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Sample records for additive layer manufacturing

  1. Preliminary Investigation of Keyhole Phenomena during Single Layer Fabrication in Laser Additive Manufacturing of Stainless Steel

    NASA Astrophysics Data System (ADS)

    Matilainen, Ville-Pekka; Piili, Heidi; Salminen, Antti; Nyrhilä, Olli

    Laser additive manufacturing (LAM) is a fabrication technology that enables production of complex parts from metallic materials with mechanical properties comparable to conventionally manufactured parts. In the LAM process, parts are manufactured by melting metallic powder layer-by-layer with a laser beam. This manufacturing technology is nowadays called powder bed fusion (PBF) according to the ASTM F2792-12a standard. This strategy involves several different independent and dependent thermal cycles, all of which have an influence on the final properties of the manufactured part. The quality of PBF parts depends strongly on the characteristics of each single laser-melted track and each single layer. This study consequently concentrates on investigating the effects of process parameters such as laser power on single track and layer formation and laser-material interaction phenomena occurring during the PBF process. Experimental tests were done with two different machines: a modified research machine based on an EOS EOSINT M-series system and an EOS EOSINT M280 system. The material used was EOS stainless steel 17-4 PH. Process monitoring was done with an active illuminated high speed camera system. After microscopy analysis, it was concluded that a keyhole can form during laser additive manufacturing of stainless steel. It was noted that heat input has an important effect on the likelihood of keyhole formation. The threshold intensity value for keyhole formation of 106 W/cm2 was exceeded in all manufactured single tracks. Laser interaction time was found to have an effect on penetration depth and keyhole formation, since the penetration depth increased with increased laser interaction time. It was also concluded that active illuminated high speed camera systems are suitable for monitoring of the manufacturing process and facilitate process control.

  2. The impact of layer thickness on the performance of additively manufactured lapping tools

    NASA Astrophysics Data System (ADS)

    Williams, Wesley B.

    2015-10-01

    Lower cost additive manufacturing (AM) machines which have emerged in recent years are capable of producing tools, jigs, and fixtures that are useful in optical fabrication. In particular, AM tooling has been shown to be useful in lapping glass workpieces. Various AM machines are distinguished by the processes, materials, build times, and build resolution they provide. This research investigates the impact of varied build resolution (specifically layer resolution) on the lapping performance of tools built using the stereolithographic assembly (SLA) process in 50 μm and 100 μm layer thicknesses with a methacrylate photopolymer resin on a high resolution desktop printer. As with previous work, the lapping tools were shown to remove workpiece material during the lapping process, but the tools themselves also experienced significant wear on the order of 2-3 times the mass loss of the glass workpieces. The tool wear rates for the 100 μm and 50 μm layer tools were comparable, but the 50 μm layer tool was 74% more effective at removing material from the glass workpiece, which is attributed to some abrasive particles being trapped in the coarser surface of the 100 um layer tooling and not being available to interact with the glass workpiece. Considering the tool wear, these additively manufactured tools are most appropriate for prototype tooling where the low cost (<$45) and quick turnaround make them attractive when compared to a machined tool.

  3. Logic For Qualification And Industrialisation Of Additive Layer Manufacturing Parts For Spatial Application

    NASA Astrophysics Data System (ADS)

    Brindeau, Aymeric; Lopes, Jean-Louis; Brivot, Frederic; Bourneaud, Florent; Desagulier, Christian

    2012-07-01

    ASTRIUM Space Transportation has been manufacturing composite equipments for satellite for 25 years. For this business, the development of Additive Layer Manufacturing (ALM) processes has been identified as a real opportunity to improve design and performances. For satellite equipments, ASTRIUM ST has chosen to investigate in the Electron Beam Melting process (patented EBM® process from Arcam AB company) for the manufacturing of Titanium parts, in collaboration with MECACHROME who has developed strong skills in this ALM process. This first development step has been achieved by introducing a titanium part realised by EBM on an equipment of Atlantic Bird 7 satellite launched in September 2011. The new step consists in the formal industrialisation of the EBM process for the procurement of titanium parts for satellite equipments. The present paper describes the logic retained for this industrialisation. It includes the technical requirements but also the verifications and inspections which have to be performed to guarantee that technical requirements are met.

  4. Heat transfer and material flow during laser assisted multi-layer additive manufacturing

    SciTech Connect

    Manvatkar, V.; De, A.; DebRoy, T.

    2014-09-28

    A three-dimensional, transient, heat transfer, and fluid flow model is developed for the laser assisted multilayer additive manufacturing process with coaxially fed austenitic stainless steel powder. Heat transfer between the laser beam and the powder particles is considered both during their flight between the nozzle and the growth surface and after they deposit on the surface. The geometry of the build layer obtained from independent experiments is compared with that obtained from the model. The spatial variation of melt geometry, cooling rate, and peak temperatures is examined in various layers. The computed cooling rates and solidification parameters are used to estimate the cell spacings and hardness in various layers of the structure. Good agreement is achieved between the computed geometry, cell spacings, and hardness with the corresponding independent experimental results.

  5. Heat transfer and material flow during laser assisted multi-layer additive manufacturing

    NASA Astrophysics Data System (ADS)

    Manvatkar, V.; De, A.; DebRoy, T.

    2014-09-01

    A three-dimensional, transient, heat transfer, and fluid flow model is developed for the laser assisted multilayer additive manufacturing process with coaxially fed austenitic stainless steel powder. Heat transfer between the laser beam and the powder particles is considered both during their flight between the nozzle and the growth surface and after they deposit on the surface. The geometry of the build layer obtained from independent experiments is compared with that obtained from the model. The spatial variation of melt geometry, cooling rate, and peak temperatures is examined in various layers. The computed cooling rates and solidification parameters are used to estimate the cell spacings and hardness in various layers of the structure. Good agreement is achieved between the computed geometry, cell spacings, and hardness with the corresponding independent experimental results.

  6. Additive Manufacturing Infrared Inspection

    NASA Technical Reports Server (NTRS)

    Gaddy, Darrell

    2014-01-01

    Additive manufacturing is a rapid prototyping technology that allows parts to be built in a series of thin layers from plastic, ceramics, and metallics. Metallic additive manufacturing is an emerging form of rapid prototyping that allows complex structures to be built using various metallic powders. Significant time and cost savings have also been observed using the metallic additive manufacturing compared with traditional techniques. Development of the metallic additive manufacturing technology has advanced significantly over the last decade, although many of the techniques to inspect parts made from these processes have not advanced significantly or have limitations. Several external geometry inspection techniques exist such as Coordinate Measurement Machines (CMM), Laser Scanners, Structured Light Scanning Systems, or even traditional calipers and gages. All of the aforementioned techniques are limited to external geometry and contours or must use a contact probe to inspect limited internal dimensions. This presentation will document the development of a process for real-time dimensional inspection technique and digital quality record of the additive manufacturing process using Infrared camera imaging and processing techniques.

  7. Load-dependent Optimization of Honeycombs for Sandwich Components - New Possibilities by Using Additive Layer Manufacturing

    NASA Astrophysics Data System (ADS)

    Riss, Fabian; Schilp, Johannes; Reinhart, Gunther

    Due to their feasible geometric complexity, additive layer manufacturing (ALM) processes show a highpotential for the production of lightweight components.Therefore, ALM processes enable the realization of bionic-designedcomponents like honeycombs, which are optimized depending upon load and outer boundary conditions.This optimization is based on a closed-loop, three-steps methodology: At first, each honeycomb is conformed to the surface of the part. Secondly, the structure is optimizedfor lightweight design.It is possible to achieve a homogeneous stress distribution in the part by varying the wall thickness, honeycombdiameter and the amount of honeycombs, depending on the subjected stresses and strains. At last, the functional components like threads or bearing carriers are integrated directly into the honeycomb core.Using all these steps as an iterative process, it is possible to reduce the mass of sandwich components about 50 percent compared to conventional approaches.

  8. Perspectives on Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Bourell, David L.

    2016-07-01

    Additive manufacturing (AM) has skyrocketed in visibility commercially and in the public sector. This article describes the development of this field from early layered manufacturing approaches of photosculpture, topography, and material deposition. Certain precursors to modern AM processes are also briefly described. The growth of the field over the last 30 years is presented. Included is the standard delineation of AM technologies into seven broad categories. The economics of AM part generation is considered, and the impacts of the economics on application sectors are described. On the basis of current trends, the future outlook will include a convergence of AM fabricators, mass-produced AM fabricators, enabling of topology optimization designs, and specialization in the AM legal arena. Long-term developments with huge impact are organ printing and volume-based printing.

  9. Simulation of Powder Layer Deposition in Additive Manufacturing Processes Using the Discrete Element Method

    SciTech Connect

    Herbold, E. B.; Walton, O.; Homel, M. A.

    2015-10-26

    This document serves as a final report to a small effort where several improvements were added to a LLNL code GEODYN-­L to develop Discrete Element Method (DEM) algorithms coupled to Lagrangian Finite Element (FE) solvers to investigate powder-­bed formation problems for additive manufacturing. The results from these simulations will be assessed for inclusion as the initial conditions for Direct Metal Laser Sintering (DMLS) simulations performed with ALE3D. The algorithms were written and performed on parallel computing platforms at LLNL. The total funding level was 3-­4 weeks of an FTE split amongst two staff scientists and one post-­doc. The DEM simulations emulated, as much as was feasible, the physical process of depositing a new layer of powder over a bed of existing powder. The DEM simulations utilized truncated size distributions spanning realistic size ranges with a size distribution profile consistent with realistic sample set. A minimum simulation sample size on the order of 40-­particles square by 10-­particles deep was utilized in these scoping studies in order to evaluate the potential effects of size segregation variation with distance displaced in front of a screed blade. A reasonable method for evaluating the problem was developed and validated. Several simulations were performed to show the viability of the approach. Future investigations will focus on running various simulations investigating powder particle sizing and screen geometries.

  10. Additive manufacturing of liquid/gas diffusion layers for low-cost and high-efficiency hydrogen production

    DOE PAGESBeta

    Mo, Jingke; Zhang, Feng -Yuan; Dehoff, Ryan R.; Peter, William H.; Toops, Todd J.; Green, Jr., Johney Boyd

    2016-01-14

    The electron beam melting (EBM) additive manufacturing technology was used to fabricate titanium liquid/gas diffusion media with high-corrosion resistances and well-controllable multifunctional parameters, including two-phase transport and excellent electric/thermal conductivities, has been first demonstrated. Their applications in proton exchange membrane eletrolyzer cells have been explored in-situ in a cell and characterized ex-situ with SEM and XRD. Compared with the conventional woven liquid/gas diffusion layers (LGDLs), much better performance with EBM fabricated LGDLs is obtained due to their significant reduction of ohmic loss. The EBM technology components exhibited several distinguished advantages in fabricating gas diffusion layer: well-controllable pore morphology and structure,more » rapid prototyping, fast manufacturing, highly customizing and economic. In addition, by taking advantage of additive manufacturing, it possible to fabricate complicated three-dimensional designs of virtually any shape from a digital model into one single solid object faster, cheaper and easier, especially for titanium. More importantly, this development will provide LGDLs with control of pore size, pore shape, pore distribution, and therefore porosity and permeability, which will be very valuable to develop modeling and to validate simulations of electrolyzers with optimal and repeatable performance. Further, it will lead to a manufacturing solution to greatly simplify the PEMEC/fuel cell components and to couple the LGDLs with other parts, since they can be easily integrated together with this advanced manufacturing process« less

  11. Fatigue Life of Titanium Alloys Fabricated by Additive Layer Manufacturing Techniques for Dental Implants

    NASA Astrophysics Data System (ADS)

    Chan, Kwai S.; Koike, Marie; Mason, Robert L.; Okabe, Toru

    2013-02-01

    Additive layer deposition techniques such as electron beam melting (EBM) and laser beam melting (LBM) have been utilized to fabricate rectangular plates of Ti-6Al-4V with extra low interstitial (ELI) contents. The layer-by-layer deposition techniques resulted in plates that have different surface finishes which can impact significantly on the fatigue life by providing potential sites for fatigue cracks to initiate. The fatigue life of Ti-6Al-4V ELI alloys fabricated by EBM and LBM deposition techniques was investigated by three-point testing of rectangular beams of as-fabricated and electro-discharge machined surfaces under stress-controlled conditions at 10 Hz until complete fracture. Fatigue life tests were also performed on rolled plates of Ti-6Al-4V ELI, regular Ti-6Al-4V, and CP Ti as controls. Fatigue surfaces were characterized by scanning electron microscopy to identify the crack initiation site in the various types of specimen surfaces. The fatigue life data were analyzed statistically using both analysis of variance techniques and the Kaplan-Meier survival analysis method with the Gehan-Breslow test. The results indicate that the LBM Ti-6Al-4V ELI material exhibits a longer fatigue life than the EBM counterpart and CP Ti, but a shorter fatigue life compared to rolled Ti-6Al-4V ELI. The difference in the fatigue life behavior may be largely attributed to the presence of rough surface features that act as fatigue crack initiation sites in the EBM material.

  12. Powder Layer Preparation Using Vibration-controlled Capillary Steel Nozzles for Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Stichel, Thomas; Laumer, Tobias; Baumüller, Tobias; Amend, Philipp; Roth, Stephan

    In this report, the dry delivery of polyamide 12 powders by vibrating capillary steel nozzles is investigated and discussed regarding its potential for powder layer preparation in Laser Beam Melting. Therefore, a setup including a steel nozzle assembled on a piezoelectric actuator is presented, which enables the precise control over very small powder quantities by vibration excitation. An analysis reveals that the mass flow through the nozzle can be adjusted by the vibration modes in a certain range depending on the nozzle's specifications, whereas the vibration modes themselves show a complicated behaviour. Using a positioning system in combination with the vibrating nozzle, single-layer patterns consisting of polyamide 12 are produced and characterized regarding surface homogeneity and selectivity using a laser stripe sensor.

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

    NASA Astrophysics Data System (ADS)

    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

  14. Evaluation of advanced polymers for additive manufacturing

    SciTech Connect

    Rios, Orlando; Morrison, Crystal

    2015-09-01

    The goal of this Manufacturing Demonstration Facility (MDF) technical collaboration project between Oak Ridge National Laboratory (ORNL) and PPG Industries, Inc. 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 is inherently low-cost.

  15. Neutron Characterization for Additive Manufacturing

    NASA Technical Reports Server (NTRS)

    Watkins, Thomas; Bilheux, Hassina; An, Ke; Payzant, Andrew; DeHoff, Ryan; Duty, Chad; Peter, William; Blue, Craig; Brice, Craig A.

    2013-01-01

    Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL

  16. Out of bounds additive manufacturing

    SciTech Connect

    Holshouser, Chris; Newell, Clint; Palas, Sid; Love, Lonnie J.; Kunc, Vlastimil; Lind, Randall F.; Lloyd, Peter D.; Rowe, John C.; Blue, Craig A.; Duty, Chad E.; Peter, William H.; Dehoff, Ryan R.

    2013-03-01

    Lockheed Martin and Oak Ridge National Laboratory are working on an additive manufacturing system capable of manufacturing components measured not in terms of inches or feet, but multiple yards in all dimensions with the potential to manufacture parts that are completely unbounded in size.

  17. Metal Additive Manufacturing: A Review

    NASA Astrophysics Data System (ADS)

    Frazier, William E.

    2014-06-01

    This paper reviews the state-of-the-art of an important, rapidly emerging, manufacturing technology that is alternatively called additive manufacturing (AM), direct digital manufacturing, free form fabrication, or 3D printing, etc. A broad contextual overview of metallic AM is provided. AM has the potential to revolutionize the global parts manufacturing and logistics landscape. It enables distributed manufacturing and the productions of parts-on-demand while offering the potential to reduce cost, energy consumption, and carbon footprint. This paper explores the material science, processes, and business consideration associated with achieving these performance gains. It is concluded that a paradigm shift is required in order to fully exploit AM potential.

  18. [INVITED] Lasers in additive manufacturing

    NASA Astrophysics Data System (ADS)

    Pinkerton, Andrew J.

    2016-04-01

    Additive manufacturing is a topic of considerable ongoing interest, with forecasts predicting it to have major impact on industry in the future. This paper focusses on the current status and potential future development of the technology, with particular reference to the role of lasers within it. It begins by making clear the types and roles of lasers in the different categories of additive manufacturing. This is followed by concise reviews of the economic benefits and disadvantages of the technology, current state of the market and use of additive manufacturing in different industries. Details of these fields are referenced rather than expanded in detail. The paper continues, focusing on current indicators to the future of additive manufacturing. Barriers to its development, trends and opportunities in major industrial sectors, and wider opportunities for its development are covered. Evidence indicates that additive manufacturing may not become the dominant manufacturing technology in all industries, but represents an excellent opportunity for lasers to increase their influence in manufacturing as a whole.

  19. Additive manufacturing in production: challenges and opportunities

    NASA Astrophysics Data System (ADS)

    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.

  20. Additive Manufacturing of Hybrid Circuits

    NASA Astrophysics Data System (ADS)

    Sarobol, Pylin; Cook, Adam; Clem, Paul G.; Keicher, David; Hirschfeld, Deidre; Hall, Aaron C.; Bell, Nelson S.

    2016-07-01

    There is a rising interest in developing functional electronics using additively manufactured components. Considerations in materials selection and pathways to forming hybrid circuits and devices must demonstrate useful electronic function; must enable integration; and must complement the complex shape, low cost, high volume, and high functionality of structural but generally electronically passive additively manufactured components. This article reviews several emerging technologies being used in industry and research/development to provide integration advantages of fabricating multilayer hybrid circuits or devices. First, we review a maskless, noncontact, direct write (DW) technology that excels in the deposition of metallic colloid inks for electrical interconnects. Second, we review a complementary technology, aerosol deposition (AD), which excels in the deposition of metallic and ceramic powder as consolidated, thick conformal coatings and is additionally patternable through masking. Finally, we show examples of hybrid circuits/devices integrated beyond 2-D planes, using combinations of DW or AD processes and conventional, established processes.

  1. Sustainability Characterization for Additive Manufacturing

    PubMed Central

    Mani, Mahesh; Lyons, Kevin W; Gupta, SK

    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. PMID:26601038

  2. Sustainability Characterization for Additive Manufacturing.

    PubMed

    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. PMID:26601038

  3. Additively manufactured porous tantalum implants.

    PubMed

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

    2015-03-01

    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 its good biocompatibility. In this study selective laser melting technology was used for the first time to manufacture highly porous pure tantalum implants with fully interconnected open pores. The architecture of the porous structure in combination with the material properties of tantalum result in mechanical properties close to those of human bone and allow for bone ingrowth. The bone regeneration performance of the porous tantalum was evaluated in vivo using an orthotopic load-bearing bone defect model in the rat femur. After 12 weeks, substantial bone ingrowth, good quality of the regenerated bone and a strong, functional implant-bone interface connection were observed. Compared to identical porous Ti-6Al-4V structures, laser-melted tantalum shows excellent osteoconductive properties, has a higher normalized fatigue strength and allows for more plastic deformation due to its high ductility. It is therefore concluded that this is a first step towards a new generation of open porous tantalum implants manufactured using selective laser melting. PMID:25500631

  4. Additive manufacturing of hybrid circuits

    DOE PAGESBeta

    Bell, Nelson S.; Sarobol, Pylin; Cook, Adam; Clem, Paul G.; Keicher, David M.; Hirschfeld, Deidre; Hall, Aaron Christopher

    2016-03-26

    There is a rising interest in developing functional electronics using additively manufactured components. Considerations in materials selection and pathways to forming hybrid circuits and devices must demonstrate useful electronic function; must enable integration; and must complement the complex shape, low cost, high volume, and high functionality of structural but generally electronically passive additively manufactured components. This article reviews several emerging technologies being used in industry and research/development to provide integration advantages of fabricating multilayer hybrid circuits or devices. First, we review a maskless, noncontact, direct write (DW) technology that excels in the deposition of metallic colloid inks for electrical interconnects.more » Second, we review a complementary technology, aerosol deposition (AD), which excels in the deposition of metallic and ceramic powder as consolidated, thick conformal coatings and is additionally patternable through masking. As a result, we show examples of hybrid circuits/devices integrated beyond 2-D planes, using combinations of DW or AD processes and conventional, established processes.« less

  5. Emerging technologies in arthroplasty: additive manufacturing.

    PubMed

    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. PMID:24764230

  6. Additive manufacturing of RF absorbers

    NASA Astrophysics Data System (ADS)

    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.

  7. Additive manufacturing: From implants to organs.

    PubMed

    Douglas, Tania S

    2014-06-01

    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 planning, implants, assistive devices and scaffold-based tissue engineering. The use of AM to print tissues and organs that mimic nature in structure and function remains an elusive goal, but has the potential to transform personalised medicine, drug development and scientific understanding of the mechanisms of disease.  PMID:25214247

  8. Surface texture measurement for additive manufacturing

    NASA Astrophysics Data System (ADS)

    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.

  9. An Additive Manufacturing Test Artifact

    PubMed Central

    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

  10. An Additive Manufacturing Test Artifact.

    PubMed

    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

  11. Bubble formation in additive manufacturing of glass

    NASA Astrophysics Data System (ADS)

    Luo, Junjie; Gilbert, Luke J.; Peters, Daniel C.; Bristow, Douglas A.; Landers, Robert G.; Goldstein, Jonathan T.; Urbas, Augustine M.; Kinzel, Edward C.

    2016-05-01

    Bubble formation is a common problem in glass manufacturing. The spatial density of bubbles in a piece of glass is a key limiting factor to the optical quality of the glass. Bubble formation is also a common problem in additive manufacturing, leading to anisotropic material properties. In glass Additive Manufacturing (AM) two separate types of bubbles have been observed: a foam layer caused by the reboil of the glass melt and a periodic pattern of bubbles which appears to be unique to glass additive manufacturing. This paper presents a series of studies to relate the periodicity of bubble formation to part scan speed, laser power, and filament feed rate. These experiments suggest that bubbles are formed by the reboil phenomena why periodic bubbles result from air being trapped between the glass filament and the substrate. Reboil can be detected using spectroscopy and avoided by minimizing the laser power while periodic bubbles can be avoided by a two-step laser melting process to first establish good contact between the filament and substrate before reflowing the track with higher laser power.

  12. Numerical investigation of the mechanical properties of the additive manufactured bone scaffolds fabricated by FDM: The effect of layer penetration and post-heating.

    PubMed

    Naghieh, S; Karamooz Ravari, M R; Badrossamay, M; Foroozmehr, E; Kadkhodaei, M

    2016-06-01

    In recent years, thanks to additive manufacturing technology, researchers have gone towards the optimization of bone scaffolds for the bone reconstruction. Bone scaffolds should have appropriate biological as well as mechanical properties in order to play a decisive role in bone healing. Since the fabrication of scaffolds is time consuming and expensive, numerical methods are often utilized to simulate their mechanical properties in order to find a nearly optimum one. Finite element analysis is one of the most common numerical methods that is used in this regard. In this paper, a parametric finite element model is developed to assess the effects of layers penetration׳s effect on inter-layer adhesion, which is reflected on the mechanical properties of bone scaffolds. To be able to validate this model, some compression test specimens as well as bone scaffolds are fabricated with biocompatible and biodegradable poly lactic acid using fused deposition modeling. All these specimens are tested in compression and their elastic modulus is obtained. Using the material parameters of the compression test specimens, the finite element analysis of the bone scaffold is performed. The obtained elastic modulus is compared with experiment indicating a good agreement. Accordingly, the proposed finite element model is able to predict the mechanical behavior of fabricated bone scaffolds accurately. In addition, the effect of post-heating of bone scaffolds on their elastic modulus is investigated. The results demonstrate that the numerically predicted elastic modulus of scaffold is closer to experimental outcomes in comparison with as-built samples. PMID:26874065

  13. Additive Manufacturing of Aerospace Propulsion Components

    NASA Technical Reports Server (NTRS)

    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.

  14. Computational Process Modeling for Additive Manufacturing (OSU)

    NASA Technical Reports Server (NTRS)

    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.

  15. Additive manufacturing of glass for optical applications

    NASA Astrophysics Data System (ADS)

    Luo, Junjie; Gilbert, Luke J.; Bristow, Douglas A.; Landers, Robert G.; Goldstein, Jonathan T.; Urbas, Augustine M.; Kinzel, Edward C.

    2016-04-01

    Glasses including fused quartz have significant scientific and engineering applications including optics, communications, electronics, and hermetic seals. This paper investigates a filament fed process for Additive Manufacturing (AM) of fused quartz. Additive manufacturing has several potential benefits including increased design freedom, faster prototyping, and lower processing costs for small production volumes. However, current research in AM of glasses is limited and has focused on non-optical applications. Fused quartz is studied here because of its desirability for high-quality optics due to its high transmissivity and thermal stability. Fused quartz also has a higher working temperature than soda lime glass which poses a challenge for AM. In this work, fused quartz filaments are fed into a CO2 laser generated melt pool, smoothly depositing material onto the work piece. Single tracks are printed to explore the effects that different process parameters have on the morphology of printed fused quartz. A spectrometer is used to measure the thermal radiation incandescently emitted from the melt pool. Thin-walls are printed to study the effects of layer-to-layer height. Finally, a 3D fused quartz cube is printed using the newly acquired layer height and polished on each surface. The transmittance and index homogeneity of the polished cube are both measured. These results show that the filament fed process has the potential to print fused quartz with optical transparency and of index of refraction uniformity approaching bulk processed glass.

  16. Design and additive manufacture for flow chemistry.

    PubMed

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

    2013-12-01

    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. PMID:24100659

  17. Additive manufacturing of tools for lapping glass

    NASA Astrophysics Data System (ADS)

    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.

  18. Cincinnati Big Area Additive Manufacturing (BAAM)

    SciTech Connect

    Duty, Chad E.; Love, Lonnie J.

    2015-03-04

    Oak Ridge National Laboratory (ORNL) worked with Cincinnati Incorporated (CI) to demonstrate Big Area Additive Manufacturing which increases the speed of the additive manufacturing (AM) process by over 1000X, increases the size of parts by over 10X and shows a cost reduction of over 100X. ORNL worked with CI to transition the Big Area Additive Manufacturing (BAAM) technology from a proof-of-principle (TRL 2-3) demonstration to a prototype product stage (TRL 7-8).

  19. Embedded sensors in layered manufacturing

    NASA Astrophysics Data System (ADS)

    Li, Xiaochun

    Layered Manufacturing can be applied to build ``smart'' parts with sensors, integrated circuits, and actuators placed within the component. Embedded sensors can be used to gain data for validating or improving designs during the prototype stage or to obtain information on the performance and structural integrity of components in service. Techniques for embedding fiber optic sensors in metals, polymers, and ceramics have been investigated. Embedding optical fibers into metals is especially challenging because engineering alloys tend to exhibit high melting temperatures. In the present research an embedding sequence was developed capable of embedding fiber sensors into parts made of metal alloys with high melting temperatures. Fiber Bragg Grating (FBG) sensors were selected as the most promising sensor candidate. The embedded FBG sensors were characterized for temperature and strain measurements. The embedded FBG sensors in nickel and stainless steel provided high sensitivity, good accuracy, and high temperature capacity for temperature measurements. Temperature sensitivity approximately 100% higher than that of bare FBGs was demonstrated. For strain measurements, the sensors embedded in metal and polyurethane yielded high sensitivity, accuracy, and linearity. The sensitivity of the embedded FBGs was in good agreement with that of bare FBGs. Moreover, a decoupling technique for embedded FBG sensors was developed to separate temperature and strain effects. The embedded FBG sensors were used to monitor the accumulation of residual stresses during the laser- assisted Layered Manufacturing, to measure the strain field in layered materials, to measure pressure, and to monitor temperature and strain simultaneously. New techniques have been developed for temperature and strain measurements of rotating components with FBG sensors embedded or attached to the surface. Tunable laser diodes were incorporated into the sensing system for monitoring the Bragg grating wavelength

  20. Laser Additive Manufacturing of Gas Permeable Structures

    NASA Astrophysics Data System (ADS)

    Klahn, C.; Bechmann, F.; Hofmann, S.; Dinkel, M.; Emmelmann, C.

    Laser additive manufacturing offers a variety of new design possibilities. In mold making laser additive manufactured inserts with conformal cooling channels are already state of the art. Pneumatic ejectors for injection molds are a new application for laser additive manufacturing. The pneumatic ejectors require a durable gas permeable material. This material is produced by placing the scan vectors for the laser additive manufacturing process in a defined pattern. Trials with different plastics proofed the function and reliability of the pneumatic ejector concept in the injection molding cycle.

  1. Breaking Barriers in Polymer Additive Manufacturing

    SciTech Connect

    Love, Lonnie J; Duty, Chad E; Post, Brian K; Lind, Randall F; Lloyd, Peter D; Kunc, Vlastimil; Peter, William H; Blue, Craig A

    2015-01-01

    Additive Manufacturing (AM) enables the creation of complex structures directly from a computer-aided design (CAD). There are limitations that prevent the technology from realizing its full potential. AM has been criticized for being slow and expensive with limited build size. Oak Ridge National Laboratory (ORNL) has developed a large scale AM system that improves upon each of these areas by more than an order of magnitude. The Big Area Additive Manufacturing (BAAM) system directly converts low cost pellets into a large, three-dimensional part at a rate exceeding 25 kg/h. By breaking these traditional barriers, it is possible for polymer AM to penetrate new manufacturing markets.

  2. Effusion plate using additive manufacturing methods

    DOEpatents

    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.

  3. Energetic additive manufacturing process with feed wire

    SciTech Connect

    Harwell, Lane D.; Griffith, Michelle L.; Greene, Donald L.; Pressly, Gary A.

    2000-11-07

    A process for additive manufacture by energetic wire deposition is described. A source wire is fed into a energy beam generated melt-pool on a growth surface as the melt-pool moves over the growth surface. This process enables the rapid prototyping and manufacture of fully dense, near-net shape components, as well as cladding and welding processes. Alloys, graded materials, and other inhomogeneous materials can be grown using this process.

  4. Multiprocessing and Correction Algorithm of 3D-models for Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Anamova, R. R.; Zelenov, S. V.; Kuprikov, M. U.; Ripetskiy, A. V.

    2016-07-01

    This article addresses matters related to additive manufacturing preparation. A layer-by-layer model presentation was developed on the basis of a routing method. Methods for correction of errors in the layer-by-layer model presentation were developed. A multiprocessing algorithm for forming an additive manufacturing batch file was realized.

  5. Metrology Needs for Metal Additive Manufacturing Powders

    NASA Astrophysics Data System (ADS)

    Slotwinski, John A.; Garboczi, Edward J.

    2015-03-01

    Additive manufacturing (AM) processes can produce highly complex and customized parts without the need for dedicated tooling and can produce parts directly from the part design information. These types of processes are poised to revolutionize the manufacturing industry, yet several challenges are currently preventing more widespread adoption of AM technologies. Among these challenges are metrology issues associated with the measurement and characterization of the metal powders used for AM systems. This article will describe the technical challenges and needs for characterizing metal AM powders, recent research efforts to address those needs, and current work to standardize characterization methods in ASTM and ISO, such as the recently released ASTM F3049, Standard Guide for Characterizing Properties of Metal Powders Used for Additive Manufacturing Processes.

  6. Additive Manufacturing: From Rapid Prototyping to Flight

    NASA Technical Reports Server (NTRS)

    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.

  7. Additive manufacturing of materials: Opportunities and challenges

    DOE PAGESBeta

    Babu, Sudarsanam Suresh; Love, Lonnie J.; Dehoff, Ryan R.; Peter, William H.; Watkins, Thomas R.; Pannala, Sreekanth

    2015-11-01

    Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performancemore » computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.« less

  8. Additive manufacturing of materials: Opportunities and challenges

    SciTech Connect

    Babu, Sudarsanam Suresh; Love, Lonnie J.; Dehoff, Ryan R.; Peter, William H.; Watkins, Thomas R.; Pannala, Sreekanth

    2015-11-01

    Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performance computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.

  9. Computational Process Modeling for Additive Manufacturing

    NASA Technical Reports Server (NTRS)

    Bagg, Stacey; Zhang, Wei

    2014-01-01

    Computational Process and Material Modeling of Powder Bed additive manufacturing of IN 718. Optimize material build parameters with reduced time and cost through modeling. Increase understanding of build properties. Increase reliability of builds. Decrease time to adoption of process for critical hardware. Potential to decrease post-build heat treatments. Conduct single-track and coupon builds at various build parameters. Record build parameter information and QM Meltpool data. Refine Applied Optimization powder bed AM process model using data. Report thermal modeling results. Conduct metallography of build samples. Calibrate STK models using metallography findings. Run STK models using AO thermal profiles and report STK modeling results. Validate modeling with additional build. Photodiode Intensity measurements highly linear with power input. Melt Pool Intensity highly correlated to Melt Pool Size. Melt Pool size and intensity increase with power. Applied Optimization will use data to develop powder bed additive manufacturing process model.

  10. Inspection of additive manufactured parts using laser ultrasonics

    NASA Astrophysics Data System (ADS)

    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.

  11. Approaches to the manufacture of layered nanocomposites

    NASA Astrophysics Data System (ADS)

    Zhang, Yan; Evans, Julian R. G.

    2012-01-01

    Clay-polymer nanocomposites, resulting from industrial research, have emerged as a new class of material because a low addition of clay in a polymer matrix causes dramatic improvement in mechanical and barrier properties. They represent the low volume fraction (<4 vol.%) end of the composition range. The question now is: what will emerge from attempts to explore the high volume fraction (>60 vol.%) end? Naturally occurring materials, such as nacre, show that a combination of a high platelet content in a polymer with a layered structure is strong and tough (4-10 MPa m1/2), even if the reinforcement, aragonite in this case, is inherently brittle (∼1 MPa m1/2). This achievement of nature has inspired the synthesis of materials to mimic the nacre structure using high aspect ratio reinforcements of high elastic modulus such as smectite clay tactoids. Preliminary successes were based on layer-by-layer assembly methods and it will be interesting to find out whether sufficient order can be obtained in composites assembled by more rapid manufacturing pathways. We are interested in the factors affecting dispersion, orientation and intercalation of platelets and here we survey the strategies that have been adopted in order to create organized structures of layered nanocomposites.

  12. Femtosecond fiber laser additive manufacturing of tungsten

    NASA Astrophysics Data System (ADS)

    Bai, Shuang; Liu, Jian; Yang, Pei; Zhai, Meiyu; Huang, Huan; Yang, Lih-Mei

    2016-04-01

    Additive manufacturing (AM) is promising to produce complex shaped components, including metals and alloys, to meet requirements from different industries such as aerospace, defense and biomedicines. Current laser AM uses CW lasers and very few publications have been reported for using pulsed lasers (esp. ultrafast lasers). In this paper, additive manufacturing of Tungsten materials is investigated by 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. Fully dense Tungsten part with refined grain and increased hardness was obtained and compared with parts made with different pulse widths and CW laser. The results are evidenced that the fs laser based AM provides more dimensions to modify mechanical properties with controlled heating, rapid melting and cooling rates compared with a CW or long pulsed laser. This can greatly benefit to the make of complicated structures and materials that could not be achieved before.

  13. Additive manufacturing of polymer-derived ceramics.

    PubMed

    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. PMID:26721993

  14. Evolution of solidification texture during additive manufacturing

    PubMed Central

    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 <100> 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

  15. Evolution of solidification texture during additive manufacturing

    DOE PAGESBeta

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

    2015-11-10

    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 <100> preferred growth directions in face centered cubic alloys. Furthermore, 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 numericalmore » 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.« less

  16. Evolution of solidification texture during additive manufacturing

    SciTech Connect

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

    2015-11-10

    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 <100> preferred growth directions in face centered cubic alloys. Furthermore, 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.

  17. Additive manufacturing of polymer-derived ceramics

    NASA Astrophysics Data System (ADS)

    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.

  18. A new application for food customization with additive manufacturing technologies

    NASA Astrophysics Data System (ADS)

    Serenó, L.; Vallicrosa, G.; Delgado, J.; Ciurana, J.

    2012-04-01

    Additive Manufacturing (AM) technologies have emerged as a freeform approach capable of producing almost any complete three dimensional (3D) objects from computer-aided design (CAD) data by successively adding material layer by layer. Despite the broad range of possibilities, commercial AM technologies remain complex and expensive, making them suitable only for niche applications. The developments of the Fab@Home system as an open AM technology discovered a new range of possibilities of processing different materials such as edible products. The main objective of this work is to analyze and optimize the manufacturing capacity of this system when producing 3D edible objects. A new heated syringe deposition tool was developed and several process parameters were optimized to adapt this technology to consumers' needs. The results revealed in this study show the potential of this system to produce customized edible objects without qualified personnel knowledge, therefore saving manufacturing costs compared to traditional technologies.

  19. Printability of alloys for additive manufacturing

    DOE PAGESBeta

    Mukherjee, T.; Zuback, J. S.; De, A.; DebRoy, T.

    2016-01-22

    Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is usedmore » to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. Here, the findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts.« less

  20. Printability of alloys for additive manufacturing.

    PubMed

    Mukherjee, T; Zuback, J S; De, A; DebRoy, T

    2016-01-01

    Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is used to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. The findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts. PMID:26796864

  1. Printability of alloys for additive manufacturing

    PubMed Central

    Mukherjee, T.; Zuback, J. S.; De, A.; DebRoy, T.

    2016-01-01

    Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is used to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. The findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts. PMID:26796864

  2. Printability of alloys for additive manufacturing

    NASA Astrophysics Data System (ADS)

    Mukherjee, T.; Zuback, J. S.; de, A.; Debroy, T.

    2016-01-01

    Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is used to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. The findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts.

  3. Additive manufacturing: Overview and NDE challenges

    NASA Astrophysics Data System (ADS)

    Slotwinski, J. A.

    2014-02-01

    Additive manufacturing (AM) processes are capable of producing highly complex and customized parts, without the need for dedicated tooling, and can produce parts directly from the part design information. These types of processes are poised to revolutionize the manufacturing industry, yet there are several challenges that are currently preventing more widespread adoption of AM technologies. Traditional Non-Destructive Evaluation (NDE) methods could be utilized in both in-process and post-process applications to help overcome these challenges, although currently there are very few examples of in-situ sensors for monitoring AM processes. This paper gives an overview of AM technology, and discusses the potential benefits and challenges of using NDE in AM applications.

  4. Additive manufacturing of biologically-inspired materials.

    PubMed

    Studart, André R

    2016-01-21

    Additive manufacturing (AM) technologies offer an attractive pathway towards the fabrication of functional materials featuring complex heterogeneous architectures inspired by biological systems. In this paper, recent research on the use of AM approaches to program the local chemical composition, structure and properties of biologically-inspired materials is reviewed. A variety of structural motifs found in biological composites have been successfully emulated in synthetic systems using inkjet-based, direct-writing, stereolithography and slip casting technologies. The replication in synthetic systems of design principles underlying such structural motifs has enabled the fabrication of lightweight cellular materials, strong and tough composites, soft robots and autonomously shaping structures with unprecedented properties and functionalities. Pushing the current limits of AM technologies in future research should bring us closer to the manufacturing capabilities of living organisms, opening the way for the digital fabrication of advanced materials with superior performance, lower environmental impact and new functionalities. PMID:26750617

  5. Additive Manufacturing: Making Imagination the Major Limitation

    NASA Astrophysics Data System (ADS)

    Zhai, Yuwei; Lados, Diana A.; LaGoy, Jane L.

    2014-05-01

    Additive manufacturing (AM) refers to an advanced technology used for the fabrication of three-dimensional near-net-shaped functional components directly from computer models, using unit materials. The fundamentals and working principle of AM offer several advantages, including near-net-shape capabilities, superior design and geometrical flexibility, innovative multi-material fabrication, reduced tooling and fixturing, shorter cycle time for design and manufacturing, instant local production at a global scale, and material, energy, and cost efficiency. Well suiting the requests of modern manufacturing climate, AM is viewed as the new industrial revolution, making its way into a continuously increasing number of industries, such as aerospace, defense, automotive, medical, architecture, art, jewelry, and food. This overview was created to relate the historical evolution of the AM technology to its state-of-the-art developments and emerging applications. Generic thoughts on the microstructural characteristics, properties, and performance of AM-fabricated materials will also be discussed, primarily related to metallic materials. This write-up will introduce the general reader to specifics of the AM field vis-à-vis advantages and common techniques, materials and properties, current applications, and future opportunities.

  6. Laser Additive Manufacturing and Bionics: Redefining Lightweight Design

    NASA Astrophysics Data System (ADS)

    Emmelmann, C.; Sander, P.; Kranz, J.; Wycisk, E.

    New layer wise manufacturing technologies such as Laser Additive Manufacturing (LAM) allow innovative approaches to product design. Especially for lightweight design in aircraft applications LAM offers new possibilities for load-adapted structures. However, to fully capture lightweight potential of LAM technologies new design guidelines and processes have to be developed. A novel approach to extreme lightweight design is realized by incorporating structural optimization tools, bionic structures and LAM guidelines into one design process. By consequently following this design process designers can achieve lightweight savings in designing new aircraft structures.

  7. Mechanical properties of additively manufactured octagonal honeycombs.

    PubMed

    Hedayati, R; Sadighi, M; Mohammadi-Aghdam, M; Zadpoor, A A

    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. PMID:27612831

  8. Manipulation of microstructure in laser additive manufacturing

    NASA Astrophysics Data System (ADS)

    Bai, Shuang; Yang, Lihmei; Liu, Jian

    2016-05-01

    In this paper, additive manufacturing (AM) of tungsten parts is investigated by using femtosecond fiber lasers. For the first time, manipulating microstructures of AM parts is systematically investigated and reported. Various processing conditions are studied, which leads to desired characteristics in terms of morphology, porosity, hardness, and microstructural and mechanical properties of the processed components. Fully dense tungsten part with refined grain and increased hardness was obtained for femtosecond laser, compared with parts made with different pulse widths and CW laser. Micro-hardness is investigated for the fabricated samples. This can greatly benefit to the make of complicated structures and materials that could not be achieved before.

