accelerated the crystallization rate of iPP, while SDCNF at 10 wt % retarded the crystallization rate by restricting crystal growth and moderately increasing the nucleation density of iPP. Additionally, adding MAPP into iPP/SDCNF composites accelerated the crystallization rate of iPP. The effective activation energy of iPP increased when more than 10 wt % SDCNF was added. Scanning electron microscopy and polarized light microscopy results indicated that high SDCNF content led to a reduced gap size among SDCNF, which hindered the iPP crystal growth. The coefficient of thermal expansion of iPP/SDCNF10% was 11.7% lower than the neat iPP. In summary, SDCNF, at 10 wt %, can be used to reduce the warping of iPP during extrusion-based additive manufacturing.

The Current State of Additive Manufacturing in Wind Energy Systems

Energy Technology Data Exchange (ETDEWEB)

Mann, Margaret [National Renewable Energy Lab. (NREL), Golden, CO (United States); Palmer, Sierra [Worcester Polytechnic Institute (WPI), , Worcester, MA (United States); Lee, Dominic [National Renewable Energy Lab. (NREL), Golden, CO (United States); Kurup, Parthiv [National Renewable Energy Lab. (NREL), Golden, CO (United States); Remo, Timothy [National Renewable Energy Lab. (NREL), Golden, CO (United States); Jenne, Dale Scott [National Renewable Energy Lab. (NREL), Golden, CO (United States); Richardson, Bradley S. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Love, Lonnie J. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Post, Brian K. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2017-12-01

Wind power is an inexhaustible form of energy that is being captured throughout the U.S. to power the engine of our economy. A robust, domestic wind industry promises to increase U.S. industry growth and competitiveness, strengthen U.S. energy security independence, and promote domestic manufacturing nationwide. As of 2016, ~82GW of wind capacity had been installed, and wind power now provides more than 5.5% of the nation’s electricity and supports more than 100,000 domestic jobs, including 500 manufacturing facilities in 43 States. To reach the U.S. Department of Energy’s (DOE’s) 2015 Wind Vision study scenario of wind power serving 35% of the nation's end-use demand by 2050, significant advances are necessary in all areas of wind technologies and market. An area that can greatly impact the cost and rate of innovation in wind technologies is the use of advanced manufacturing, with one of the most promising areas being additive manufacturing (AM). Considering the tremendous promise offered by advanced manufacturing, it is the purpose of this report to identify the use of AM in the production and operation of wind energy systems. The report has been produced as a collaborative effort for the DOE Wind Energy Technology Office (WETO), between Oak Ridge National Laboratory (ORNL) and the National Renewable Energy Laboratory (NREL).

3D-Printing: How Additive Manufacturing impacts Supply Chain Business Processes and Management Components

OpenAIRE

Oettmeier, Katrin; Hofmann, Erik

2016-01-01

Purpose The business implications of additive manufacturing (AM) are explored; specific focus thereby lies on the impact of AM technology adoption in customized parts production. Design/methodology/approach Based on two explorative case studies from the hearing aid industry, the impact of AM technology adoption on supply chain business processes and management components is analyzed. General systems theory and a supply chain management framework serve as theoretical underpinning....

3D Volume Rendering and 3D Printing (Additive Manufacturing).

Science.gov (United States)

Katkar, Rujuta A; Taft, Robert M; Grant, Gerald T

2018-07-01

Three-dimensional (3D) volume-rendered images allow 3D insight into the anatomy, facilitating surgical treatment planning and teaching. 3D printing, additive manufacturing, and rapid prototyping techniques are being used with satisfactory accuracy, mostly for diagnosis and surgical planning, followed by direct manufacture of implantable devices. The major limitation is the time and money spent generating 3D objects. Printer type, material, and build thickness are known to influence the accuracy of printed models. In implant dentistry, the use of 3D-printed surgical guides is strongly recommended to facilitate planning and reduce risk of operative complications. Copyright © 2018 Elsevier Inc. All rights reserved.

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control.

Science.gov (United States)

Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

2014-01-01

Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented.