  9. 3D-additive manufactured optical mount

    NASA Astrophysics Data System (ADS)

    Mammini, Paul V.; Ciscel, David; Wooten, John

    2015-09-01

    The Area Defense Anti-Munitions (ADAM) is a low cost and effective high power laser weapon system. It's designed to address and negate important threats such as short-range rockets, UAVs, and small boats. Many critical optical components operate in the system. The optics and mounts must accommodate thermal and mechanical stresses, plus maintain an exceptional wave front during operation. Lockheed Martin Space Systems Company (LMSSC) developed, designed, and currently operates ADAM. This paper covers the design and development of a key monolithic, flexured, titanium mirror mount that was manufactured by CalRAM using additive processes.

  10. IN718 Additive Manufacturing Properties and Influences

    NASA Technical Reports Server (NTRS)

    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.

  11. IN718 Additive Manufacturing Properties and Influences

    NASA Technical Reports Server (NTRS)

    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.

  12. Microstructural Control of Additively Manufactured Metallic Materials

    NASA Astrophysics Data System (ADS)

    Collins, P. C.; Brice, D. A.; Samimi, P.; Ghamarian, I.; Fraser, H. L.

    2016-07-01

    In additively manufactured (AM) metallic materials, the fundamental interrelationships that exist between composition, processing, and microstructure govern these materials’ properties and potential improvements or reductions in performance. For example, by using AM, it is possible to achieve highly desirable microstructural features (e.g., highly refined precipitates) that could not otherwise be achieved by using conventional approaches. Simultaneously, opportunities exist to manage macro-level microstructural characteristics such as residual stress, porosity, and texture, the last of which might be desirable. To predictably realize optimal microstructures, it is necessary to establish a framework that integrates processing variables, alloy composition, and the resulting microstructure. Although such a framework is largely lacking for AM metallic materials, the basic scientific components of the framework exist in literature. This review considers these key components and presents them in a manner that highlights key interdependencies that would form an integrated framework to engineer microstructures using AM.

  13. Additively Manufactured Metals in Oxygen Systems Project

    NASA Technical Reports Server (NTRS)

    Tylka, Jonathan

    2015-01-01

    Metals produced by additive manufacturing methods, such as Powder Bed Fusion Technology, are now mature enough to be considered for qualification in human spaceflight oxygen systems. The mechanical properties of metals produced through AM processes are being systematically studied. However, it is unknown whether AM metals in oxygen applications may present an increased risk of flammability or ignition as compared to wrought metals of the same metallurgical composition due to increased porosity. Per NASA-STD-6001B materials to be used in oxygen system applications shall be based on flammability and combustion test data, followed by a flammability assessment. Without systematic flammability and ignition testing in oxygen there is no credible method for NASA to accurately evaluate the risk of using AM metals in oxygen systems.

  14. The metallurgy and processing science of metal additive manufacturing

    SciTech Connect

    Sames, William J.; List, III, Frederick Alyious; Pannala, Sreekanth; Dehoff, Ryan R.; Babu, Sudarsanam Suresh

    2016-01-01

    Here, 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 (using many different names) have been developed to accomplish this via melting or solid - state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid- state precipitation, mechanical properties, and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Few alloys have been developed for commercial production, but recent development efforts are presented as a path for the ongoing development of new materials for AM processes.

  15. Multiscale Modeling of Powder Bed–Based Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Markl, Matthias; Körner, Carolin

    2016-07-01

    Powder bed fusion processes are additive manufacturing technologies that are expected to induce the third industrial revolution. Components are built up layer by layer in a powder bed by selectively melting confined areas, according to sliced 3D model data. This technique allows for manufacturing of highly complex geometries hardly machinable with conventional technologies. However, the underlying physical phenomena are sparsely understood and difficult to observe during processing. Therefore, an intensive and expensive trial-and-error principle is applied to produce components with the desired dimensional accuracy, material characteristics, and mechanical properties. This review presents numerical modeling approaches on multiple length scales and timescales to describe different aspects of powder bed fusion processes. In combination with tailored experiments, the numerical results enlarge the process understanding of the underlying physical mechanisms and support the development of suitable process strategies and component topologies.

  16. The metallurgy and processing science of metal additive manufacturing

    DOE PAGESBeta

    Sames, William J.; List, III, Frederick Alyious; Pannala, Sreekanth; Dehoff, Ryan R.; Babu, Sudarsanam Suresh

    2016-03-07

    Here, 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 (using many different names) have been developed to accomplish this via melting or solid - state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid- state precipitation, mechanical properties, and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Few alloys have been developedmore » for commercial production, but recent development efforts are presented as a path for the ongoing development of new materials for AM processes.« less

  17. Monitoring system for the quality assessment in additive manufacturing

    NASA Astrophysics Data System (ADS)

    Carl, Volker

    2015-03-01

    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

  18. Monitoring system for the quality assessment in additive manufacturing

    SciTech Connect

    Carl, Volker

    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

  19. Additive Manufacturing: Ensuring Quality for Spacecraft Applications

    NASA Technical Reports Server (NTRS)

    Swanson, Theodore; Stephenson, Timothy

    2014-01-01

    Reliable manufacturing requires that material properties and fabrication processes be well defined in order to insure that the manufactured parts meet specified requirements. While this issue is now relatively straightforward for traditional processes such as subtractive manufacturing and injection molding, this capability is still evolving for AM products. Hence, one of the principal challenges within AM is in qualifying and verifying source material properties and process control. This issue is particularly critical for applications in harsh environments and demanding applications, such as spacecraft.

  20. Cost Estimation of Laser Additive Manufacturing of Stainless Steel

    NASA Astrophysics Data System (ADS)

    Piili, Heidi; Happonen, Ari; Väistö, Tapio; Venkataramanan, Vijaikrishnan; Partanen, Jouni; Salminen, Antti

    Laser additive manufacturing (LAM) is a layer wise fabrication method in which a laser beam melts metallic powder to form solid objects. Although 3D printing has been invented 30 years ago, the industrial use is quite limited whereas the introduction of cheap consumer 3D printers, in recent years, has familiarized the 3D printing. Interest is focused more and more in manufacturing of functional parts. Aim of this study is to define and discuss the current economic opportunities and restrictions of LAM process. Manufacturing costs were studied with different build scenarios each with estimated cost structure by calculated build time and calculating the costs of the machine, material and energy with optimized machine utilization. All manufacturing and time simulations in this study were carried out with a research machine equal to commercial EOS M series equipment. The study shows that the main expense in LAM is the investment cost of the LAM machine, compared to which the relative proportions of the energy and material costs are very low. The manufacturing time per part is the key factor to optimize costs of LAM.

  1. The Importance of Carbon Fiber to Polymer Additive Manufacturing

    SciTech Connect

    Love, Lonnie J; Kunc, Vlastimil; Rios, Orlando; Duty, Chad E; Post, Brian K; Blue, Craig A

    2014-01-01

    Additive manufacturing holds tremendous promise in terms of revolutionizing manufacturing. However, fundamental hurdles limit mass adoption of the technology. First, production rates are extremely low. Second, the physical size of parts is generally small, less than a cubic foot. Third, while there is much excitement about metal additive manufacturing, the major growth area is in polymer additive manufacturing systems. Unfortunately, the mechanical properties of the polymer parts are poor, limiting the potential for direct part replacement. To address this issue, we describe three benefits of blending carbon fiber with polymer additive manufacturing. First, development of carbon fiber reinforced polymers for additive manufacturing achieves specific strengths approaching aerospace quality aluminum. Second, carbon fiber radically changes the behavior of the material during deposition, enabling large scale, out-of-the-oven, high deposition rate manufacturing. Finally, carbon fiber technology and additive manufacturing complement each other. Merging the two manufacturing processes enables the construction of complex components that would not be possible otherwise.

  2. Structure Property Studies for Additively Manufactured Parts

    SciTech Connect

    Milenski, Helen M; Schmalzer, Andrew Michael; Kelly, Daniel

    2015-08-17

    Since the invention of modern Additive Manufacturing (AM) processes engineers and designers have worked hard to capitalize on the unique building capabilities that AM allows. By being able to customize the interior fill of parts it is now possible to design components with a controlled density and customized internal structure. The creation of new polymers and polymer composites allow for even greater control over the mechanical properties of AM parts. One of the key reasons to explore AM, is to bring about a new paradigm in part design, where materials can be strategically optimized in a way that conventional subtractive methods cannot achieve. The two processes investigated in my research were the Fused Deposition Modeling (FDM) process and the Direct Ink Write (DIW) process. The objectives of the research were to determine the impact of in-fill density and morphology on the mechanical properties of FDM parts, and to determine if DIW printed samples could be produced where the filament diameter was varied while the overall density remained constant.

  3. Additive Manufacturing of Ultem Polymers and Composites

    NASA Technical Reports Server (NTRS)

    Chuang, Kathy C.; Grady, Joseph E.; Draper, Robert D.; Shin, Euy-Sik E.; Patterson, Clark; Santelle, Thomas D.

    2015-01-01

    The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimdes Ultem 9085 and experimental Ultem 1000 filled 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 25-31. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties.

  4. Elastic constants of Ultrasonic Additive Manufactured Al 3003-H18.

    PubMed

    Foster, D R; Dapino, M J; Babu, S S

    2013-01-01

    Ultrasonic Additive Manufacturing (UAM), also known as Ultrasonic Consolidation (UC), is a layered manufacturing process in which thin metal foils are ultrasonically bonded to a previously bonded foil substrate to create a net part. Optimization of process variables (amplitude, normal load and velocity) is done to minimize voids along the bonded interfaces. This work pertains to the evaluation of bonds in UAM builds through ultrasonic testing of a build's elastic constants. Results from ultrasonic testing on UAM parts indicate orthotropic material symmetry and a reduction of up to 48% in elastic constant values compared to a control sample. The reduction in elastic constant values is attributed to interfacial voids. In addition, the elastic constants in the plane of the Al foils have nearly the same value, while the constants normal to the foil direction have much different values. In contrast, measurements from builds made with Very High Power Ultrasonic Additive Manufacturing (VHP UAM) show a drastic improvement in elastic properties, approaching values similar to that of bulk aluminum. PMID:22939821

  5. Additive Manufacturing of High-Entropy Alloys by Laser Processing

    NASA Astrophysics Data System (ADS)

    Ocelík, V.; Janssen, N.; Smith, S. N.; De Hosson, J. Th. M.

    2016-07-01

    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 different amounts of aluminum prepared by arc melting were investigated and compared with the laser beam remelted HEAs with the same composition. Attempts to form HEAs coatings with a direct laser deposition from the mixture of elemental powders were made for AlCoCrFeNi and AlCrFeNiTa composition. A strong influence of solidification rate on the amounts of face-centered cubic and body-centered cubic phase, their chemical composition, and spatial distribution was detected for two-phase AlCoCrFeNi HEAs. It is concluded that a high-power laser is a versatile tool to synthesize interesting HEAs with additive manufacturing processing. Critical issues are related to the rate of (re)solidification, the dilution with the substrate, powder efficiency during cladding, and differences in melting points of clad powders making additive manufacturing processing from a simple mixture of elemental powders a challenging approach.

  6. Additive Manufacturing of High-Entropy Alloys by Laser Processing

    NASA Astrophysics Data System (ADS)

    Ocelík, V.; Janssen, N.; Smith, S. N.; De Hosson, J. Th. M.

    2016-04-01

    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 different amounts of aluminum prepared by arc melting were investigated and compared with the laser beam remelted HEAs with the same composition. Attempts to form HEAs coatings with a direct laser deposition from the mixture of elemental powders were made for AlCoCrFeNi and AlCrFeNiTa composition. A strong influence of solidification rate on the amounts of face-centered cubic and body-centered cubic phase, their chemical composition, and spatial distribution was detected for two-phase AlCoCrFeNi HEAs. It is concluded that a high-power laser is a versatile tool to synthesize interesting HEAs with additive manufacturing processing. Critical issues are related to the rate of (re)solidification, the dilution with the substrate, powder efficiency during cladding, and differences in melting points of clad powders making additive manufacturing processing from a simple mixture of elemental powders a challenging approach.

  7. Fabricating specialised orthopaedic implants using additive manufacturing

    NASA Astrophysics Data System (ADS)

    Unwin, Paul

    2014-03-01

    It has been hypothesised that AM is ideal for patient specific orthopaedic implants such as those used in bone cancer treatment, that can rapidly build structures such as lattices for bone and tissues to in-grow, that would be impossible using current conventional subtractive manufacturing techniques. The aim of this study was to describe the adoption of AM (direct metal laser sintering and electron beam melting) into the design manufacturing and post-manufacturing processes and the early clinical use. Prior to the clinical use of AM implants, extensive metallurgical and mechanical testing of both laser and electron beam fabrications were undertaken. Concurrently, post-manufacturing processes evaluated included hipping, cleaning and coating treatments. The first clinical application of a titanium alloy mega-implant was undertaken in November 2010. A 3D model of the pelvic wing implant was designed from CT scans. Novel key features included extensive lattice structures at the bone interfaces and integral flanges to fix the implant to the bone. The pelvic device was implanted with the aid of navigation and to date the patient remains active. A further 18 patient specific mega-implants have now been implanted. The early use of this advanced manufacturing route for patient specific implants has been very encouraging enabling the engineer to produce more advanced and anatomical conforming implants. However, there are a new set of design, manufacturing and regulatory challenges that require addressing to permit this technique to be used more widely. This technology is changing the design and manufacturing paradigm for the fabrication of specialised orthopaedic implants.

  8. Anomaly Detection In Additively Manufactured Parts Using Laser Doppler Vibrometery

    SciTech Connect

    Hernandez, Carlos A.

    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.

  9. Additive manufacturing techniques for the production of tissue engineering constructs.

    PubMed

    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. PMID:23172792

  10. Additive Manufacturing a Liquid Hydrogen Rocket Engine

    NASA Technical Reports Server (NTRS)

    Jones, Carl P.; Robertson, Elizabeth H.; Koelbl, Mary Beth; Singer, Chris

    2016-01-01

    Space Propulsion is a 5 day event being held from 2nd May to the 6th May 2016 at the Rome Marriott Park Hotel in Rome, Italy. This event showcases products like Propulsion sub-systems and components, Production and manufacturing issues, Liquid, Solid, Hybrid and Air-breathing Propulsion Systems for Launcher and Upper Stages, Overview of current programmes, AIV issues and tools, Flight testing and experience, Technology building blocks for Future Space Transportation Propulsion Systems : Launchers, Exploration platforms & Space Tourism, Green Propulsion for Space Transportation, New propellants, Rocket propulsion & global environment, Cost related aspects of Space Transportation propulsion, Modelling, Pressure-Thrust oscillations issues, Impact of new requirements and regulations on design etc. in the Automotive, Manufacturing, Fabrication, Repair & Maintenance industries.

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

    NASA Technical Reports Server (NTRS)

    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.

  12. Composite Layer Manufacturing with Fewer Interruptions

    NASA Technical Reports Server (NTRS)

    Jang, Bor Z.; Liu, Junhai; Chen, Shizu

    2009-01-01

    An improved version of composite layer manufacturing (CLM) has been invented. CLM is a type of solid freeform fabrication (SFF) -- an automated process in which a three-dimensional object is built up, point-by-point, through extrusion of a matrix/fiber composite-material precursor. In CLM, the translation and the extrusion operation are such that the final size and shape of the fabricated object are as specified by a computer-aided design (CAD). Sometimes, in order to achieve the desired final shape,

  13. The Application of Powder Rheology in Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Clayton, Jamie; Millington-Smith, Doug; Armstrong, Brian

    2015-03-01

    Additive manufacturing (AM) is sensitive to powder variability when applying fine layers in a uniform manner. This demands a high degree of consistency and repeatability in the feedstock. Particle size is often used as a critical quality attribute, but this is not sufficient to fully qualify a feedstock. Indeed, it is inadequate to suggest that any parameter from a single test, e.g., Hall flowmeter or Hausner ratio, can comprehensively describe a powder's characteristics. This article uses four case studies to demonstrate the limitations of single parameter characterization and how the rheological properties of several metal powders used in AM applications are used to establish in-process performance. In the first study, the significantly reduced permeability and increased specific energy of a one batch of powder demonstrate a clear link to poor layer uniformity. The second study investigates the impact of metal powder manufacturing methods and suppliers, and it shows how shear properties alone cannot be relied on to identify properties that influence the process. The effect of additives on the processability of polymer blends used in AM is also evaluated, and the results show that even small quantities can have a significant effect on the permeability and basic flowability energy of feedstocks. The final study demonstrates the how rheological measurements can be used to identify the optimum blend of fresh and used material when reusing metal powders to manufacture components. These case studies illustrate the ability of a modern powder rheometer to detect minor variations in powders that are directly relevant to performance in AM processes in a way that traditional characterization methods cannot.

  14. NASA OSMA NDE Program Additive Manufacturing Foundational Effort

    NASA Technical Reports Server (NTRS)

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

    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.

  15. Overview of additive manufacturing activities at MTU aero engines

    NASA Astrophysics Data System (ADS)

    Bamberg, Joachim; Dusel, Karl-Heinz; Satzger, Wilhelm

    2015-03-01

    Additive Manufacturing (AM) is a promising technology to produce parts easily and effectively, just by using metallic powder or wire as starting material and a sophisticated melting process. In contrast to milling or turning technologies complex shaped and hollow parts can be built up in one step. That reduces the production costs and allows the implementation of complete new 3D designs. Therefore AM is also of great interest for aerospace and aero engine industry. MTU Aero Engines has focused its AM activities to the selective laser melting technique (SLM). This technique uses metallic powder and a laser for melting and building up the part layer by layer. It is shown which lead part was selected for AM and how the first production line was established. A special focus is set on the quality assurance of the selective laser melting process. In addition to standard non-destructive inspection techniques a new online monitoring tool was developed and integrated into the SLM machines. The basics of this technique is presented.

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

    SciTech Connect

    Love, Lonnie J.

    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.

  17. UTILITY OF BIG AREA ADDITIVE MANUFACTURING (BAAM) FOR THE RAPID MANUFACTURE OF CUSTOMIZED ELECTRIC VEHICLES

    SciTech Connect

    Love, Lonnie J

    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 1was 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.

  18. Applications of Metal Additive Manufacturing in Veterinary Orthopedic Surgery

    NASA Astrophysics Data System (ADS)

    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.

  19. Epitaxy and Microstructure Evolution in Metal Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Basak, Amrita; Das, Suman

    2016-07-01

    Metal additive manufacturing (AM) works on the principle of incremental layer-by-layer material consolidation, facilitating the fabrication of objects of arbitrary complexity through the controlled melting and resolidification of feedstock materials by using high-power energy sources. The focus of metal AM is to produce complex-shaped components made of metals and alloys to meet demands from various industrial sectors such as defense, aerospace, automotive, and biomedicine. Metal AM involves a complex interplay between multiple modes of energy and mass transfer, fluid flow, phase change, and microstructural evolution. Understanding the fundamental physics of these phenomena is a key requirement for metal AM process development and optimization. The effects of material characteristics and processing conditions on the resulting epitaxy and microstructure are of critical interest in metal AM. This article reviews various metal AM processes in the context of fabricating metal and alloy parts through epitaxial solidification, with material systems ranging from pure-metal and prealloyed to multicomponent materials. The aim is to cover the relationships between various AM processes and the resulting microstructures in these material systems.

  20. Computed Tomography Inspection and Analysis for Additive Manufacturing Components

    NASA Technical Reports Server (NTRS)

    Beshears, Ronald D.

    2016-01-01

    Computed tomography (CT) inspection was performed on test articles additively manufactured from metallic materials. Metallic AM and machined wrought alloy test articles with programmed flaws were inspected using a 2MeV linear accelerator based CT system. Performance of CT inspection on identically configured wrought and AM components and programmed flaws was assessed using standard image analysis techniques to determine the impact of additive manufacturing on inspectability of objects with complex geometries.

  1. Fabrication of Turbine Disk Materials by Additive Manufacturing

    NASA Technical Reports Server (NTRS)

    Sudbrack, Chantal; Bean, Quincy A.; Cooper, Ken; Carter, Robert; Semiatin, S. Lee; Gabb, Tim

    2014-01-01

    Precipitation-strengthened, nickel-based superalloys are widely used in the aerospace and energy industries due to their excellent environmental resistance and outstanding mechanical properties under extreme conditions. Powder-bed additive manufacturing (AM) technologies offer the potential to revolutionize the processing of superalloy turbine components by eliminating the need for extensive inventory or expensive legacy tooling. Like selective laser melting (SLM), electron beam melting (EBM) constructs three-dimensional dense components layer-by-layer by melting and solidification of atomized, pre-alloyed powder feedstock within 50-200 micron layers. While SLM has been more widely used for AM of nickel alloys like 718, EBM offers several distinct advantages, such as less retained residual stress, lower risk of contamination, and faster build rates with multiple-electron-beam configurations. These advantages are particularly attractive for turbine disks, for which excessive residual stress and contamination can shorten disk life during high-temperature operation. In this presentation, we will discuss the feasibility of fabricating disk superalloy components using EBM AM. Originally developed using powder metallurgy forging processing, disk superalloys contain a higher refractory content and precipitate volume fraction than alloy 718, thus making them more prone to thermal cracking during AM. This and other challenges to produce homogeneous builds with desired properties will be presented. In particular, the quality of lab-scale samples fabricated via a design of experiments, in which the beam current, build temperature, and beam velocity were varied, will be summarized. The relationship between processing parameters, microstructure, grain orientation, and mechanical response will be discussed.

  2. The design of impact absorbing structures for additive manufacture

    NASA Astrophysics Data System (ADS)

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

    2012-08-01

    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.

  3. Cleaning Process Development for Metallic Additively Manufactured Parts

    NASA Technical Reports Server (NTRS)

    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.

  4. Thermodynamically consistent microstructure prediction of additively manufactured materials

    NASA Astrophysics Data System (ADS)

    Smith, Jacob; Xiong, Wei; Cao, Jian; Liu, Wing Kam

    2016-03-01

    Additive manufacturing has risen to the top of research interest in advanced manufacturing in recent years due to process flexibility, achievability of geometric complexity, and the ability to locally modify and optimize materials. The present work is focused on providing an approach for incorporating thermodynamically consistent properties and microstructure evolution for non-equilibrium supercooling, as observed in additive manufacturing processes, into finite element analysis. There are two primary benefits of this work: (1) the resulting prediction is based on the material composition and (2) the nonlinear behavior caused by the thermodynamic properties of the material during the non-equilibrium solution is accounted for with extremely high resolution. The predicted temperature response and microstructure evolution for additively manufactured stainless steel 316L using standard handbook-obtained thermodynamic properties are compared with the thermodynamic properties calculated using the CALculation of PHAse Diagrams (CALPHAD) approach. Data transfer from the CALPHAD approach to finite element analysis is discussed.

  5. Friction Stir Additive Manufacturing: Route to High Structural Performance

    NASA Astrophysics Data System (ADS)

    Palanivel, S.; Sidhar, H.; Mishra, R. S.

    2015-03-01

    Aerospace and automotive industries provide the next big opportunities for additive manufacturing. Currently, the additive industry is confronted with four major challenges that have been identified in this article. These challenges need to be addressed for the additive technologies to march into new frontiers and create additional markets. Specific potential success in the transportation sectors is dependent on the ability to manufacture complicated structures with high performance. Most of the techniques used for metal-based additive manufacturing are fusion based because of their ability to fulfill the computer-aided design to component vision. Although these techniques aid in fabrication of complex shapes, achieving high structural performance is a key problem due to the liquid-solid phase transformation. In this article, friction stir additive manufacturing (FSAM) is shown as a potential solid-state process for attaining high-performance lightweight alloys for simpler geometrical applications. To illustrate FSAM as a high-performance route, manufactured builds of Mg-4Y-3Nd and AA5083 are shown as examples. In the Mg-based alloy, an average hardness of 120 HV was achieved in the built structure and was significantly higher than that of the base material (97 HV). Similarly for the Al-based alloy, compared with the base hardness of 88 HV, the average built hardness was 104 HV. A potential application of FSAM is illustrated by taking an example of a simple stiffener assembly.

  6. Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

    NASA Technical Reports Server (NTRS)

    O'Neal, 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. The near-net shape DMLS parts have been delivered and final machining is underway. Fabrication of the traditionally manufactured hardware is also proceeding. Testing in liquid oxygen is planned for Q2 of FY2017. This topic explores the design of the turbopump along with fabrication and material testing of the DMLS hardware.

  7. Ceramic Stereolithography: Additive Manufacturing for Ceramics by Photopolymerization

    NASA Astrophysics Data System (ADS)

    Halloran, John W.

    2016-07-01

    Ceramic stereolithography and related additive manufacturing methods involving photopolymerization of ceramic powder suspensions are reviewed in terms of the capabilities of current devices. The practical fundamentals of the cure depth, cure width, and cure profile are related to the optical properties of the monomer, ceramic, and photo-active components. Postpolymerization steps, including harvesting and cleaning the objects, binder burnout, and sintering, are discussed and compared with conventional methods. The prospects for practical manufacturing are discussed.

  8. Evaluation of Additive Manufacturing for Composite Part Molds

    SciTech Connect

    Duty, Chad E.; Springfield, Robert M.

    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.

  9. Embracing additive manufacture: implications for foot and ankle orthosis design

    PubMed Central

    2012-01-01

    Background The design of foot and ankle orthoses is currently limited by the methods used to fabricate the devices, particularly in terms of geometric freedom and potential to include innovative new features. Additive manufacturing (AM) technologies, where objects are constructed via a series of sub-millimetre layers of a substrate material, may present the opportunity to overcome these limitations and allow novel devices to be produced that are highly personalised for the individual, both in terms of fit and functionality. Two novel devices, a foot orthosis (FO) designed to include adjustable elements to relieve pressure at the metatarsal heads, and an ankle foot orthosis (AFO) designed to have adjustable stiffness levels in the sagittal plane, were developed and fabricated using AM. The devices were then tested on a healthy participant to determine if the intended biomechanical modes of action were achieved. Results The adjustable, pressure relieving FO was found to be able to significantly reduce pressure under the targeted metatarsal heads. The AFO was shown to have distinct effects on ankle kinematics which could be varied by adjusting the stiffness level of the device. Conclusions The results presented here demonstrate the potential design freedom made available by AM, and suggest that it may allow novel personalised orthotic devices to be produced which are beyond the current state of the art. PMID:22642941

  10. Additive Manufacturing Design Considerations for Liquid Engine Components

    NASA Technical Reports Server (NTRS)

    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.

  11. Material Characterization of Additively Manufactured Components for Rocket Propulsion

    NASA Technical Reports Server (NTRS)

    Carter, Robert; Draper, Susan; Locci, Ivan; Lerch, Bradley; Ellis, David; Senick, Paul; Meyer, Michael; Free, James; Cooper, Ken; Jones, Zachary

    2015-01-01

    To advance Additive Manufacturing (AM) technologies for production of rocket propulsion components the NASA Glenn Research Center (GRC) is applying state of the art characterization techniques to interrogate microstructure and mechanical properties of AM materials and components at various steps in their processing. The materials being investigated for upper stage rocket engines include titanium, copper, and nickel alloys. Additive manufacturing processes include laser powder bed, electron beam powder bed, and electron beam wire fed processes. Various post build thermal treatments, including Hot Isostatic Pressure (HIP), have been studied to understand their influence on microstructure, mechanical properties, and build density. Micro-computed tomography, electron microscopy, and mechanical testing in relevant temperature environments has been performed to develop relationships between build quality, microstructure, and mechanical performance at temperature. A summary of GRCs Additive Manufacturing roles and experimental findings will be presented.

  12. Materials Characterization of Additively Manufactured Components for Rocket Propulsion

    NASA Technical Reports Server (NTRS)

    Carter, Robert; Draper, Susan; Locci, Ivan; Lerch, Bradley; Ellis, David; Senick, Paul; Meyer, Michael; Free, James; Cooper, Ken; Jones, Zachary

    2015-01-01

    To advance Additive Manufacturing (AM) technologies for production of rocket propulsion components the NASA Glenn Research Center (GRC) is applying state of the art characterization techniques to interrogate microstructure and mechanical properties of AM materials and components at various steps in their processing. The materials being investigated for upper stage rocket engines include titanium, copper, and nickel alloys. Additive manufacturing processes include laser powder bed, electron beam powder bed, and electron beam wire fed processes. Various post build thermal treatments, including Hot Isostatic Pressure (HIP), have been studied to understand their influence on microstructure, mechanical properties, and build density. Micro-computed tomography, electron microscopy, and mechanical testing in relevant temperature environments has been performed to develop relationships between build quality, microstructure, and mechanical performance at temperature. A summary of GRC's Additive Manufacturing roles and experimental findings will be presented.

  13. Femtosecond laser additive manufacturing of iron and tungsten parts

    NASA Astrophysics Data System (ADS)

    Nie, Bai; Yang, Lihmei; Huang, Huan; Bai, Shuang; Wan, Peng; Liu, Jian

    2015-06-01

    For the first time, femtosecond laser additive manufacturing is demonstrated. Pure iron and tungsten powders, having very different melting temperature and mechanical properties, are used for the demonstration. Parts with various shapes, such as ring and cube, are fabricated. Micro-hardness and ultimate tensile strength are investigated for the fabricated samples. The results are also compared to the similar parts made by a continuous-wave laser. It is found that fs laser additive manufacturing can obtain better mechanical properties and fabricate materials that are not possible before.

  14. Additive manufacturing method for SRF components of various geometries

    DOEpatents

    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.

  15. Additive Manufacturing of Metal Cellular Structures: Design and Fabrication

    NASA Astrophysics Data System (ADS)

    Yang, Li; Harrysson, Ola; Cormier, Denis; West, Harvey; Gong, Haijun; Stucker, Brent

    2015-03-01

    With the rapid development of additive manufacturing (AM), high-quality fabrication of lightweight design-efficient structures no longer poses an insurmountable challenge. On the other hand, much of the current research and development with AM technologies still focuses on material and process development. With the design for additive manufacturing in mind, this article explores the design issue for lightweight cellular structures that could be efficiently realized via AM processes. A unit-cell-based modeling approach that combines experimentation and limited-scale simulation was demonstrated, and it was suggested that this approach could potentially lead to computationally efficient design optimizations with the lightweight structures in future applications.

  16. Additive Manufacturing of Low Cost Upper Stage Propulsion Components

    NASA Technical Reports Server (NTRS)

    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.

  17. Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing

    NASA Technical Reports Server (NTRS)

    Hofmann, Douglas C.; Borgonia, John Paul C.; Dillon, Robert P.; Suh, Eric J.; Mulder, jerry L.; Gardner, Paul B.

    2013-01-01

    Recently, additive manufacturing (AM) techniques have been developed that may shift the paradigm of traditional metal production by allowing complex net-shaped hardware to be built up layer-by-layer, rather than being machined from a billet. The AM process is ubiquitous with polymers due to their low melting temperatures, fast curing, and controllable viscosity, and 3D printers are widely available as commercial or consumer products. 3D printing with metals is inherently more complicated than with polymers due to their higher melting temperatures and reactivity with air, particularly when heated or molten. The process generally requires a high-power laser or other focused heat source, like an electron beam, for precise melting and deposition. Several promising metal AM techniques have been developed, including laser deposition (also called laser engineered net shaping or LENS® and laser deposition technology (LDT)), direct metal laser sintering (DMLS), and electron beam free-form (EBF). These machines typically use powders or wire feedstock that are melted and deposited using a laser or electron beam. Complex net-shape parts have been widely demonstrated using these (and other) AM techniques and the process appears to be a promising alternative to machining in some cases. Rather than simply competing with traditional machining for cost and time savings, the true advantage of AM involves the fabrication of hardware that cannot be produced using other techniques. This could include parts with "blind" features (like foams or trusses), parts that are difficult to machine conventionally, or parts made from materials that do not exist in bulk forms. In this work, the inventors identify that several AM techniques can be used to develop metal parts that change composition from one location in the part to another, allowing for complete control over the mechanical or physical properties. This changes the paradigm for conventional metal fabrication, which relies on an

  18. Characterization of Metal Powders Used for Additive Manufacturing

    PubMed Central

    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

  19. A Modular Aerospike Engine Design Using Additive Manufacturing

    NASA Technical Reports Server (NTRS)

    Peugeot, John; Garcia, Chance; Burkhardt, Wendel

    2014-01-01

    A modular aerospike engine concept has been developed with the objective of demonstrating the viability of the aerospike design using additive manufacturing techniques. The aerospike system is a self-compensating design that allows for optimal performance over the entire flight regime and allows for the lowest possible mass vehicle designs. At low altitudes, improvements in Isp can be traded against chamber pressure, staging, and payload. In upper stage applications, expansion ratio and engine envelope can be traded against nozzle efficiency. These features provide flexibility to the System Designer optimizing a complete vehicle stage. The aerospike concept is a good example of a component that has demonstrated improved performance capability, but traditionally has manufacturing requirements that are too expensive and complex to use in a production vehicle. In recent years, additive manufacturing has emerged as a potential method for improving the speed and cost of building geometrically complex components in rocket engines. It offers a reduction in tooling overhead and significant improvements in the integration of the designer and manufacturing method. In addition, the modularity of the engine design provides the ability to perform full scale testing on the combustion devices outside of the full engine configuration. The proposed design uses a hydrocarbon based gas-generator cycle, with plans to take advantage of existing powerhead hardware while focusing DDT&E resources on manufacturing and sub-system testing of the combustion devices. The major risks for the modular aerospike concept lie in the performance of the propellant feed system, the structural integrity of the additive manufactured components, and the aerodynamic efficiency of the exhaust flow.

  20. Sustainability issues in laser-based additive manufacturing

    NASA Astrophysics Data System (ADS)

    Sreenivasan, R.; Goel, A.; Bourell, D. L.

    Sustainability is a consideration of resource utilization without depletion or adverse environmental impact. In manufacturing, important sustainability issues include energy consumption, waste generation, water usage and the environmental impact of the manufactured part in service. This paper deals with three aspects of sustainability as it applies to additive manufacturing. First is a review of the research needs for energy and sustainability as applied to additive manufacturing based on the 2009 Roadmap for Additive Manufacturing Workshop. The second part is an energy assessment for selective laser sintering (SLS) of polymers. Using polyamide powder in a 3D Systems Vanguard HiQ Sinterstation, energy loss during a build was measured due to the chamber heaters, the roller mechanism, the piston elevators and the laser. This accounted for 95% of the total energy consumption. An overall energy assessment was accomplished using eco-indicators. The last topic is electrochemical deposition of porous SLS non-polymeric preforms. The goal is to reduce energy consumption in SLS of non-polymeric materials. The approach was to mix a transient binder with the material, to create an SLS green part, to convert the binder, and then to remove the open, connected porosity and to densify the part by chemical deposition at room temperature within the pore network. The model system was silicon carbide powder mixed with a phenolic transient binder coupled with electrolytic deposition of nickel. Deposition was facilitated by inserting a conductive graphite cathode in the part center to draw the positive nickel ions through the interconnected porous network and to deposit them on the pore walls. The Roadmap for Additive Manufacturing Workshop was sponsored by the National Science Foundation under Grant CMMI-0906212 and by the Office of Naval Research under Grant N00014-09-1-0558. The electrolytic deposition research was sponsored by the National Science Foundation, Grant CMMI-0926316.

  1. Additive Manufacturing in Production: A Study Case Applying Technical Requirements

    NASA Astrophysics Data System (ADS)

    Ituarte, Iñigo Flores; Coatanea, Eric; Salmi, Mika; Tuomi, Jukka; Partanen, Jouni

    Additive manufacturing (AM) is expanding the manufacturing capabilities. However, quality of AM produced parts is dependent on a number of machine, geometry and process parameters. The variability of these parameters affects the manufacturing drastically and therefore standardized processes and harmonized methodologies need to be developed to characterize the technology for end use applications and enable the technology for manufacturing. This research proposes a composite methodology integrating Taguchi Design of Experiments, multi-objective optimization and statistical process control, to optimize the manufacturing process and fulfil multiple requirements imposed to an arbitrary geometry. The proposed methodology aims to characterize AM technology depending upon manufacturing process variables as well as to perform a comparative assessment of three AM technologies (Selective Laser Sintering, Laser Stereolithography and Polyjet). Results indicate that only one machine, laser-based Stereolithography, was feasible to fulfil simultaneously macro and micro level geometrical requirements but mechanical properties were not at required level. Future research will study a single AM system at the time to characterize AM machine technical capabilities and stimulate pre-normative initiatives of the technology for end use applications.

  2. Additive manufacturing of stretchable tactile sensors: Processes, materials, and applications

    NASA Astrophysics Data System (ADS)

    Vatani, Morteza

    3D printing technology is becoming more ubiquitous every day especially in the area of smart structures. However, fabrication of multi-material, functional, and smart structures is problematic because of the process and material limitations. This thesis sought to develop a Direct Print Photopolymerization (DPP) fabrication technique that appreciably extends the manufacturing space for the 3D smart structures. This method employs a robotically controlled micro-extrusion of a filament equipped with a photopolymerization process. The ability to use polymers and ultimately their nanocomposites in this process is the advantage of the proposed process over the current fabrication methods in the fabrication of 3D structures featuring mechanical, physical, and electrical functionalities. In addition, this study focused to develop a printable, conductive, and stretchable nanocomposite based on a photocurable and stretchable liquid resin filled with multi-walled carbon nanotubes (MWNTs). This nanocomposite exhibited piezoresistivity, means its resistivity changes as it deforms. This property is a favorable factor in developing resistance based tactile sensors. They were also able to resist high tensile strains while they showed conductivity. Furthermore, this study offered a possible and low-cost method to have a unique and highly stretchable pressure sensitive polymer. This disruptive pressure sensitive polymer composed of an Ionic Liquid (IL) and a stretchable photopolymer embedded between two layers of Carbon Nanotube (CNTs) based stretchable electrodes. The developed IL-polymer showed both field effect property and piezoresistivity that can detect large tensile strains up 30%. In summary, this research study focused to present feasible methods and materials for printing a 3D smart structure especially in the context of flexible tactile sensors. This study provides a foundation for the future efforts in fabrication of skin like tactile sensors in three-dimensional motifs

  3. On- and offline ultrasonic characterization of components built by SLM additive manufacturing

    NASA Astrophysics Data System (ADS)

    Rieder, Hans; Spies, Martin; Bamberg, Joachim; Henkel, Benjamin

    2016-02-01

    Additive manufacturing processes have become commercially available and are particularly interesting for the production of free-formed parts. Selective laser melting allows for manufacturing components by localized melting of successive layers of metal powder. In this contribution, we report on investigations in view of the influence of the process parameter `laser power' on the microstructure of the manufactured component. It turned out that the online recorded A-scans allow inferring conclusions about the quality of the SLM process. We also report on offline measurements which have been performed to support the online results.

  4. Ultrasonic online monitoring of additive manufacturing processes based on selective laser melting

    NASA Astrophysics Data System (ADS)

    Rieder, Hans; Dillhöfer, Alexander; Spies, Martin; Bamberg, Joachim; Hess, Thomas

    2015-03-01

    Additive manufacturing processes have become commercially available and are particularly interesting for the production of free-formed parts. Selective laser melting allows to manufacture components by localized melting of successive layers of metal powder. In order to be able to describe and to understand the complex dynamics of selective laser melting processes more accurately, online measurements using ultrasound have been performed for the first time. In this contribution, we report on the integration of the measurement technique into the manufacturing facility and on a variety of promising monitoring results.

  5. 21 CFR 1140.12 - Additional responsibilities of manufacturers.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 21 Food and Drugs 8 2011-04-01 2011-04-01 false Additional responsibilities of manufacturers. 1140.12 Section 1140.12 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) TOBACCO PRODUCTS CIGARETTES AND SMOKELESS TOBACCO Prohibition of Sale and...

  6. 21 CFR 1140.12 - Additional responsibilities of manufacturers.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Additional responsibilities of manufacturers. 1140.12 Section 1140.12 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) TOBACCO PRODUCTS CIGARETTES AND SMOKELESS TOBACCO; Eff. 6-22-10 Prohibition of Sale and Distribution to Persons Younger Than 18...

  7. Porosity of additive manufacturing parts for process monitoring

    SciTech Connect

    Slotwinski, J. A.; Garboczi, E. J.

    2014-02-18

    Some metal additive manufacturing processes can produce parts with internal porosity, either intentionally (with careful selection of the process parameters) or unintentionally (if the process is not well-controlled.) Material porosity is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants, since surface-breaking pores allow 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 process. We are developing an ultrasonic sensor for detecting changes in porosity in metal parts during fabrication on a metal powder bed fusion system, for use as a process monitor. This paper will describe our work to develop an ultrasonic-based sensor for monitoring part porosity during an additive build, including background theory, the development and detailed characterization of reference additive porosity samples, and a potential design for in-situ implementation.

  8. Porosity of additive manufacturing parts for process monitoring

    NASA Astrophysics Data System (ADS)

    Slotwinski, J. A.; Garboczi, E. J.

    2014-02-01

    Some metal additive manufacturing processes can produce parts with internal porosity, either intentionally (with careful selection of the process parameters) or unintentionally (if the process is not well-controlled.) Material porosity is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants, since surface-breaking pores allow 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 process. We are developing an ultrasonic sensor for detecting changes in porosity in metal parts during fabrication on a metal powder bed fusion system, for use as a process monitor. This paper will describe our work to develop an ultrasonic-based sensor for monitoring part porosity during an additive build, including background theory, the development and detailed characterization of reference additive porosity samples, and a potential design for in-situ implementation.

  9. Nano-Magnets and Additive Manufacturing for Electric Motors

    NASA Technical Reports Server (NTRS)

    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.

  10. Summary of NDE of Additive Manufacturing Efforts in NASA

    NASA Technical Reports Server (NTRS)

    Waller, Jess; Saulsberry, Regor; Parker, Bradford; Hodges, Kenneth; Burke, Eric; Taminger, Karen

    2014-01-01

    (1) General Rationale for Additive Manufacturing (AM): (a) Operate under a 'design-to-constraint' paradigm, make parts too complicated to fabricate otherwise, (b) Reduce weight by 20 percent with monolithic parts, (c) Reduce waste (green manufacturing), (e) Eliminate reliance on Original Equipment Manufacturers for critical spares, and (f) Extend life of in-service parts by innovative repair methods; (2) NASA OSMA NDE of AM State-of-the-Discipline Report; (3) Overview of NASA AM Efforts at Various Centers: (a) Analytical Tools, (b) Ground-Based Fabrication (c) Space-Based Fabrication; and (d) Center Activity Summaries; (4) Overview of NASA NDE data to date on AM parts; and (5) Gap Analysis/Recommendations for NDE of AM.

  11. Simulation of Laser Additive Manufacturing and its Applications

    NASA Astrophysics Data System (ADS)

    Lee, Yousub

    Laser and metal powder based additive manufacturing (AM), a key category of advanced Direct Digital Manufacturing (DDM), produces metallic components directly from a digital representation of the part such as a CAD file. It is well suited for the production of high-value, customizable components with complex geometry and the repair of damaged components. Currently, the main challenges for laser and metal powder based AM include the formation of defects (e.g., porosity), low surface finish quality, and spatially non-uniform properties of material. Such challenges stem largely from the limited knowledge of complex physical processes in AM especially the molten pool physics such as melting, molten metal flow, heat conduction, vaporization of alloying elements, and solidification. Direct experimental measurement of melt pool phenomena is highly difficult since the process is localized (on the order of 0.1 mm to 1 mm melt pool size) and transient (on the order of 1 m/s scanning speed). Furthermore, current optical and infrared cameras are limited to observe the melt pool surface. As a result, fluid flows in the melt pool, melt pool shape and formation of sub-surface defects are difficult to be visualized by experiment. On the other hand, numerical simulation, based on rigorous solution of mass, momentum and energy transport equations, can provide important quantitative knowledge of complex transport phenomena taking place in AM. The overarching goal of this dissertation research is to develop an analytical foundation for fundamental understanding of heat transfer, molten metal flow and free surface evolution. Two key types of laser AM processes are studied: a) powder injection, commonly used for repairing of turbine blades, and b) powder bed, commonly used for manufacturing of new parts with complex geometry. In the powder injection simulation, fluid convection, temperature gradient (G), solidification rate (R) and melt pool shape are calculated using a heat transfer

  12. Terahertz imaging and tomography as efficient instruments for testing polymer additive manufacturing objects.

    PubMed

    Perraud, J B; Obaton, A F; Bou-Sleiman, J; Recur, B; Balacey, H; Darracq, F; Guillet, J P; Mounaix, P

    2016-05-01

    Additive manufacturing (AM) technology is not only used to make 3D objects but also for rapid prototyping. In industry and laboratories, quality controls for these objects are necessary though difficult to implement compared to classical methods of fabrication because the layer-by-layer printing allows for very complex object manufacturing that is unachievable with standard tools. Furthermore, AM can induce unknown or unexpected defects. Consequently, we demonstrate terahertz (THz) imaging as an innovative method for 2D inspection of polymer materials. Moreover, THz tomography may be considered as an alternative to x-ray tomography and cheaper 3D imaging for routine control. This paper proposes an experimental study of 3D polymer objects obtained by additive manufacturing techniques. This approach allows us to characterize defects and to control dimensions by volumetric measurements on 3D data reconstructed by tomography. PMID:27140357

  13. Application of Additive Manufacturing in Oral and Maxillofacial Surgery.

    PubMed

    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

  14. Metal Additive Manufacturing: A Review of Mechanical Properties

    NASA Astrophysics Data System (ADS)

    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.

  15. Highly oriented carbon fiber–polymer composites via additive manufacturing

    DOE PAGESBeta

    Tekinalp, Halil L.; Kunc, Vlastimil; Velez-Garcia, Gregorio M.; Duty, Chad E.; Love, Lonnie J.; Naskar, Amit K.; Blue, Craig A.; Ozcan, Soydan

    2014-10-16

    Additive manufacturing, diverging from traditional manufacturing techniques, such as casting and machining materials, can handle complex shapes with great design flexibility without the typical waste. Although this technique has been mainly used for rapid prototyping, interest is growing in using this method to directly manufacture actual parts of complex shape. To use 3D-printing additive manufacturing in wide spread applications, the technique and the feedstock materials require improvements to meet the mechanical requirements of load-bearing components. Thus, we investigated the short fiber (0.2 mm to 0.4 mm) reinforced acrylonitrile-butadiene-styrene composites as a feedstock for 3D-printing in terms of their processibility, microstructuremore » and mechanical performance; and also provided comparison with traditional compression molded composites. The tensile strength and modulus of 3D-printed samples increased ~115% and ~700%, respectively. 3D-printer yielded samples with very high fiber orientation in printing direction (up to 91.5 %), whereas, compression molding process yielded samples with significantly less fiber orientation. Microstructure-mechanical property relationships revealed that although the relatively high porosity is observed in the 3D-printed composites as compared to those produced by the conventional compression molding technique, they both exhibited comparable tensile strength and modulus. Furthermore, this phenomena is explained based on the changes in fiber orientation, dispersion and void formation.« less

  16. Highly oriented carbon fiber–polymer composites via additive manufacturing

    SciTech Connect

    Tekinalp, Halil L.; Kunc, Vlastimil; Velez-Garcia, Gregorio M.; Duty, Chad E.; Love, Lonnie J.; Naskar, Amit K.; Blue, Craig A.; Ozcan, Soydan

    2014-10-16

    Additive manufacturing, diverging from traditional manufacturing techniques, such as casting and machining materials, can handle complex shapes with great design flexibility without the typical waste. Although this technique has been mainly used for rapid prototyping, interest is growing in using this method to directly manufacture actual parts of complex shape. To use 3D-printing additive manufacturing in wide spread applications, the technique and the feedstock materials require improvements to meet the mechanical requirements of load-bearing components. Thus, we investigated the short fiber (0.2 mm to 0.4 mm) reinforced acrylonitrile-butadiene-styrene composites as a feedstock for 3D-printing in terms of their processibility, microstructure and mechanical performance; and also provided comparison with traditional compression molded composites. The tensile strength and modulus of 3D-printed samples increased ~115% and ~700%, respectively. 3D-printer yielded samples with very high fiber orientation in printing direction (up to 91.5 %), whereas, compression molding process yielded samples with significantly less fiber orientation. Microstructure-mechanical property relationships revealed that although the relatively high porosity is observed in the 3D-printed composites as compared to those produced by the conventional compression molding technique, they both exhibited comparable tensile strength and modulus. Furthermore, this phenomena is explained based on the changes in fiber orientation, dispersion and void formation.

  17. Colloidal-based additive manufacturing of bio-inspired composites

    NASA Astrophysics Data System (ADS)

    Studart, Andre R.

    Composite materials in nature exhibit heterogeneous architectures that are tuned to fulfill the functional demands of the surrounding environment. Examples range from the cellulose-based organic structure of plants to highly mineralized collagen-based skeletal parts like bone and teeth. Because they are often utilized to combine opposing properties such as strength and low-density or stiffness and wear resistance, the heterogeneous architecture of natural materials can potentially address several of the technical limitations of artificial homogeneous composites. However, current man-made manufacturing technologies do not allow for the level of composition and fiber orientation control found in natural heterogeneous systems. In this talk, I will present two additive manufacturing technologies recently developed in our group to build composites with exquisite architectures only rivaled by structures made by living organisms in nature. Since the proposed techniques utilize colloidal suspensions as feedstock, understanding the physics underlying the stability, assembly and rheology of the printing inks is key to predict and control the architecture of manufactured parts. Our results will show that additive manufacturing routes offer a new exciting pathway for the fabrication of biologically-inspired composite materials with unprecedented architectures and functionalities.

  18. Application of Additively Manufactured Components in Rocket Engine Turbopumps

    NASA Technical Reports Server (NTRS)

    Calvert, Marty, Jr.; Hanks, Andrew; Schmauch, Preston; Delessio, Steve

    2015-01-01

    The use of additive manufacturing technology has the potential to revolutionize the development of turbopump components in liquid rocket engines. When designing turbomachinery with the additive process there are several benefits and risks that are leveraged relative to a traditional development cycle. This topic explores the details and development of a 90,000 RPM Liquid Hydrogen Turbopump from which 90% of the parts were derived from the additive process. This turbopump was designed, developed and will be tested later this year at Marshall Space Flight Center.

  19. Multi-layer laminate structure and manufacturing method

    DOEpatents

    Keenihan, James R.; Cleereman, Robert J.; Eurich, Gerald; Graham, Andrew T.; Langmaid, Joe A.

    2012-04-24

    The present invention is premised upon a multi-layer laminate structure and method of manufacture, more particularly to a method of constructing the multi-layer laminate structure utilizing a laminate frame and at least one energy activated flowable polymer.

  20. Multi-layer laminate structure and manufacturing method

    SciTech Connect

    Keenihan, James R.; Cleereman, Robert J.; Eurich, Gerald; Graham, Andrew T.; Langmaid, Joe A.

    2013-01-29

    The present invention is premised upon a multi-layer laminate structure and method of manufacture, more particularly to a method of constructing the multi-layer laminate structure utilizing a laminate frame and at least one energy activated flowable polymer.

  1. A manufacturing method for multi-layer polysilicon surface-micromachining technology

    SciTech Connect

    Sniegowski, J.J.; Rodgers, M.S.

    1998-01-01

    An advanced manufacturing technology which provides multi-layered polysilicon surface micromachining technology for advanced weapon systems is presented. Specifically, the addition of another design layer to a 4 levels process to create a 5 levels process allows consideration of fundamentally new architecture in designs for weapon advanced surety components.

  2. Complex Modelling Scheme Of An Additive Manufacturing Centre

    NASA Astrophysics Data System (ADS)

    Popescu, Liliana Georgeta

    2015-09-01

    This paper presents a modelling scheme sustaining the development of an additive manufacturing research centre model and its processes. This modelling is performed using IDEF0, the resulting model process representing the basic processes required in developing such a centre in any university. While the activities presented in this study are those recommended in general, changes may occur in specific existing situations in a research centre.

  3. Mechanical Properties of Austenitic Stainless Steel Made by Additive Manufacturing.

    PubMed

    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. PMID:26601037

  4. Mechanical Properties of Austenitic Stainless Steel Made by Additive Manufacturing

    PubMed Central

    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. PMID:26601037

  5. Developing gradient metal alloys through radial deposition additive manufacturing.

    PubMed

    Hofmann, Douglas C; Roberts, Scott; Otis, Richard; Kolodziejska, Joanna; Dillon, R Peter; Suh, Jong-ook; Shapiro, Andrew A; Liu, Zi-Kui; Borgonia, John-Paul

    2014-01-01

    Interest in additive manufacturing (AM) has dramatically expanded in the last several years, owing to the paradigm shift that the process provides over conventional manufacturing. Although the vast majority of recent work in AM has focused on three-dimensional printing in polymers, AM techniques for fabricating metal alloys have been available for more than a decade. Here, laser deposition (LD) is used to fabricate multifunctional metal alloys that have a strategically graded composition to alter their mechanical and physical properties. Using the technique in combination with rotational deposition enables fabrication of compositional gradients radially from the center of a sample. A roadmap for developing gradient alloys is presented that uses multi-component phase diagrams as maps for composition selection so as to avoid unwanted phases. Practical applications for the new technology are demonstrated in low-coefficient of thermal expansion radially graded metal inserts for carbon-fiber spacecraft panels. PMID:24942329

  6. Developing Gradient Metal Alloys through Radial Deposition Additive Manufacturing

    PubMed Central

    Hofmann, Douglas C.; Roberts, Scott; Otis, Richard; Kolodziejska, Joanna; Dillon, R. Peter; Suh, Jong-ook; Shapiro, Andrew A.; Liu, Zi-Kui; Borgonia, John-Paul

    2014-01-01

    Interest in additive manufacturing (AM) has dramatically expanded in the last several years, owing to the paradigm shift that the process provides over conventional manufacturing. Although the vast majority of recent work in AM has focused on three-dimensional printing in polymers, AM techniques for fabricating metal alloys have been available for more than a decade. Here, laser deposition (LD) is used to fabricate multifunctional metal alloys that have a strategically graded composition to alter their mechanical and physical properties. Using the technique in combination with rotational deposition enables fabrication of compositional gradients radially from the center of a sample. A roadmap for developing gradient alloys is presented that uses multi-component phase diagrams as maps for composition selection so as to avoid unwanted phases. Practical applications for the new technology are demonstrated in low-coefficient of thermal expansion radially graded metal inserts for carbon-fiber spacecraft panels. PMID:24942329

  7. Characterization and Control of Powder Properties for Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Strondl, A.; Lyckfeldt, O.; Brodin, H.; Ackelid, U.

    2015-03-01

    Powder characterization and handling in powder metallurgy are important issues and the required powder properties will vary between different component manufacturing processes. By understanding and controlling these, the final material properties for different applications can be improved and become more reliable. In this study, the metal powders used in additive manufacturing (AM) in terms of electron beam melting and selective laser melting have been investigated regarding particle size and shape using dynamic image analysis. In parallel, powder flow characteristics have been evaluated with a powder rheometer. Correlations within the results have been found between particle shape and powder flow characteristics that could explain certain effects of the powder processing in the AM processes. The impact, however, in the processing performance as well as in ultimate material properties was found to be limited.

  8. Electrostatic Levitation for Studies of Additive Manufactured Materials

    NASA Technical Reports Server (NTRS)

    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

  9. An identification method for enclosed voids restriction in manufacturability design for additive manufacturing structures

    NASA Astrophysics Data System (ADS)

    Liu, Shutian; Li, Quhao; Chen, Wenjiong; Tong, Liyong; Cheng, Gengdong

    2015-06-01

    Additive manufacturing (AM) technologies, such as selective laser sintering (SLS) and fused deposition modeling (FDM), have become the powerful tools for direct manufacturing of complex parts. This breakthrough in manufacturing technology makes the fabrication of new geometrical features and multiple materials possible. Past researches on designs and design methods often focused on how to obtain desired functional performance of the structures or parts, specific manufacturing capabilities as well as manufacturing constraints of AM were neglected. However, the inherent constraints in AM processes should be taken into account in design process. In this paper, the enclosed voids, one type of manufacturing constraints of AM, are investigated. In mathematics, enclosed voids restriction expressed as the solid structure is simplyconnected. We propose an equivalent description of simply-connected constraint for avoiding enclosed voids in structures, named as virtual temperature method (VTM). In this method, suppose that the voids in structure are filled with a virtual heating material with high heat conductivity and solid areas are filled with another virtual material with low heat conductivity. Once the enclosed voids exist in structure, the maximum temperature value of structure will be very high. Based upon this method, the simplyconnected constraint is equivalent to maximum temperature constraint. And this method can be easily used to formulate the simply-connected constraint in topology optimization. The effectiveness of this description method is illustrated by several examples. Based upon topology optimization, an example of 3D cantilever beam is used to illustrate the trade-off between manufacturability and functionality. Moreover, the three optimized structures are fabricated by FDM technology to indicate further the necessity of considering the simply-connected constraint in design phase for AM.

  10. Fundamental Aspects of Selective Melting Additive Manufacturing Processes

    SciTech Connect

    van Swol, Frank B.; Miller, James E.

    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.

  11. Overview of Materials Qualification Needs for Metal Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Seifi, Mohsen; Salem, Ayman; Beuth, Jack; Harrysson, Ola; Lewandowski, John J.

    2016-03-01

    This overview highlights some of the key aspects regarding materials qualification needs across the additive manufacturing (AM) spectrum. AM technology has experienced considerable publicity and growth in the past few years with many successful insertions for non-mission-critical applications. However, to meet the full potential that AM has to offer, especially for flight-critical components (e.g., rotating parts, fracture-critical parts, etc.), qualification and certification efforts are necessary. While development of qualification standards will address some of these needs, this overview outlines some of the other key areas that will need to be considered in the qualification path, including various process-, microstructure-, and fracture-modeling activities in addition to integrating these with lifing activities targeting specific components. Ongoing work in the Advanced Manufacturing and Mechanical Reliability Center at Case Western Reserve University is focusing on fracture and fatigue testing to rapidly assess critical mechanical properties of some titanium alloys before and after post-processing, in addition to conducting nondestructive testing/evaluation using micro-computerized tomography at General Electric. Process mapping studies are being conducted at Carnegie Mellon University while large area microstructure characterization and informatics (EBSD and BSE) analyses are being conducted at Materials Resources LLC to enable future integration of these efforts via an Integrated Computational Materials Engineering approach to AM. Possible future pathways for materials qualification are provided.

  12. System and method for high power diode based additive manufacturing

    DOEpatents

    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.

  13. Cases for Additive Manufacturing on the International Space Station

    NASA Technical Reports Server (NTRS)

    Cooper, Kenneth G.; McLemore, Carole; Anderson, Theodore " Ted"

    2012-01-01

    There are thousands of plastic or non-structural metal components on the International Space Station (ISS), any of which could require replacing sometime between resupply missions. While these may not be life critical, it can cause significant delays to flight projects that have to wait several weeks to months to receive a key part one that could have been designed and built on-board the ISS within a few hours. A plastic deposition additive manufacturing process is a low-energy, low-mass solution to many common needs on board the ISS.

  14. Additive Manufacturing of Medical Models--Applications in Rhinology.

    PubMed

    Raos, Pero; Klapan, Ivica; Galeta, Tomislav

    2015-09-01

    In the paper we are introducing guidelines and suggestions for use of 3D image processing SW in head pathology diagnostic and procedures for obtaining physical medical model by additive manufacturing/rapid prototyping techniques, bearing in mind the improvement of surgery performance, its maximum security and faster postoperative recovery of patients. This approach has been verified in two case reports. In the treatment we used intelligent classifier-schemes for abnormal patterns using computer-based system for 3D-virtual and endoscopic assistance in rhinology, with appropriate visualization of anatomy and pathology within the nose, paranasal sinuses, and scull base area. PMID:26898064

  15. Effective Mechanical Properties of Lattice Material Fabricated by Material Extrusion Additive Manufacturing

    SciTech Connect

    Park, Sang-In; Choi, Seung-kyum; Rosen, David W; Duty, Chad E

    2014-01-01

    In this paper, a two-step homogenization method is proposed and implemented for evaluating effective mechanical properties of lattice structured material fabricated by the material extrusion additive manufacturing process. In order to consider the characteristics of the additive manufacturing process in estimation procedures, the levels of scale for homogenization are divided into three stages the levels of layer deposition, structural element, and lattice structure. The method consists of two transformations among stages. In the first step, the transformation between layer deposition and structural element levels is proposed to find the geometrical and material effective properties of structural elements in the lattice structure. In the second step, the method to estimate effective mechanical properties of lattice material is presented, which uses a unit cell and is based on the discretized homogenization method for periodic structure. The method is implemented for cubic lattice structure and compared to experimental results for validation purposes.

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

    NASA Astrophysics Data System (ADS)

    Xiong, Jun; Zhang, Guangjun

    2013-11-01

    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.

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

    NASA Astrophysics Data System (ADS)

    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.

  18. Characterization of In-Situ Alloyed and Additively Manufactured Titanium Aluminides

    NASA Astrophysics Data System (ADS)

    Ma, Yan; Cuiuri, Dominic; Hoye, Nicholas; Li, Huijun; Pan, Zengxi

    2014-12-01

    Titanium aluminide components were fabricated using in-situ alloying and layer additive manufacturing based on the gas tungsten arc welding process combined with separate wire feeding of titanium and aluminum elements. The new fabrication process promises significant time and cost saving in comparison to traditional methods. In the present study, issues such as processing parameters, microstructure, and properties are discussed. The results presented here demonstrate the potential to produce full density titanium aluminide components directly using the new technique.

  19. Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control

    PubMed Central

    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. PMID:26601041

  20. Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control.

    PubMed

    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. PMID:26601041

  1. Cooling Rate Determination in Additively Manufactured Aluminum Alloy 2219

    NASA Astrophysics Data System (ADS)

    Brice, Craig A.; Dennis, Noah

    2015-05-01

    Metallic additive manufacturing processes generally utilize a conduction mode, welding-type approach to create beads of deposited material that can be arranged into a three-dimensional structure. As with welding, the cooling rates in the molten pool are relatively rapid compared to traditional casting techniques. Determination of the cooling rate in the molten pool is critical for predicting the solidified microstructure and resultant properties. In this experiment, wire-fed electron beam additive manufacturing was used to melt aluminum alloy 2219 under different thermal boundary conditions. The dendrite arm spacing was measured in the remelted material, and this information was used to estimate cooling rates in the molten pool based on established empirical relationships. The results showed that the thermal boundary conditions have a significant effect on the resulting cooling rate in the molten pool. When thermal conduction is limited due to a small thermal sink, the dendrite arm spacing varies between 15 and 35 µm. When thermal conduction is active, the dendrite arm spacing varies between 6 and 12 µm. This range of dendrite arm spacing implies cooling rates ranging from 5 to 350 K/s. Cooling rates can vary greatly as thermal conditions change during deposition. A cooling rate at the higher end of the range could lead to significant deviation from microstructural equilibrium during solidification.

  2. Neutron Characterization of Additively Manufactured Components. Workshop Report

    SciTech Connect

    Watkins, Thomas R.; Payzant, E. Andrew; Babu, Sudarsanam Suresh

    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.

  3. 40 CFR 80.1613 - Standards and other requirements for gasoline additive manufacturers and blenders.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... manufacturers, as defined in 40 CFR 79.2(f), who manufacture additives with a maximum allowed treatment rate of... gasoline additive manufacturers and blenders. 80.1613 Section 80.1613 Protection of Environment... Gasoline Sulfur § 80.1613 Standards and other requirements for gasoline additive manufacturers and...

  4. X-ray computed tomography for additive manufacturing: a review

    NASA Astrophysics Data System (ADS)

    Thompson, A.; Maskery, I.; Leach, R. K.

    2016-07-01

    In this review, the use of x-ray computed tomography (XCT) is examined, identifying the requirement for volumetric dimensional measurements in industrial verification of additively manufactured (AM) parts. The XCT technology and AM processes are summarised, and their historical use is documented. The use of XCT and AM as tools for medical reverse engineering is discussed, and the transition of XCT from a tool used solely for imaging to a vital metrological instrument is documented. The current states of the combined technologies are then examined in detail, separated into porosity measurements and general dimensional measurements. In the conclusions of this review, the limitation of resolution on improvement of porosity measurements and the lack of research regarding the measurement of surface texture are identified as the primary barriers to ongoing adoption of XCT in AM. The limitations of both AM and XCT regarding slow speeds and high costs, when compared to other manufacturing and measurement techniques, are also noted as general barriers to continued adoption of XCT and AM.

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

    NASA Technical Reports Server (NTRS)

    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.

  6. 3D Printing, Additive Manufacturing, and Solid Freeform Fabrication: The Technologies of the Past, Present and Future

    NASA Astrophysics Data System (ADS)

    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.

  7. Laser Assisted Additively Manufactured Transition Metal Coating on Aluminum

    NASA Astrophysics Data System (ADS)

    Vora, Hitesh D.; Rajamure, Ravi Shanker; Roy, Anurag; Srinivasan, S. G.; Sundararajan, G.; Banerjee, Rajarshi; Dahotre, Narendra B.

    2016-07-01

    Various physical and chemical properties of surface and subsurface regions of Al can be improved by the formation of transition metal intermetallic phases (Al x TM y ) via coating of the transition metal (TM). The lower equilibrium solid solubility of TM in Al (<1 at.%) is a steep barrier to the formation of solid solutions using conventional alloying methods. In contrast, as demonstrated in the present work, surface engineering via a laser-aided additive manufacturing approach can effectively synthesize TM intermetallic coatings on the surface of Al. The focus of the present work included the development of process control to achieve thermodynamic and kinetic conditions necessary for desirable physical, microstructural and compositional attributes. A multiphysics finite element model was developed to predict the temperature profile, cooling rate, melt depth, dilution of W in Al matrix and corresponding micro-hardness in the coating, and the interface between the coating and the base material and the base material.

  8. Laser Assisted Additively Manufactured Transition Metal Coating on Aluminum

    NASA Astrophysics Data System (ADS)

    Vora, Hitesh D.; Rajamure, Ravi Shanker; Roy, Anurag; Srinivasan, S. G.; Sundararajan, G.; Banerjee, Rajarshi; Dahotre, Narendra B.

    2016-05-01

    Various physical and chemical properties of surface and subsurface regions of Al can be improved by the formation of transition metal intermetallic phases (Al x TM y ) via coating of the transition metal (TM). The lower equilibrium solid solubility of TM in Al (<1 at.%) is a steep barrier to the formation of solid solutions using conventional alloying methods. In contrast, as demonstrated in the present work, surface engineering via a laser-aided additive manufacturing approach can effectively synthesize TM intermetallic coatings on the surface of Al. The focus of the present work included the development of process control to achieve thermodynamic and kinetic conditions necessary for desirable physical, microstructural and compositional attributes. A multiphysics finite element model was developed to predict the temperature profile, cooling rate, melt depth, dilution of W in Al matrix and corresponding micro-hardness in the coating, and the interface between the coating and the base material and the base material.

  9. Developing novel 3D antennas using advanced additive manufacturing technology

    NASA Astrophysics Data System (ADS)

    Mirzaee, Milad

    In today's world of wireless communication systems, antenna engineering is rapidly advancing as the wireless services continue to expand in support of emerging commercial applications. Antennas play a key role in the performance of advanced transceiver systems where they serve to convert electric power to electromagnetic waves and vice versa. Researchers have held significant interest in developing this crucial component for wireless communication systems by employing a variety of design techniques. In the past few years, demands for electrically small antennas continues to increase, particularly among portable and mobile wireless devices, medical electronics and aerospace systems. This trend toward smaller electronic devices makes the three dimensional (3D) antennas very appealing, since they can be designed in a way to use every available space inside the devise. Additive Manufacturing (AM) method could help to find great solutions for the antennas design for next generation of wireless communication systems. In this thesis, the design and fabrication of 3D printed antennas using AM technology is studied. To demonstrate this application of AM, different types of antennas structures have been designed and fabricated using various manufacturing processes. This thesis studies, for the first time, embedded conductive 3D printed antennas using PolyLactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS) for substrate parts and high temperature carbon paste for conductive parts which can be a good candidate to overcome the limitations of direct printing on 3D surfaces that is the most popular method to fabricate conductive parts of the antennas. This thesis also studies, for the first time, the fabrication of antennas with 3D printed conductive parts which can contribute to the new generation of 3D printed antennas.

  10. Accelerating Industrial Adoption of Metal Additive Manufacturing Technology

    NASA Astrophysics Data System (ADS)

    Vartanian, Kenneth; McDonald, Tom

    2016-03-01

    While metal additive manufacturing (AM) technology has clear benefits, there are still factors preventing its adoption by industry. These factors include the high cost of metal AM systems, the difficulty for machinists to learn and operate metal AM machines, the long approval process for part qualification/certification, and the need for better process controls; however, the high AM system cost is the main barrier deterring adoption. In this paper, we will discuss an America Makes-funded program to reduce AM system cost by combining metal AM technology with conventional computerized numerical controlled (CNC) machine tools. Information will be provided on how an Optomec-led team retrofitted a legacy CNC vertical mill with laser engineered net shaping (LENS®—LENS is a registered trademark of Sandia National Labs) AM technology, dramatically lowering deployment cost. The upgraded system, dubbed LENS Hybrid Vertical Mill, enables metal additive and subtractive operations to be performed on the same machine tool and even on the same part. Information on the LENS Hybrid system architecture, learnings from initial system deployment and continuing development work will also be provided to help guide further development activities within the materials community.

  11. 40 CFR 79.20 - Application for registration by additive manufacturer.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... additive manufacturer. 79.20 Section 79.20 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) AIR PROGRAMS (CONTINUED) REGISTRATION OF FUELS AND FUEL ADDITIVES Additive Registration Procedures § 79.20 Application for registration by additive manufacturer. Any manufacturer of a...

  12. 40 CFR 79.20 - Application for registration by additive manufacturer.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... additive manufacturer. 79.20 Section 79.20 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) AIR PROGRAMS (CONTINUED) REGISTRATION OF FUELS AND FUEL ADDITIVES Additive Registration Procedures § 79.20 Application for registration by additive manufacturer. Any manufacturer of a...

  13. Finishing of additively manufactured titanium alloy by shape adaptive grinding (SAG)

    NASA Astrophysics Data System (ADS)

    Beaucamp, Anthony T.; Namba, Yoshiharu; Charlton, Phillip; Jain, Samyak; Graziano, Arthur A.

    2015-06-01

    In recent years, rapid prototyping of titanium alloy components for medical and aeronautics application has become viable thanks to advances in technologies such as electron beam melting (EBM) and selective laser sintering (SLS). However, for many applications the high surface roughness generated by additive manufacturing techniques demands a post-finishing operation to improve the surface quality prior to usage. In this paper, the novel shape adaptive grinding process has been applied to finishing titanium alloy (Ti6Al4V) additively manufactured by EBM and SLS. It is shown that the micro-structured surface layer resulting from the melting process can be removed, and the surface can then be smoothed down to less than 10 nm Ra (starting from 4-5 μm Ra) using only three different diamond grit sizes. This paper also demonstrates application of the technology to freeform shapes, and documents the dimensional accuracy of finished artifacts.

  14. Process monitoring of additive manufacturing by using optical tomography

    SciTech Connect

    Zenzinger, Guenter E-mail: alexander.ladewig@mtu.de; Bamberg, Joachim E-mail: alexander.ladewig@mtu.de; Ladewig, Alexander E-mail: alexander.ladewig@mtu.de; Hess, Thomas E-mail: alexander.ladewig@mtu.de; Henkel, Benjamin E-mail: alexander.ladewig@mtu.de; Satzger, Wilhelm E-mail: alexander.ladewig@mtu.de

    2015-03-31

    Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure. A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim structure. Results of our optical tomography (OT) method as obtained on real defects are presented.

  15. Process monitoring of additive manufacturing by using optical tomography

    NASA Astrophysics Data System (ADS)

    Zenzinger, Guenter; Bamberg, Joachim; Ladewig, Alexander; Hess, Thomas; Henkel, Benjamin; Satzger, Wilhelm

    2015-03-01

    Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure. A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim structure. Results of our optical tomography (OT) method as obtained on real defects are presented.

  16. Sensitivity analysis of geometric errors in additive manufacturing medical models.

    PubMed

    Pinto, Jose Miguel; Arrieta, Cristobal; Andia, Marcelo E; Uribe, Sergio; Ramos-Grez, Jorge; Vargas, Alex; Irarrazaval, Pablo; Tejos, Cristian

    2015-03-01

    Additive manufacturing (AM) models are used in medical applications for surgical planning, prosthesis design and teaching. For these applications, the accuracy of the AM models is essential. Unfortunately, this accuracy is compromised due to errors introduced by each of the building steps: image acquisition, segmentation, triangulation, printing and infiltration. However, the contribution of each step to the final error remains unclear. We performed a sensitivity analysis comparing errors obtained from a reference with those obtained modifying parameters of each building step. Our analysis considered global indexes to evaluate the overall error, and local indexes to show how this error is distributed along the surface of the AM models. Our results show that the standard building process tends to overestimate the AM models, i.e. models are larger than the original structures. They also show that the triangulation resolution and the segmentation threshold are critical factors, and that the errors are concentrated at regions with high curvatures. Errors could be reduced choosing better triangulation and printing resolutions, but there is an important need for modifying some of the standard building processes, particularly the segmentation algorithms. PMID:25649961

  17. Summary of NDE of additive manufacturing efforts in NASA

    NASA Astrophysics Data System (ADS)

    Waller, Jess M.; Saulsberry, Regor L.; Parker, Bradford H.; Hodges, Kenneth L.; Burke, Eric R.; Taminger, Karen M.

    2015-03-01

    One of the major obstacles slowing the acceptance of parts made by additive manufacturing (AM) in NASA applications is the lack of a broadly accepted materials and process quality systems; and more specifically, the lack of adequate nondestructive evaluation (NDE) processes integrated into AM. Matching voluntary consensus standards are also needed to control the consistency of input materials, process equipment, process methods, finished part properties, and how those properties are characterized. As for nondestructive characterization, procedures are needed to interrogate features unique to parts made by AM, such as fine-scale porosity, deeply embedded flaws, complex part geometry, and intricate internal features. The NDE methods developed must be tailored to meet materials, design and test requirements encountered throughout the part life cycle, whether during process optimization, real-time process monitoring, finished part qualification and certification (especially of flight hardware), or in situ health monitoring. Restated, individualized process/product-specific NDE methods are needed to satisfy NASA's various quality assurance requirements. To date, only limited data have been acquired by NASA on parts made by AM. This paper summarizes the NASA AM effort, highlights available NDE data, and outlines the approach NASA is taking to apply NDE to its various AM efforts.

  18. Recommended Protocol for Round Robin Studies in Additive Manufacturing

    PubMed Central

    Moylan, Shawn; Brown, Christopher U.; Slotwinski, John

    2016-01-01

    One way to improve confidence and encourage proliferation of additive manufacturing (AM) technologies and parts is by generating more high quality data describing the performance of AM processes and parts. Many in the AM community see round robin studies as a way to generate large data sets while distributing the cost among the participants, thereby reducing the cost to individual users. The National Institute of Standards and Technology (NIST) has conducted and participated in several of these AM round robin studies. While the results of these studies are interesting and informative, many of the lessons learned in conducting these studies concern the logistics and methods of the study and unique issues presented by AM. Existing standards for conducting interlaboratory studies of measurement methods, along with NIST’s experience, form the basis for recommended protocols for conducting AM round robin studies. The role of round robin studies in AM qualification, some of the limitations of round robin studies, and the potential benefit of less formal collaborative experiments where multiple factors, AM machine being only one, are varied simultaneously are also discussed. PMID:27274602

  19. Bioinspired Cellular Structures: Additive Manufacturing and Mechanical Properties

    NASA Astrophysics Data System (ADS)

    Stampfl, J.; Pettermann, H. E.; Liska, R.

    Biological materials (e.g., wood, trabecular bone, marine skeletons) rely heavily on the use of cellular architecture, which provides several advantages. (1) The resulting structures can bear the variety of "real life" load spectra using a minimum of a given bulk material, featuring engineering lightweight design principles. (2) The inside of the structures is accessible to body fluids which deliver the required nutrients. (3) Furthermore, cellular architectures can grow organically by adding or removing individual struts or by changing the shape of the constituting elements. All these facts make the use of cellular architectures a reasonable choice for nature. Using additive manufacturing technologies (AMT), it is now possible to fabricate such structures for applications in engineering and biomedicine. In this chapter, we present methods that allow the 3D computational analysis of the mechanical properties of cellular structures with open porosity. Various different cellular architectures including disorder are studied. In order to quantify the influence of architecture, the apparent density is always kept constant. Furthermore, it is shown that how new advanced photopolymers can be used to tailor the mechanical and functional properties of the fabricated structures.

  20. Additively Manufactured Combustion Devices Components for LOX/Methane Applications

    NASA Technical Reports Server (NTRS)

    Greene, Sandra Elam; Protz, Christopher; Garcia, Chance; Goodman, Dwight; Baker, Kevin

    2016-01-01

    Marshall Space Flight Center (MSFC) has designed, fabricated, and hot-fire tested a variety of successful injectors, chambers, and igniters for potential liquid oxygen (LOX) and methane (CH4) systems since 2005. The most recent efforts have focused on components with additive manufacturing (AM) to include unique design features, minimize joints, and reduce final machining efforts. Inconel and copper alloys have been used with AM processes to produce a swirl coaxial injector and multiple methane cooled thrust chambers. The initial chambers included unique thermocouple ports for measuring local coolant channel temperatures along the length of the chamber. Results from hot-fire testing were used to anchor thermal models and generate a regeneratively cooled thruster for a 4,000 lbf LOX/CH4 engine. The completed thruster will be hot-fire tested in the summer of 2016 at MSFC. The thruster design can also be easily scaled and used on a 25,000 lbf engine. To further support the larger engine design, an AM gas generator injector has been designed. Hot-fire testing on this injector is planned for the summer of 2016 at MSFC.

  1. Cleaning and Cleanliness Measurement of Additive Manufactured Parts

    NASA Technical Reports Server (NTRS)

    Welker, Roger W.; Mitchell, Mark A.

    2015-01-01

    The successful acquisition and utilization of piece parts and assemblies for contamination sensitive applications requires application of cleanliness acceptance criteria. Contamination can be classified using many different schemes. One common scheme is classification as organic, ionic and particulate contaminants. These may be present in and on the surface of solid components and assemblies or may be dispersed in various gaseous or liquid media. This discussion will focus on insoluble particle contamination on the surface of piece parts and assemblies. Cleanliness of parts can be controlled using two strategies, referred to as gross cleanliness and precision cleanliness. Under a gross cleanliness strategy acceptance is based on visual cleanliness. This approach introduces a number of concerns that render it unsuitable for controlling cleanliness of high technology products. Under the precision cleanliness strategy, subjective, visual assessment of cleanliness is replaced by objective measurement of cleanliness. When a precision cleanliness strategy is adopted there naturally arises the question: How clean is clean enough? The six commonly used methods for establishing objective cleanliness acceptance limits will be discussed. Special emphasis shall focus on the use of multiple extraction, a technique that has been demonstrated for additively manufactured parts.

  2. Additive Manufacturing and Characterization of Ultem Polymers and Composites

    NASA Technical Reports Server (NTRS)

    Chuang, Kathy C.; Grady, Joseph E.; Draper, Robert D.; Shin, Euy-Sik E.; Patterson, Clark; Santelle, Thomas D.

    2015-01-01

    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 percent 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 25-31 percent. Coupons of Ultem 9085 and experimental Ultem 1000 composites were tested at room temperature and 400 degrees Fahrenheit to evaluate their corresponding mechanical properties.

  3. Additive manufacturing metrology: State of the art and needs assessment

    NASA Astrophysics Data System (ADS)

    Koester, L.; Taheri, H.; Bond, L. J.; Barnard, D.; Gray, J.

    2016-02-01

    Additive manufacturing (AM) is a technology that first emerged in 1987 with stereolithography (SL) of plastic materials from 3D Systems. It saw light use for rapid prototyping and very low volume production for a number of years. However, in the past few years AM of metallic materials has become a practical fabrication technology, use is rapidly increasing and is projected to continue with double digit growth in coming years. The promise and flexibility shown by AM has spurred efforts to begin standardization of this type of process. This paper provides an assessment of the state of the art for in-situ process monitoring of AM processes with an emphasis on the production of metallic components. It is seen that with the implementation of proper process control there is potential to create reliable and reproducible materials and geometries previously unachievable using metal removal based means of production. A reliable methodology for detection and control of microstructure and defects would be of great value in terms of enabling broader AM utilization.

  4. Scanning laser ultrasound and wavenumber spectroscopy for in-process inspection of additively manufactured parts

    NASA Astrophysics Data System (ADS)

    Koskelo, EliseAnne C.; Flynn, Eric B.

    2016-04-01

    We present a new in-process laser ultrasound inspection technique for additive manufacturing. Ultrasonic energy was introduced to the part by attaching an ultrasonic transducer to the printer build-plate and driving it with a single-tone, harmonic excitation. The full-field response of the part was measured using a scanning laser Doppler vibrometer after each printer layer. For each scan, we analyzed both the local amplitudes and wavenumbers of the response in order to identify defects. For this study, we focused on the detection of delamination between layers in a fused deposition modeling process. Foreign object damage, localized heating damage, and the resulting delamination between layers were detected in using the technique as indicated by increased amplitude and wavenumber responses within the damaged area.

  5. 22 CFR 124.9 - Additional clauses required only in manufacturing license agreements.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... manufacturing license agreements. 124.9 Section 124.9 Foreign Relations DEPARTMENT OF STATE INTERNATIONAL... Additional clauses required only in manufacturing license agreements. (a) Clauses for all manufacturing license agreements. The following clauses must be included only in manufacturing license agreements:...

  6. 22 CFR 124.9 - Additional clauses required only in manufacturing license agreements.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... manufacturing license agreements. 124.9 Section 124.9 Foreign Relations DEPARTMENT OF STATE INTERNATIONAL... Additional clauses required only in manufacturing license agreements. (a) Clauses for all manufacturing license agreements. The following clauses must be included only in manufacturing license agreements:...

  7. 22 CFR 124.9 - Additional clauses required only in manufacturing license agreements.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... manufacturing license agreements. 124.9 Section 124.9 Foreign Relations DEPARTMENT OF STATE INTERNATIONAL... Additional clauses required only in manufacturing license agreements. (a) Clauses for all manufacturing license agreements. The following clauses must be included only in manufacturing license agreements:...

  8. 22 CFR 124.9 - Additional clauses required only in manufacturing license agreements.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... manufacturing license agreements. 124.9 Section 124.9 Foreign Relations DEPARTMENT OF STATE INTERNATIONAL... Additional clauses required only in manufacturing license agreements. (a) Clauses for all manufacturing license agreements. The following clauses must be included only in manufacturing license agreements:...

  9. Characterization of Effect of Support Structures in Laser Additive Manufacturing of Stainless Steel

    NASA Astrophysics Data System (ADS)

    Järvinen, Jukka-Pekka; Matilainen, Ville; Li, Xiaoyun; Piili, Heidi; Salminen, Antti; Mäkelä, Ismo; Nyrhilä, Olli

    Laser additive manufacturing (LAM) of stainless steel is a layer wisetechnology for fabricating 3D parts from metal powder via selectively melting powder with laser beam. Support structures play a significant role in LAM process as they help to remove heat away from the process and on the other hand hold the work piece in its place. A successful design of support structures can help to achievea building process fast and inexpensive with high quality. Aimof this study was to characterize the usability of two types of support structures: web and tube supports. Purpose of this studywas also to analyze how suitable they are in two industrial application cases: case for dental application and case for jewelry application. It was concluded that the removability of web supports was much better than tube supports. It was noticed that support structures are an important part of LAM process and they strongly affect the manufacturability and the end quality of the part.