Development of strength-hardness relationships in additively manufactured titanium alloys

Energy Technology Data Exchange (ETDEWEB)

Keist, Jayme S., E-mail: keist@psu.edu; Palmer, Todd A., E-mail: tap103@psu.edu

2017-05-02

A major concern for additively manufactured (AM) Ti-6Al-4V components is how AM processing parameters and post-process heat treatments impact the resulting mechanical behavior. The applicability of using microhardness measurements as a predictive tool for yield and tensile strengths of AM Ti-6Al-4V would provide a rapid and useful screening mechanism for ensuring that properties meet requirements in complex geometries. However, microhardness measurements on Ti-6Al-4V exhibit high levels of data variability due to the orientational impact of the α phase. In order to overcome this variability in hardness measurements, a methodology for aggregating microhardness data in individual builds has been developed and validated. By compiling mean microhardness values from various AM components produced by electron beam based directed energy deposition (DED), laser based DED, and laser based powder bed fusion (PBF) processes in the as-deposited and post-process heat treated conditions, strong linear correlations between strength and hardness can be developed in AM materials having a lamellar α+β microstructure. With the addition of strain hardening and α phase orientation contributions to the mean microhardness measurement, the strength-hardness correlations of AM Ti-6Al-4V followed empirically derived models, opening the possibility of using these models to predict strengths from AM components regardless of the AM process or post-process state.

Additive Manufacturing of Tooling for Refrigeration Cabinet Foaming Processes

Energy Technology Data Exchange (ETDEWEB)

Post, Brian K [ORNL; Nuttall, David [ORNL; Cukier, Michael Z [ORNL; Hile, Michael B [ORNL

2016-07-29

The primary objective of this project was to leverage the Big Area Additive Manufacturing (BAAM) process and materials into a long term, quick change tooling concept to drastically reduce product lead and development timelines and costs. Current refrigeration foam molds are complicated to manufacture involving casting several aluminum parts in an approximate shape, machining components of the molds and post fitting and shimming of the parts in an articulated fixture. The total process timeline can take over 6 months. The foaming process is slower than required for production, therefore multiple fixtures, 10 to 27, are required per refrigerator model. Molds are particular to a specific product configuration making mixed model assembly challenging for sequencing, mold changes or auto changeover features. The initial goal was to create a tool leveraging the ORNL materials and additive process to build a tool in 4 to 6 weeks or less. A secondary goal was to create common fixture cores and provide lightweight fixture sections that could be revised in a very short time to increase equipment flexibility reduce lead times, lower the barriers to first production trials, and reduce tooling costs.

Evaluation of marginal and internal gap of three-unit metal framework according to subtractive manufacturing and additive manufacturing of CAD/CAM systems.

Science.gov (United States)

Kim, Dong-Yeon; Kim, Eo-Bin; Kim, Hae-Young; Kim, Ji-Hwan; Kim, Woong-Chul

2017-12-01

To evaluate the fit of a three-unit metal framework of fixed dental prostheses made by subtractive and additive manufacturing. One master model of metal was fabricated. Twenty silicone impressions were made on the master die, working die of 10 poured with Type 4 stone, and working die of 10 made of scannable stone. Ten three-unit wax frameworks were fabricated by wax-up from Type IV working die. Stereolithography files of 10 three-unit frameworks were obtained using a model scanner and three-dimensional design software on a scannable working die. The three-unit wax framework was fabricated using subtractive manufacturing (SM) by applying the prepared stereolithography file, and the resin framework was fabricated by additive manufacturing (AM); both used metal alloy castings for metal frameworks. Marginal and internal gap were measured using silicone replica technique and digital microscope. Measurement data were analyzed by Kruskal-Wallis H test and Mann-Whitney U-test (α=.05). The lowest and highest gaps between premolar and molar margins were in the SM group and the AM group, respectively. There was a statistically significant difference in the marginal gap among the 3 groups ( P manufacturing are clinically applicable. However, additive manufacturing requires more research to be applied clinically.

Microstructure and Corrosion Resistance of Laser Additively Manufactured 316L Stainless Steel

Science.gov (United States)

Trelewicz, Jason R.; Halada, Gary P.; Donaldson, Olivia K.; Manogharan, Guha

2016-03-01

Additive manufacturing (AM) of metal alloys to produce complex part designs via powder bed fusion methods such as laser melting promises to be a transformative technology for advanced materials processing. However, effective implementation of AM processes requires a clear understanding of the processing-structure-properties-performance relationships in fabricated components. In this study, we report on the formation of micro and nanoscale structures in 316L stainless steel samples printed by laser AM and their implications for general corrosion resistance. A variety of techniques including x-ray diffraction, optical, scanning and transmission electron microscopy, x-ray fluorescence, and energy dispersive x-ray spectroscopy were employed to characterize the microstructure and chemistry of the laser additively manufactured 316L stainless steel, which are compared with wrought 316L coupons via electrochemical polarization. Apparent segregation of Mo has been found to contribute to a loss of passivity and an increased anodic current density. While porosity will also likely impact the environmental performance (e.g., facilitating crevice corrosion) of AM alloys, this work demonstrates the critical influence of microstructure and heterogeneous solute distributions on the corrosion resistance of laser additively manufactured 316L stainless steel.