  10. Additively Manufactured Device for Dynamic Culture of Large Arrays of 3D Tissue Engineered Constructs.

    PubMed

    Costa, Pedro F; Hutmacher, Dietmar W; Theodoropoulos, Christina; Gomes, Manuela E; Reis, Rui L; Vaquette, Cédryck

    2015-04-22

    The ability to test large arrays of cell and biomaterial combinations in 3D environments is still rather limited in the context of tissue engineering and regenerative medicine. This limitation can be generally addressed by employing highly automated and reproducible methodologies. This study reports on the development of a highly versatile and upscalable method based on additive manufacturing for the fabrication of arrays of scaffolds, which are enclosed into individualized perfusion chambers. Devices containing eight scaffolds and their corresponding bioreactor chambers are simultaneously fabricated utilizing a dual extrusion additive manufacturing system. To demonstrate the versatility of the concept, the scaffolds, while enclosed into the device, are subsequently surface-coated with a biomimetic calcium phosphate layer by perfusion with simulated body fluid solution. 96 scaffolds are simultaneously seeded and cultured with human osteoblasts under highly controlled bidirectional perfusion dynamic conditions over 4 weeks. Both coated and noncoated resulting scaffolds show homogeneous cell distribution and high cell viability throughout the 4 weeks culture period and CaP-coated scaffolds result in a significantly increased cell number. The methodology developed in this work exemplifies the applicability of additive manufacturing as a tool for further automation of studies in the field of tissue engineering and regenerative medicine. PMID:25721231

  11. Application of laser ultrasonic non-destructive evaluation technique to additive manufacturing

    NASA Astrophysics Data System (ADS)

    Manzo, Anthony J.; Kenderian, Shant; Helvajian, Henry

    2016-04-01

    The change in properties of a propagating ultrasonic wave has been a mainstay characterization tool of the nondestructive evaluation (NDE) industry for identifying subsurface defects (e.g. damage). A variant of this concept could be applicable to 3D additive manufacturing where the existence of defects (e.g. pores) within a sub-layer could mark a product as non-qualifying. We have been exploring the utility of pulsed laser ultrasonic excitation coupled with CW laser heterodyne detection as an all optical scheme for characterizing sub surface layer properties. The all-optical approach permits a straight forward integration into a laser additive processing tool. To test the concept, we have developed an experimental system that generates pulsed ultrasonic waves (the probe) with high bandwidth (<<10MHz) and a surface displacement sensor that can capture the ultrasonic "return" signal with bandwidth close to 300 MHz. The use of high frequencies enables the detection of smaller defect sites. The technique is time resolved with the sensor and probe as point (>>30-200 microns) beams. Current tests include characterizing properties of spot weld joints between two thin stainless steel plates. The long term objective is to transition the technique into a laser additive manufacturing tool.

  12. Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

    NASA Technical Reports Server (NTRS)

    Liou, Frank; Newkirk, Joseph; Fan, Zhiqiang; Sparks, Todd; Chen, Xueyang; Fletcher, Kenneth; Zhang, Jingwei; Zhang, Yunlu; Kumar, Kannan Suresh; Karnati, Sreekar

    2015-01-01

    The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition

  13. Characterization of Steel-Ta Dissimilar Metal Builds Made Using Very High Power Ultrasonic Additive Manufacturing (VHP-UAM)

    NASA Astrophysics Data System (ADS)

    Sridharan, Niyanth; Norfolk, Mark; Babu, Sudarsanam Suresh

    2016-05-01

    Ultrasonic additive manufacturing is a solid-state additive manufacturing technique that utilizes ultrasonic vibrations to bond metal tapes into near net-shaped components. The major advantage of this process is the ability to manufacture layered structures with dissimilar materials without any intermetallic formation. Majority of the published literature had focused only on the bond formation mechanism in Aluminum alloys. The current work pertains to explain the microstructure evolution during dissimilar joining of iron and tantalum using very high power ultrasonic additive manufacturing and characterization of the interfaces using electron back-scattered diffraction and Nano-indentation measurement. The results showed extensive grain refinement at the bonded interfaces of these metals. This phenomenon was attributed to continuous dynamic recrystallization process driven by the high strain rate plastic deformation and associated adiabatic heating that is well below 50 pct of melting point of both iron and Ta.

  14. Thermal Imaging for Assessment of Electron-Beam Free Form Fabrication (EBF(sup 3)) Additive Manufacturing Welds

    NASA Technical Reports Server (NTRS)

    Zalameda, Joseph N.; Burke, Eric R.; Hafley, Robert A.; Taminger, Karen M.; Domack, Christopher S.; Brewer, Amy R.; Martin, Richard E.

    2013-01-01

    Additive manufacturing is a rapidly growing field where 3-dimensional parts can be produced layer by layer. NASA s electron beam free-form fabrication (EBF(sup 3)) technology is being evaluated to manufacture metallic parts in a space environment. The benefits of EBF(sup 3) technology are weight savings to support space missions, rapid prototyping in a zero gravity environment, and improved vehicle readiness. The EBF(sup 3) system is composed of 3 main components: electron beam gun, multi-axis position system, and metallic wire feeder. The electron beam is used to melt the wire and the multi-axis positioning system is used to build the part layer by layer. To insure a quality weld, a near infrared (NIR) camera is used to image the melt pool and solidification areas. This paper describes the calibration and application of a NIR camera for temperature measurement. In addition, image processing techniques are presented for weld assessment metrics.

  15. Investigation in the use of plasma arc welding and alternative feedstock delivery method in additive manufacture

    NASA Astrophysics Data System (ADS)

    Alhuzaim, Abdullah F.

    The work conducted for this thesis was to investigate the use of plasma arc welding (PAW) and steel shot as a means of additive manufacturing. A robotic PAW system and automatic shot feeder were used to manufacture linear walls approximately 100 mm long by 7 mm wide and 20 mm tall. The walls were built, layer-by-layer, on plain carbon steel substrate by adding individual 2.5 mm diameter plain carbon steel shot. Each layer was built, shot-by-shot, using a pulse of arc current to form a molten pool on the deposit into which each shot was deposited and melted. The deposition rate, a measure of productivity, was approximately 50 g/hour. Three walls were built using the same conditions except for the deposit preheat temperature prior to adding each new layer. The deposit preheat temperature was controlled by allowing the deposit to cool after each layer for an amount of time called the inter-layer wait time. The walls were sectioned and grain size and hardness distribution were measured as a function of wall height. The results indicated that, for all specimens, deposit grain size increased and hardness decreased as wall height increased. Furthermore, average grain size decreased and hardness increased as interlayer wait time increased. An analytical heat flow model was developed to study the influence of interlayer wait time on deposit temperature and therefore grain size and hardness. The results of the model indicated that as wall height increased, the rate of deposit heat removal by conduction to the substrate decreased leading to a higher preheat temperature after a fixed interlayer wait time causing grain size to increase as wall height increased. However, the model results also show that as wall height increased, the deposit surface area from which heat energy is lost via convection and radiation increased. The model also demonstrated that the use of a means of forced convection to rapidly remove heat from the deposit could be an effective way to boost

  16. 40 CFR 79.21 - Information and assurances to be provided by the additive manufacturer.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... provided by the additive manufacturer. 79.21 Section 79.21 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) AIR PROGRAMS (CONTINUED) REGISTRATION OF FUELS AND FUEL ADDITIVES Additive Registration Procedures § 79.21 Information and assurances to be provided by the additive manufacturer....

  17. Fabrication of Flex Joint Utilizing Additively Manufactured Parts

    NASA Technical Reports Server (NTRS)

    Eddleman, David; Richard, Jim

    2015-01-01

    The Selective Laser Melting (SLM) manufacturing technique has been utilized in the manufacture of a flex joint typical of those found in rocket engine and main propulsion system ducting. The SLM process allowed for the combination of parts that are typically machined separately and welded together. This resulted in roughly a 65% reduction of the total number of parts, roughly 70% reduction in the total number of welds, and an estimated 60% reduction in the number of machining operations. The majority of the new design was in three SLM pieces. These pieces, as well as a few traditionally fabricated parts, were assembled into a complete unit, which has been pressure tested. The design and planned cryogenic testing of the unit will be presented.

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

    NASA Technical Reports Server (NTRS)

    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.; Patterson, Clark; Santelle, Tom; Mehl, Jeremy

    2015-01-01

    The research and development activities reported in this publication were carried out under NASA Aeronautics Research Institute (NARI) funded project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing." The objective of the project was to conduct evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. The results of the activities are described in three part report. The first part of the report contains the data and analysis 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. The technical scope of activities included an assessment of the feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composites, which were accomplished by fabricating prototype engine components and testing them in simulated engine operating conditions. The manufacturing process parameters were developed and optimized for polymer and ceramic composites (described in detail in the second and third part of the report). A number of prototype components (inlet guide vane (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included turbine nozzle components. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

  19. Analysis of CNT additives in porous layered thin film lubrication with electric double layer

    NASA Astrophysics Data System (ADS)

    Rao, T. V. V. L. N.; Rani, A. M. A.; Sufian, S.; Mohamed, N. M.

    2015-07-01

    This paper presents an analysis of thin film lubrication of porous layered carbon nanotubes (CNTs) additive slider bearing with electric double layer. The CNTs additive lubricant flow in the thin fluid film and porous layers are governed by Stokes and Brinkman equations respectively, including electro-kinetic force. The apparent viscosity and nondimensional pressure expression are derived. The nondimensional load capacity increases under the influence of electro-viscosity, CNT additives volume fraction, permeability and thickness of porous layer. A CNTs additive lubricated porous thin film slider bearing with electric double layer provides higher load capacity.

  20. Part height control of laser metal additive manufacturing process

    NASA Astrophysics Data System (ADS)

    Pan, Yu-Herng

    Laser Metal Deposition (LMD) has been used to not only make but also repair damaged parts in a layer-by-layer fashion. Parts made in this manner may produce less waste than those made through conventional machining processes. However, a common issue of LMD involves controlling the deposition's layer thickness. Accuracy is important, and as it increases, both the time required to produce the part and the material wasted during the material removal process (e.g., milling, lathe) decrease. The deposition rate is affected by multiple parameters, such as the powder feed rate, laser input power, axis feed rate, material type, and part design, the values of each of which may change during the LMD process. Using a mathematical model to build a generic equation that predicts the deposition's layer thickness is difficult due to these complex parameters. In this thesis, we propose a simple method that utilizes a single device. This device uses a pyrometer to monitor the current build height, thereby allowing the layer thickness to be controlled during the LMD process. This method also helps the LMD system to build parts even with complex parameters and to increase material efficiency.

  1. Failure mechanisms of additively manufactured porous biomaterials: Effects of porosity and type of unit cell.

    PubMed

    Kadkhodapour, J; Montazerian, H; Darabi, A Ch; Anaraki, A P; Ahmadi, S M; Zadpoor, A A; Schmauder, S

    2015-10-01

    Since the advent of additive manufacturing techniques, regular porous biomaterials have emerged as promising candidates for tissue engineering scaffolds owing to their controllable pore architecture and feasibility in producing scaffolds from a variety of biomaterials. The architecture of scaffolds could be designed to achieve similar mechanical properties as in the host bone tissue, thereby avoiding issues such as stress shielding in bone replacement procedure. In this paper, the deformation and failure mechanisms of porous titanium (Ti6Al4V) biomaterials manufactured by selective laser melting from two different types of repeating unit cells, namely cubic and diamond lattice structures, with four different porosities are studied. The mechanical behavior of the above-mentioned porous biomaterials was studied using finite element models. The computational results were compared with the experimental findings from a previous study of ours. The Johnson-Cook plasticity and damage model was implemented in the finite element models to simulate the failure of the additively manufactured scaffolds under compression. The computationally predicted stress-strain curves were compared with the experimental ones. The computational models incorporating the Johnson-Cook damage model could predict the plateau stress and maximum stress at the first peak with less than 18% error. Moreover, the computationally predicted deformation modes were in good agreement with the results of scaling law analysis. A layer-by-layer failure mechanism was found for the stretch-dominated structures, i.e. structures made from the cubic unit cell, while the failure of the bending-dominated structures, i.e. structures made from the diamond unit cells, was accompanied by the shearing bands of 45°. PMID:26143351

  2. Preliminary Comparison of Properties between Ni-electroplated Stainless Steel Parts Fabricated with Laser Additive Manufacturing and Conventional Machining

    NASA Astrophysics Data System (ADS)

    Mäkinen, Mika; Jauhiainen, Eeva; Matilainen, Ville-Pekka; Riihimäki, Jaakko; Ritvanen, Jussi; Piili, Heidi; Salminen, Antti

    Laser additive manufacturing (LAM) is a fabrication technology, which enables production of complex parts from metallic materials with mechanical properties comparable to those of conventionally machined parts. These LAM parts are manufactured via melting metallic powder layer by layer with laser beam. Aim of this study is to define preliminarily the possibilities of using electroplating to supreme surface properties. Electrodeposited nickel and chromium as well as electroless (autocatalytic) deposited nickel was used to enhance laser additive manufactured and machined parts properties, like corrosion resistance, friction and wearing. All test pieces in this study were manufactured with a modified research AM equipment, equal to commercial EOS M series. The laser system used for tests was IPG 200 W CW fiber laser. The material used in this study for additive manufacturing was commercial stainless steel powder grade named SS316L. This SS316L is not equal to AISI 316L grade, but commercial name of this kind of powder is widely known in additive manufacturing as SS316L. Material used for fabrication of comparison test pieces (i.e. conventionally manufactured) was AISI 316L stainless steel bar. Electroplating was done in matrix cell and electroless was done in plastic sink properties of plated parts were tested within acetic acid salt spray corrosion chamber (AASS, SFS-EN-ISO 9227 standard). Adhesion of coating, friction and wearing properties were tested with Pin-On-Rod machine. Results show that in these preliminary tests, LAM parts and machined parts have certain differences due to manufacturing route and surface conditions. These have an effect on electroplated and electroless parts features on adhesion, corrosion, wearing and friction. However, further and more detailed studies are needed to fully understand these phenomena.

  3. Temperature Profile and Imaging Analysis of Laser Additive Manufacturing of Stainless Steel

    NASA Astrophysics Data System (ADS)

    Islam, M.; Purtonen, T.; Piili, H.; Salminen, A.; Nyrhilä, O.

    Powder bed fusion is a laser additive manufacturing (LAM) technology which is used to manufacture parts layer-wise from powdered metallic materials. The technology has advanced vastly in the recent years and current systems can be used to manufacture functional parts for e.g. aerospace industry. The performance and accuracy of the systems have improved also, but certain difficulties in the powder fusion process are reducing the final quality of the parts. One of these is commonly known as the balling phenomenon. The aim of this study was to define some of the process characteristics in powder bed fusion by performing comparative studies with two different test setups. This was done by comparing measured temperature profiles and on-line photography of the process. The material used during the research was EOS PH1 stainless steel. Both of the test systems were equipped with 200 W single mode fiber lasers. The main result of the research was that some of the process instabilities are resulting from the energy input during the process.

  4. Thermographic process monitoring in powderbed based additive manufacturing

    SciTech Connect

    Krauss, Harald Zaeh, Michael F.; Zeugner, Thomas

    2015-03-31

    Selective Laser Melting is utilized to build metallic parts directly from CAD-Data by solidification of thin powder layers through application of a fast scanning laser beam. In this study layerwise monitoring of the temperature distribution is used to gather information about the process stability and the resulting part quality. The heat distribution varies with different kinds of parameters including scan vector length, laser power, layer thickness and inter-part distance in the job layout which in turn influence the resulting part quality. By integration of an off-axis mounted uncooled thermal detector the solidification as well as the layer deposition are monitored and evaluated. Errors in the generation of new powder layers usually result in a locally varying layer thickness that may cause poor part quality. For effect quantification, the locally applied layer thickness is determined by evaluating the heat-up of the newly deposited powder. During the solidification process space and time-resolved data is used to characterize the zone of elevated temperatures and to derive locally varying heat dissipation properties. Potential quality indicators are evaluated and correlated to the resulting part quality: Thermal diffusivity is derived from a simplified heat dissipation model and evaluated for every pixel and cool-down phase of a layer. This allows the quantification of expected material homogeneity properties. Maximum temperature and time above certain temperatures are measured in order to detect hot spots or delamination issues that may cause a process breakdown. Furthermore, a method for quantification of sputter activity is presented. Since high sputter activity indicates unstable melt dynamics this can be used to identify parameter drifts, improper atmospheric conditions or material binding errors. The resulting surface structure after solidification complicates temperature determination on the one hand but enables the detection of potential surface defects

  5. Thermographic process monitoring in powderbed based additive manufacturing

    NASA Astrophysics Data System (ADS)

    Krauss, Harald; Zeugner, Thomas; Zaeh, Michael F.

    2015-03-01

    Selective Laser Melting is utilized to build metallic parts directly from CAD-Data by solidification of thin powder layers through application of a fast scanning laser beam. In this study layerwise monitoring of the temperature distribution is used to gather information about the process stability and the resulting part quality. The heat distribution varies with different kinds of parameters including scan vector length, laser power, layer thickness and inter-part distance in the job layout which in turn influence the resulting part quality. By integration of an off-axis mounted uncooled thermal detector the solidification as well as the layer deposition are monitored and evaluated. Errors in the generation of new powder layers usually result in a locally varying layer thickness that may cause poor part quality. For effect quantification, the locally applied layer thickness is determined by evaluating the heat-up of the newly deposited powder. During the solidification process space and time-resolved data is used to characterize the zone of elevated temperatures and to derive locally varying heat dissipation properties. Potential quality indicators are evaluated and correlated to the resulting part quality: Thermal diffusivity is derived from a simplified heat dissipation model and evaluated for every pixel and cool-down phase of a layer. This allows the quantification of expected material homogeneity properties. Maximum temperature and time above certain temperatures are measured in order to detect hot spots or delamination issues that may cause a process breakdown. Furthermore, a method for quantification of sputter activity is presented. Since high sputter activity indicates unstable melt dynamics this can be used to identify parameter drifts, improper atmospheric conditions or material binding errors. The resulting surface structure after solidification complicates temperature determination on the one hand but enables the detection of potential surface defects

  6. Additive Manufacturing of Anatomical Models from Computed Tomography Scan Data.

    PubMed

    Gür, Y

    2014-12-01

    The purpose of the study presented here was to investigate the manufacturability of human anatomical models from Computed Tomography (CT) scan data via a 3D desktop printer which uses fused deposition modelling (FDM) technology. First, Digital Imaging and Communications in Medicine (DICOM) CT scan data were converted to 3D Standard Triangle Language (STL) format by using In Vaselius digital imaging program. Once this STL file is obtained, a 3D physical version of the anatomical model can be fabricated by a desktop 3D FDM printer. As a case study, a patient's skull CT scan data was considered, and a tangible version of the skull was manufactured by a 3D FDM desktop printer. During the 3D printing process, the skull was built using acrylonitrile-butadiene-styrene (ABS) co-polymer plastic. The printed model showed that the 3D FDM printing technology is able to fabricate anatomical models with high accuracy. As a result, the skull model can be used for preoperative surgical planning, medical training activities, implant design and simulation to show the potential of the FDM technology in medical field. It will also improve communication between medical stuff and patients. Current result indicates that a 3D desktop printer which uses FDM technology can be used to obtain accurate anatomical models. PMID:26336695

  7. 3D printed microfluidic circuitry via multijet-based additive manufacturing.

    PubMed

    Sochol, R D; Sweet, E; Glick, C C; Venkatesh, S; Avetisyan, A; Ekman, K F; Raulinaitis, A; Tsai, A; Wienkers, A; Korner, K; Hanson, K; Long, A; Hightower, B J; Slatton, G; Burnett, D C; Massey, T L; Iwai, K; Lee, L P; Pister, K S J; Lin, L

    2016-02-21

    The miniaturization of integrated fluidic processors affords extensive benefits for chemical and biological fields, yet traditional, monolithic methods of microfabrication present numerous obstacles for the scaling of fluidic operators. Recently, researchers have investigated the use of additive manufacturing or "three-dimensional (3D) printing" technologies - predominantly stereolithography - as a promising alternative for the construction of submillimeter-scale fluidic components. One challenge, however, is that current stereolithography methods lack the ability to simultaneously print sacrificial support materials, which limits the geometric versatility of such approaches. In this work, we investigate the use of multijet modelling (alternatively, polyjet printing) - a layer-by-layer, multi-material inkjetting process - for 3D printing geometrically complex, yet functionally advantageous fluidic components comprised of both static and dynamic physical elements. We examine a fundamental class of 3D printed microfluidic operators, including fluidic capacitors, fluidic diodes, and fluidic transistors. In addition, we evaluate the potential to advance on-chip automation of integrated fluidic systems via geometric modification of component parameters. Theoretical and experimental results for 3D fluidic capacitors demonstrated that transitioning from planar to non-planar diaphragm architectures improved component performance. Flow rectification experiments for 3D printed fluidic diodes revealed a diodicity of 80.6 ± 1.8. Geometry-based gain enhancement for 3D printed fluidic transistors yielded pressure gain of 3.01 ± 0.78. Consistent with additional additive manufacturing methodologies, the use of digitally-transferrable 3D models of fluidic components combined with commercially-available 3D printers could extend the fluidic routing capabilities presented here to researchers in fields beyond the core engineering community. PMID:26725379

  8. 40 CFR 79.21 - Information and assurances to be provided by the additive manufacturer.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... fuel additive will be sold, offered for sale, or introduced into commerce, and the fuel additive manufacturer's recommended range of concentration and purpose-in-use for each such type of fuel. (e) Such other... (e) of this section as provided in § 79.5(b). (g) Assurances that the additive manufacturer will...

  9. Thermographic In-Situ Process Monitoring of the Electron Beam Melting Technology used in Additive Manufacturing

    SciTech Connect

    Dinwiddie, Ralph Barton; Dehoff, Ryan R; Lloyd, Peter D; Lowe, Larry E; Ulrich, Joseph B

    2013-01-01

    Oak Ridge National Laboratory (ORNL) has been utilizing the ARCAM electron beam melting technology to additively manufacture complex geometric structures directly from powder. Although the technology has demonstrated the ability to decrease costs, decrease manufacturing lead-time and fabricate complex structures that are impossible to fabricate through conventional processing techniques, certification of the component quality can be challenging. Because the process involves the continuous deposition of successive layers of material, each layer can be examined without destructively testing the component. However, in-situ process monitoring is difficult due to metallization on inside surfaces caused by evaporation and condensation of metal from the melt pool. This work describes a solution to one of the challenges to continuously imaging inside of the chamber during the EBM process. Here, the utilization of a continuously moving Mylar film canister is described. Results will be presented related to in-situ process monitoring and how this technique results in improved mechanical properties and reliability of the process.

  10. Properties of Inconel 625 Mesh Structures Grown by Electron Beam Additive Manufacturing

    SciTech Connect

    List III, Frederick Alyious; Dehoff, Ryan R; Lowe, Larry E; Sames, William J

    2014-01-01

    Relationships between electron beam parameters (beam current, beam speed, and beam focus) and physical properties (mass, diameter, elastic modulus, and yield strength) have been investigated for Inconel 625 mesh cubes fabricated using an additive manufacturing technology based on electron beam melting. The elastic modulus and yield strength of the mesh cubes have been systematically varied by approximately a factor of ten by changing the electron beam parameters. Simple models have been used to understand better these relationships. Structural anisotropies of the mesh associated with the layered build architecture have been observed and may contribute, along with microstructural anisotropies, to the anisotropic mechanical properties of the mesh. Knowledge of this kind is likely applicable to other metal and alloy systems and is essential to rapidly realize the full potential of this burgeoning technology.

  11. Microstructural Characterization of Bonding Interfaces in Aluminum 3003 Blocks Fabricated by Ultrasonic Additive Manufacturing

    SciTech Connect

    Schick, D. E.; Babu, Sudarsanam Suresh; Lippold, John C; Hahnlen, R.M.; Dapino, M.J.; Dehoff, Ryan R; Collins, P.

    2010-01-01

    Ultrasonic additive manufacturing (UAM) is a process by which hybrid and near-netshaped products can be manufactured from thin metallic tapes. One of the main concerns of UAM is the development of anisotropic mechanical properties. In this work, the microstructures in the bond regions are characterized with optical and electron microscopy. Recrystallization and grain growth across the interface are proposed as a mechanism for the bond formation. The presence of voids or unbonded areas, which reduce the load-bearing cross section and create a stress intensity factor, is attributed to the transfer of the sonotrode texture to the new foil layer. This results in large peaks and valleys that are not filled in during processing. Tensile testing revealed the weld interface strength was 15% of the bulk foil. Shear tests of the weld interfaces showed almost 50% of the bulk shear strength of the material. Finally, optical microscopy of the fracture surfaces from the tensile tests revealed 34% of the interface area was unbonded.

  12. Evaluation of laser ultrasonic testing for inspection of metal additive manufacturing

    NASA Astrophysics Data System (ADS)

    Everton, Sarah; Dickens, Phill; Tuck, Chris; Dutton, Ben

    2015-03-01

    Additive Manufacturing (AM) offers a number of benefits over conventional processes. However, in order for these benefits to be realised, further development and integration of suitable monitoring and closed loop control systems are needed. Laser Ultrasonic Testing (LUT) is an inspection technology which shows potential for in-situ monitoring of metallic AM processes. Non-contact measurements can be performed on curved surfaces and in difficult to reach areas, even at elevated temperatures. Interrogation of each build layer generates defect information which can be used to highlight processing errors and allow for real-time modification of processing parameters, enabling improved component quality and yield. This study evaluates the use of laser-generated surface waves to detect artificially generated defects in titanium alloy (Ti- 6Al-4V) samples produced by laser-based Powder Bed Fusion. The trials undertaken utilise the latest LUT equipment, recently installed at Manufacturing Technology Centre which is capable of being controlled remotely. This will allow the system to optimise or adapt "on-the-fly", simplifying the eventual integration of the system within an AM machine.

  13. Next-generation biomedical implants using additive manufacturing of complex, cellular and functional mesh arrays.

    PubMed

    Murr, L E; Gaytan, S M; Medina, F; Lopez, H; Martinez, E; Machado, B I; Hernandez, D H; Martinez, L; Lopez, M I; Wicker, R B; Bracke, J

    2010-04-28

    In this paper, we examine prospects for the manufacture of patient-specific biomedical implants replacing hard tissues (bone), particularly knee and hip stems and large bone (femoral) intramedullary rods, using additive manufacturing (AM) by electron beam melting (EBM). Of particular interest is the fabrication of complex functional (biocompatible) mesh arrays. Mesh elements or unit cells can be divided into different regions in order to use different cell designs in different areas of the component to produce various or continually varying (functionally graded) mesh densities. Numerous design elements have been used to fabricate prototypes by AM using EBM of Ti-6Al-4V powders, where the densities have been compared with the elastic (Young) moduli determined by resonant frequency and damping analysis. Density optimization at the bone-implant interface can allow for bone ingrowth and cementless implant components. Computerized tomography (CT) scans of metal (aluminium alloy) foam have also allowed for the building of Ti-6Al-4V foams by embedding the digital-layered scans in computer-aided design or software models for EBM. Variations in mesh complexity and especially strut (or truss) dimensions alter the cooling and solidification rate, which alters the alpha-phase (hexagonal close-packed) microstructure by creating mixtures of alpha/alpha' (martensite) observed by optical and electron metallography. Microindentation hardness measurements are characteristic of these microstructures and microstructure mixtures (alpha/alpha') and sizes. PMID:20308113

  14. Net shape manufacturing of ceramic micro parts with tailored graded layers

    NASA Astrophysics Data System (ADS)

    Hassanin, H.; Jiang, K.

    2014-01-01

    Presented in this paper is a novel net shape manufacturing technology for making three-dimensional micro parts with functionally graded layers. Alumina/zirconia micro parts with either core-shell or top-bottom functionally graded material (FGM) profiles have been successfully fabricated by altering both the surface characteristics of polydimethylsiloxane (PDMS) micro moulds and ceramic suspensions composition. PDMS surface modifications were performed to achieve moulds with hydrophilic surfaces, which were used to form core/shell FGM green layers. On the other hand, moulds with hydrophobic surfaces were used to form top-bottom green layers. Cracks have been found between consecutive layers in both the green and sintered micro parts. It was found that, at dispersant concentration of about 9.0 mg g-1, the differences in the drying shrinkage between layers is less than 0.5%. In addition, layers of composition of 100% Al2O3-0% YSZ, 20% Al2O3-80% YSZ and 40% Al2O3-60% YSZ were found to produce less shrinkage difference during sintering. After optimization of both green and sintering layers, crack free core/shell and top-bottom alumina/zirconia FGM micro parts were successfully obtained. The proposed process enables the production of micro patterns tailored with functionally graded microstructures to locally enhance properties and performance.

  15. Manufacturing three-dimensional nickel titanium articles using layer-by-layer laser-melting technology

    NASA Astrophysics Data System (ADS)

    Shishkovsky, I. V.; Yadroitsev, I. A.; Smurov, I. Yu.

    2013-12-01

    Specific features of layer-by-layer synthesis of three-dimensional (3D) nickel titanium (NiTi, nitinol) articles by selective laser melting (SLM) technology have been studied. Nonporous 3D nitinol articles have been obtained for the first time in a single technological cycle. A necessary condition was that the NiTi powder medium was heated to 500°C during sintering. The structure and composition of intermetallic phases in SLM-synthesized samples have been studied by optical metallography, microhardness measurements, scanning electron microscopy, X-ray diffraction, and energy-dispersive x-ray analysis techniques. Optimum SLM regimes for manufacturing NiTi articles and promising medical applications of this material are considered.

  16. The use of elemental powder mixes in laser-based additive manufacturing

    NASA Astrophysics Data System (ADS)

    Clayton, Rodney Michael

    This study examines the use and functionality of laser depositing alloys from mixes of elemental metallic powders. Through the use of laser-based additive manufacturing (LAM), near net-shaped 3-Dimensional metallic parts can be produced in a layer-by-layer fashion. It is customary for pre-alloyed powders to be used in this process. However, mixes of elemental powders can be used to produce alloys that are formed during the deposition process. This alternative technique requires that the elemental powders adequately mix during deposition for a homogeneous deposit to be produced. Cost savings and versatility are among several of the advantages to using elemental powder mixes in LAM. Representative alloys of 316 and 430 Stainless Steel (SS) and Ti-6Al-4V were produced with elemental powder mixes during this research. These deposits were then compared to deposits of the same material manufactured with pre-alloyed powder. Comparison between the two types of samples included; EDS analysis to examine chemical homogeneity, metallography techniques to compare microstructures, and finally hardness testing to observe mechanical properties. The enthalpy of mixing is also discussed as this can impact the resulting homogeneity of deposits produced with mixes of elemental powders. Some differences were observed between the two types of deposits for 430 SS and Ti-6Al-4V. Results indicate that deposits fabricated with mixes of elemental powders can be produced to an equivalent quality of pre-alloyed powder deposits for 316 SS. This research also proposes potential alloys that could be considered for use in an elemental powder mixing technique.

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

    NASA Technical Reports Server (NTRS)

    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.

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

    PubMed

    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. PMID:23349081

  19. Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University

    NASA Astrophysics Data System (ADS)

    Nassar, Abdalla R.; Reutzel, Edward W.; Brown, Stephen W.; Morgan, John P.; Morgan, Jacob P.; Natale, Donald J.; Tutwiler, Rick L.; Feck, David P.; Banks, Jeffery C.

    2016-04-01

    Additive manufacturing of metal components through directed energy deposition or powder bed fusion is a complex undertaking, often involving hundreds or thousands of individual laser deposits. During processing, conditions may fluctuate, e.g. material feed rate, beam power, surrounding gas composition, local and global temperature, build geometry, etc., leading to unintended variations in final part geometry, microstructure and properties. To assess or control as-deposited quality, researchers have used a variety of methods, including those based on sensing of melt pool and plume emission characteristics, characteristics of powder application, and layer-wise imaging. Here, a summary of ongoing process monitoring activities at Penn State is provided, along with a discussion of recent advancements in the area of layer-wise image acquisition and analysis during powder bed fusion processing. Specifically, methods that enable direct comparisons of CAD model, build images, and 3D micro-tomographic scan data will be covered, along with thoughts on how such analyses can be related to overall process quality.

  20. Unexpected δ-Phase Formation in Additive-Manufactured Ni-Based Superalloy

    NASA Astrophysics Data System (ADS)

    Idell, Y.; Levine, L. E.; Allen, A. J.; Zhang, F.; Campbell, C. E.; Olson, G. B.; Gong, J.; Snyder, D. R.; Deutchman, H. Z.

    2016-03-01

    An as-built and solutionized Ni-based superalloy built by additive manufacturing through a direct metal laser sintering technique is characterized to understand the microstructural differences as compared to the as-wrought alloy. Initially, each layer undergoes rapid solidification as it is melted by the laser; however, as the part is built, the underlying layers experience a variety of heating and cooling cycles that produce significant microsegregation of niobium which allows for the formation of the deleterious δ-phase. The as-built microstructure was characterized through Vickers hardness, optical microscopy, scanning and transmission electron microscopy, electron back-scattering diffraction, x-ray diffraction, and synchrotron x-ray microLaue diffraction. The isothermal formation and growth of the δ-phase were characterized using synchrotron-based in situ small angle and wide angle x-ray scattering experiments. These experimental results are compared with multicomponent diffusion simulations that predict the phase fraction and composition. The high residual stresses and unexpected formation of the δ-phase will require further annealing treatments to be designed so as to remove these deficiencies and obtain an optimized microstructure.

  1. Magnetically anisotropic additive for scalable manufacturing of polymer nanocomposite: iron-coated carbon nanotubes

    NASA Astrophysics Data System (ADS)

    Yamamoto, Namiko; Manohara, Harish; Platzman, Ellen

    2016-02-01

    Novel nanoparticles additives for polymer nanocomposites were prepared by coating carbon nanotubes (CNTs) with ferromagnetic iron (Fe) layers, so that their micro-structures can be bulk-controlled by external magnetic field application. Application of magnetic fields is a promising, scalable method to deliver bulk amount of nanocomposites while maintaining organized nanoparticle assembly throughout the uncured polymer matrix. In this work, Fe layers (˜18 nm thick) were deposited on CNTs (˜38 nm diameter and ˜50 μm length) to form thin films with high aspect ratio, resulting in a dominance of shape anisotropy and thus high coercivity of ˜50-100 Oe. The Fe-coated CNTs were suspended in water and applied with a weak magnetic field of ˜75 G, and yet preliminary magnetic assembly was confirmed. Our results demonstrate that the fabricated Fe-coated CNTs are magnetically anisotropic and effectively respond to magnetic fields that are ˜103 times smaller than other existing work (˜105 G). We anticipate this work will pave the way for effective property enhancement and bulk application of CNT-polymer nanocomposites, through controlled micro-structure and scalable manufacturing.

  2. Characterization and analysis of surface notches on Ti-alloy plates fabricated by additive manufacturing techniques

    NASA Astrophysics Data System (ADS)

    Chan, Kwai S.

    2015-12-01

    Rectangular plates of Ti-6Al-4V with extra low interstitial (ELI) were fabricated by layer-by-layer deposition techniques that included electron beam melting (EBM) and laser beam melting (LBM). The surface conditions of these plates were characterized using x-ray micro-computed tomography. The depth and radius of surface notch-like features on the LBM and EBM plates were measured from sectional images of individual virtual slices of the rectangular plates. The stress concentration factors of individual surface notches were computed and analyzed statistically to determine the appropriate distributions for the notch depth, notch radius, and stress concentration factor. These results were correlated with the fatigue life of the Ti-6Al-4V ELI alloys from an earlier investigation. A surface notch analysis was performed to assess the debit in the fatigue strength due to the surface notches. The assessment revealed that the fatigue lives of the additively manufactured plates with rough surface topographies and notch-like features are dominated by the fatigue crack growth of large cracks for both the LBM and EBM materials. The fatigue strength reduction due to the surface notches can be as large as 60%-75%. It is concluded that for better fatigue performance, the surface notches on EBM and LBM materials need to be removed by machining and the surface roughness be improved to a surface finish of about 1 μm.

  3. Additive Manufacturing and Characterization of Polylactic Acid (PLA) Composites Containing Metal Reinforcements

    NASA Technical Reports Server (NTRS)

    Kuentz, Lily; Salem, Anton; Singh, M.; Halbig, M. C.; Salem, J. A.

    2016-01-01

    Additive manufacturing of polymeric systems using 3D printing has become quite popular recently due to rapid growth and availability of low cost and open source 3D printers. Two widely used 3D printing filaments are based on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) systems. PLA is much more environmentally friendly in comparison to ABS since it is made from renewable resources such as corn, sugarcane, and other starches as precursors. Recently, polylactic acid-based metal powder containing composite filaments have emerged which could be utilized for multifunctional applications. The composite filaments have higher density than pure PLA, and the majority of the materials volume is made up of polylactic acid. In order to utilize functionalities of composite filaments, printing behavior and properties of 3-D printed composites need to be characterized and compared with the pure PLA materials. In this study, pure PLA and composite specimens with different metallic reinforcements (Copper, Bronze, Tungsten, Iron, etc) were 3D printed at various layer heights and resulting microstructures and properties were characterized. Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) behavior of filaments with different reinforcements were studied. The microscopy results show an increase in porosity between 3-D printed regular PLA and the metal composite PLA samples, which could produce weaker mechanical properties in the metal composite materials. Tensile strength and fracture toughness behavior of specimens as a function of print layer height will be presented.

  4. The Use of Additive Manufacturing for Fabrication of Multi-Function Small Satellite Structures

    SciTech Connect

    Horais, Brian J; Love, Lonnie J; Dehoff, Ryan R

    2013-01-01

    The use of small satellites in constellations is limited only by the growing functionality of smallsats themselves. Additive manufacturing provides exciting new design opportunities for development of multifunction CubeSat structures that integrate such functions as propulsion and thermal control into the satellite structures themselves. Manufacturing of these complex multifunction structures is now possible in lightweight, high strength, materials such as titanium by using existing electron beam melting additive manufacturing processes. However, the use of today's additive manufacturing capabilities is often cost-prohibitive for small companies due to the large capital investments required. To alleviate this impediment the U.S. Department of Energy has established a Manufacturing Demonstration Facility (MDF) at their Oak Ridge National Laboratory (ORNL) in Tennessee that provides industry access to a broad range of energy-efficient additive manufacturing equipment for collaborative use by both small and large organizations. This paper presents a notional CubeSat multifunction design that integrates the propulsion system into a three-unit (3U) CubeSat structure. The full-scale structure has been designed and fabricated at the ORNL MDF. The use of additive manufacturing for spacecraft fabrication is opening up many new possibilities in design and fabrication capabilities for what had previously been impossible structures to fabricate.

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

    NASA Technical Reports Server (NTRS)

    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.

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

    NASA Technical Reports Server (NTRS)

    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.

  7. Carbon additives for electrical double layer capacitor electrodes

    NASA Astrophysics Data System (ADS)

    Weingarth, D.; Cericola, D.; Mornaghini, F. C. F.; Hucke, T.; Kötz, R.

    2014-11-01

    Electrochemical double layer capacitors (EDLCs) are inherently high power devices when compared to rechargeable batteries. While capacitance and energy storage ability are mainly increased by optimizing the electrode active material or the electrolyte, the power capability could be improved by including conductive additives in the electrode formulations. This publication deals with the use of four different carbon additives - two carbon blacks and two graphites - in standard activated carbon based EDLC electrodes. The investigations include: (i) physical characterization of carbon powder mixtures such as surface area, press density, and electrical resistivity measurements, and (ii), electrochemical characterization via impedance spectroscopy and cyclic voltammetry of full cells made with electrodes containing 5 wt.% of carbon additive and compared to cells made with pure activated carbon electrodes in organic electrolyte. Improved cell performance was observed in both impedance and cyclic voltammetry responses. The results are discussed considering the main characteristics of the different carbon additives, and important considerations about electrode structure and processability are drawn.

  8. 3D Machine Vision and Additive Manufacturing: Concurrent Product and Process Development

    NASA Astrophysics Data System (ADS)

    Ilyas, Ismet P.

    2013-06-01

    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.

  9. Precipitation Reactions in Age-Hardenable Alloys During Laser Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Jägle, Eric A.; Sheng, Zhendong; Wu, Liang; Lu, Lin; Risse, Jeroen; Weisheit, Andreas; Raabe, Dierk

    2016-03-01

    We describe and study the thermal profiles experienced by various age-hardenable alloys during laser additive manufacturing (LAM), employing two different manufacturing techniques: selective laser melting and laser metal deposition. Using scanning electron microscopy and atom probe tomography, we reveal at which stages during the manufacturing process desired and undesired precipitation reactions can occur in age-hardenable alloys. Using examples from a maraging steel, a nickel-base superalloy and a scandium-containing aluminium alloy, we demonstrate that precipitation can already occur during the production of the powders used as starting material, during the deposition of material (i.e. during solidification and subsequent cooling), during the intrinsic heat treatment effected by LAM (i.e. in the heat affected zones) and, naturally, during an ageing post-heat treatment. These examples demonstrate the importance of understanding and controlling the thermal profile during the entire additive manufacturing cycle of age-hardenable materials including powder synthesis.

  10. Nondestructive Evaluation of Additive Manufacturing State-of-the-Discipline Report

    NASA Technical Reports Server (NTRS)

    Waller, Jess M.; Parker, Bradford H.; Hodges, Kenneth L.; Burke, Eric R.; Walker, James L.

    2014-01-01

    This report summarizes the National Aeronautics and Space Administrations (NASA) state of the art of nondestructive evaluation (NDE) for additive manufacturing (AM), or "3-D printed", hardware. NASA's unique need for highly customized spacecraft and instrumentation is suited for AM, which offers a compelling alternative to traditional subtractive manufacturing approaches. The Agency has an opportunity to push the envelope on how this technology is used in zero gravity, an enable in-space manufacturing of flight spares and replacement hardware crucial for long-duration, manned missions to Mars. The Agency is leveraging AM technology developed internally and by industry, academia, and other government agencies for its unique needs. Recent technical interchange meetings and workshops attended by NASA have identified NDE as a universal need for all aspects of additive manufacturing. The impact of NDE on AM is cross cutting and spans materials, processing quality assurance, testing and modeling disciplines. Appropriate NDE methods are needed before, during, and after the AM production process.

  11. Ti-6Al-4V Additively Manufactured by Selective Laser Melting with Superior Mechanical Properties

    NASA Astrophysics Data System (ADS)

    Xu, W.; Sun, S.; Elambasseril, J.; Liu, Q.; Brandt, M.; Qian, M.

    2015-03-01

    The Achilles' heel of additively manufactured Ti-6Al-4V by selective laser melting (SLM) is its inferior mechanical properties compared with its wrought (forged) counterparts. Acicular α' martensite resulted from rapid cooling by SLM is primarily responsible for high strength but inadequate tensile ductility achieved in the as-fabricated state. This study presents a solution to eliminating the adverse effect of the nonequilibrium α' martensite. This is achieved by enabling in situ martensite decomposition into a novel ultrafine (200-300 nm) lamellar ( α + β) microstructure via the selection of an array of processing variables including the layer thickness, energy density, and focal offset distance. The resulting tensile elongation reached 11.4% while the yield strength was kept above 1100 MPa. These properties compare favorably with those of mill-annealed Ti-6Al-4V consisting of globular α and β. The fatigue life of SLM-fabricated Ti-6Al-4V with an ultrafine lamellar ( α + β) structure has approached that of the mill-annealed counterparts and is much superior to that of SLM-fabricated Ti-6Al-4V with α' martensite.

  12. The influence of heat accumulation on the surface roughness in powder-bed additive manufacturing

    NASA Astrophysics Data System (ADS)

    Jamshidinia, Mahdi; Kovacevic, Radovan

    2015-03-01

    The influence of heat accumulation on surface roughness during powder-bed additive manufacturing was investigated. A series of Ti-6Al-4V thin plates were produced by using an identical heat input by electron beam melting® (EBM). Spacing distances of 5 mm, 10 mm, and 20 mm were used. The surface roughness of as-built thin plates was measured using a two-axis profilometer. A numerical model was developed to study the influence of spacing distance on heat accumulation. An inverse relationship between the spacing distance and surface roughness was revealed. The experimental and numerical results showed that the surface quality of buildups could be controlled not only by process parameters, but also by the arrangement of components in the buildup chamber. At a constant spacing distance, an increase in the number of powder layers resulted in the accumulation of more heat between the thin plates. An increase in the spacing distance resulted in an upward translation of the Bearing Area Curve (BAC) toward shallower depths, with a reduced core roughness depth (Rk) and peak height (Rpk). A logarithmic regression equation was established from the experimental data. This equation could be used to predict the surface roughness of parts fabricated by EBM® in the studied range of spacing distances.

  13. Mechanically tunable aspheric lenses via additive manufacture of hanging elastomeric droplets for microscopic applications

    NASA Astrophysics Data System (ADS)

    Fuh, Yiin-Kuen; Chen, Pin-Wen; Lai, Zheng-Hong

    2016-07-01

    Mechanically deformable lenses with dynamically tunable focal lengths have been developed in this work. The fabricated five types of aspheric polydimethylsiloxane (PDMS) lenses presented here have an initial focal length of 7.0, 7.8, 9.0, 10.0 and 10.2 mm. Incorporating two modes of operation in biconvex and concave-convex configurations, the focal lengths can be tuned dynamically as 5.2-10.2, 5.5-9.9, 6.6-11.9, 6.1-13.5 and 6.6-13.5 mm respectively. Additive manufacturing was utilized to fabricate these five types of aspheric lenses (APLs) via sequential layering of PDMS materials. Complex structures with three-dimensional features and shorter focal lengths can be successfully produced by repeatedly depositing, inverting and curing controlled PDMS volume onto previously cured PDMS droplets. From our experiments, we empirically found a direct dependence of the focal length of the lenses with the amount (volume) of deposited PDMS droplets. This new mouldless, low-cost, and flexible lens fabrication method is able to transform an ordinary commercial smartphone camera into a low-cost portable microscope. A few microscopic features can be readily visualized, such as wrinkles of ladybird pupa and printed circuit board. The fabrication technique by successively applying hanging droplet and facile mechanical focal-length-tuning set-up can be easily adopted in the development of high-performance optical lenses.

  14. Experimental Study of Disruption of Columnar Grains During Rapid Solidification in Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Manogharan, Guha; Yelamanchi, Bharat; Aman, Ronald; Mahbooba, Zaynab

    2016-03-01

    Over the years, many studies have been conducted to study and analyze the grain structures of metal alloys during additive manufacturing to improve mechanical properties. In particular, columnar grains are observed predominantly during rapid solidification of molten metal. This leads to lower mechanical properties and requires expensive secondary heat-treatment processes. This study is aimed at disrupting the formation of columnar grain growth during rapid solidification using ultrasonic vibration and analyzes the effects on grain structure and mechanical properties. A gas-metal arc welder mounted on a Rep-Rap-based low-cost metal 3 Dimension printer was used to deposit ER70S-6 mild steel layers on a plate. A contact-type ultrasonic transducer with a control system to vary the frequency and power of the vibration was used. The effects of ultrasonic vibration were determined from the statistical analysis of microstructure and micro-indentation techniques on the deposited layer and heat-affected zone. It was found that both frequency and interaction between frequency and power had significant impact on the refinement of average grain size up to 10.64% and increased the number of grains by approximately 41.78%. Analysis of micro-indentation tests showed that there was an increase of approximately 14.30% in micro-hardness due to the applied frequency during rapid solidification. A pole diagram shows that application of vibration causes randomization of grain orientation. Along with the results from this study, further efforts in modeling and experimentation of multi-directional vibrations would lead to a better understanding of disrupting columnar grains in applications that use mechanical vibrations, such as welding, directed energy deposition, brazing, etc.

  15. Rapid additive manufacturing of MR compatible multipinhole collimators with selective laser melting of tungsten powder

    SciTech Connect

    Deprez, Karel; Vandenberghe, Stefaan; Van Audenhaege, Karen; Van Vaerenbergh, Jonas; Van Holen, Roel

    2013-01-15

    Purpose: The construction of complex collimators with a high number of oblique pinholes is very labor intensive, expensive or is sometimes impossible with the current available techniques (drilling, milling or electric discharge machining). All these techniques are subtractive: one starts from solid plates and the material at the position of the pinholes is removed. The authors used a novel technique for collimator construction, called metal additive manufacturing. This process starts with a solid piece of tungsten on which a first layer of tungsten powder is melted. Each subsequent layer is then melted on the previous layer. This melting is done by selective laser melting at the locations where the CAD design file defines solid material. Methods: A complex collimator with 20 loftholes with 500 {mu}m diameter pinhole opening was designed and produced (16 mm thick and 70 Multiplication-Sign 52 mm{sup 2} transverse size). The density was determined, the production accuracy was measured (GOM ATOS II Triple Scan, Nikon AZ100M microscope, Olympus IMT200 microscope). Point source measurements were done by mounting the collimator on a SPECT detector. Because there is increasing interest in dual-modality SPECT-MR imaging, the collimator was also positioned in a 7T MRI scanner (Bruker Pharmascan). A uniform phantom was acquired using T1, T2, and T2* sequences to check for artifacts or distortion of the phantom images due to the collimator presence. Additionally, three tungsten sample pieces (250, 500, and 750 {mu}m thick) were produced. The density, attenuation (140 keV beam), and uniformity (GE eXplore Locus SP micro-CT) of these samples were measured. Results: The density of the collimator was equal to 17.31 {+-} 0.10 g/cm{sup 3} (89.92% of pure tungsten). The production accuracy ranges from -260 to +650 {mu}m. The aperture positions have a mean deviation of 5 {mu}m, the maximum deviation was 174 {mu}m and the minimum deviation was -122 {mu}m. The mean aperture diameter

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

    DOE PAGESBeta

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

    2016-07-08

    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,more » 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. Additionally, the experimental strain distribution can help validate finite element models which many industries use to predict the residual stress distributions in additive manufactured components.« less

  17. An academic, clinical and industrial update on electrospun, additive manufactured and imprinted medical devices.

    PubMed

    Ryan, Christina N M; Fuller, Kieran P; Larrañaga, Aitor; Biggs, Manus; Bayon, Yves; Sarasua, Jose R; Pandit, Abhay; Zeugolis, Dimitrios I

    2015-01-01

    Electrospinning, additive manufacturing and imprint lithography scaffold fabrication technologies have attracted great attention in biomedicine, as they allow production of two- and three- dimensional constructs with tuneable topographical and geometrical features. In vitro data demonstrate that electrospun and imprinted substrates offer control over permanently differentiated and stem cell function. Advancements in functionalisation strategies have further enhanced the bioactivity and reparative capacity of electrospun and additive manufactured devices, as has been evidenced in several preclinical models. Despite this overwhelming success in academic setting, only a few technologies have reached the clinic and only a fraction of them have become commercially available products. PMID:26111642

  18. Investigation of plasma arc welding as a method for the additive manufacturing of titanium-(6)aluminum-(4)vanadium alloy components

    NASA Astrophysics Data System (ADS)

    Stavinoha, Joe N.

    The process of producing near net-shape components by material deposition is known as additive manufacturing. All additive manufacturing processes are based on the addition of material with the main driving forces being cost reduction and flexibility in both manufacturing and product design. With wire metal deposition, metal is deposited as beads side-by-side and layer-by-layer in a desired pattern to build a complete component or add features on a part. There are minimal waste products, low consumables, and an efficient use of energy and feedstock associated with additive manufacturing processes. Titanium and titanium alloys are useful engineering materials that possess an extraordinary combination of properties. Some of the properties that make titanium advantageous for structural applications are its high strength-to-weight ratio, low density, low coefficient of thermal expansion, and good corrosion resistance. The most commonly used titanium alloy, Ti-6Al-4V, is typically used in aerospace applications, pressure vessels, aircraft gas turbine disks, cases and compressor blades, and surgical implants. Because of the high material prices associated with titanium alloys, the production of near net-shape components by additive manufacturing is an attractive option for the manufacturing of Ti-6Al-4V alloy components. In this thesis, the manufacturing of cylindrical Ti-6Al-4V alloy specimens by wire metal deposition utilizing the plasma arc welding process was demonstrated. Plasma arc welding is a cost effective additive manufacturing technique when compared to other current additive manufacturing methods such as laser beam welding and electron beam welding. Plasma arc welding is considered a high-energy-density welding processes which is desirable for the successful welding of titanium. Metal deposition was performed using a constant current plasma arc welding power supply, flow-purged welding chamber, argon shielding and orifice gas, ERTi-5 filler metal, and Ti-6Al

  19. Solving the Big Data (BD) Problem in Advanced Manufacturing (Subcategory for work done at Georgia Tech. Study Process and Design Factors for Additive Manufacturing Improvement)

    SciTech Connect

    Clark, Brett W.; Diaz, Kimberly A.; Ochiobi, Chinaza Darlene; Paynabar, Kamran

    2015-09-01

    3D printing originally known as additive manufacturing is a process of making 3 dimensional solid objects from a CAD file. This ground breaking technology is widely used for industrial and biomedical purposes such as building objects, tools, body parts and cosmetics. An important benefit of 3D printing is the cost reduction and manufacturing flexibility; complex parts are built at the fraction of the price. However, layer by layer printing of complex shapes adds error due to the surface roughness. Any such error results in poor quality products with inaccurate dimensions. The main purpose of this research is to measure the amount of printing errors for parts with different geometric shapes and to analyze them for finding optimal printing settings to minimize the error. We use a Design of Experiments framework, and focus on studying parts with cone and ellipsoid shapes. We found that the orientation and the shape of geometric shapes have significant effect on the printing error. From our analysis, we also determined the optimal orientation that gives the least printing error.

  20. An additive manufacturing acrylic for use in the 32 Tesla all superconducting magnet

    NASA Astrophysics Data System (ADS)

    Johnson, Zachary

    The National High Magnetic Field Laboratory is building a world record all superconducting magnet known as the "32T". It requires many thousands of parts, but in particular one kind is unusually expensive to manufacture, called "heater lead covers". These parts are traditionally made out of a glass filled epoxy known as G-10, and conventionally machined. The machining is the expensive portion, as there are many tight tolerance details. The proposal in this paper is to change the material and manufacturing method to additive manufacturing with the material called "RGD 430". The cost per part with traditional machining is approximately 1,500 each. The cost per part with additive manufacturing of RGD 430 is approximately 32.5 each. There will be at least 14 of this style of part on the completed 32T project. Thus the total cost for the project will be reduced from 21,000 to 455, a 98% cost savings. The additive manufacturing also allows the machine designers to expand the dimensions of the part to any shape possible. Through testing of the material it was found to follow the common polymer characteristics. Its linear elastic modulus at cryogenic temperatures approached 10 GPa. The yield strength was always over 100 MPa, when not damaged. The fracture mechanism was repeatable, and brittle in cryogenic environments. The geometric tolerancing of the additive manufacturing process are, as expected extremely precise. The final tolerances for dimensions in the profile of the printer are more precise than +/- 0.10mm. The final tolerances for dimensions in the thickness of the printer are more precise than +/-0.25mm. Before utilizing the material, there should be a few additional tests run on it to ensure it will work in-situ. Those tests are outside the scope of this thesis.

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

    NASA Technical Reports Server (NTRS)

    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

  2. Evaluation of Additively Manufactured Metals for Use in Oxygen Systems Project

    NASA Technical Reports Server (NTRS)

    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.

  3. Pyramidal Fin Arrays Performance Using Streamwise Anisotropic Materials by Cold Spray Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Cormier, Yannick; Dupuis, Philippe; Jodoin, Bertrand; Corbeil, Antoine

    2016-01-01

    This work evaluates the thermal and hydrodynamic performance of pyramidal fin arrays produced using cold spray as an additive manufacturing process. Near-net-shaped pyramidal fin arrays of pure aluminum, pure nickel, and stainless steel 304 were manufactured. Fin array characterization such as fin porosity level and surface roughness evaluation was performed. The thermal conductivities of the three different coating materials were measured by laser flash analysis. The results obtained show a lower thermal efficiency for stainless steel 304, whereas the performances of the aluminum and nickel fin arrays are similar. This result is explained by looking closely at the fin and substrate roughness induced by the cold gas dynamic additive manufacturing process. The multi-material fin array sample has a better thermal efficiency than stainless steel 304. The work demonstrates the potential of the process to produce streamwise anisotropic fin arrays as well as the benefits of such arrays.

  4. Investigation of smart inspection of critical layer reticles using additional designer data to determine defect significance

    NASA Astrophysics Data System (ADS)

    Volk, William W.; Hess, Carl; Ruch, Wayne; Yu, Zongchang; Ma, Weimin; Fisher, Lisa; Vickery, Carl; Ma, Z. Mark

    2003-12-01

    With expected implementation of low k1 lithography on 193nm scanners for 65nm node wafer production, high resolution defect inspection will be needed to insure reticle quality and reticle manufacture process monitoring. Reticle cost and reticle defectivity are both increasing with each shrink to the next node. Simultaneously, system on chip (SoC) designs are increasing in which a large area of the exposure field typically contains dummy patterns and other features which are not electrically active. Knowing which defects will electrically impact device yield and performance can improve reticle manufacturing yield and cycle time -- resulting in lower reticle costs. This investigation examines the feasibility of using additional design data layers for die-to-database reticle inspection to determine in real time the relevance of a reticle defect by its location in the device (Smart InspectionTM). The impact to data preparation and inspection throughput is evaluated. The current prototype algorithm is built on the XPA and XPE die-to-database algorithms for chrome-on-glass and EPSM reticles, respectively. The algorithms implement variable sensitivity based on the additional design data regions. During defect review the defects are intelligently binned into the different predetermined design regions. Tests show the new Smart Inspection algorithm provides the capability of using higher than normal sensitivity in critical regions while reducing sensitivity in less critical regions to filter total defect counts and allow for the review of just defects that matter. Performance characterization of a variable sensitivity Smart Inspection algorithm is discussed in addition to the filtering of the total defect count during review to show the defects that matter to device performance. Using seven critical layer production reticles from a system on chip device we examine the applications of Smart Inspection by layer including active, poly, contact, metal and via layers. Data volume

  5. 40 CFR 79.21 - Information and assurances to be provided by the additive manufacturer.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... under 42 U.S.C. 7545(f)(4). (i) The manufacturer shall submit, or shall reference prior submissions... data and information as are specified in the designation of the additive in subpart D. (f) Assurances... the provisions of subpart F of this part....

  6. 40 CFR 79.21 - Information and assurances to be provided by the additive manufacturer.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... under 42 U.S.C. 7545(f)(4). (i) The manufacturer shall submit, or shall reference prior submissions... data and information as are specified in the designation of the additive in subpart D. (f) Assurances... the provisions of subpart F of this part....

  7. 3D/Additive Printing Manufacturing: A Brief History and Purchasing Guide

    ERIC Educational Resources Information Center

    Hughes, Bill; Wilson, Greg

    2016-01-01

    3D printing is recognized as a collection of technologies known as rapid prototyping, solid freeform fabrication, and most commonly, additive manufacturing (AM). With these emerging technologies it is possible to print (but not limited to): architectural models, discontinued car-part foundry patterns, industry-wide prototypes, human tissues, the…

  8. Perfusion electrodeposition of calcium phosphate on additive manufactured titanium scaffolds for bone engineering.

    PubMed

    Chai, Yoke Chin; Truscello, Silvia; Bael, Simon Van; Luyten, Frank P; Vleugels, Jozef; Schrooten, Jan

    2011-05-01

    A perfusion electrodeposition (P-ELD) system was reported to functionalize additive manufactured Ti6Al4V scaffolds with a calcium phosphate (CaP) coating in a controlled and reproducible manner. The effects and interactions of four main process parameters - current density (I), deposition time (t), flow rate (f) and process temperature (T) - on the properties of the CaP coating were investigated. The results showed a direct relation between the parameters and the deposited CaP mass, with a significant effect for t (P=0.001) and t-f interaction (P=0.019). Computational fluid dynamic analysis showed a relatively low electrolyte velocity within the struts and a high velocity in the open areas within the P-ELD chamber, which were not influenced by a change in f. This is beneficial for promoting a controlled CaP deposition and hydrogen gas removal. Optimization studies showed that a minimum t of 6 h was needed to obtain complete coating of the scaffold regardless of I, and the thickness was increased by increasing I and t. Energy-dispersive X-ray and X-ray diffraction analysis confirmed the deposition of highly crystalline synthetic carbonated hydroxyapatite under all conditions (Ca/P ratio=1.41). High cell viability and cell-material interactions were demonstrated by in vitro culture of human periosteum derived cells on coated scaffolds. This study showed that P-ELD provides a technological tool to functionalize complex scaffold structures with a biocompatible CaP layer that has controlled and reproducible physicochemical properties suitable for bone engineering. PMID:21215337

  9. Wood lens design philosophy based on a binary additive manufacturing technique

    NASA Astrophysics Data System (ADS)

    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.

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

    PubMed Central

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

    2015-01-01

    PURPOSE 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). MATERIALS AND METHODS 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). RESULTS The mean marginal gaps and internal gaps showed significant differences according to tooth type (P<.001 and P<.001, respectively) and manufacturing method (P<.037 and P<.001, respectively). Micro-SLA did not show any significant difference from CLWT regarding mean marginal gap compared to the WBM and MJM methods. CONCLUSION The mean values of gaps resulting from the four different manufacturing 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. PMID:26330976

  11. A brief survey of sensing for metal-based powder bed fusion additive manufacturing

    NASA Astrophysics Data System (ADS)

    Foster, Bryant K.; Reutzel, Edward W.; Nassar, Abdalla R.; Dickman, Corey J.; Hall, Benjamin T.

    2015-05-01

    Purpose - Powder bed fusion additive manufacturing (PBFAM) of metal components has attracted much attention, but the inability to quickly and easily ensure quality has limited its industrial use. Since the technology is currently being investigated for critical engineered components and is largely considered unsuitable for high volume production, traditional statistical quality control methods cannot be readily applied. An alternative strategy for quality control is to monitor the build in real time with a variety of sensing methods and, when possible, to correct any defects as they occur. This article reviews the cause of common defects in powder bed additive manufacturing, briefly surveys process monitoring strategies in the literature, and summarizes recently-developed strategies to monitor part quality during the build process. Design/methodology/approach - Factors that affect part quality in powder bed additive manufacturing are categorized as those influenced by machine variables and those affected by other build attributes. Within each category, multiple process monitoring methods are presented. Findings - A multitude of factors contribute to the overall quality of a part built using PBFAM. Rather than limiting processing to a pre-defined build recipe and assuming complete repeatability, part quality will be ensured by monitoring the process as it occurs and, when possible, altering the process conditions or build plan in real-time. Recent work shows promise in this area and brings us closer to the goal of wide-spread adoption of additive manufacturing technology. Originality/value - This work serves to introduce and define the possible sources of defects and errors in metal-based PBFAM, and surveys sensing and control methods which have recently been investigated to increase overall part quality. Emphasis has been placed on novel developments in the field and their contribution to the understanding of the additive manufacturing process.

  12. Fluid mechanics of additive manufacturing of metal objects by accretion of droplets - a survey

    NASA Astrophysics Data System (ADS)

    Tesař, Václav

    2016-03-01

    Paper presents a survey of principles of additive manufacturing of metal objects by accretion of molten metal droplets, focusing on fluid-mechanical problems that deserve being investigated. The main problem is slowness of manufacturing due to necessarily small size of added droplets. Increase of droplet repetition rate calls for basic research of the phenomena that take place inside and around the droplets: ballistics of their flight, internal flowfield with heat and mass transfer, oscillation of surfaces, and the ways to elimination of satellite droplets.

  13. Structure/property (constitutive and dynamic strength/damage) characterization of additively manufactured 316L SS

    NASA Astrophysics Data System (ADS)

    Gray, G. T., III; Livescu, V.; Rigg, P. A.; Trujillo, C. P.; Cady, C. M.; Chen, S. R.; Carpenter, J. S.; Lienert, T. J.; Fensin, S.

    2015-09-01

    For additive manufacturing (AM), the certification and qualification paradigm needs to evolve as there exists no "ASTM-type" additive manufacturing certified process or AM-material produced specifications. Accordingly, utilization of AM materials to meet engineering applications requires quantification of the constitutive properties of these evolving materials in comparison to conventionally-manufactured metals and alloys. Cylinders of 316L SS were produced using a LENS MR-7 laser additive manufacturing system from Optomec (Albuquerque, NM) equipped with a 1kW Yb-fiber laser. The microstructure of the AM-316L SS is detailed in both the as-built condition and following heat-treatments designed to obtain full recrystallization. The constitutive behavior as a function of strain rate and temperature is presented and compared to that of nominal annealed wrought 316L SS plate. The dynamic damage evolution and failure response of all three materials was probed using flyer-plate impact driven spallation experiments at a peak stress of 4.5 GPa to examine incipient spallation response. The spall strength of AM-produced 316L SS was found to be very similar for the peak shock stress studied to that of annealed wrought or AM-316L SS following recrystallization. The damage evolution as a function of microstructure was characterized using optical metallography.

  14. Quality control of laser- and powder bed-based Additive Manufacturing (AM) technologies

    NASA Astrophysics Data System (ADS)

    Berumen, Sebastian; Bechmann, Florian; Lindner, Stefan; Kruth, Jean-Pierre; Craeghs, Tom

    The quality of metal components manufactured by laser- and powder bed-based additive manufacturing technologies has continuously been improved over the last years. However, to establish this production technology in industries with very high quality standards the accessibility of prevalent quality management methods to all steps of the process chain needs still to be enhanced. This publication describes which tools are and will be available to fulfil those requirements from the perspective of a laser machine manufacturer. Generally five aspects of the part building process are covered by separate Quality Management (QM) modules: the powder quality, the temperature management, the process gas atmosphere, the melt pool behaviour and the documentation module. This paper sets the focus on melt pool analysis and control.

  15. Toward Efficient Thick Active PTB7 Photovoltaic Layers Using Diphenyl Ether as a Solvent Additive.

    PubMed

    Zheng, Yifan; Goh, Tenghooi; Fan, Pu; Shi, Wei; Yu, Junsheng; Taylor, André D

    2016-06-22

    The development of thick organic photovoltaics (OPV) could increase absorption in the active layer and ease manufacturing constraints in large-scale solar panel production. However, the efficiencies of most low-bandgap OPVs decrease substantially when the active layers exceed ∼100 nm in thickness (because of low crystallinity and a short exciton diffusion length). Herein, we report the use of solvent additive diphenyl ether (DPE) that facilitates the fabrication of thick (180 nm) active layers and triples the power conversion efficiency (PCE) of conventional thienothiophene-co-benzodithiophene polymer (PTB7)-based OPVs from 1.75 to 6.19%. These results demonstrate a PCE 20% higher than those of conventional (PTB7)-based OPV devices using 1,8-diiodooctane. Morphology studies reveal that DPE promotes the formation of nanofibrillar networks and ordered packing of PTB7 in the active layer that facilitate charge transport over longer distances. We further demonstrate that DPE improves the fill factor and photocurrent collection by enhancing the overall optical absorption, reducing the series resistance, and suppressing bimolecular recombination. PMID:27253271

  16. Additive manufacturing capabilities applied to inertial confinement confusion at Los Alamos National Laboratory

    DOE PAGESBeta

    Cardenas, Tana; Schmidt, Derek William; Peterson, Dominic S.

    2016-06-30

    We describe the use at Los Alamos National Laboratory of additive manufacturing (AM) for a variety of jigs and coating, assembly, and radiography fixtures. Additive manufacturing has also been used to produce shipping containers of complex design that would be too costly to have fabricated using traditional techniques. The current goal for AM use in target fabrication is to increase target accuracy and rigidity. This has been realized by implementing AM into target stalk fabrication, allowing increased complexity to address target strength and the addition of features for alignment at facilities. As a result, we will describe the fabrication ofmore » these components and our plans to utilize AM in the future.« less

  17. Analysis of Glass-Filled Nylon in Laser Powder Bed Fusion Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Slotwinski, John; LaBarre, Erin; Forrest, Ryan; Crane, Emily

    2016-03-01

    At the Johns Hopkins University Applied Physics Laboratory (APL), glass bead-filled polyamide (a.k.a. nylon) (GFN) is being used frequently for functional parts and systems, built using a laser-based powder bed fusion (PBF) additive manufacturing (AM) system. Since these parts have performance requirements, it is important to understand the mechanical properties of the additively-made GFN as a function of build orientation and build parameters. In addition, the performance of the AM system used to manufacture these parts must be evaluated in order to understand its capabilities, especially in order to determine the dimensional precision and repeatability of features built with this system. This paper summarizes recent APL efforts to characterize the GFN powder, the mechanical properties of parts made with GFN, and the performance of the laser PBF machine while running GFN using an AM test artifact.

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

    PubMed

    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. PMID:25639605

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

    PubMed

    Hirshfield, Laura; Giridhar, Arun; Taylor, Lynne S; Harris, Michael T; Reklaitis, Gintaras V

    2014-02-01

    In recent years, the US Food and Drug Administration has encouraged pharmaceutical companies to develop more innovative and efficient manufacturing methods with improved online monitoring and control. Mini-manufacturing of medicine is one such method enabling the creation of individualized product forms for each patient. This work presents dropwise additive manufacturing of pharmaceutical products (DAMPP), an automated, controlled mini-manufacturing method that deposits active pharmaceutical ingredients (APIs) directly onto edible substrates using drop-on-demand (DoD) inkjet printing technology. The use of DoD technology allows for precise control over the material properties, drug solid state form, drop size, and drop dynamics and can be beneficial in the creation of high-potency drug forms, combination drugs with multiple APIs or individualized medicine products tailored to a specific patient. In this work, DAMPP was used to create dosage forms from solvent-based formulations consisting of API, polymer, and solvent carrier. The forms were then analyzed to determine the reproducibility of creating an on-target dosage form, the morphology of the API of the final form and the dissolution behavior of the drug over time. DAMPP is found to be a viable alternative to traditional mass-manufacturing methods for solvent-based oral dosage forms. PMID:24311373

  20. An investigation of an additional layer during sunset period

    NASA Astrophysics Data System (ADS)

    Zhao, Biqiang; Wan, Weixing

    F3 layer is a very common feature within ±10° of the magnetic equatorial ionosphere in the daytime. According to Balan et al. (1998), the F3 layer occurs mainly during the morning-noon ( 08:30 -16:30 LT) period due to the combined effect of the upward EB drift and the neutral wind that provides vertically upward plasma drifts at and above the F2 layer. The F3 layer occurs not only in summer (higher occurrences) months but also in winter months, and to be observed less frequently with increasing solar activity. In this study, characteristic of the sunset F3 layer is first investigated from an analysis of a solar cycle ionosonde data (1995-2009) over Jicamarca (-12.0° , 283.2° , Dip 0.284-1.12° ) and ionosonde data (2004-2007) over Kwajalein (9.0° , 167° , Dip 7.7° ). Evidence shows that the local time distribution of the occurrence of the F3 layer can extend to the post-sunset time (18-21 LT) during the geomagnetic quiet period. The sunset F3 layer has a strong seasonal dependence which occurs mainly during the November-February months. Unlike the daytime F3 layer, occurrences of the sunset F3 layer clearly increases with increasing solar activity and the virtue height of the bottom side of the F3 layer statistically increases from 620 km to 1000 km. The occurrence of the sunset F3 layer at Kwajalein equatorial station is much less than that at Jicamarca. These features of the dependence on the season, solar activity and the longitude are clearly related to the geomagnetic distribution of the equatorial pre-reversal drift.

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

    NASA Technical Reports Server (NTRS)

    Grady, Joseph E.

    2015-01-01

    The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute, represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies to fabricate polymer matrix composite and ceramic matrix composite turbine engine components. The benefits include: 50 weight reduction compared to metallic parts, reduced manufacturing costs, reduced part count and rapid design iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature polymer filaments. The CMC effort uses a binder jet process to fabricate silicon carbide test coupons and demonstration articles. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The research project includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

  2. Additive manufacture (3d printing) of plasma diagnostic components and assemblies for fusion experiments

    NASA Astrophysics Data System (ADS)

    Sieck, Paul; Woodruff, Simon; Stuber, James; Romero-Talamas, Carlos; Rivera, William; You, Setthivoine; Card, Alexander

    2015-11-01

    Additive manufacturing (or 3D printing) is now becoming sufficiently accurate with a large range of materials for use in printing sensors needed universally in fusion energy research. Decreasing production cost and significantly lowering design time of energy subsystems would realize significant cost reduction for standard diagnostics commonly obtained through research grants. There is now a well-established set of plasma diagnostics, but these expensive since they are often highly complex and require customization, sometimes pace the project. Additive manufacturing (3D printing) is developing rapidly, including open source designs. Basic components can be printed for (in some cases) less than 1/100th costs of conventional manufacturing. We have examined the impact that AM can have on plasma diagnostic cost by taking 15 separate diagnostics through an engineering design using Conventional Manufacturing (CM) techniques to determine costs of components and labor costs associated with getting the diagnostic to work as intended. With that information in hand, we set about optimizing the design to exploit the benefits of AM. Work performed under DOE Contract DE-SC0011858.

  3. Cloud-Based Automated Design and Additive Manufacturing: A Usage Data-Enabled Paradigm Shift

    PubMed Central

    Lehmhus, Dirk; Wuest, Thorsten; Wellsandt, Stefan; Bosse, Stefan; Kaihara, Toshiya; Thoben, Klaus-Dieter; Busse, Matthias

    2015-01-01

    Integration of sensors into various kinds of products and machines provides access to in-depth usage information as basis for product optimization. Presently, this large potential for more user-friendly and efficient products is not being realized because (a) sensor integration and thus usage information is not available on a large scale and (b) product optimization requires considerable efforts in terms of manpower and adaptation of production equipment. However, with the advent of cloud-based services and highly flexible additive manufacturing techniques, these obstacles are currently crumbling away at rapid pace. The present study explores the state of the art in gathering and evaluating product usage and life cycle data, additive manufacturing and sensor integration, automated design and cloud-based services in manufacturing. By joining and extrapolating development trends in these areas, it delimits the foundations of a manufacturing concept that will allow continuous and economically viable product optimization on a general, user group or individual user level. This projection is checked against three different application scenarios, each of which stresses different aspects of the underlying holistic concept. The following discussion identifies critical issues and research needs by adopting the relevant stakeholder perspectives. PMID:26703606

  4. Cloud-Based Automated Design and Additive Manufacturing: A Usage Data-Enabled Paradigm Shift.

    PubMed

    Lehmhus, Dirk; Wuest, Thorsten; Wellsandt, Stefan; Bosse, Stefan; Kaihara, Toshiya; Thoben, Klaus-Dieter; Busse, Matthias

    2015-01-01

    Integration of sensors into various kinds of products and machines provides access to in-depth usage information as basis for product optimization. Presently, this large potential for more user-friendly and efficient products is not being realized because (a) sensor integration and thus usage information is not available on a large scale and (b) product optimization requires considerable efforts in terms of manpower and adaptation of production equipment. However, with the advent of cloud-based services and highly flexible additive manufacturing techniques, these obstacles are currently crumbling away at rapid pace. The present study explores the state of the art in gathering and evaluating product usage and life cycle data, additive manufacturing and sensor integration, automated design and cloud-based services in manufacturing. By joining and extrapolating development trends in these areas, it delimits the foundations of a manufacturing concept that will allow continuous and economically viable product optimization on a general, user group or individual user level. This projection is checked against three different application scenarios, each of which stresses different aspects of the underlying holistic concept. The following discussion identifies critical issues and research needs by adopting the relevant stakeholder perspectives. PMID:26703606

  5. Highly Aligned Carbon Fiber in Polymer Composite Structures via Additive Manufacturing

    DOE PAGESBeta

    Tekinalp, Halil L; Kunc, Vlastimil; Velez-Garcia, Gregorio M; Duty, Chad E; Love, Lonnie J; Naskar, Amit K; Blue, Craig A; Ozcan, Soydan

    2014-01-01

    Additive manufacturing, diverging from traditional manufacturing techniques, such as casting and machining materials, can handle complex shapes with great design flexibility without the typical waste. Although this technique has been mainly used for rapid prototyping, interest is growing in using this method to directly manufacture actual parts of complex shape. To use 3D-printing additive manufacturing in wide spread applications, the technique and the feedstock materials require improvements to meet the mechanical requirements of load-bearing components. Thus, we investigated the short fiber (0.2 mm to 0.4 mm) reinforced acrylonitrile-butadiene-styrene composites as a feedstock for 3D-printing in terms of their processibility, microstructuremore » and mechanical performance; and also provided comparison with traditional compression molded composites. The tensile strength and modulus of 3D-printed samples increased ~115% and ~700%, respectively. 3D-printer yielded samples with very high fiber orientation in printing direction (up to 91.5 %), whereas, compression molding process yielded samples with significantly less fiber orientation. Microstructure-mechanical property relationships revealed that although the relatively high porosity is observed in the 3D-printed composites as compared to those produced by the conventional compression molding technique, they both exhibited comparable tensile strength and modulus. This phenomena is explained based on the changes in fiber orientation, dispersion and void formation.« less

  6. A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

    NASA Technical Reports Server (NTRS)

    Grady, Joseph E.

    2014-01-01

    The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in

  7. Additive Manufacturing by selective laser melting the realizer desktop machine and its application for the dental industry

    NASA Astrophysics Data System (ADS)

    Gebhardt, Andreas; Schmidt, Frank-Michael; Hötter, Jan-Steffen; Sokalla, Wolfgang; Sokalla, Patrick

    Additive Manufacturing of metal parts by Selective Laser Melting has become a powerful tool for the direct manufacturing of complex parts mainly for the aerospace and medical industry. With the introduction of its desktop machine, Realizer targeted the dental market. The contribution describes the special features of the machine, discusses details of the process and shows manufacturing results focused on metal dental devices.

  8. Rationalization of Microstructure Heterogeneity in INCONEL 718 Builds Made by the Direct Laser Additive Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Tian, Yuan; McAllister, Donald; Colijn, Hendrik; Mills, Michael; Farson, Dave; Nordin, Mark; Babu, Sudarsanam

    2014-09-01

    Simulative builds, typical of the tip-repair procedure, with matching compositions were deposited on an INCONEL 718 substrate using the laser additive manufacturing process. In the as-processed condition, these builds exhibit spatial heterogeneity in microstructure. Electron backscattering diffraction analyses showed highly misoriented grains in the top region of the builds compared to those of the lower region. Hardness maps indicated a 30 pct hardness increase in build regions close to the substrate over those of the top regions. Detailed multiscale characterizations, through scanning electron microscopy, electron backscattered diffraction imaging, high-resolution transmission electron microscopy, and ChemiSTEM, also showed microstructure heterogeneities within the builds in different length scales including interdendritic and interprecipitate regions. These multiscale heterogeneities were correlated to primary solidification, remelting, and solid-state precipitation kinetics of γ″ induced by solute segregation, as well as multiple heating and cooling cycles induced by the laser additive manufacturing process.

  9. Hierarchical tailoring of strut architecture to control permeability of additive manufactured titanium implants.

    PubMed

    Zhang, Z; Jones, D; Yue, S; Lee, P D; Jones, J R; Sutcliffe, C J; Jones, E

    2013-10-01

    Porous titanium implants are a common choice for bone augmentation. Implants for spinal fusion and repair of non-union fractures must encourage blood flow after implantation so that there is sufficient cell migration, nutrient and growth factor transport to stimulate bone ingrowth. Additive manufacturing techniques allow a large number of pore network designs. This study investigates how the design factors offered by selective laser melting technique can be used to alter the implant architecture on multiple length scales to control and even tailor the flow. Permeability is a convenient parameter that characterises flow, correlating to structure openness (interconnectivity and pore window size), tortuosity and hence flow shear rates. Using experimentally validated computational simulations, we demonstrate how additive manufacturing can be used to tailor implant properties by controlling surface roughness at a microstructual level (microns), and by altering the strut ordering and density at a mesoscopic level (millimetre). PMID:23910314

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

    PubMed

    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. PMID:24616012

  11. Next Generation Orthopaedic Implants by Additive Manufacturing Using Electron Beam Melting

    PubMed Central

    Murr, Lawrence E.; Gaytan, Sara M.; Martinez, Edwin; Medina, Frank; Wicker, Ryan B.

    2012-01-01

    This paper presents some examples of knee and hip implant components containing porous structures and fabricated in monolithic forms utilizing electron beam melting (EBM). In addition, utilizing stiffness or relative stiffness versus relative density design plots for open-cellular structures (mesh and foam components) of Ti-6Al-4V and Co-29Cr-6Mo alloy fabricated by EBM, it is demonstrated that stiffness-compatible implants can be fabricated for optimal stress shielding for bone regimes as well as bone cell ingrowth. Implications for the fabrication of patient-specific, monolithic, multifunctional orthopaedic implants using EBM are described along with microstructures and mechanical properties characteristic of both Ti-6Al-4V and Co-29Cr-6Mo alloy prototypes, including both solid and open-cellular prototypes manufactured by additive manufacturing (AM) using EBM. PMID:22956957

  12. Material Development for Tooling Applications Using Big Area Additive Manufacturing (BAAM)

    SciTech Connect

    Duty, Chad E.; Drye, Tom; Franc, Alan

    2015-03-01

    Techmer Engineered Solutions (TES) is working with Oak Ridge National Laboratory (ORNL) to develop materials and evaluate their use for ORNL s recently developed Big Area Additive Manufacturing (BAAM) system for tooling applications. The first phase of the project established the performance of some commercially available polymer compositions deposited with the BAAM system. Carbon fiber reinforced ABS demonstrated a tensile strength of nearly 10 ksi, which is sufficient for a number of low temperature tooling applications.

  13. Additive manufactured Ti6Al4V scaffolds with the RF- magnetron sputter deposited hydroxyapatite coating

    NASA Astrophysics Data System (ADS)

    Chudinova, E.; Surmeneva, M.; Koptioug, A.; Scoglund, P.; Surmenev, R.

    2016-01-01

    Present paper reports on the results of surface modification of the additively manufactured porous Ti6Al4V scaffolds. Radio frequency (RF) magnetron sputtering was used to modify the surface of the alloy via deposition of the biocompatible hydroxyapatite (HA) coating. The surface morphology, chemical and phase composition of the HA-coated alloy were studied. It was revealed that RF magnetron sputtering allows preparing a homogeneous HA coating onto the entire surface of scaffolds.

  14. A Study of Aluminum Combustion in Solids, Powders, Foams, Additively-Manufactured Lattices, and Composites

    NASA Astrophysics Data System (ADS)

    Black, James; Trammell, Norman; Batteh, Jad; Curran, Nicholas; Rogers, John; Littrell, Donald

    2015-06-01

    This study examines the fireball characteristics, blast parameters, and combustion efficiency of explosively-shocked aluminum-based materials. The materials included structural and non-structural aluminum forms - such as solid cylinders, foams, additively-manufactured lattices, and powders - and some polytetrafluoroethylene-aluminum (PTFE-Al) composites. The materials were explosively dispersed in a small blast chamber, and the blast properties and products were measured with pressure transducers, thermocouples, slow and fast ultraviolet/visible spectrometers, and high-speed video.

  15. The method of manufacture of nylon dental partially removable prosthesis using additive technologies

    NASA Astrophysics Data System (ADS)

    Kashapov, R. N.; Korobkina, A. I.; Platonov, E. V.; Saleeva, G. T.

    2014-12-01

    The article is devoted to the topic of creating new methods of dental prosthesis. The aim of this work is to investigate the possibility of using additive technology to create nylon prosthesis. As a result of experimental studies, was made a sample of nylon partially removable prosthesis using 3D printing has allowed to simplify, accelerate and reduce the coat of manufacturing high-precision nylon dentures.

  16. Thermographic in-situ process monitoring of the electron-beam melting technology used in additive manufacturing

    NASA Astrophysics Data System (ADS)

    Dinwiddie, Ralph B.; Dehoff, Ryan R.; Lloyd, Peter D.; Lowe, Larry E.; Ulrich, Joe B.