Carbon Nanotube Chopped Fiber for Enhanced Properties in Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Menchhofer, Paul A [ORNL; Lindahl, John M [ORNL; JohnsonPhD, DR Joseph E. [Nanocomp Technologies, Inc.

2016-06-06

Nanocomp Technologies, Inc. is working with Oak Ridge National Laboratory to develop carbon nanotube (CNT) composite materials and evaluate their use in additive manufacturing (3D printing). The first phase demonstrated feasibility and improvements for carbon nanotube (CNT)- acrylonitrile butadiene styrene (ABS) composite filaments use in additive manufacturing, with potential future work centering on further improvements. By focusing the initial phase on standard processing methods (developed mainly for the incorporation of carbon fibers in ABS) and characterization techniques, a basis of knowledge for the incorporation of CNTs in ABS was learned. The ability to understand the various processing variables is critical to the successful development of these composites. From the degradation effects on ABS (caused by excessive temperatures), to the length of time the ABS is in the melt state, to the order of addition of constituents, and also to the many possible mixing approaches, a workable flow sequence that addresses each processing step is critical to the final material properties. Although this initial phase could not deal with each of these variables in-depth, a future study is recommended that will build on the lessons learned for this effort.

Imaging requirements for medical applications of additive manufacturing.

Science.gov (United States)

Huotilainen, Eero; Paloheimo, Markku; Salmi, Mika; Paloheimo, Kaija-Stiina; Björkstrand, Roy; Tuomi, Jukka; Markkola, Antti; Mäkitie, Antti

2014-02-01

Additive manufacturing (AM), formerly known as rapid prototyping, is steadily shifting its focus from industrial prototyping to medical applications as AM processes, bioadaptive materials, and medical imaging technologies develop, and the benefits of the techniques gain wider knowledge among clinicians. This article gives an overview of the main requirements for medical imaging affected by needs of AM, as well as provides a brief literature review from existing clinical cases concentrating especially on the kind of radiology they required. As an example application, a pair of CT images of the facial skull base was turned into 3D models in order to illustrate the significance of suitable imaging parameters. Additionally, the model was printed into a preoperative medical model with a popular AM device. Successful clinical cases of AM are recognized to rely heavily on efficient collaboration between various disciplines - notably operating surgeons, radiologists, and engineers. The single main requirement separating tangible model creation from traditional imaging objectives such as diagnostics and preoperative planning is the increased need for anatomical accuracy in all three spatial dimensions, but depending on the application, other specific requirements may be present as well. This article essentially intends to narrow the potential communication gap between radiologists and engineers who work with projects involving AM by showcasing the overlap between the two disciplines.

Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review.

Science.gov (United States)

Savio, Gianpaolo; Rosso, Stefano; Meneghello, Roberto; Concheri, Gianmaria

2018-01-01

Advances in additive manufacturing technologies facilitate the fabrication of cellular materials that have tailored functional characteristics. The application of solid freeform fabrication techniques is especially exploited in designing scaffolds for tissue engineering. In this review, firstly, a classification of cellular materials from a geometric point of view is proposed; then, the main approaches on geometric modeling of cellular materials are discussed. Finally, an investigation on porous scaffolds fabricated by additive manufacturing technologies is pointed out. Perspectives in geometric modeling of scaffolds for tissue engineering are also proposed.

Standardization of Fat:SNF ratio of milk and addition of sprouted wheat fada (semolina) for the manufacture of halvasan.

Science.gov (United States)

Chaudhary, Apurva H; Patel, H G; Prajapati, P S; Prajapati, J P

2015-04-01

Traditional Indian Dairy Products such as Halvasan are manufactured in India using an age old practice. For manufacture of such products industrially, a standard formulation is required. Halvasan is a region specific, very popular heat desiccated milk product but has not been studied scientifically. Fat and Solids-not-fat (SNF) plays an important role in physico-chemical, sensory, textural characteristics and also the shelf life of any milk sweet. Hence for process standardization of Halvasan manufacture, different levels of Fat:SNF ratios i.e. 0.44, 0.55, 0.66 and 0.77 of milk were studied so that an optimum level yielding best organoleptic characteristics in final product can be selected. The product was made from milk standardized to these ratios of Fat:SNF and the product was manufactured as per the method tentatively employed on the basis of characterization of market samples of the product in laboratory. Based on the sensory results obtained, a Fat:SNF ratio of 0.66 for the milk has been selected. In the similar way, for standardizing the rate of addition of fada (semolina); 30, 40, 50 and 60 g fada (semolina) per kg of milk were added and based on the sensory observations, the level of fada (semolina) addition @50 gm/kg of milk was adjudged the best for Halvasan manufacture and hence selected.