    2013-05-01

    Oak Ridge National Laboratory (ORNL) has been utilizing the ARCAM electron beam melting technology to additively manufacture complex geometric structures directly from powder. Although the technology has demonstrated the ability to decrease costs, decrease manufacturing lead-time and fabricate complex structures that are impossible to fabricate through conventional processing techniques, certification of the component quality can be challenging. Because the process involves the continuous deposition of successive layers of material, each layer can be examined without destructively testing the component. However, in-situ process monitoring is difficult due to metallization on inside surfaces caused by evaporation and condensation of metal from the melt pool. This work describes a solution to one of the challenges to continuously imaging inside of the chamber during the EBM process. Here, the utilization of a continuously moving Mylar film canister is described. Results will be presented related to in-situ process monitoring and how this technique results in improved mechanical properties and reliability of the process.

  17. Additive manufacturing of poly[(R)-3-hydroxybutyrate-co-(R)-3-hydroxyhexanoate] scaffolds for engineered bone development.

    PubMed

    Mota, Carlos; Wang, Shen-Yu; Puppi, Dario; Gazzarri, Matteo; Migone, Chiara; Chiellini, Federica; Chen, Guo-Qiang; Chiellini, Emo

    2014-05-30

    A wide range of poly(hydroxyalkanoate)s (PHAs), a class of biodegradable polyesters produced by various bacteria grown under unbalanced conditions, have been proposed for the fabrication of tissue-engineering scaffolds. In this study, the manufacture of poly[(R)-3-hydroxybutyrate-co-(R)-3-hydroxyhexanoate] (or PHBHHx) scaffolds, by means of an additive manufacturing technique based on a computer-controlled wet-spinning system, was investigated. By optimizing the processing parameters, three-dimensional scaffolds with different internal architectures were fabricated, based on a layer-by-layer approach. The resulting scaffolds were characterized by scanning electron microscopy, which showed good control over the fibre alignment and a fully interconnected porous network, with porosity in the range 79-88%, fibre diameter 47-76 µm and pore size 123-789 µm. Moreover, the resulting fibres presented an internal porosity connected to the external fibre surface as a consequence of the phase-inversion process governing the solidification of the polymer solution. Scaffold compressive modulus and yield stress and strain could be varied in a certain range by changing the architectural parameters. Cell-culture experiments employing the MC3T3-E1 murine pre-osteoblast cell line showed good cell proliferation after 21 days of culture. The PHBHHx scaffolds demonstrated promising results in terms of cell differentiation towards an osteoblast phenotype. Copyright © 2014 John Wiley & Sons, Ltd. PMID:24889107

  18. Biomimetic calcium phosphate coating of additively manufactured porous CoCr implants

    NASA Astrophysics Data System (ADS)

    Lindahl, Carl; Xia, Wei; Engqvist, Håkan; Snis, Anders; Lausmaa, Jukka; Palmquist, Anders

    2015-10-01

    The aim of this work was to study the feasibility to use a biomimetic method to prepare biomimetic hydroxyapatite (HA) coatings on CoCr substrates with short soaking times and to characterize the properties of such coatings. A second objective was to investigate if the coatings could be applied to porous CoCr implants manufactured by electron beam melting (EBM). The coating was prepared by immersing the pretreated CoCr substrates and EBM implants into the phosphate-buffered solution with Ca2+ in sealed plastic bottles, kept at 60 °C for 3 days. The formed coating was partially crystalline, slightly calcium deficient and composed of plate-like crystallites forming roundish flowers in the size range of 300-500 nm. Cross-section imaging showed a thickness of 300-500 nm. In addition, dissolution tests in Tris-HCl up to 28 days showed that a substantial amount of the coating had dissolved, however, undergoing only minor morphological changes. A uniform coating was formed within the porous network of the additive manufactured implants having similar thickness and morphology as for the flat samples. In conclusion, the present coating procedure allows coatings to be formed on CoCr and could be used for complex shaped, porous implants made by additive manufacturing.

  19. Revival of pure titanium for dynamically loaded porous implants using additive manufacturing.

    PubMed

    Wauthle, Ruben; Ahmadi, Seyed Mohammad; Amin Yavari, Saber; Mulier, Michiel; Zadpoor, Amir Abbas; Weinans, Harrie; Van Humbeeck, Jan; Kruth, Jean-Pierre; Schrooten, Jan

    2015-09-01

    Additive manufacturing techniques are getting more and more established as reliable methods for producing porous metal implants thanks to the almost full geometrical and mechanical control of the designed porous biomaterial. Today, Ti6Al4V ELI is still the most widely used material for porous implants, and none or little interest goes to pure titanium for use in orthopedic or load-bearing implants. Given the special mechanical behavior of cellular structures and the material properties inherent to the additive manufacturing of metals, the aim of this study is to investigate the properties of selective laser melted pure unalloyed titanium porous structures. Therefore, the static and dynamic compressive properties of pure titanium structures are determined and compared to previously reported results for identical structures made from Ti6Al4V ELI and tantalum. The results show that porous Ti6Al4V ELI still remains the strongest material for statically loaded applications, whereas pure titanium has a mechanical behavior similar to tantalum and is the material of choice for cyclically loaded porous implants. These findings are considered to be important for future implant developments since it announces a potential revival of the use of pure titanium for additively manufactured porous implants. PMID:26046272

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

    NASA Astrophysics Data System (ADS)

    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.

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

    PubMed

    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. PMID:26520408

  2. Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

    DOE PAGESBeta

    Carpenter, John S.; Beese, Allison M.; Bourell, David L.; Hamilton, Reginald F.; Mishra, Rajiv; Sears, James

    2015-06-26

    Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

  3. Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

    SciTech Connect

    Carpenter, John S.; Beese, Allison M.; Bourell, David L.; Hamilton, Reginald F.; Mishra, Rajiv; Sears, James

    2015-06-26

    Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. This symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.

  4. Emerging Technologies in the Built Environment: Geographic Information Science (GIS), 3D Printing, and Additive Manufacturing

    SciTech Connect

    New, Joshua Ryan

    2014-01-01

    Abstract 1: Geographic information systems emerged as a computer application in the late 1960s, led in part by projects at ORNL. The concept of a GIS has shifted through time in response to new applications and new technologies, and is now part of a much larger world of geospatial technology. This presentation discusses the relationship of GIS and estimating hourly and seasonal energy consumption profiles in the building sector at spatial scales down to the individual parcel. The method combines annual building energy simulations for city-specific prototypical buildings and commonly available geospatial data in a GIS framework. Abstract 2: This presentation focuses on 3D printing technologies and how they have rapidly evolved over the past couple of years. At a basic level, 3D printing produces physical models quickly and easily from 3D CAD, BIM (Building Information Models), and other digital data. Many AEC firms have adopted 3D printing as part of commercial building design development and project delivery. This presentation includes an overview of 3D printing, discusses its current use in building design, and talks about its future in relation to the HVAC industry. Abstract 3: This presentation discusses additive manufacturing and how it is revolutionizing the design of commercial and residential facilities. Additive manufacturing utilizes a broad range of direct manufacturing technologies, including electron beam melting, ultrasonic, extrusion, and laser metal deposition for rapid prototyping. While there is some overlap with the 3D printing talk, this presentation focuses on the materials aspect of additive manufacturing and also some of the more advanced technologies involved with rapid prototyping. These technologies include design of carbon fiber composites, lightweight metals processing, transient field processing, and more.

  5. Possibilities of CT Scanning as Analysis Method in Laser Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Karme, Aleksis; Kallonen, Aki; Matilainen, Ville-Pekka; Piili, Heidi; Salminen, Antti

    Laser additive manufacturing is an established and constantly developing technique. Structural assessment should be a key component to ensure directed evolution towards higher level of manufacturing. The macroscopic properties of metallic structures are determined by their internal microscopic features, which are difficult to assess using conventional surface measuring methodologies. X-ray microtomography (CT) is a promising technique for three-dimensional non-destructive probing of internal composition and build of various materials. Aim of this study is to define the possibilities of using CT scanning as quality control method in LAM fabricated parts. Since the parts fabricated with LAM are very often used in high quality and accuracy demanding applications in various industries such as medical and aerospace, it is important to be able to define the accuracy of the build parts. The tubular stainless steel test specimens were 3D modelled, manufactured with a modified research AM equipment and imaged after manufacturing with a high-power, high-resolution CT scanner. 3D properties, such as surface texture and the amount and distribution of internal pores, were also evaluated in this study. Surface roughness was higher on the interior wall of the tube, and deviation from the model was systematically directed towards the central axis. Pore distribution showed clear organization and divided into two populations; one following the polygon model seams along both rims, and the other being associated with the concentric and equidistant movement path of the laser. Assessment of samples can enhance the fabrication by guiding the improvement of both modelling and manufacturing process.

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

    PubMed

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

    2015-08-01

    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. PMID:26737367

  7. Additive Manufacturing for Cost Efficient Production of Compact Ceramic Heat Exchangers and Recuperators

    SciTech Connect

    Shulman, Holly; Ross, Nicole

    2015-10-30

    An additive manufacture technique known as laminated object manufacturing (LOM) was used to fabricate compact ceramic heat exchanger prototypes. LOM uses precision CO2 laser cutting of ceramic green tapes, which are then precision stacked to build a 3D object with fine internal features. Modeling was used to develop prototype designs and predict the thermal response, stress, and efficiency in the ceramic heat exchangers. Build testing and materials analyses were used to provide feedback for the design selection. During this development process, laminated object manufacturing protocols were established. This included laser optimization, strategies for fine feature integrity, lamination fluid control, green handling, and firing profile. Three full size prototypes were fabricated using two different designs. One prototype was selected for performance testing. During testing, cross talk leakage prevented the application of a high pressure differential, however, the prototype was successful at withstanding the high temperature operating conditions (1300 °F). In addition, analysis showed that the bulk of the part did not have cracks or leakage issues. This led to the development of a module method for next generation LOM heat exchangers. A scale-up cost analysis showed that given a purpose built LOM system, these ceramic heat exchangers would be affordable for the applications.

  8. Additive Manufacturing of Multifunctional Components Using High Density Carbon Nanotube Yarn Filaments

    NASA Technical Reports Server (NTRS)

    Gardner, John M.; Sauti, Godfrey; Kim, Jae-Woo; Cano, Roberto J.; Wincheski, Russell A.; Stelter, Christopher J.; Grimsley, Brian W.; Working, Dennis C.; Siochi, Emilie J.

    2016-01-01

    Additive manufacturing allows for design freedom and part complexity not currently attainable using traditional manufacturing technologies. Fused Filament Fabrication (FFF), for example, can yield novel component geometries and functionalities because the method provides a high level of control over material placement and processing conditions. This is achievable by extrusion of a preprocessed filament feedstock material along a predetermined path. However if fabrication of a multifunctional part relies only on conventional filament materials, it will require a different material for each unique functionality printed into the part. Carbon nanotubes (CNTs) are an attractive material for many applications due to their high specific strength as well as good electrical and thermal conductivity. The presence of this set of properties in a single material presents an opportunity to use one material to achieve multifunctionality in an additively manufactured part. This paper describes a recently developed method for processing continuous CNT yarn filaments into three-dimensional articles, and summarizes the mechanical, electrical, and sensing performance of the components fabricated in this way.

  9. Using Additive Manufacturing to Print a CubeSat Propulsion System

    NASA Technical Reports Server (NTRS)

    Marshall, William M.; Zemba, Michael; Shemelya, Corey; Wicker, Ryan; Espalin, David; MacDonald, Eric; Keif, Craig; Kwas, Andrew

    2015-01-01

    Small satellites, such as CubeSats, are increasingly being called upon to perform missions traditionally ascribed to larger satellite systems. However, the market of components and hardware for small satellites, particularly CubeSats, still falls short of providing the necessary capabilities required by ever increasing mission demands. One way to overcome this shortfall is to develop the ability to customize every build. By utilizing fabrication methods such as additive manufacturing, mission specific capabilities can be built into a system, or into the structure, that commercial off-the-shelf components may not be able to provide. A partnership between the University of Texas at El Paso, COSMIAC at the University of New Mexico, Northrop Grumman, and the NASA Glenn Research Center is looking into using additive manufacturing techniques to build a complete CubeSat, under the Small Spacecraft Technology Program. The W. M. Keck Center at the University of Texas at El Paso has previously demonstrated the ability to embed electronics and wires into the addtively manufactured structures. Using this technique, features such as antennas and propulsion systems can be included into the CubeSat structural body. Of interest to this paper, the team is investigating the ability to take a commercial micro pulsed plasma thruster and embed it into the printing process. Tests demonstrating the dielectric strength of the printed material and proof-of-concept demonstration of the printed thruster will be shown.

  10. Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: A review.

    PubMed

    Wang, Xiaojian; Xu, Shanqing; Zhou, Shiwei; Xu, Wei; Leary, Martin; Choong, Peter; Qian, M; Brandt, Milan; Xie, Yi Min

    2016-03-01

    One of the critical issues in orthopaedic regenerative medicine is the design of bone scaffolds and implants that replicate the biomechanical properties of the host bones. Porous metals have found themselves to be suitable candidates for repairing or replacing the damaged bones since their stiffness and porosity can be adjusted on demands. Another advantage of porous metals lies in their open space for the in-growth of bone tissue, hence accelerating the osseointegration process. The fabrication of porous metals has been extensively explored over decades, however only limited controls over the internal architecture can be achieved by the conventional processes. Recent advances in additive manufacturing have provided unprecedented opportunities for producing complex structures to meet the increasing demands for implants with customized mechanical performance. At the same time, topology optimization techniques have been developed to enable the internal architecture of porous metals to be designed to achieve specified mechanical properties at will. Thus implants designed via the topology optimization approach and produced by additive manufacturing are of great interest. This paper reviews the state-of-the-art of topological design and manufacturing processes of various types of porous metals, in particular for titanium alloys, biodegradable metals and shape memory alloys. This review also identifies the limitations of current techniques and addresses the directions for future investigations. PMID:26773669

  11. Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components

    SciTech Connect

    Huang, Runze; Riddle, Matthew; Graziano, Diane; Warren, Joshua; Das, Sujit; Nimbalkar, Sachin; Cresko, Joe; Masanet, Eric

    2015-05-08

    Additive manufacturing (AM) holds great potential for improving materials efficiency, reducing life-cycle impacts, and enabling greater engineering functionality compared to conventional manufacturing (CM) processes. For these reasons, AM has been adopted by a growing number of aircraft component manufacturers to achieve more lightweight, cost-effective designs. This study estimates the net changes in life-cycle primary energy and greenhouse gas emissions associated with AM technologies for lightweight metallic aircraft components through the year 2050, to shed light on the environmental benefits of a shift from CM to AM processes in the U.S. aircraft industry. A systems modeling framework is presented, with integrates engineering criteria, life-cycle environmental data, and aircraft fleet stock and fuel use models under different AM adoption scenarios. Estimated fleetwide life-cycle primary energy savings in a rapid adoption scenario reach 70-174 million GJ/year in 2050, with cumulative savings of 1.2-2.8 billion GJ. Associated cumulative emission reduction potentials of CO2e were estimated at 92.8-217.4 million metric tons. About 95% of the savings is attributed to airplane fuel consumption reductions due to lightweighting. In addition, about 4050 tons aluminum, 7600 tons titanium and 8100 tons of nickel alloys could be saved per year in 2050. The results indicate a significant role of AM technologies in helping society meet its long-term energy use and GHG emissions reduction goals, and highlight barriers and opportunities for AM adoption for the aircraft industry.

  12. Additive Manufacturing of Reactive In Situ Zr Based Ultra-High Temperature Ceramic Composites

    NASA Astrophysics Data System (ADS)

    Sahasrabudhe, Himanshu; Bandyopadhyay, Amit

    2016-03-01

    Reactive in situ multi-material additive manufacturing of ZrB2-based ultra-high-temperature ceramics in a Zr metal matrix was demonstrated using LENS™. Sound metallurgical bonding was achieved between the Zr metal and Zr-BN composites with Ti6Al4V substrate. Though the feedstock Zr power had α phase, LENS™ processing of the Zr powder and Zr-BN premix powder mixture led to the formation of some β phase of Zr. Microstructure of the Zr-BN composite showed primary grains of zirconium diboride phase in zirconium metal matrix. The presence of ZrB2 ceramic phase was confirmed by X-ray diffraction (XRD) analysis. Hardness of pure Zr was measured as 280 ± 12 HV and, by increasing the BN content in the feedstock, the hardness was found to increase. In Zr-5%BN composite, the hardness was 421 ± 10 HV and the same for Zr-10%BN composite was 562 ± 10 HV. It is envisioned that such multi-materials additive manufacturing will enable products in the future that cannot be manufactured using traditional approaches particularly in the areas of high-temperature metal-ceramic composites with compositional and functional gradation.

  13. thin films grown with additional NaF layers

    NASA Astrophysics Data System (ADS)

    Kim, Gee Yeong; Kim, Juran; Jo, William; Son, Dae-Ho; Kim, Dae-Hwan; Kang, Jin-Kyu

    2014-10-01

    CZTS precursors [SLG/Mo (300 nm)/ZnS (460 nm)/SnS (480 nm)/Cu (240 nm)] were deposited by RF/DC sputtering, and then NaF layers (0, 15, and 30 nm) were grown by electron beam evaporation. The precursors were annealed in a furnace with Se metals at 590°C for 20 minutes. The final composition of the CZTSSe thin-films was of Cu/(Zn + Sn) ~ 0.88 and Zn/Sn ~ 1.05, with a metal S/Se ratio estimated at ~0.05. The CZTSSe thin-films have different NaF layer thicknesses in the range from 0 to 30 nm, achieving a ~3% conversion efficiency, and the CZTSSe thin-films contain ~3% of Na. Kelvin probe force microscopy was used to identify the local potential difference that varied according to the thickness of the NaF layer on the CZTSSe thin-films. The potential values at the grain boundaries were observed to increase as the NaF thickness increased. Moreover, the ratio of the positively charged GBs in the CZTSSe thin-films with an NaF layer was higher than that of pure CZTSSe thin-films. A positively charged potential was observed around the grain boundaries of the CZTSSe thin-films, which is a beneficial characteristic that can improve the performance of a device.

  14. Infrared thermography for laser-based powder bed fusion additive manufacturing processes

    SciTech Connect

    Moylan, Shawn; Whitenton, Eric; Lane, Brandon; Slotwinski, John

    2014-02-18

    Additive manufacturing (AM) has the potential to revolutionize discrete part manufacturing, but improvements in processing of metallic materials are necessary before AM will see widespread adoption. A better understanding of AM processes, resulting from physics-based modeling as well as direct process metrology, will form the basis for these improvements. Infrared (IR) thermography of AM processes can provide direct process metrology, as well as data necessary for the verification of physics-based models. We review selected works examining how IR thermography was implemented and used in various powder-bed AM processes. This previous work, as well as significant experience at the National Institute of Standards and Technology in temperature measurement and IR thermography for machining processes, shapes our own research in AM process metrology with IR thermography. We discuss our experimental design, as well as plans for future IR measurements of a laser-based powder bed fusion AM process.

  15. Processing of New Materials by Additive Manufacturing: Iron-Based Alloys Containing Silver for Biomedical Applications

    NASA Astrophysics Data System (ADS)

    Niendorf, Thomas; Brenne, Florian; Hoyer, Peter; Schwarze, Dieter; Schaper, Mirko; Grothe, Richard; Wiesener, Markus; Grundmeier, Guido; Maier, Hans Jürgen

    2015-07-01

    In the biomedical sector, production of bioresorbable implants remains challenging due to improper dissolution rates or deficient strength of many candidate alloys. Promising materials for overcoming the prevalent drawbacks are iron-based alloys containing silver. However, due to immiscibility of iron and silver these alloys cannot be manufactured based on conventional processing routes. In this study, iron-manganese-silver alloys were for the first time synthesized by means of additive manufacturing. Based on combined mechanical, microscopic, and electrochemical studies, it is shown that silver particles well distributed in the matrix can be obtained, leading to cathodic sites in the composite material. Eventually, this results in an increased dissolution rate of the alloy. Stress-strain curves showed that the incorporation of silver barely affects the mechanical properties.

  16. Infrared thermography for laser-based powder bed fusion additive manufacturing processes

    NASA Astrophysics Data System (ADS)

    Moylan, Shawn; Whitenton, Eric; Lane, Brandon; Slotwinski, John

    2014-02-01

    Additive manufacturing (AM) has the potential to revolutionize discrete part manufacturing, but improvements in processing of metallic materials are necessary before AM will see widespread adoption. A better understanding of AM processes, resulting from physics-based modeling as well as direct process metrology, will form the basis for these improvements. Infrared (IR) thermography of AM processes can provide direct process metrology, as well as data necessary for the verification of physics-based models. We review selected works examining how IR thermography was implemented and used in various powder-bed AM processes. This previous work, as well as significant experience at the National Institute of Standards and Technology in temperature measurement and IR thermography for machining processes, shapes our own research in AM process metrology with IR thermography. We discuss our experimental design, as well as plans for future IR measurements of a laser-based powder bed fusion AM process.

  17. Composite scaffolds for osteochondral repair obtained by combination of additive manufacturing, leaching processes and hMSC-CM functionalization.

    PubMed

    Díaz Lantada, Andrés; Alarcón Iniesta, Hernán; García-Ruíz, Josefa Predestinación

    2016-02-01

    Articular repair is a relevant and challenging area for the emerging fields of tissue engineering and biofabrication. The need of significant gradients of properties, for the promotion of osteochondral repair, has led to the development of several families of composite biomaterials and scaffolds, using different effective approaches, although a perfect solution has not yet been found. In this study we present the design, modeling, rapid manufacturing and in vitro testing of a composite scaffold aimed at osteochondral repair. The presented composite scaffold stands out for having a functional gradient of density and stiffness in the bony phase, obtained in titanium by means of computer-aided design combined with additive manufacture using selective laser sintering. The chondral phase is obtained by sugar leaching, using a PDMS matrix and sugar as porogen, and is joined to the bony phase during the polymerization of PDMS, therefore avoiding the use of supporting adhesives or additional intermediate layers. The mechanical performance of the construct is biomimetic and the stiffness values of the bony and chondral phases can be tuned to the desired applications, by means of controlled modifications of different parameters. A human mesenchymal stem cell (h-MSC) conditioned medium (CM) is used for improving scaffold response. Cell culture results provide relevant information regarding the viability of the composite scaffolds used. PMID:26652367

  18. New layer-based imaging and rapid prototyping techniques for computer-aided design and manufacture of custom dental restoration.

    PubMed

    Lee, M-Y; Chang, C-C; Ku, Y C

    2008-01-01

    Fixed dental restoration by conventional methods greatly relies on the skill and experience of the dental technician. The quality and accuracy of the final product depends mostly on the technician's subjective judgment. In addition, the traditional manual operation involves many complex procedures, and is a time-consuming and labour-intensive job. Most importantly, no quantitative design and manufacturing information is preserved for future retrieval. In this paper, a new device for scanning the dental profile and reconstructing 3D digital information of a dental model based on a layer-based imaging technique, called abrasive computer tomography (ACT) was designed in-house and proposed for the design of custom dental restoration. The fixed partial dental restoration was then produced by rapid prototyping (RP) and computer numerical control (CNC) machining methods based on the ACT scanned digital information. A force feedback sculptor (FreeForm system, Sensible Technologies, Inc., Cambridge MA, USA), which comprises 3D Touch technology, was applied to modify the morphology and design of the fixed dental restoration. In addition, a comparison of conventional manual operation and digital manufacture using both RP and CNC machining technologies for fixed dental restoration production is presented. Finally, a digital custom fixed restoration manufacturing protocol integrating proposed layer-based dental profile scanning, computer-aided design, 3D force feedback feature modification and advanced fixed restoration manufacturing techniques is illustrated. The proposed method provides solid evidence that computer-aided design and manufacturing technologies may become a new avenue for custom-made fixed restoration design, analysis, and production in the 21st century. PMID:18183523

  19. Adv. Simulation for Additive Manufacturing: 11/2014 Wkshp. Report for U.S. DOE/EERE/AMO

    SciTech Connect

    Turner, John A.; Babu, Sudarsanam Suresh; Blue, Craig A.

    2015-07-01

    The overarching question for the workshop was as following: How do we best utilize advanced modeling and high-performance computing (HPC) to address key challenges and opportunities in order to realize the full potential of additive manufacturing; and what are the key challenges of additive manufacturing to which modeling and simulation can contribute solutions, and what will it take to meet these challenges?

  20. Additive Manufacturing of SiC Based Ceramics and Ceramic Matrix Composites

    NASA Technical Reports Server (NTRS)

    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.

  1. Modeling and additive manufacturing of bio-inspired composites with tunable fracture mechanical properties.

    PubMed

    Dimas, Leon S; Buehler, Markus J

    2014-07-01

    Flaws, imperfections and cracks are ubiquitous in material systems and are commonly the catalysts of catastrophic material failure. As stresses and strains tend to concentrate around cracks and imperfections, structures tend to fail far before large regions of material have ever been subjected to significant loading. Therefore, a major challenge in material design is to engineer systems that perform on par with pristine structures despite the presence of imperfections. In this work we integrate knowledge of biological systems with computational modeling and state of the art additive manufacturing to synthesize advanced composites with tunable fracture mechanical properties. Supported by extensive mesoscale computer simulations, we demonstrate the design and manufacturing of composites that exhibit deformation mechanisms characteristic of pristine systems, featuring flaw-tolerant properties. We analyze the results by directly comparing strain fields for the synthesized composites, obtained through digital image correlation (DIC), and the computationally tested composites. Moreover, we plot Ashby diagrams for the range of simulated and experimental composites. Our findings show good agreement between simulation and experiment, confirming that the proposed mechanisms have a significant potential for vastly improving the fracture response of composite materials. We elucidate the role of stiffness ratio variations of composite constituents as an important feature in determining the composite properties. Moreover, our work validates the predictive ability of our models, presenting them as useful tools for guiding further material design. This work enables the tailored design and manufacturing of composites assembled from inferior building blocks, that obtain optimal combinations of stiffness and toughness. PMID:24700202

  2. Influence of Alumina Addition to Aluminum Fins for Compact Heat Exchangers Produced by Cold Spray Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Farjam, Aslan; Cormier, Yannick; Dupuis, Philippe; Jodoin, Bertrand; Corbeil, Antoine

    2015-10-01

    In this work, aluminum and aluminum-alumina powder mixtures were used to produce pyramidal fin arrays on aluminum substrates using cold spray as an additive manufacturing process. Using aluminum-alumina mixtures instead of pure aluminum powder could be seen as a cost-effective measure, preventing nozzle clogging or the need to use expensive polymer nozzles that wear out rapidly during cold spray. The fin geometries that were produced were observed using a 3D digital microscope to determine the flow passages width and fins' geometric details. Heat transfer and pressure drop tests were carried out using different ranges of appropriate Reynolds numbers for the sought commercial application to compare each fin array and determine the effect of alumina content. It was found that the presence of alumina reduces the fins' performance when compared to pure aluminum fins but that they were still outperforming traditional fins. Numerical simulations were performed to model the fin arrays and were used to predict the pressure loss in the fin array and compare these results with experimental values. The numerical model opens up new avenues in predicting different applicable operating conditions and other possible fin shapes using the same fin composition, instead of performing costly and time-consuming experiments.

  3. Load bearing and stiffness tailored NiTi implants produced by additive manufacturing: a simulation study

    NASA Astrophysics Data System (ADS)

    Rahmanian, Rasool; Shayesteh Moghaddam, Narges; Haberland, Christoph; Dean, David; Miller, Michael; Elahinia, Mohammad

    2014-03-01

    Common metals for stable long-term implants (e.g. stainless steel, Titanium and Titanium alloys) are much stiffer than spongy cancellous and even stiffer than cortical bone. When bone and implant are loaded this stiffness mismatch results in stress shielding and as a consequence, degradation of surrounding bony structure can lead to disassociation of the implant. Due to its lower stiffness and high reversible deformability, which is associated with the superelastic behavior, NiTi is an attractive biomaterial for load bearing implants. However, the stiffness of austenitic Nitinol is closer to that of bone but still too high. Additive manufacturing provides, in addition to the fabrication of patient specific implants, the ability to solve the stiffness mismatch by adding engineered porosity to the implant. This in turn allows for the design of different stiffness profiles in one implant tailored to the physiological load conditions. This work covers a fundamental approach to bring this vision to reality. At first modeling of the mechanical behavior of different scaffold designs are presented as a proof of concept of stiffness tailoring. Based on these results different Nitinol scaffolds can be produced by additive manufacturing.

  4. Multi-material additive manufacturing of robot components with integrated sensor arrays

    NASA Astrophysics Data System (ADS)

    Saari, Matt; Cox, Bryan; Galla, Matt; Krueger, Paul S.; Richer, Edmond; Cohen, Adam L.

    2015-06-01

    Fabricating a robotic component comprising 100s of distributed, connected sensors can be very difficult with current approaches. To address these challenges, we are developing a novel additive manufacturing technology to enable the integrated fabrication of robotic structural elements with distributed, interconnected sensors and actuators. The focus is on resistive and capacitive sensors and electromagnetic actuators, though others are anticipated. Anticipated applications beyond robotics include advanced prosthetics, wearable electronics, and defense electronics. This paper presents preliminary results for printing polymers and conductive material simultaneously to form small sensor arrays. Approaches to optimizing sensor performance are discussed.

  5. [INVITED] Laser-induced forward transfer: A high resolution additive manufacturing technology

    NASA Astrophysics Data System (ADS)

    Delaporte, Philippe; Alloncle, Anne-Patricia

    2016-04-01

    Among the additive manufacturing techniques, laser-induced forward transfer addresses the challenges of printing thin films in solid phase or small volume droplets in liquid phase with very high resolution. This paper reviews the physics of this process and explores the pros and cons of this technology versus other digital printing technologies. The main field of applications are printed electronics, organic electronics and tissue engineering, and the most promising short terms ones concern digital laser printing of sensors and conductive tracks. Future directions and emerging areas of interest are discussed such as printing solid from a liquid phase and 3D digital nanomanufacturing.

  6. Synchrotron X-ray CT characterization of titanium parts fabricated by additive manufacturing. Part I. Morphology.

    PubMed

    Scarlett, Nicola Vivienne Yorke; Tyson, Peter; Fraser, Darren; Mayo, Sheridan; Maksimenko, Anton

    2016-07-01

    Synchrotron X-ray tomography has been applied to the study of titanium parts fabricated by additive manufacturing (AM). The AM method employed here was the Arcam EBM(®) (electron beam melting) process which uses powdered titanium alloy, Ti64 (Ti alloy with approximately 6%Al and 4%V), as the feed and an electron beam for the sintering/welding. The experiment was conducted on the Imaging and Medical Beamline of the Australian Synchrotron. Samples were chosen to examine the effect of build direction and complexity of design on the surface morphology and final dimensions of the piece. PMID:27359150

  7. Layered YSZ/SCSZ/YSZ Electrolytes for Intermediate Temperature SOFC Part I: Design and Manufacturing

    SciTech Connect

    Orlovskaya, Nina; Klimov, Mikhail; Huang, Xinyu; Cullen, David A; Graule, Thomas; Kuebler, Jakob

    2012-01-01

    (Sc2O3)0.1(CeO2)0.01(ZrO2)0.89 (SCSZ) ceramic electrolyte has superior ionic conductivity in the intermediate temperature range (700 800 C), but it does not exhibit good phase and chemical stability in comparison with 8 mol% Y2O3 ZrO2 (YSZ). To maintain high ionic conductivity and improve the stability in the whole electrolyte, layered structures with YSZ outer layers and SCSZ inner layers were designed. Because of a mismatch of coefficients of thermal expansion and Young's moduli of SCSZ and YSZ phases, upon cooling of the electrolytes after sintering, thermal residual stresses will arise, leading to a possible strengthening of the layered composite and, therefore, an increase in the reliability of the electrolyte. Laminated electrolytes with three, four, and six layers design were manufactured using tape-casting, lamination, and sintering techniques. After sintering, while the thickness of YSZ outer layers remained constant at 30 m, the thickness of the SCSZ inner layer varied from 30 m for a Y SC Y three-layered electrolyte, 60 m for a Y 2SC Y four-layered electrolyte, and 120 m for a Y 4SC Y six-layered electrolyte. The microstructure, crystal structure, impurities present, and the density of the sintered electrolytes were characterized by scanning and transmission electron microscopy, X-ray and neutron diffraction, secondary ion mass spectroscopy, and water immersion techniques.

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

    PubMed

    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 (<28% of the total amount) were found to exceed the minimum inhibitory concentrations of Staphylococcus aureus (16μg/mL) and Staphylococcus epidermidis (1μg/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. PMID:27127071

  9. Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components

    DOE PAGESBeta

    Huang, Runze; Riddle, Matthew; Graziano, Diane; Warren, Joshua; Das, Sujit; Nimbalkar, Sachin; Cresko, Joe; Masanet, Eric

    2015-05-08

    Additive manufacturing (AM) holds great potential for improving materials efficiency, reducing life-cycle impacts, and enabling greater engineering functionality compared to conventional manufacturing (CM) processes. For these reasons, AM has been adopted by a growing number of aircraft component manufacturers to achieve more lightweight, cost-effective designs. This study estimates the net changes in life-cycle primary energy and greenhouse gas emissions associated with AM technologies for lightweight metallic aircraft components through the year 2050, to shed light on the environmental benefits of a shift from CM to AM processes in the U.S. aircraft industry. A systems modeling framework is presented, with integratesmore » engineering criteria, life-cycle environmental data, and aircraft fleet stock and fuel use models under different AM adoption scenarios. Estimated fleetwide life-cycle primary energy savings in a rapid adoption scenario reach 70-174 million GJ/year in 2050, with cumulative savings of 1.2-2.8 billion GJ. Associated cumulative emission reduction potentials of CO2e were estimated at 92.8-217.4 million metric tons. About 95% of the savings is attributed to airplane fuel consumption reductions due to lightweighting. In addition, about 4050 tons aluminum, 7600 tons titanium and 8100 tons of nickel alloys could be saved per year in 2050. The results indicate a significant role of AM technologies in helping society meet its long-term energy use and GHG emissions reduction goals, and highlight barriers and opportunities for AM adoption for the aircraft industry.« less

  10. Modeling, Simulation, Additive Manufacturing, and Experimental Evaluation of Solid and Porous NiTi

    NASA Astrophysics Data System (ADS)

    Taheri Andani, Mohsen

    In recent years, shape memory alloys (SMAs) have entered a wide range of engineering applications in fields such as aerospace and medical applications. Nickel-titanium (NiTi) is the most commonly used SMAs due to its excellent functional characteristics (shape memory effect and superelasticity behavior). These properties are based on a solid-solid phase transformation between martensite and austenite. Beside these two characteristics, low stiffness, biocompatibility and corrosion properties of NiTi make it an attractive candidate for biomedical applications (e.g., bone plates, bone screws, and vascular stents). It is well know that manufacturing and processing of NiTi is very challenging. The functional properties of NiTi are significantly affected by the impurity level and due to the high titanium content, NiTi are highly reactive. Therefore, high temperature processed parts through methods such as melting and casting which result in increased impurity levels have inadequate structural and functional properties. Furthermore, high ductility and elasticity of NiTi, adhesion, work hardening and spring back effects make machining quite challenging. These unfavorable effects for machining cause significant tool wear along with decreasing the quality of work piece. Recently, additive manufacturing (AM) has gained significant attention for manufacturing NiTi. Since AM can create a part directly from CAD data, it is predicted that AM can overcome most of the manufacturing difficulties. This technique provides the possibility of fabricating highly complex parts, which cannot be processed by any other methods. Curved holes, designed porosity, and lattice like structures are some examples of mentioned complex parts. This work investigates manufacturing superelastic NiTi by selective laser melting (SLM) technique (using PXM by Phenix/3D Systems). An extended experimental study is conducted on the effect of subsequent heat treatments with different aging conditions on phase

  11. Metrology test object for dimensional verification in additive manufacturing of metals for biomedical applications.

    PubMed

    Teeter, Matthew G; Kopacz, Alexander J; Nikolov, Hristo N; Holdsworth, David W

    2015-01-01

    Additive manufacturing continues to increase in popularity and is being used in applications such as biomaterial ingrowth that requires sub-millimeter dimensional accuracy. The purpose of this study was to design a metrology test object for determining the capabilities of additive manufacturing systems to produce common objects, with a focus on those relevant to medical applications. The test object was designed with a variety of features of varying dimensions, including holes, cylinders, rectangles, gaps, and lattices. The object was built using selective laser melting, and the produced dimensions were compared to the target dimensions. Location of the test objects on the build plate did not affect dimensions. Features with dimensions less than 0.300 mm did not build or were overbuilt to a minimum of 0.300 mm. The mean difference between target and measured dimensions was less than 0.100 mm in all cases. The test object is applicable to multiple systems and materials, tests the effect of location on the build, uses a minimum of material, and can be measured with a variety of efficient metrology tools (including measuring microscopes and micro-CT). Investigators can use this test object to determine the limits of systems and adjust build parameters to achieve maximum accuracy. PMID:25542613

  12. Evaluation of Select Surface Processing Techniques for In Situ Application During the Additive Manufacturing Build Process

    NASA Astrophysics Data System (ADS)

    Book, Todd A.; Sangid, Michael D.

    2016-07-01

    Although additive manufacturing offers numerous performance advantages for different applications, it is not being used for critical applications due to uncertainties in structural integrity as a result of innate process variability and defects. To minimize uncertainty, the current approach relies on the concurrent utilization of process monitoring, post-processing, and non-destructive inspection in addition to an extensive material qualification process. This paper examines an alternative approach by evaluating the application of select surface process techniques, to include sliding severe plastic deformation (SPD) and fine particle shot peening, on direct metal laser sintering-produced AlSi10Mg materials. Each surface processing technique is compared to baseline as-built and post-processed samples as a proof of concept for surface enhancement. Initial results pairing sliding SPD with the manufacture's recommended thermal stress relief cycle demonstrated uniform recrystallization of the microstructure, resulting in a more homogeneous distribution of strain among the microstructure than as-built or post-processed conditions. This result demonstrates the potential for the in situ application of various surface processing techniques during the layerwise direct metal laser sintering build process.

  13. Compliance and control characteristics of an additive manufactured-flexure stage

    SciTech Connect

    Lee, ChaBum; Tarbutton, Joshua A.

    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.

  14. Low Cost Injection Mold Creation via Hybrid Additive and Conventional Manufacturing

    SciTech Connect

    Dehoff, Ryan R.; Watkins, Thomas R.; List, III, Frederick Alyious; Carver, Keith; England, Roger

    2015-12-01

    The purpose of the proposed project between Cummins and ORNL is to significantly reduce the cost of the tooling (machining and materials) required to create injection molds to make plastic components. Presently, the high cost of this tooling forces the design decision to make cast aluminum parts because Cummins typical production volumes are too low to allow injection molded plastic parts to be cost effective with the amortized cost of the injection molding tooling. In addition to reducing the weight of components, polymer injection molding allows the opportunity for the alternative cooling methods, via nitrogen gas. Nitrogen gas cooling offers an environmentally and economically attractive cooling option, if the mold can be manufactured economically. In this project, a current injection molding design was optimized for cooling using nitrogen gas. The various components of the injection mold tooling were fabricated using the Renishaw powder bed laser additive manufacturing technology. Subsequent machining was performed on the as deposited components to form a working assembly. The injection mold is scheduled to be tested in a projection setting at a commercial vendor selected by Cummins.

  15. Micro-Plasma Transferred Arc Additive Manufacturing for Die and Mold Surface Remanufacturing

    NASA Astrophysics Data System (ADS)

    Jhavar, Suyog; Paul, Christ Prakash; Jain, Neelesh Kumar

    2016-07-01

    Micro-plasma transferred arc ( µPTA) additive manufacturing is one of the newest options for remanufacturing of dies and molds surfaces in the near-millimeter range leading to extended usage of the same. We deployed an automatic micro-plasma deposition setup to deposit a wire of 300 µm of AISI P20 tool steel on the substrate of same material for the potential application in remanufacturing of the die and mold surface. Our present research effort is to establish µPTA additive manufacturing as a viable economical and cleaner methodology for potential industrial applications. We undertook the optimization of single weld bead geometry as the first step in our present study. Bead-on-plate trials were conducted to deposit single bead geometry at various processing parameters. The bead geometry (shape and size) and dilution were measured and the parametric dependence was derived. A set of parameters leading to reproducible regular and smooth single bead geometry were identified and used to prepare a thin wall for mechanical testing. The deposits were subjected to material characterization such as microscopic studies, micro-hardness measurements and tensile testing. The process was compared qualitatively with other deposition processes involving high-energy density beams and was found to be advantageous in terms of low initial and running costs with comparable properties. The outcome of the study confirmed the process capability of µPTA deposition leading to deployment of cost-effective and environmentally friendlier technology for die and mold remanufacturing.

  16. Comparative Shock Response of Additively Manufactured Versus Conventionally Wrought 304L Stainless Steel*

    NASA Astrophysics Data System (ADS)

    Wise, J. L.; Adams, D. P.; Nishida, E. E.; Song, B.; Maguire, M. C.; Carroll, J.; Reedlunn, B.; Bishop, J. E.

    2015-06-01

    Gas-gun experiments have probed the compression and release behavior of impact-loaded 304L stainless steel specimens machined from additively manufactured (AM) blocks as well as baseline ingot-derived bar stock. The AM technology allows direct fabrication of metal parts. For the present study, a velocity interferometer (VISAR) measured the time-resolved motion of samples subjected to one-dimensional (i.e., uniaxial strain) shock compression to peak stresses ranging from 0.2 to 7.5 GPa. The acquired wave-profile data have been analyzed to determine the comparative Hugoniot Elastic Limit (HEL), Hugoniot equation of state, spall strength, and high-pressure yield strength of the AM and conventional materials. Observed differences in shock loading and unloading characteristics for the two 304L source variants have been correlated to complementary Kolsky bar results for compressive and tensile testing at lower strain rates. The effects of composition, porosity, microstructure (e.g., grain size and morphology), residual stress, and sample axis orientation relative to the additive manufacturing deposition trajectory have been assessed to explain differences between the AM and baseline 304L dynamic mechanical properties. Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's National Nuclear Security Administration under Contract DE-AC04-94AL85000.

  17. Compliance and control characteristics of an additive manufactured-flexure stage.

    PubMed

    Lee, ChaBum; Tarbutton, Joshua A

    2015-04-01

    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. PMID:25933897

  18. Compliance and control characteristics of an additive manufactured-flexure stage

    NASA Astrophysics Data System (ADS)

    Lee, ChaBum; Tarbutton, Joshua A.

    2015-04-01

    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.

  19. Using Additive Manufacturing to Print a CubeSat Propulsion System

    NASA Technical Reports Server (NTRS)

    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.

  20. Micro-Plasma Transferred Arc Additive Manufacturing for Die and Mold Surface Remanufacturing

    NASA Astrophysics Data System (ADS)

    Jhavar, Suyog; Paul, Christ Prakash; Jain, Neelesh Kumar

    2016-05-01

    Micro-plasma transferred arc (µPTA) additive manufacturing is one of the newest options for remanufacturing of dies and molds surfaces in the near-millimeter range leading to extended usage of the same. We deployed an automatic micro-plasma deposition setup to deposit a wire of 300 µm of AISI P20 tool steel on the substrate of same material for the potential application in remanufacturing of the die and mold surface. Our present research effort is to establish µPTA additive manufacturing as a viable economical and cleaner methodology for potential industrial applications. We undertook the optimization of single weld bead geometry as the first step in our present study. Bead-on-plate trials were conducted to deposit single bead geometry at various processing parameters. The bead geometry (shape and size) and dilution were measured and the parametric dependence was derived. A set of parameters leading to reproducible regular and smooth single bead geometry were identified and used to prepare a thin wall for mechanical testing. The deposits were subjected to material characterization such as microscopic studies, micro-hardness measurements and tensile testing. The process was compared qualitatively with other deposition processes involving high-energy density beams and was found to be advantageous in terms of low initial and running costs with comparable properties. The outcome of the study confirmed the process capability of µPTA deposition leading to deployment of cost-effective and environmentally friendlier technology for die and mold remanufacturing.

  1. Evaluation of Select Surface Processing Techniques for In Situ Application During the Additive Manufacturing Build Process

    NASA Astrophysics Data System (ADS)

    Book, Todd A.; Sangid, Michael D.

    2016-03-01

    Although additive manufacturing offers numerous performance advantages for different applications, it is not being used for critical applications due to uncertainties in structural integrity as a result of innate process variability and defects. To minimize uncertainty, the current approach relies on the concurrent utilization of process monitoring, post-processing, and non-destructive inspection in addition to an extensive material qualification process. This paper examines an alternative approach by evaluating the application of select surface process techniques, to include sliding severe plastic deformation (SPD) and fine particle shot peening, on direct metal laser sintering-produced AlSi10Mg materials. Each surface processing technique is compared to baseline as-built and post-processed samples as a proof of concept for surface enhancement. Initial results pairing sliding SPD with the manufacture's recommended thermal stress relief cycle demonstrated uniform recrystallization of the microstructure, resulting in a more homogeneous distribution of strain among the microstructure than as-built or post-processed conditions. This result demonstrates the potential for the in situ application of various surface processing techniques during the layerwise direct metal laser sintering build process.

  2. Additive manufacturing and mechanical characterization of graded porosity scaffolds designed based on triply periodic minimal surface architectures.

    PubMed

    Afshar, M; Anaraki, A Pourkamali; Montazerian, H; Kadkhodapour, J

    2016-09-01

    Since the advent of additive manufacturing techniques, triply periodic minimal surfaces have emerged as a novel tool for designing porous scaffolds. Whereas scaffolds are expected to provide multifunctional performance, spatially changing pore patterns have been a promising approach to integrate mechanical characteristics of different architectures into a unique scaffold. Smooth morphological variations are also frequently seen in nature particularly in bone and cartilage structures and can be inspiring for designing of artificial tissues. In this study, we carried out experimental and numerical procedures to uncover the mechanical properties and deformation mechanisms of linearly graded porosity scaffolds for two different mathematically defined pore structures. Among TPMS-based scaffolds, P and D surfaces were subjected to gradient modeling to explore the mechanical responses for stretching and bending dominated deformations, respectively. Moreover, the results were compared to their corresponding uniform porosity structures. Mechanical properties were found to be by far greater for the stretching dominated structure (P-Surface). For bending dominated architecture (D-Surface), although there was no global fracture for uniform structures, graded structure showed a brittle fracture at 0.08 strain. A layer by layer deformation mechanism for stretching dominated structure was observed. For bending dominated scaffolds, deformation was accompanied by development of 45° shearing bands. Finite element simulations were also performed and the results showed a good agreement with the experimental observations. PMID:27281165

  3. Study of mandible reconstruction using a fibula flap with application of additive manufacturing technology

    PubMed Central

    2014-01-01

    Background This study aimed to establish surgical guiding techniques for completing mandible lesion resection and reconstruction of the mandible defect area with fibula sections in one surgery by applying additive manufacturing technology, which can reduce the surgical duration and enhance the surgical accuracy and success rate. Methods A computer assisted mandible reconstruction planning (CAMRP) program was used to calculate the optimal cutting length and number of fibula pieces and design the fixtures for mandible cutting, registration, and arrangement of the fibula segments. The mandible cutting and registering fixtures were then generated using an additive manufacturing system. The CAMRP calculated the optimal fibula cutting length and number of segments based on the location and length of the defective portion of the mandible. The mandible cutting jig was generated according to the boundary surface of the lesion resection on the mandible STL model. The fibular cutting fixture was based on the length of each segment, and the registered fixture was used to quickly arrange the fibula pieces into the shape of the defect area. In this study, the mandibular lesion was reconstructed using registered fibular sections in one step, and the method is very easy to perform. Results and conclusion The application of additive manufacturing technology provided customized models and the cutting fixtures and registered fixtures, which can improve the efficiency of clinical application. This study showed that the cutting fixture helped to rapidly complete lesion resection and fibula cutting, and the registered fixture enabled arrangement of the fibula pieces and allowed completion of the mandible reconstruction in a timely manner. Our method can overcome the disadvantages of traditional surgery, which requires a long and different course of treatment and is liable to cause error. With the help of optimal cutting planning by the CAMRP and the 3D printed mandible resection jig and

  4. Cranial reconstruction: 3D biomodel and custom-built implant created using additive manufacturing.

    PubMed

    Jardini, André Luiz; Larosa, Maria Aparecida; Maciel Filho, Rubens; Zavaglia, Cecília Amélia de Carvalho; Bernardes, Luis Fernando; Lambert, Carlos Salles; Calderoni, Davi Reis; Kharmandayan, Paulo

    2014-12-01

    Additive manufacturing (AM) technology from engineering has helped to achieve several advances in the medical field, particularly as far as fabrication of implants is concerned. The use of AM has made it possible to carry out surgical planning and simulation using a three-dimensional physical model which accurately represents the patient's anatomy. AM technology enables the production of models and implants directly from a 3D virtual model, facilitating surgical procedures and reducing risks. Furthermore, AM has been used to produce implants designed for individual patients in areas of medicine such as craniomaxillofacial surgery, with optimal size, shape and mechanical properties. This work presents AM technologies which were applied to design and fabricate a biomodel and customized implant for the surgical reconstruction of a large cranial defect. A series of computed tomography data was obtained and software was used to extract the cranial geometry. The protocol presented was used to create an anatomic biomodel of the bone defect for surgical planning and, finally, the design and manufacture of the patient-specific implant. PMID:25175080

  5. Biomechanical investigation into the structural design of porous additive manufactured cages using numerical and experimental approaches.

    PubMed

    Tsai, Pei-I; Hsu, Ching-Chi; Chen, San-Yuan; Wu, Tsung-Han; Huang, Chih-Chieh

    2016-09-01

    Traditional solid cages have been widely used in posterior lumbar interbody fusion (PLIF) surgery. However, solid cages significantly affect the loading mechanism of the human spine due to their extremely high structural stiffness. Previous studies proposed and investigated porous additive manufactured (AM) cages; however, their biomechanical performances were analyzed using oversimplified bone-implant numerical models. Thus, the aim of this study was to investigate the outer shape and inner porous structure of the AM cages. The outer shape of the AM cages was discovered using a simulation-based genetic algorithm; their inner porous structure was subsequently analyzed parametrically using T10-S1 multilevel spine models. Finally, six types of the AM cages, which were manufactured using selective laser melting, were tested to validate the numerical outcomes. The subsidence resistance of the optimum design was superior to the conventional cage designs. A porous AM cage with a pillar diameter of 0.4mm, a pillar angle of 40°, and a porosity of between 69% and 80% revealed better biomechanical performances. Both the numerical and experimental outcomes can help surgeons to understand the biomechanics of PLIF surgery combined with the use of AM cages. PMID:27392226

  6. Active metal-matrix composites with embedded smart materials by ultrasonic additive manufacturing

    NASA Astrophysics Data System (ADS)

    Hahnlen, Ryan; Dapino, Marcelo J.

    2010-04-01

    This paper presents the development of active aluminum-matrix composites manufactured by Ultrasonic Additive Manufacturing (UAM), an emerging rapid prototyping process based on ultrasonic metal welding. Composites created through this process experience temperatures as low as 25 °C during fabrication, in contrast to current metal-matrix fabrication processes which require temperatures of 500 °C and above. UAM thus provides unprecedented opportunities to develop adaptive structures with seamlessly embedded smart materials and electronic components without degrading the properties that make these materials and components attractive. This research focuses on developing UAM composites with aluminum matrices and embedded shape memory NiTi, magnetostrictive Galfenol, and electroactive PVDF phases. The research on these composites will focus on: (i) electrical insulation between NiTi and Al phases for strain sensors, investigation and modeling of NiTi-Al composites as tunable stiffness materials and thermally invariant structures based on the shape memory effect; (ii) process development and composite testing for Galfenol-Al composites; and (iii) development of PVDF-Al composites for embedded sensing applications. We demonstrate a method to electrically insulate embedded materials from the UAM matrix, the ability create composites containing up to 22.3% NiTi, and their resulting dimensional stability and thermal actuation characteristics. Also demonstrated is Galfenol-Al composite magnetic actuation of up to 54 μ(see manuscript), and creation of a PVDF-Al composite sensor.

  7. Repurposing mainstream CNC machine tools for laser-based additive manufacturing

    NASA Astrophysics Data System (ADS)

    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.

  8. The role and future of the Laser Technology in the Additive Manufacturing environment

    NASA Astrophysics Data System (ADS)

    Levy, Gideon N.

    The Additive Manufacturing (AM) was, in the early days, strongly inspired by upcoming laser technologies. The trend to apply lasers in manufacturing in the 1970's might be also be seen as the ignition point, as is evident in early precedent patents. During the evolvement of AM processes, many new systems based on various physical principals were evident; alternative energy sources for AM are in use today. Starting with the 'historical' background followed by a detailed classification analyzing the enablers in use, relevant laser technologies have been identified. This paper focuses on powder bed technologies for plastics and metals as the relevant Laser technology. It concentrates on laser influences and state-of-the-art knowledge. The paper will present a generalized, 'big picture' overview indicating 'lessons learned' and where future emphasis should be focused. Opportunities and challenges, including actual development status, will be described in view of the desired outcomes. Finally, future research challenges and conclusions will be stated and several relevant references for further readings will be given.

  9. Failure location prediction by finite element analysis for an additive manufactured mandible implant.

    PubMed

    Huo, Jinxing; Dérand, Per; Rännar, Lars-Erik; Hirsch, Jan-Michaél; Gamstedt, E Kristofer

    2015-09-01

    In order to reconstruct a patient with a bone defect in the mandible, a porous scaffold attached to a plate, both in a titanium alloy, was designed and manufactured using additive manufacturing. Regrettably, the implant fractured in vivo several months after surgery. The aim of this study was to investigate the failure of the implant and show a way of predicting the mechanical properties of the implant before surgery. All computed tomography data of the patient were preprocessed to remove metallic artefacts with metal deletion technique before mandible geometry reconstruction. The three-dimensional geometry of the patient's mandible was also reconstructed, and the implant was fixed to the bone model with screws in Mimics medical imaging software. A finite element model was established from the assembly of the mandible and the implant to study stresses developed during mastication. The stress distribution in the load-bearing plate was computed, and the location of main stress concentration in the plate was determined. Comparison between the fracture region and the location of the stress concentration shows that finite element analysis could serve as a tool for optimizing the design of mandible implants. PMID:26227805

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

    NASA Astrophysics Data System (ADS)

    Klassen, Alexander; Scharowsky, Thorsten; Körner, Carolin

    2014-07-01

    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.

  11. Deformation Mechanisms in NiTi-Al Composites Fabricated by Ultrasonic Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Chen, Xiang; Hehr, Adam; Dapino, Marcelo J.; Anderson, Peter M.

    2015-09-01

    Thermally active NiTi shape memory alloy (SMA) fibers can be used to tune or tailor the effective coefficient of thermal expansion (CTE) of a metallic matrix composite. In this paper, a novel NiTi-Al composite is fabricated using ultrasonic additive manufacturing (UAM). A combined experimental-simulation approach is used to develop and validate a microstructurally based finite element model of the composite. The simulations are able to closely reproduce the macroscopic strain versus temperature cyclic response, including initial transient effects in the first cycle. They also show that the composite CTE is minimized if the austenite texture in the SMA wires is <001>B2, that a fiber aspect ratio >10 maximizes fiber efficiency, and that the UAM process may reduce hysteresis in embedded SMA wires.

  12. Additive Manufacturing and High-Performance Computing: a Disruptive Latent Technology

    NASA Astrophysics Data System (ADS)

    Goodwin, Bruce

    2015-03-01

    This presentation will discuss the relationship between recent advances in Additive Manufacturing (AM) technology, High-Performance Computing (HPC) simulation and design capabilities, and related advances in Uncertainty Quantification (UQ), and then examines their impacts upon national and international security. The presentation surveys how AM accelerates the fabrication process, while HPC combined with UQ provides a fast track for the engineering design cycle. The combination of AM and HPC/UQ almost eliminates the engineering design and prototype iterative cycle, thereby dramatically reducing cost of production and time-to-market. These methods thereby present significant benefits for US national interests, both civilian and military, in an age of austerity. Finally, considering cyber security issues and the advent of the ``cloud,'' these disruptive, currently latent technologies may well enable proliferation and so challenge both nuclear and non-nuclear aspects of international security.

  13. Application and testing of additive manufacturing for mirrors and precision structures

    NASA Astrophysics Data System (ADS)

    Sweeney, Michael; Acreman, Martyn; Vettese, Tom; Myatt, Ray; Thompson, Mike

    2015-09-01

    Additive Manufacturing (aka AM, and 3-D printing) is widely touted in the media as the foundation for the next industrial revolution. Beneath the hype, AM does indeed offer profound advantages in lead-time, dramatically reduced consumption of expensive raw materials, while enabling new and innovative design forms that cannot be produced by other means. General Dynamics and their industry partners have begun to embrace this technology for mirrors and precision structures used in the aerospace, defense, and precision optical instrumentation industries. Aggressively lightweighted, open and closed back test mirror designs, 75-150 mm in size, were first produced by AM from several different materials. Subsequent optical finishing and test experiments have exceeded expectations for density, surface finish, dimensional stability and isotropy of thermal expansion on the optical scale of measurement. Materials currently under examination include aluminum, titanium, beryllium, aluminum beryllium, Inconel 625, stainless steel/bronze, and PEKK polymer.

  14. Additive Manufacturing of a Microbial Fuel Cell—A detailed study

    PubMed Central

    Calignano, Flaviana; Tommasi, Tonia; Manfredi, Diego; Chiolerio, Alessandro

    2015-01-01

    In contemporary society we observe an everlasting permeation of electron devices, smartphones, portable computing tools. The tiniest living organisms on Earth could become the key to address this challenge: energy generation by bacterial processes from renewable stocks/waste through devices such as microbial fuel cells (MFCs). However, the application of this solution was limited by a moderately low efficiency. We explored the limits, if any, of additive manufacturing (AM) technology to fabricate a fully AM-based powering device, exploiting low density, open porosities able to host the microbes, systems easy to fuel continuously and to run safely. We obtained an optimal energy recovery close to 3 kWh m−3 per day that can power sensors and low-power appliances, allowing data processing and transmission from remote/harsh environments. PMID:26611142

  15. Microstructure of Interpass Rolled Wire + Arc Additive Manufacturing Ti-6Al-4V Components

    NASA Astrophysics Data System (ADS)

    Martina, Filomeno; Colegrove, Paul A.; Williams, Stewart W.; Meyer, Jonathan

    2015-12-01

    Mechanical property anisotropy is one of the issues that are limiting the industrial adoption of additive manufacturing (AM) Ti-6Al-4V components. To improve the deposits' microstructure, the effect of high-pressure interpass rolling was evaluated, and a flat and a profiled roller were compared. The microstructure was changed from large columnar prior β grains that traversed the component to equiaxed grains that were between 56 and 139 μm in size. The repetitive variation in Widmanstätten α lamellae size was retained; however, with rolling, the overall size was reduced. A "fundamental study" was used to gain insight into the microstructural changes that occurred due to the combination of deformation and deposition. High-pressure interpass rolling can overcome many of the shortcomings of AM, potentially aiding industrial implementation of the process.

  16. Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

    SciTech Connect

    King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.; Khairallah, S. A.; Rubencik, A. M.

    2015-12-29

    The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this study, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

  17. Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

    SciTech Connect

    King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Khairallah, S. A.; Kamath, C.; Rubenchik, A. M.

    2015-12-15

    The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this paper, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

  18. An Assessment of Nondestructive Evaluation Capability for Complex Additive Manufacturing Aerospace Components

    NASA Technical Reports Server (NTRS)

    Walker, James; Beshears, Ron; Lambert, Dennis; Tilson, William

    2016-01-01

    The primary focus of this work is to investigate some of the fundamental relationships between processing, mechanical testing, materials characterization, and NDE for additively manufactured (AM) components using the powder bed fusion direct melt laser sintered process. The goal is to understand the criticality of defects unique to the AM process and then how conventional nondestructive evaluation methods as well as some of the more non-traditional methods such as computed tomography, are effected by the AM material. Specific defects including cracking, porosity and partially/unfused powder will be addressed. Besides line-of-site NDE, as appropriate these inspection capabilities will be put into the context of complex AM geometries where hidden features obscure, or inhibit traditional NDE methods.

  19. Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

    NASA Astrophysics Data System (ADS)

    King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.; Khairallah, S. A.; Rubenchik, A. M.

    2015-12-01

    The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this paper, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

  20. Additive Manufacturing of a Microbial Fuel Cell--A detailed study.

    PubMed

    Calignano, Flaviana; Tommasi, Tonia; Manfredi, Diego; Chiolerio, Alessandro

    2015-01-01

    In contemporary society we observe an everlasting permeation of electron devices, smartphones, portable computing tools. The tiniest living organisms on Earth could become the key to address this challenge: energy generation by bacterial processes from renewable stocks/waste through devices such as microbial fuel cells (MFCs). However, the application of this solution was limited by a moderately low efficiency. We explored the limits, if any, of additive manufacturing (AM) technology to fabricate a fully AM-based powering device, exploiting low density, open porosities able to host the microbes, systems easy to fuel continuously and to run safely. We obtained an optimal energy recovery close to 3 kWh m(-3) per day that can power sensors and low-power appliances, allowing data processing and transmission from remote/harsh environments. PMID:26611142

  1. Additive Manufacturing of a Microbial Fuel Cell—A detailed study

    NASA Astrophysics Data System (ADS)

    Calignano, Flaviana; Tommasi, Tonia; Manfredi, Diego; Chiolerio, Alessandro

    2015-11-01

    In contemporary society we observe an everlasting permeation of electron devices, smartphones, portable computing tools. The tiniest living organisms on Earth could become the key to address this challenge: energy generation by bacterial processes from renewable stocks/waste through devices such as microbial fuel cells (MFCs). However, the application of this solution was limited by a moderately low efficiency. We explored the limits, if any, of additive manufacturing (AM) technology to fabricate a fully AM-based powering device, exploiting low density, open porosities able to host the microbes, systems easy to fuel continuously and to run safely. We obtained an optimal energy recovery close to 3 kWh m-3 per day that can power sensors and low-power appliances, allowing data processing and transmission from remote/harsh environments.

  2. Additive Manufacturing of Al-12Si Alloy Via Pulsed Selective Laser Melting

    NASA Astrophysics Data System (ADS)

    Chou, R.; Milligan, J.; Paliwal, M.; Brochu, M.

    2015-03-01

    Additive manufacturing (AM) of metallic materials is experiencing a research and commercialization craze in almost all industrial sectors. However, to date, AM has been limited to a small numbers of alloys. With respect to aluminum, two alloys received some attention: Al-12Si and Al-10Si-1Mg. In both cases, fully dense components have been achieved using a continuous-wave selective laser melting system. In this article, a new approach of selective laser melting using a pulsed-laser source as opposed to a continuous-wave laser is proposed. Pulse selective laser melting (P-SLM) would allow for greater control over the heat input and thus further optimization possibilities of the microstructure. P-SLM was demonstrated using the Al-12Si system. Si refinement below 200 nm was achieved throughout the component. Density up to 95% and high hardness of above 135 HV were obtained. The solidification mechanism is also explained.

  3. Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

    DOE PAGESBeta

    King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.; Khairallah, S. A.; Rubencik, A. M.

    2015-12-29

    The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In thismore » study, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.« less

  4. A correlative imaging based methodology for accurate quantitative assessment of bone formation in additive manufactured implants.

    PubMed

    Geng, Hua; Todd, Naomi M; Devlin-Mullin, Aine; Poologasundarampillai, Gowsihan; Kim, Taek Bo; Madi, Kamel; Cartmell, Sarah; Mitchell, Christopher A; Jones, Julian R; Lee, Peter D

    2016-06-01

    A correlative imaging methodology was developed to accurately quantify bone formation in the complex lattice structure of additive manufactured implants. Micro computed tomography (μCT) and histomorphometry were combined, integrating the best features from both, while demonstrating the limitations of each imaging modality. This semi-automatic methodology registered each modality using a coarse graining technique to speed the registration of 2D histology sections to high resolution 3D μCT datasets. Once registered, histomorphometric qualitative and quantitative bone descriptors were directly correlated to 3D quantitative bone descriptors, such as bone ingrowth and bone contact. The correlative imaging allowed the significant volumetric shrinkage of histology sections to be quantified for the first time (~15 %). This technique demonstrated the importance of location of the histological section, demonstrating that up to a 30 % offset can be introduced. The results were used to quantitatively demonstrate the effectiveness of 3D printed titanium lattice implants. PMID:27153828

  5. Cost-Effective Additive Manufacturing in Space: HELIOS Technology Challenge Guide

    NASA Technical Reports Server (NTRS)

    DeVieneni, Alayna; Velez, Carlos Andres; Benjamin, David; Hollenbeck, Jay

    2012-01-01

    Welcome to the HELIOS Technology Challenge Guide. This document is intended to serve as a general road map for participants of the HELIOS Technology Challenge [HTC] Program and the associated inaugural challenge: HTC-01: Cost-Effective Additive Manufacturing in Space. Please note that this guide is not a rule book and is not meant to hinder the development of innovative ideas. Its primary goal is to highlight the objectives of the HTC-01 Challenge and to describe possible solution routes and pitfalls that such technology may encounter in space. Please also note that participants wishing to demonstrate any hardware developed under this program during any future HELIOS Technology Challenge showcase event(s) may be subject to event regulations to be published separately at a later date.

  6. Evaluation of SHM System Produced by Additive Manufacturing via Acoustic Emission and Other NDT Methods

    PubMed Central

    Strantza, Maria; Aggelis, Dimitrios G.; de Baere, Dieter; Guillaume, Patrick; van Hemelrijck, Danny

    2015-01-01

    During the last decades, structural health monitoring (SHM) systems are used in order to detect damage in structures. We have developed a novel structural health monitoring approach, the so-called “effective structural health monitoring” (eSHM) system. The current SHM system is incorporated into a metallic structure by means of additive manufacturing (AM) and has the possibility to advance life safety and reduce direct operative costs. It operates based on a network of capillaries that are integrated into an AM structure. The internal pressure of the capillaries is continuously monitored by a pressure sensor. When a crack nucleates and reaches the capillary, the internal pressure changes signifying the existence of the flaw. The main objective of this paper is to evaluate the crack detection capacity of the eSHM system and crack location accuracy by means of various non-destructive testing (NDT) techniques. During this study, detailed acoustic emission (AE) analysis was applied in AM materials for the first time in order to investigate if phenomena like the Kaiser effect and waveform parameters used in conventional metals can offer valuable insight into the damage accumulation of the AM structure as well. Liquid penetrant inspection, eddy current and radiography were also used in order to confirm the fatigue damage and indicate the damage location on un-notched four-point bending AM metallic specimens with an integrated eSHM system. It is shown that the eSHM system in combination with NDT can provide correct information on the damage condition of additive manufactured metals. PMID:26506349

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

    NASA Astrophysics Data System (ADS)

    Lee, ChaBum; Tarbutton, Joshua A.

    2014-09-01

    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.

  8. Additive manufactured polymeric 3D scaffolds with tailored surface topography influence mesenchymal stromal cells activity.

    PubMed

    Neves, Sara C; Mota, Carlos; Longoni, Alessia; Barrias, Cristina C; Granja, Pedro L; Moroni, Lorenzo

    2016-06-01

    Additive manufactured three-dimensional (3D) scaffolds with tailored surface topography constitute a clear advantage in tissue regeneration strategies to steer cell behavior. 3D fibrous scaffolds of poly(ethylene oxide terephthalate)/poly(butylene terephthalate) block copolymer presenting different fiber surface features were successfully fabricated by additive manufacturing combined with wet-spinning, in a single step, without any post-processing. The optimization of the processing parameters, mainly driven by different solvent/non-solvent combinations, led to four distinct scaffold types, with average surface roughness values ranging from 0.071 ± 0.012 μm to 1.950 ± 0.553 μm, average pore sizes in the x- and y-axis between 351.1 ± 33.6 μm and 396.1 ± 32.3 μm, in the z-axis between 36.5 ± 5.3 μm and 70.7 ± 8.8 μm, average fiber diameters between 69.4 ± 6.1 μm and 99.0 ± 9.4 μm, and porosity values ranging from 60.2 ± 0.8% to 71.7 ± 2.6%. Human mesenchymal stromal cells (hMSCs) cultured on these scaffolds adhered, proliferated, and produced endogenous extracellular matrix. The effect of surface roughness and topography on hMSCs differentiation was more evident for cells seeded at lower density, where the percentage of cells in direct contact with the surface was higher compared to more densely seeded scaffolds. Under osteogenic conditions, lower surface roughness values (0.227 ± 0.035 μm) had a synergistic effect on hMSCs behavior, while chondrogenesis was favored on rougher surfaces (1.950 ± 0.553 μm). PMID:27219645

  9. Evaluation of SHM system produced by additive manufacturing via acoustic emission and other NDT methods.

    PubMed

    Strantza, Maria; Aggelis, Dimitrios G; de Baere, Dieter; Guillaume, Patrick; van Hemelrijck, Danny

    2015-01-01

    During the last decades, structural health monitoring (SHM) systems are used in order to detect damage in structures. We have developed a novel structural health monitoring approach, the so-called "effective structural health monitoring" (eSHM) system. The current SHM system is incorporated into a metallic structure by means of additive manufacturing (AM) and has the possibility to advance life safety and reduce direct operative costs. It operates based on a network of capillaries that are integrated into an AM structure. The internal pressure of the capillaries is continuously monitored by a pressure sensor. When a crack nucleates and reaches the capillary, the internal pressure changes signifying the existence of the flaw. The main objective of this paper is to evaluate the crack detection capacity of the eSHM system and crack location accuracy by means of various non-destructive testing (NDT) techniques. During this study, detailed acoustic emission (AE) analysis was applied in AM materials for the first time in order to investigate if phenomena like the Kaiser effect and waveform parameters used in conventional metals can offer valuable insight into the damage accumulation of the AM structure as well. Liquid penetrant inspection, eddy current and radiography were also used in order to confirm the fatigue damage and indicate the damage location on un-notched four-point bending AM metallic specimens with an integrated eSHM system. It is shown that the eSHM system in combination with NDT can provide correct information on the damage condition of additive manufactured metals. PMID:26506349

  10. Development of flexible, free-standing, thin films for additive manufacturing and localized energy generation

    SciTech Connect

    Clark, Billy; McCollum, Jena; Pantoya, Michelle L.; Heaps, Ronald J.; Daniels, Michael A.

    2015-08-01

    Film energetics are becoming increasingly popular because a variety of technologies are driving a need for localized energy generation in a stable, safe and flexible form. Aluminum (Al) and molybdenum trioxide (MoO₃) composites were mixed into a silicon binder and extruded using a blade casting technique to form flexible free-standing films ideal for localized energy generation. Since this material can be extruded onto a surface it is well suited to additive manufacturing applications. This study examines the influence of 0-35% by mass potassium perchlorate (KClO₄) additive on the combustion behavior of these energetic films. Without KClO₄ the film exhibits thermal instabilities that produce unsteady energy propagation upon reaction. All films were cast at a thickness of 1 mm with constant volume percent solids to ensure consistent rheological properties. The films were ignited and flame propagation was measured. The results show that as the mass percent KClO₄ increased, the flame speed increased and peaked at 0.43 cm/s and 30 wt% KClO₄. Thermochemical equilibrium simulations show that the heat of combustion increases with increasing KClO₄ concentration up to a maximum at 20 wt% when the heat of combustion plateaus, indicating that the increased chemical energy liberated by the additional KClO₄ promotes stable energy propagation. Differential scanning calorimeter and thermogravimetric analysis show that the silicone binder participates as a fuel and reacts with KClO₄ adding energy to the reaction and promoting propagation.

  11. Characterization of embedded fiber optic strain sensors into metallic structures via ultrasonic additive manufacturing

    NASA Astrophysics Data System (ADS)

    Schomer, John J.; Hehr, Adam J.; Dapino, Marcelo J.

    2016-04-01

    Fiber Bragg Grating (FBG) sensors measure deviation in a reflected wavelength of light to detect in-situ strain. These sensors are immune to electromagnetic interference, and the inclusion of multiple FBGs on the same fiber allows for a seamlessly integrated sensing network. FBGs are attractive for embedded sensing in aerospace applications due to their small noninvasive size and prospect of constant, real-time nondestructive evaluation. In this study, FBG sensors are embedded in aluminum 6061 via ultrasonic additive manufacturing (UAM), a rapid prototyping process that uses high power ultrasonic vibrations to weld similar and dissimilar metal foils together. UAM was chosen due to the desire to embed FBG sensors at low temperatures, a requirement that excludes other additive processes such as selective laser sintering or fusion deposition modeling. In this paper, the embedded FBGs are characterized in terms of birefringence losses, post embedding strain shifts, consolidation quality, and strain sensing performance. Sensors embedded into an ASTM test piece are compared against an exterior surface mounted foil strain gage at both room and elevated temperatures using cyclic tensile tests.

  12. A Metallurgical Evaluation of the Powder-Bed Laser Additive Manufactured 4140 Steel Material

    NASA Astrophysics Data System (ADS)

    Wang, Wesley; Kelly, Shawn

    2016-03-01

    Using laser powder bed fusion (PBF-L) additive manufacturing (AM) process for steel or iron powder has been attempted for decades. This work used a medium carbon steel (AISI 4140) powder to explore the feasibility of AM. The high carbon equivalent of 4140 steel (CEIIW ≈ 0.83) has a strong tendency toward cold cracking. As such, the process parameters must be carefully controlled to ensure the AM build quality. Through an orthogonally designed experimental matrix, a laser-welding procedure was successfully developed to produce 4140 steel AM builds with no welding defects. In addition, the microstructure and micro-cleanliness of the as-welded PBF-L AM builds were also examined. The results showed an ultra-fine martensite lath structure and an ultra-clean internal quality with minimal oxide inclusion distribution. After optimizing the PBF-L AM process parameters, including the laser power and scan speed, the as-welded AM builds yielded an average tensile strength higher than 1482 MPa and an average 33 J Charpy V-notch impact toughness at -18°C. The surface quality, tensile strength, and Charpy V-notch impact toughness of AM builds were comparable to the wrought 4140 steel. The excellent mechanical properties of 4140 steel builds created by the PBF-L AM AM process make industrial production more feasible, which shows great potential for application in the aerospace, automobile, and machinery industries.

  13. Additive Manufacturing Enabled Ubiquitous Sensing in Aerospace and Integrated Building Systems

    NASA Astrophysics Data System (ADS)

    Mantese, Joseph

    2015-03-01

    Ubiquitous sensing is rapidly emerging as a means for globally optimizing systems of systems by providing both real time PHM (prognostics, diagnostics, and health monitoring), as well as expanded in-the-loop control. In closed or proprietary systems, such as in aerospace vehicles and life safety or security building systems; wireless signals and power must be supplied to a sensor network via single or multiple data concentrators in an architecture that ensures reliable/secure interconnectivity. In addition, such networks must be robust to environmental factors, including: corrosion, EMI/RFI, and thermal/mechanical variations. In this talk, we describe the use of additive manufacturing processes guided by physics based models for seamlessly embedding a sensor suite into aerospace and building system components; while maintaining their structural integrity and providing wireless power, sensor interrogation, and real-time diagnostics. We detail this approach as it specifically applies to industrial gas turbines for stationary land power. This work is supported through a grant from the National Energy Technology Laboratory (NETL), a division of the Department of Energy.

  14. Manipulation and Characterization of a Novel Titanium Powder Precursor for Additive Manufacturing Applications

    NASA Astrophysics Data System (ADS)

    Sun, Y. Y.; Gulizia, S.; Oh, C. H.; Doblin, C.; Yang, Y. F.; Qian, M.

    2015-03-01

    Lowering the cost of feedstock powder has been a major issue for wider applications of additive manufacturing (AM) of titanium (Ti) and its alloys. A novel and inexpensive Ti sponge material was selected as a precursor and processed using a CSIRO proprietary powder manipulation technology (PMT). The manipulated powder was characterized in terms of the particle size distribution (PSD), roundness, flowability in the Hall Funnel flowmeter, static angle of repose (AOR), apparent density and tap density. In addition, a universal powder bed (UPB) system was used to characterize the manipulated powder behavior after raking. Two benchmark powders, virgin Arcam Ti-6Al-4V powder and used Arcam Ti-6Al-4V powder, were assessed for a comparison. PMT processing of the Ti powder precursor produced near spherically shaped Ti powder in the size range of 75-106 µm, which performed very similarly to the used Arcam powder in the UPB system. The CSIRO PMT offers a cost-effective manipulation process to produce Ti powder promising for AM applications, while the UPB system allows a quick assessment of the powder spreading behavior in AM processes.

  15. Variation in mechanical behavior due to different build directions of Titanium6Aluminum4Vanadium fabricated by electron beam additive manufacturing technology

    NASA Astrophysics Data System (ADS)

    Roy, Lalit

    Titanium has always been a metal of great interest since its discovery especially for critical applications because of its excellent mechanical properties such as light weight (almost half of that of the steel), low density (4.4 gm/cc) and high strength (almost similar to steel). It creates a stable and adherent oxide layer on its surface upon exposure to air or water which gives it a great resistance to corrosion and has made it a great choice for structures in severe corrosive environment and sea water. Its non-allergic property has made it suitable for biomedical application for manufacturing implants. Having a very high melting temperature, it has a very good potential for high temperature applications. But high production and processing cost has limited its application. Ti6Al4V is the most used titanium alloy for which it has acquired the title as `workhouse' of the Ti family. Additive layer Manufacturing (ALM) has brought revolution in manufacturing industries. Today, this additive manufacturing has developed into several methods and formed a family. This method fabricates a product by adding layer after layer as per the geometry given as input into the system. Though the conception was developed to fabricate prototypes and making tools initially, but its highly economic aspect i.e., very little waste material for less machining and comparatively lower production lead time, obviation of machine tools have drawn attention for its further development towards mass production. Electron Beam Melting (EBM) is the latest addition to ALM family developed by Arcam, ABRTM located in Sweden. The electron beam that is used as heat source melts metal powder to form layers. For this thesis work, three different types of specimens have been fabricated using EBM system. These specimens differ in regard of direction of layer addition. Mechanical properties such as ultimate tensile strength, elastic modulus and yield strength, have been measured and compared with standard data

  16. Development of flexible, free-standing, thin films for additive manufacturing and localized energy generation

    SciTech Connect

    Clark, Billy; McCollum, Jena; Pantoya, Michelle L.; Heaps, Ronald J.; Daniels, Michael A.

    2015-08-15

    Film energetics are becoming increasingly popular because a variety of technologies are driving a need for localized energy generation in a stable, safe and flexible form. Aluminum (Al) and molybdenum trioxide (MoO{sub 3}) composites were mixed into a silicon binder and extruded using a blade casting technique to form flexible free-standing films ideal for localized energy generation. Since this material can be extruded onto a surface it is well suited to additive manufacturing applications. This study examines the influence of 0-35% by mass potassium perchlorate (KClO{sub 4}) additive on the combustion behavior of these energetic films. Without KClO{sub 4} the film exhibits thermal instabilities that produce unsteady energy propagation upon reaction. All films were cast at a thickness of 1 mm with constant volume percent solids to ensure consistent rheological properties. The films were ignited and flame propagation was measured. The results show that as the mass percent KClO{sub 4} increased, the flame speed increased and peaked at 0.43 cm/s and 30 wt% KClO{sub 4}. Thermochemical equilibrium simulations show that the heat of combustion increases with increasing KClO{sub 4} concentration up to a maximum at 20 wt% when the heat of combustion plateaus, indicating that the increased chemical energy liberated by the additional KClO{sub 4} promotes stable energy propagation. Differential scanning calorimeter and thermogravimetric analysis show that the silicone binder participates as a fuel and reacts with KClO{sub 4} adding energy to the reaction and promoting propagation.

  17. Development of flexible, free-standing, thin films for additive manufacturing and localized energy generation

    DOE PAGESBeta

    Clark, Billy; McCollum, Jena; Pantoya, Michelle L.; Heaps, Ronald J.; Daniels, Michael A.

    2015-08-01

    Film energetics are becoming increasingly popular because a variety of technologies are driving a need for localized energy generation in a stable, safe and flexible form. Aluminum (Al) and molybdenum trioxide (MoO₃) composites were mixed into a silicon binder and extruded using a blade casting technique to form flexible free-standing films ideal for localized energy generation. Since this material can be extruded onto a surface it is well suited to additive manufacturing applications. This study examines the influence of 0-35% by mass potassium perchlorate (KClO₄) additive on the combustion behavior of these energetic films. Without KClO₄ the film exhibits thermalmore » instabilities that produce unsteady energy propagation upon reaction. All films were cast at a thickness of 1 mm with constant volume percent solids to ensure consistent rheological properties. The films were ignited and flame propagation was measured. The results show that as the mass percent KClO₄ increased, the flame speed increased and peaked at 0.43 cm/s and 30 wt% KClO₄. Thermochemical equilibrium simulations show that the heat of combustion increases with increasing KClO₄ concentration up to a maximum at 20 wt% when the heat of combustion plateaus, indicating that the increased chemical energy liberated by the additional KClO₄ promotes stable energy propagation. Differential scanning calorimeter and thermogravimetric analysis show that the silicone binder participates as a fuel and reacts with KClO₄ adding energy to the reaction and promoting propagation.« less

  18. Role of additional PCBM layer between ZnO and photoactive layers in inverted bulk-heterojunction solar cells

    PubMed Central

    Cho, Shinuk; Kim, Kwang-Dae; Heo, Jinhee; Lee, Joo Yul; Cha, Gihoon; Seo, Bo Yeol; Kim, Young Dok; Kim, Yong Soo; Choi, Si-young; Lim, Dong Chan

    2014-01-01

    In order to induce greater light absorption, nano-patterning is often applied to the metal-oxide buffer layer in inverted bulk-heterojunction(BHJ) solar cells. However, current homogeneity was significantly disturbed at the interface, leading to an efficiency that was not fully optimized. In this work, an additional PC61BM layer was inserted between the ZnO ripple and the photoactive layer to enhance the electron extraction. The insertion of additional PC61BM layer provided substantial advantages in the operation of inverted BHJ solar cells; specifically, it enhanced current homogeneity and lowered accumulation and trapping of photogenerated charges at the ZnO interface. Inclusion of the additional PC61BM layer led to effective quenching of electron–hole recombination by a reduction in the number of accumulated charges at the surface of ZnO ripples. This resulted in a 16% increase in the efficiency of inverted BHJ solar cells to 7.7%, compared to solar cells without the additional PC61BM layer. PMID:24603531

  19. Studying the issues in the additive manufacturing of dental implants by Electron Beam MeltingRTM (EBM)

    NASA Astrophysics Data System (ADS)

    Jamshidinia, Mahdi

    The ability of additive manufacturing (AM) processes to produce complex geometries is resulting in their rapid acceptance by a number of industries. This unique capability could be used for the optimization of the design of functional components that could find an application in different industries such as aerospace, automotive, energy, medical, and implants. However, there are still some challenges confronting this technology such as surface finish, residual stress, dimensional tolerance, processing speed, and anisotropy in microstructure and mechanical properties. Any of the mentioned issues could be influenced by the thermal history of a 3D printed component during the layer-by-layer manufacturing. Therefore, an understanding of the thermal cycling during the AM process is essential. In recent years, significant advances have been achieved in the design, manufacturing, and materials used for dental implants. However, there are still some differences between the natural tooth and a dental implant that might decrease patient satisfaction. One of the differences between the natural tooth and a dental implant is in its modulus of elasticity, which could result in an issue known as bone atrophy. The second important difference between a dental implant and a natural tooth is the fact that a natural tooth is surrounded by a periodontal ligament that allows the tooth to move in three directions. However, the periodontal ligament is destroyed during the extraction of a natural tooth. In the absence of the periodontal ligament, the biting force is directly transferred to the jawbone, resulting in discomfort for the patient. Also, the implant cannot be incorporated with the surrounding natural tooth and form a bridge. In this study, the application of a lattice structure for the manufacturing of a biocompatible dental implant is investigated. Three different lattice structures with different unit cell sizes were experimentally and numerically analyzed. The mechanical

  20. 76 FR 82308 - Guidance for Industry: Current Good Tissue Practice and Additional Requirements for Manufacturers...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2011-12-30

    .... The guidance is intended for any HCT/P establishment that performs a manufacturing step and is... 1271, subpart E. The guidance is intended for any HCT/P establishment that performs a manufacturing... 16, 2009 (74 FR 3055), FDA announced the availability of the draft guidance of the same title...

  1. Empirical Approach to Understanding the Fatigue Behavior of Metals Made Using Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Witkin, David B.; Albright, Thomas V.; Patel, Dhruv N.

    2016-04-01

    High-cycle fatigue measurements were performed on alloys prepared by powder-bed fusion additive manufacturing techniques. Selective laser melted (SLM) nickel-based superalloy 625 and electron beam melted (EBM) Ti-6Al-4V specimens were prepared as round fatigue specimens and tested with as-built surfaces at stress ratios of -1, 0.1 and 0.5. Data collected at R = -1 were used to construct Goodman diagrams that correspond closely to measured experimental data collected at R > 0. A second way to interpret the HCF data is based on the influence of surface roughness on fatigue, and approximate the surface feature size as a notch. On this basis, the data were interpreted using the fatigue notch factor k f and average stress models relating k f and stress concentration factor K t. The depth and root radius of surface features associated with fatigue crack initiation were used to estimate a K t of 2.8 for SLM 625. For Ti-6Al-4V, a direct estimate of K t from HCF data was not possible, but approximate values of k f based on HCF data and K t from crack initiation site geometry are found to explain other published EBM Ti-6Al-4V.

  2. Continuous Digital Light Processing (cDLP): Highly Accurate Additive Manufacturing of Tissue Engineered Bone Scaffolds.

    PubMed

    Dean, David; Jonathan, Wallace; Siblani, Ali; Wang, Martha O; Kim, Kyobum; Mikos, Antonios G; Fisher, John P

    2012-03-01

    Highly accurate rendering of the external and internal geometry of bone tissue engineering scaffolds effects fit at the defect site, loading of internal pore spaces with cells, bioreactor-delivered nutrient and growth factor circulation, and scaffold resorption. It may be necessary to render resorbable polymer scaffolds with 50 μm or less accuracy to achieve these goals. This level of accuracy is available using Continuous Digital Light processing (cDLP) which utilizes a DLP(®) (Texas Instruments, Dallas, TX) chip. One such additive manufacturing device is the envisionTEC (Ferndale, MI) Perfactory(®). To use cDLP we integrate a photo-crosslinkable polymer, a photo-initiator, and a biocompatible dye. The dye attenuates light, thereby limiting the depth of polymerization. In this study we fabricated scaffolds using the well-studied resorbable polymer, poly(propylene fumarate) (PPF), titanium dioxide (TiO(2)) as a dye, Irgacure(®) 819 (BASF [Ciba], Florham Park, NJ) as an initiator, and diethyl fumarate as a solvent to control viscosity. PMID:23066427

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

    NASA Astrophysics Data System (ADS)

    Zhang, Yanning; Sahasrabudhe, Himanshu; Bandyopadhyay, Amit

    2015-08-01

    In this study, Laser Engineered Net Shaping (LENSTM) 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 HV0.2) > 100% Ti-N coating (1846 ± 68.5 HV0.2) > 75% Ti-25% Si-N coating (1375.3 ± 61.4 HV0.2). However, wear resistance was more dependent on inherent Si content, and samples with higher Si content showed better wear resistance.

  4. Mechanical Characterization of an Additively Manufactured Inconel 718 Theta-Shaped Specimen

    NASA Astrophysics Data System (ADS)

    Cakmak, Ercan; Watkins, Thomas R.; Bunn, Jeffrey R.; Cooper, Ryan C.; Cornwell, Paris A.; Wang, Yanli; Sochalski-Kolbus, Lindsay M.; Dehoff, Ryan R.; Babu, Sudarsanam S.

    2016-02-01

    Two sets of "theta"-shaped specimens were additively manufactured with Inconel 718 powders using an electron beam melting technique with two distinct scan strategies. Light optical microscopy, mechanical testing coupled with a digital image correlation (DIC) technique, finite element modeling, and neutron diffraction with in situ loading characterizations were conducted. The cross-members of the specimens were the focus. Light optical micrographs revealed that different microstructures were formed with different scan strategies. Ex situ mechanical testing revealed each build to be stable under load until ductility was observed on the cross-members before failure. The elastic moduli were determined by forming a correlation between the elastic tensile stresses determined from FEM, and the elastic strains obtained from DIC. The lattice strains were mapped with neutron diffraction during in situ elastic loading; and a good correlation between the average axial lattice strains on the cross-member and those determined from the DIC analysis was found. The spatially resolved stresses in the elastic deformation regime are derived from the lattice strains and increased with applied load, showing a consistent distribution along the cross-member.

  5. Time-Resolved In Situ Measurements During Rapid Alloy Solidification: Experimental Insight for Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    McKeown, Joseph T.; Zweiacker, Kai; Liu, Can; Coughlin, Daniel R.; Clarke, Amy J.; Baldwin, J. Kevin; Gibbs, John W.; Roehling, John D.; Imhoff, Seth D.; Gibbs, Paul J.; Tourret, Damien; Wiezorek, Jörg M. K.; Campbell, Geoffrey H.

    2016-03-01

    Additive manufacturing (AM) of metals and alloys is becoming a pervasive technology in both research and industrial environments, though significant challenges remain before widespread implementation of AM can be realized. In situ investigations of rapid alloy solidification with high spatial and temporal resolutions can provide unique experimental insight into microstructure evolution and kinetics that are relevant for AM processing. Hypoeutectic thin-film Al-Cu and Al-Si alloys were investigated using dynamic transmission electron microscopy to monitor pulsed-laser-induced rapid solidification across microsecond timescales. Solid-liquid interface velocities measured from time-resolved images revealed accelerating solidification fronts in both alloys. The observed microstructure evolution, solidification product, and presence of a morphological instability at the solid-liquid interface in the Al-4 at.%Cu alloy are related to the measured interface velocities and small differences in composition that affect the thermophysical properties of the alloys. These time-resolved in situ measurements can inform and validate predictive modeling efforts for AM.

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

    PubMed

    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. PMID:26504776

  7. Time-Resolved In Situ Measurements During Rapid Alloy Solidification: Experimental Insight for Additive Manufacturing

    DOE PAGESBeta

    McKeown, Joseph T.; Zweiacker, Kai; Liu, Can; Coughlin, Daniel R.; Clarke, Amy J.; Baldwin, J. Kevin; Gibbs, John W.; Roehling, John D.; Imhoff, Seth D.; Gibbs, Paul J.; et al

    2016-01-27

    In research and industrial environments, additive manufacturing (AM) of metals and alloys is becoming a pervasive technology, though significant challenges remain before widespread implementation of AM can be realized. In situ investigations of rapid alloy solidification with high spatial and temporal resolutions can provide unique experimental insight into microstructure evolution and kinetics that are relevant for AM processing. Hypoeutectic thin-film Al–Cu and Al–Si alloys were investigated using dynamic transmission electron microscopy to monitor pulsed-laser-induced rapid solidification across microsecond timescales. Solid–liquid interface velocities measured from time-resolved images revealed accelerating solidification fronts in both alloys. We observed microstructure evolution, solidification product, andmore » presence of a morphological instability at the solid–liquid interface in the Al–4 at.%Cu alloy are related to the measured interface velocities and small differences in composition that affect the thermophysical properties of the alloys. These time-resolved in situ measurements can inform and validate predictive modeling efforts for AM.« less

  8. Porous composite with negative thermal expansion obtained by photopolymer additive manufacturing

    NASA Astrophysics Data System (ADS)

    Takezawa, Akihiro; Kobashi, Makoto; Kitamura, Mitsuru

    2015-07-01

    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 properties. Negative thermal expansion is a representative effective material property realized by designing a composite made of two materials with different coefficients of thermal expansion. In this study, we developed a porous composite having planar negative thermal expansion by employing multi-material photopolymer AM. After measurement of the physical properties of bulk photopolymers, the internal geometry was designed by topology optimization, which is the most effective structural optimization in terms of both minimizing thermal stress and maximizing stiffness. The designed structure was converted to a three-dimensional stereolithography (STL) model, which is a native digital format of AM, and assembled as a test piece. The thermal expansions of the specimens were measured using a laser scanning dilatometer. Negative thermal expansion corresponding to less than -1 × 10-4 K-1 was observed for each test piece of the N = 3 experiment.

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

    PubMed Central

    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. PMID:26504776

  10. Empirical Approach to Understanding the Fatigue Behavior of Metals Made Using Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Witkin, David B.; Albright, Thomas V.; Patel, Dhruv N.

    2016-08-01

    High-cycle fatigue measurements were performed on alloys prepared by powder-bed fusion additive manufacturing techniques. Selective laser melted (SLM) nickel-based superalloy 625 and electron beam melted (EBM) Ti-6Al-4V specimens were prepared as round fatigue specimens and tested with as-built surfaces at stress ratios of -1, 0.1 and 0.5. Data collected at R = -1 were used to construct Goodman diagrams that correspond closely to measured experimental data collected at R > 0. A second way to interpret the HCF data is based on the influence of surface roughness on fatigue, and approximate the surface feature size as a notch. On this basis, the data were interpreted using the fatigue notch factor k f and average stress models relating k f and stress concentration factor K t. The depth and root radius of surface features associated with fatigue crack initiation were used to estimate a K t of 2.8 for SLM 625. For Ti-6Al-4V, a direct estimate of K t from HCF data was not possible, but approximate values of k f based on HCF data and K t from crack initiation site geometry are found to explain other published EBM Ti-6Al-4V.

  11. Continuous Digital Light Processing (cDLP): Highly Accurate Additive Manufacturing of Tissue Engineered Bone Scaffolds

    PubMed Central

    Dean, David; Wallace, Jonathan; Siblani, Ali; Wang, Martha O.; Kim, Kyobum; Mikos, Antonios G.; Fisher, John P.

    2012-01-01

    Highly accurate rendering of the external and internal geometry of bone tissue engineering scaffolds effects fit at the defect site, loading of internal pore spaces with cells, bioreactor-delivered nutrient and growth factor circulation, and scaffold resorption. It may be necessary to render resorbable polymer scaffolds with 50 μm or less accuracy to achieve these goals. This level of accuracy is available using Continuous Digital Light processing (cDLP) which utilizes a DLP® (Texas Instruments, Dallas, TX) chip. One such additive manufacturing device is the envisionTEC (Ferndale, MI) Perfactory®. To use cDLP we integrate a photo-crosslinkable polymer, a photo-initiator, and a biocompatible dye. The dye attenuates light, thereby limiting the depth of polymerization. In this study we fabricated scaffolds using the well-studied resorbable polymer, poly(propylene fumarate) (PPF), titanium dioxide (TiO2) as a dye, Irgacure® 819 (BASF [Ciba], Florham Park, NJ) as an initiator, and diethyl fumarate as a solvent to control viscosity. PMID:23066427

  12. Mechanical characterization of an additively manufactured Inconel 718 theta-shaped specimen

    SciTech Connect

    Cakmak, Ercan; Watkins, Thomas R.; Bunn, Jeffrey R.; Cornwell, Paris A.; Wang, Yanli; Dehoff, Ryan R.; Babu, Sudarsanam Suresh; Sochalski-Kolbus, Lindsay M.

    2015-11-20

    Two sets of “theta”-shaped specimens were additively manufactured with Inconel 718 powders using an electron beam melting technique with two distinct scan strategies. Light optical microscopy, mechanical testing coupled with a digital image correlation (DIC) technique, finite element modeling, and neutron diffraction with in situ loading characterizations were conducted. The cross-members of the specimens were the focus. Light optical micrographs revealed that different microstructures were formed with different scan strategies. Ex situ mechanical testing revealed each build to be stable under load until ductility was observed on the cross-members before failure. The elastic moduli were determined by forming a correlation between the elastic tensile stresses determined from FEM, and the elastic strains obtained from DIC. The lattice strains were mapped with neutron diffraction during in situ elastic loading; and a good correlation between the average axial lattice strains on the cross-member and those determined from the DIC analysis was found. Lastly, the spatially resolved stresses in the elastic deformation regime are derived from the lattice strains and increased with applied load, showing a consistent distribution along the cross-member.

  13. Mechanical characterization of an additively manufactured Inconel 718 theta-shaped specimen

    DOE PAGESBeta

    Cakmak, Ercan; Watkins, Thomas R.; Bunn, Jeffrey R.; Cornwell, Paris A.; Wang, Yanli; Dehoff, Ryan R.; Babu, Sudarsanam Suresh; Sochalski-Kolbus, Lindsay M.

    2015-11-20

    Two sets of “theta”-shaped specimens were additively manufactured with Inconel 718 powders using an electron beam melting technique with two distinct scan strategies. Light optical microscopy, mechanical testing coupled with a digital image correlation (DIC) technique, finite element modeling, and neutron diffraction with in situ loading characterizations were conducted. The cross-members of the specimens were the focus. Light optical micrographs revealed that different microstructures were formed with different scan strategies. Ex situ mechanical testing revealed each build to be stable under load until ductility was observed on the cross-members before failure. The elastic moduli were determined by forming a correlationmore » between the elastic tensile stresses determined from FEM, and the elastic strains obtained from DIC. The lattice strains were mapped with neutron diffraction during in situ elastic loading; and a good correlation between the average axial lattice strains on the cross-member and those determined from the DIC analysis was found. Lastly, the spatially resolved stresses in the elastic deformation regime are derived from the lattice strains and increased with applied load, showing a consistent distribution along the cross-member.« less

  14. Levofloxacin-loaded star poly(ε-caprolactone) scaffolds by additive manufacturing.

    PubMed

    Puppi, Dario; Piras, Anna Maria; Pirosa, Alessandro; Sandreschi, Stefania; Chiellini, Federica

    2016-03-01

    The employment of a tissue engineering scaffold able to release an antimicrobial agent with a controlled kinetics represents an effective tool for the treatment of infected tissue defects as well as for the prevention of scaffolds implantation-related infectious complications. This research activity was aimed at the development of additively manufactured star poly(ε-caprolactone) (*PCL) scaffolds loaded with levofloxacin, investigated as antimicrobial fluoroquinolone model. For this purpose a computer-aided wet-spinning technique allowing functionalizing the scaffold during the fabrication process was explored. Scaffolds with customized composition, microstructure and anatomical external shape were developed by optimizing the processing parameters. Morphological, thermal and mechanical characterization showed that drug loading did not compromise the fabrication process and the final performance of the scaffolds. The developed *PCL scaffolds showed a sustained in vitro release of the loaded antibiotic for 5 weeks. The proposed computer-aided wet-spinning technique appears well suited for the fabrication of anatomical scaffolds endowed with levofloxacin-releasing properties to be tested in vivo for the regeneration of long bone critical size defects in a rabbit model. PMID:26758891

  15. Additive manufacturing of collagen scaffolds by three-dimensional plotting of highly viscous dispersions.

    PubMed

    Lode, Anja; Meyer, Michael; Brüggemeier, Sophie; Paul, Birgit; Baltzer, Hagen; Schröpfer, Michaela; Winkelmann, Claudia; Sonntag, Frank; Gelinsky, Michael

    2016-03-01

    Additive manufacturing (AM) allows the free form fabrication of three-dimensional (3D) structures with distinct external geometry, fitting into a patient-specific defect, and defined internal pore architecture. However, fabrication of predesigned collagen scaffolds using AM-based technologies is challenging due to the low viscosity of collagen solutions, gels or dispersions commonly used for scaffold preparation. In the present study, we have developed a straightforward method which is based on 3D plotting of a highly viscous, high density collagen dispersion. The swollen state of the collagen fibrils at pH 4 enabled the homogenous extrusion of the material, the deposition of uniform strands and finally the construction of 3D scaffolds. Stabilization of the plotted structures was achieved by freeze-drying and chemical crosslinking with the carbodiimide EDC. The scaffolds exhibited high shape and dimensional fidelity and a hierarchical porosity consisting of macropores generated by strand deposition as well as an interconnected microporosity within the strands as result of the freeze-drying process. Cultivation of human mesenchymal stromal cells on the scaffolds, with and without adipogenic or osteogenic stimulation, revealed their cytocompatibility and potential applicability for adipose and bone tissue engineering. PMID:26924825

  16. Surface modification of additive manufactured Ti6Al4V alloy with Ag nanoparticles: wettability and surface morphology study

    NASA Astrophysics Data System (ADS)

    Chudinova, E.; Surmeneva, M.; Koptioug, A.; Sharonova, A.; Loza, K.; Surmenev, R.

    2016-02-01

    In this work, the use of electrophoretic deposition to modify the surface of Ti6Al4V alloy fabricated via additive manufacturing technology is reported. Poly(vinylpyrrolidone) (PVP)-stabilized silver nanoparticles (AgNPs) had a spherical shape with a diameter of the metallic core of 100±20 nm and ζ -potential -15 mV. The AgNPs- coated Ti6Al4V alloy was studied in respect with its chemical composition and surface morphology, water contact angle, hysteresis, and surface free energy. The results of SEM microphotography analysis showed that the AgNPs were homogeneously distributed over the surface. Hysteresis and water contact angle measurements revealed the effect of the deposited AgNPs layer, namely an increased water contact angle and decreased contact angle hysteresis. However, the average water contact angle was 125° for PVP-stabilized-AgNPs-coated surface, whereas ethylene glycol gave the average contact angle of 17°. A higher surface energy is observed for AgNPs-coated Ti6Al4V surface (70.17 mN/m) compared with the uncoated surface (49.07 mN/m).

  17. Review of Mechanical Properties of Ti-6Al-4V Made by Laser-Based Additive Manufacturing Using Powder Feedstock

    NASA Astrophysics Data System (ADS)

    Beese, Allison M.; Carroll, Beth E.

    2016-03-01

    Laser-based additive manufacturing (AM) of metals using powder feedstock can be accomplished via two broadly defined technologies: directed energy deposition (DED) and powder bed fusion (PBF). In these processes, metallic powder is delivered to a location and locally melted with a laser heat source. Upon deposition, the material undergoes a rapid cooling and solidification, and as subsequent layers are added to the component, the material within the component is subjected to rapid thermal cycles. In order to adopt AM for the building of structural components, a thorough understanding of the relationships among the complex thermal cycles seen in AM, the unique heterogeneous and anisotropic microstructure, and the mechanical properties must be developed. Researchers have fabricated components by both DED and PBF from the widely used titanium alloy Ti-6Al-4V and studied the resultant microstructure and mechanical properties. This review article discusses the progress to date on investigating the as-deposited and heat-treated microstructures and mechanical properties of Ti-6Al-4V structures made by powder-based laser AM using DED and PBF.

  18. Antibacterial Behavior of Additively Manufactured Porous Titanium with Nanotubular Surfaces Releasing Silver Ions.

    PubMed

    Amin Yavari, S; Loozen, L; Paganelli, F L; Bakhshandeh, S; Lietaert, K; Groot, J A; Fluit, A C; Boel, C H E; Alblas, J; Vogely, H C; Weinans, H; Zadpoor, A A

    2016-07-13

    Additive manufacturing (3D printing) has enabled fabrication of geometrically complex and fully interconnected porous biomaterials with huge surface areas that could be used for biofunctionalization to achieve multifunctional biomaterials. Covering the huge surface area of such porous titanium with nanotubes has been already shown to result in improved bone regeneration performance and implant fixation. In this study, we loaded TiO2 nanotubes with silver antimicrobial agents to equip them with an additional biofunctionality, i.e., antimicrobial behavior. An optimized anodizing protocol was used to create nanotubes on the entire surface area of direct metal printed porous titanium scaffolds. The nanotubes were then loaded by soaking them in three different concentrations (i.e., 0.02, 0.1, and 0.5 M) of AgNO3 solution. The antimicrobial behavior and cell viability of the developed biomaterials were assessed. As far as the early time points (i.e., up to 1 day) are concerned, the biomaterials were found to be extremely effective in preventing biofilm formation and decreasing the number of planktonic bacteria particularly for the middle and high concentrations of silver ions. Interestingly, nanotubes not loaded with antimicrobial agents also showed significantly smaller numbers of adherent bacteria at day 1, which may be attributed to the bactericidal effect of high aspect ratio nanotopographies. The specimens with the highest concentrations of antimicrobial agents adversely affected cell viability at day 1, but this effect is expected to decrease or disappear in the following days as the rate of release of silver ions was observed to markedly decrease within the next few days. The antimicrobial effects of the biomaterials, particularly the ones with the middle and high concentrations of antimicrobial agents, continued until 2 weeks. The potency of the developed biomaterials in decreasing the number of planktonic bacteria and hindering the formation of biofilms make

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

    NASA Astrophysics Data System (ADS)

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

    2015-03-01

    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.

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

    SciTech Connect

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

    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.

  1. Invited Review Article: Review of post-process optical form metrology for industrial-grade metal additive manufactured parts.

    PubMed

    Stavroulakis, P I; Leach, R K

    2016-04-01

    The scope of this review is to investigate the main post-process optical form measurement technologies available in industry today and to determine whether they are applicable to industrial-grade metal additive manufactured parts. An in-depth review of the operation of optical three-dimensional form measurement technologies applicable to metal additive manufacturing is presented, with a focus on their fundamental limitations. Looking into the future, some alternative candidate measurement technologies potentially applicable to metal additive manufacturing will be discussed, which either provide higher accuracy than currently available techniques but lack measurement volume, or inversely, which operate in the appropriate measurement volume but are not currently accurate enough to be used for industrial measurement. PMID:27131645

  2. Invited Review Article: Review of post-process optical form metrology for industrial-grade metal additive manufactured parts

    NASA Astrophysics Data System (ADS)

    Stavroulakis, P. I.; Leach, R. K.

    2016-04-01

    The scope of this review is to investigate the main post-process optical form measurement technologies available in industry today and to determine whether they are applicable to industrial-grade metal additive manufactured parts. An in-depth review of the operation of optical three-dimensional form measurement technologies applicable to metal additive manufacturing is presented, with a focus on their fundamental limitations. Looking into the future, some alternative candidate measurement technologies potentially applicable to metal additive manufacturing will be discussed, which either provide higher accuracy than currently available techniques but lack measurement volume, or inversely, which operate in the appropriate measurement volume but are not currently accurate enough to be used for industrial measurement.

  3. Surface energy and stiffness discrete gradients in additive manufactured scaffolds for osteochondral regeneration.

    PubMed

    Di Luca, Andrea; Longoni, Alessia; Criscenti, Giuseppe; Lorenzo-Moldero, Ivan; Klein-Gunnewiek, Michel; Vancso, Julius; van Blitterswijk, Clemens; Mota, Carlos; Moroni, Lorenzo

    2016-03-01

    Swift progress in biofabrication technologies has enabled unprecedented advances in the application of developmental biology design criteria in three-dimensional scaffolds for regenerative medicine. Considering that tissues and organs in the human body develop following specific physico-chemical gradients, in this study, we hypothesized that additive manufacturing (AM) technologies would significantly aid in the construction of 3D scaffolds encompassing such gradients. Specifically, we considered surface energy and stiffness gradients and analyzed their effect on adult bone marrow derived mesenchymal stem cell differentiation into skeletal lineages. Discrete step-wise macroscopic gradients were obtained by sequentially depositing different biodegradable biomaterials in the AM process, namely poly(lactic acid) (PLA), polycaprolactone (PCL), and poly(ethylene oxide terephthalate)/poly(butylene terephthalate) (PEOT/PBT) copolymers. At the bulk level, PEOT/PBT homogeneous scaffolds supported a higher alkaline phosphatase (ALP) activity compared to PCL, PLA, and gradient scaffolds, respectively. All homogeneous biomaterial scaffolds supported also a significantly higher amount of glycosaminoglycans (GAGs) production compared to discrete gradient scaffolds. Interestingly, the analysis of the different material compartments revealed a specific contribution of PCL, PLA, and PEOT/PBT to surface energy gradients. Whereas PEOT/PBT regions were associated to significantly higher ALP activity, PLA regions correlated with significantly higher GAG production. These results show that cell activity could be influenced by the specific spatial distribution of different biomaterial chemistries in a 3D scaffold and that engineering surface energy discrete gradients could be considered as an appealing criterion to design scaffolds for osteochondral regeneration. PMID:26924824

  4. Fabrication of Thermoelectric Devices Using Additive-Subtractive Manufacturing Techniques: Application to Waste-Heat Energy Harvesting

    NASA Astrophysics Data System (ADS)

    Tewolde, Mahder

    Thermoelectric generators (TEGs) are solid-state devices that convert heat directly into electricity. They are well suited for waste-heat energy harvesting applications as opposed to primary energy generation. Commercially available thermoelectric modules are flat, inflexible and have limited sizes available. State-of-art manufacturing of TEG devices relies on assembling prefabricated parts with soldering, epoxy bonding, and mechanical clamping. Furthermore, efforts to incorporate them onto curved surfaces such as exhaust pipes, pump housings, steam lines, mixing containers, reaction chambers, etc. require custom-built heat exchangers. This is costly and labor-intensive, in addition to presenting challenges in terms of space, thermal coupling, added weight and long-term reliability. Additive manufacturing technologies are beginning to address many of these issues by reducing part count in complex designs and the elimination of sub-assembly requirements. This work investigates the feasibility of utilizing such novel manufacturing routes for improving the manufacturing process of thermoelectric devices. Much of the research in thermoelectricity is primarily focused on improving thermoelectric material properties by developing of novel materials or finding ways to improve existing ones. Secondary to material development is improving the manufacturing process of TEGs to provide significant cost benefits. To improve the device fabrication process, this work explores additive manufacturing technologies to provide an integrated and scalable approach for TE device manufacturing directly onto engineering component surfaces. Additive manufacturing techniques like thermal spray and ink-dispenser printing are developed with the aim of improving the manufacturing process of TEGs. Subtractive manufacturing techniques like laser micromachining are also studied in detail. This includes the laser processing parameters for cutting the thermal spray materials efficiently by

  5. AFFORDABLE MULTI-LAYER CERAMIC (MLC) MANUFACTURING FOR POWER SYSTEMS (AMPS)

    SciTech Connect

    E.A. Barringer, Ph.D.

    2002-11-27

    McDermott Technology, Inc. (MTI) is attempting to develop high-performance, cost-competitive solid oxide fuel cell (SOFC) power systems. Recognizing the challenges and limitations facing the development of SOFC stacks comprised of electrode-supported cells and metallic interconnects, McDermott Technology, Inc. (MTI) has chosen to pursue an alternate path to commercialization. MTI is developing a multi-layer, co-fired, planar SOFC stack that will provide superior performance and reliability at reduced costs relative to competing designs. The MTI approach combines state-of-the-art SOFC materials with the manufacturing technology and infrastructure established for multi-layer ceramic (MLC) packages for the microelectronics industry. The rationale for using MLC packaging technology is that high quality, low-cost manufacturing has been demonstrated at high volumes. With the proper selection of SOFC materials, implementation of MLC fabrication methods offers unique designs for stacks (cells and interconnects) that are not possible through traditional fabrication methods. The MTI approach eliminates use of metal interconnects and ceramic-metal seals, which are primary sources of stack performance degradation. Co-fired cells are less susceptible to thermal cycling stresses by using material compositions that have closely matched coefficients of thermal expansion between the cell and the interconnect. The development of this SOFC stack technology was initiated in October 1999 under the DOE cosponsored program entitled ''Affordable Multi-layer Ceramic Manufacturing for Power Systems (AMPS)''. The AMPS Program was conducted as a two-phase program: Phase I--Feasibility Assessment (10/99--9/00); and Phase II--Process Development for Co-fired Stacks (10/00-3/02). This report provides a summary of the results from Phase I and a more detailed review of the results for Phase II. Phase I demonstrated the feasibility for fabricating multi-layer, co-fired cells and interconnects and

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

    NASA Astrophysics Data System (ADS)

    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.

  7. Additive manufacturing of Inconel 718 using electron beam melting: Processing, post-processing, & mechanical properties

    NASA Astrophysics Data System (ADS)

    Sames, William James, V.

    Additive Manufacturing (AM) process parameters were studied for production of the high temperature alloy Inconel 718 using Electron Beam Melting (EBM) to better understand the relationship between processing, microstructure, and mechanical properties. Processing parameters were analyzed for impact on process time, process temperature, and the amount of applied energy. The applied electron beam energy was shown to be integral to the formation of swelling defects. Standard features in the microstructure were identified, including previously unidentified solidification features such as shrinkage porosity and non-equilibrium phases. The as-solidified structure does not persist in the bulk of EBM parts due to a high process hold temperature (˜1000°C), which causes in situ homogenization. The most significant variability in as-fabricated microstructure is the formation of intragranular delta-phase needles, which can form in samples produced with lower process temperatures (< 960°C). A novel approach was developed and demonstrated for controlling the temperature of cool down, thus providing a technique for in situ heat treatment of material. This technique was used to produce material with hardness of 478+/-7 HV with no post-processing, which exceeds the hardness of peak-aged Inconel 718. Traditional post-processing methods of hot isostatic pressing (HIP) and solution treatment and aging (STA) were found to result in variability in grain growth and phase solution. Recrystallization and grain structure are identified as possible mechanisms to promote grain growth. These results led to the conclusion that the first step in thermal post-processing of EBM Inconel 718 should be an optimized solution treatment to reset phase variation in the as-fabricated microstructure without incurring significant grain growth. Such an optimized solution treatment was developed (1120°C, 2hr) for application prior to aging or HIP. The majority of as-fabricated tensile properties met ASTM

  8. Fabrication of Fe-FeAl Functionally Graded Material Using the Wire-Arc Additive Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Shen, Chen; Pan, Zengxi; Cuiuri, Dominic; Roberts, Jon; Li, Huijun

    2016-02-01

    A functionally gradient iron-aluminum wall structure with aluminum composition gradient from 0 at. pct to over 50 at. pct is fabricated using a wire-arc additive manufacturing (WAAM) system. The as-fabricated alloy is investigated using optical microstructure analysis, hardness testing, tensile testing, X-ray diffraction phase characterization, and electron-dispersive spectrometry. The comprehensive analysis of the experimental samples has shown that the WAAM system can be used for manufacturing iron aluminide functionally graded material with full density, desired composition, and reasonable mechanical properties.

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

    NASA Astrophysics Data System (ADS)

    Ding, Yaoyu; Kovacevic, Radovan

    2016-05-01

    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.

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

    NASA Astrophysics Data System (ADS)

    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.

  11. A digital process for additive manufacturing of occlusal splints: a clinical pilot study.

    PubMed

    Salmi, Mika; Paloheimo, Kaija-Stiina; Tuomi, Jukka; Ingman, Tuula; Mäkitie, Antti

    2013-07-01

    The aim of this study was to develop and evaluate a digital process for manufacturing of occlusal splints. An alginate impression was taken from the upper and lower jaws of a patient with temporomandibular disorder owing to cross bite and wear of the teeth, and then digitized using a table laser scanner. The scanned model was repaired using the 3Data Expert software, and a splint was designed with the Viscam RP software. A splint was manufactured from a biocompatible liquid photopolymer by stereolithography. The system employed in the process was SLA 350. The splint was worn nightly for six months. The patient adapted to the splint well and found it comfortable to use. The splint relieved tension in the patient's bite muscles. No sign of tooth wear or significant splint wear was detected after six months of testing. Modern digital technology enables us to manufacture clinically functional occlusal splints, which might reduce costs, dental technician working time and chair-side time. Maximum-dimensional errors of approximately 1 mm were found at thin walls and sharp corners of the splint when compared with the digital model. PMID:23614943

  12. A digital process for additive manufacturing of occlusal splints: a clinical pilot study

    PubMed Central

    Salmi, Mika; Paloheimo, Kaija-Stiina; Tuomi, Jukka; Ingman, Tuula; Mäkitie, Antti

    2013-01-01

    The aim of this study was to develop and evaluate a digital process for manufacturing of occlusal splints. An alginate impression was taken from the upper and lower jaws of a patient with temporomandibular disorder owing to cross bite and wear of the teeth, and then digitized using a table laser scanner. The scanned model was repaired using the 3Data Expert software, and a splint was designed with the Viscam RP software. A splint was manufactured from a biocompatible liquid photopolymer by stereolithography. The system employed in the process was SLA 350. The splint was worn nightly for six months. The patient adapted to the splint well and found it comfortable to use. The splint relieved tension in the patient's bite muscles. No sign of tooth wear or significant splint wear was detected after six months of testing. Modern digital technology enables us to manufacture clinically functional occlusal splints, which might reduce costs, dental technician working time and chair-side time. Maximum-dimensional errors of approximately 1 mm were found at thin walls and sharp corners of the splint when compared with the digital model. PMID:23614943

  13. Assessing the use of an infrared spectrum hyperpixel array imager to measure temperature during additive and subtractive manufacturing

    NASA Astrophysics Data System (ADS)

    Whitenton, Eric; Heigel, Jarred; Lane, Brandon; Moylan, Shawn

    2016-05-01

    Accurate non-contact temperature measurement is important to optimize manufacturing processes. This applies to both additive (3D printing) and subtractive (material removal by machining) manufacturing. Performing accurate single wavelength thermography suffers numerous challenges. A potential alternative is hyperpixel array hyperspectral imaging. Focusing on metals, this paper discusses issues involved such as unknown or changing emissivity, inaccurate greybody assumptions, motion blur, and size of source effects. The algorithm which converts measured thermal spectra to emissivity and temperature uses a customized multistep non-linear equation solver to determine the best-fit emission curve. Emissivity dependence on wavelength may be assumed uniform or have a relationship typical for metals. The custom software displays residuals for intensity, temperature, and emissivity to gauge the correctness of the greybody assumption. Initial results are shown from a laser powder-bed fusion additive process, as well as a machining process. In addition, the effects of motion blur are analyzed, which occurs in both additive and subtractive manufacturing processes. In a laser powder-bed fusion additive process, the scanning laser causes the melt pool to move rapidly, causing a motion blur-like effect. In machining, measuring temperature of the rapidly moving chip is a desirable goal to develop and validate simulations of the cutting process. A moving slit target is imaged to characterize how the measured temperature values are affected by motion of a measured target.

  14. Additive Manufacturing, Design, Testing, and Fabrication: A Full Engineering Experience at JSC

    NASA Technical Reports Server (NTRS)

    Zusack, Steven

    2016-01-01

    I worked on several projects this term. While most projects involved additive manufacturing, I was also involved with two design projects, two testing projects, and a fabrication project. The primary mentor for these was Richard Hagen. Secondary mentors were Hai Nguyen, Khadijah Shariff, and fabrication training from James Brown. Overall, my experience at JSC has been successful and what I have learned will continue to help me in my engineering education and profession long after I leave. My 3D printing projects ranged from less than a 1 cubic centimeter to about 1 cubic foot and involved several printers using different printing technologies. It was exciting to become familiar with printing technologies such as industrial grade FDM (Fused Deposition Modeling), the relatively new SLA (Stereolithography), and PolyJet. My primary duty with the FDM printers was to model parts that came in from various sources to print effectively and efficiently. Using methods my mentor taught me and the Stratasys Insight software, I was able to minimize imperfections, hasten build time, improve strength for specific forces (tensile, shear, etc...), and reduce likelihood of a print-failure. Also using FDM, I learned how to repair a part after it was printed. This is done by using a special kind of glue that chemically melts the two faces of plastic parts together to form a fused interface. My first goal with SLA technology was to bring the printer back to operational readiness. In becoming familiar with the Pegasus SLA printer, I researched the leveling, laser settings, and different vats to hold liquid material. With this research, I was successfully able to bring the Pegasus back online and have successfully printed multiple sample parts as well as functional parts. My experience with PolyJet technology has been focused on an understanding of the abilities/limits, costs, and the maintenance for daily use. Still upcoming will be experience with using a composite printer that uses FDM

  15. Evaluation Of Electrochemical Machining Technology For Surface Improvements In Additive Manufactured Components

    SciTech Connect

    Dehoff, Ryan R.; List, III, Frederick Alyious; Carver, Keith

    2015-09-23

    ORNL Manufacturing Demonstration Facility worked with ECM Technologies LLC to investigate the use of precision electro-chemical machining technology to polish the surface of parts created by Arcam electron beam melting. The goals for phase one of this project have been met. The project goal was to determine whether electro-chemical machining is a viable method to improve the surface finish of Inconel 718 parts fabricated using the Arcam EBM method. The project partner (ECM) demonstrated viability for parts of both simple and complex geometry. During the course of the project, detailed process knowledge was generated. This project has resulted in the expansion of United States operations for ECM Technologies.

  16. Laser and electron-beam powder-bed additive manufacturing of metallic implants: A review on processes, materials and designs.

    PubMed

    Sing, Swee Leong; An, Jia; Yeong, Wai Yee; Wiria, Florencia Edith

    2016-03-01

    Additive manufacturing (AM), also commonly known as 3D printing, allows the direct fabrication of functional parts with complex shapes from digital models. In this review, the current progress of two AM processes suitable for metallic orthopaedic implant applications, namely selective laser melting (SLM) and electron beam melting (EBM) are presented. Several critical design factors such as the need for data acquisition for patient-specific design, design dependent porosity for osteo-inductive implants, surface topology of the implants and design for reduction of stress-shielding in implants are discussed. Additive manufactured biomaterials such as 316L stainless steel, titanium-6aluminium-4vanadium (Ti6Al4V) and cobalt-chromium (CoCr) are highlighted. Limitations and future potential of such technologies are also explored. PMID:26488900

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

    NASA Astrophysics Data System (ADS)

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

    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.

  18. Additive Manufacturing Thermal Performance Testing of Single Channel GRCop-84 SLM Components

    NASA Technical Reports Server (NTRS)

    Garcia, Chance P.; Cross, Matthew

    2014-01-01

    The surface finish found on components manufactured by sinter laser manufacturing (SLM) is rougher (0.013 - 0.0006 inches) than parts made using traditional fabrication methods. Internal features and passages built into SLM components do not readily allow for roughness reduction processes. Alternatively, engineering literature suggests that the roughness of a surface can enhance thermal performance within a pressure drop regime. To further investigate the thermal performance of SLM fabricated pieces, several GRCop-84 SLM single channel components were tested using a thermal conduction rig at MSFC. A 20 kW power source running at 25% duty cycle and 25% power level applied heat to each component while varying water flow rates between 2.1 - 6.2 gallons/min (GPM) at a supply pressure of 550 to 700 psi. Each test was allowed to reach quasi-steady state conditions where pressure, temperature, and thermal imaging data were recorded. Presented in this work are the heat transfer responses compared to a traditional machined OHFC Copper test section. An analytical thermal model was constructed to anchor theoretical models with the empirical data.

  19. Concentrated fed-batch cell culture increases manufacturing capacity without additional volumetric capacity.

    PubMed

    Yang, William C; Minkler, Daniel F; Kshirsagar, Rashmi; Ryll, Thomas; Huang, Yao-Ming

    2016-01-10

    Biomanufacturing factories of the future are transitioning from large, single-product facilities toward smaller, multi-product, flexible facilities. Flexible capacity allows companies to adapt to ever-changing pipeline and market demands. Concentrated fed-batch (CFB) cell culture enables flexible manufacturing capacity with limited volumetric capacity; it intensifies cell culture titers such that the output of a smaller facility can rival that of a larger facility. We tested this hypothesis at bench scale by developing a feeding strategy for CFB and applying it to two cell lines. CFB improved cell line A output by 105% and cell line B output by 70% compared to traditional fed-batch (TFB) processes. CFB did not greatly change cell line A product quality, but it improved cell line B charge heterogeneity, suggesting that CFB has both process and product quality benefits. We projected CFB output gains in the context of a 2000-L small-scale facility, but the output was lower than that of a 15,000-L large-scale TFB facility. CFB's high cell mass also complicated operations, eroded volumetric productivity, and showed our current processes require significant improvements in specific productivity in order to realize their full potential and savings in manufacturing. Thus, improving specific productivity can resolve CFB's cost, scale-up, and operability challenges. PMID:26521697

  20. Sensor-based atomic layer deposition for rapid process learning and enhanced manufacturability

    NASA Astrophysics Data System (ADS)

    Lei, Wei

    In the search for sensor based atomic layer deposition (ALD) process to accelerate process learning and enhance manufacturability, we have explored new reactor designs and applied in-situ process sensing to W and HfO 2 ALD processes. A novel wafer scale ALD reactor, which features fast gas switching, good process sensing compatibility and significant similarity to the real manufacturing environment, is constructed. The reactor has a unique movable reactor cap design that allows two possible operation modes: (1) steady-state flow with alternating gas species; or (2) fill-and-pump-out cycling of each gas, accelerating the pump-out by lifting the cap to employ the large chamber volume as ballast. Downstream quadrupole mass spectrometry (QMS) sampling is applied for in-situ process sensing of tungsten ALD process. The QMS reveals essential surface reaction dynamics through real-time signals associated with byproduct generation as well as precursor introduction and depletion for each ALD half cycle, which are then used for process learning and optimization. More subtle interactions such as imperfect surface saturation and reactant dose interaction are also directly observed by QMS, indicating that ALD process is more complicated than the suggested layer-by-layer growth. By integrating in real-time the byproduct QMS signals over each exposure and plotting it against process cycle number, the deposition kinetics on the wafer is directly measured. For continuous ALD runs, the total integrated byproduct QMS signal in each ALD run is also linear to ALD film thickness, and therefore can be used for ALD film thickness metrology. The in-situ process sensing is also applied to HfO2 ALD process that is carried out in a furnace type ALD reactor. Precursor dose end-point control is applied to precisely control the precursor dose in each half cycle. Multiple process sensors, including quartz crystal microbalance (QCM) and QMS are used to provide real time process information. The

  1. Effect of Powder Reuse Times on Additive Manufacturing of Ti-6Al-4V by Selective Electron Beam Melting

    NASA Astrophysics Data System (ADS)

    Tang, H. P.; Qian, M.; Liu, N.; Zhang, X. Z.; Yang, G. Y.; Wang, J.

    2015-03-01

    An advantage of the powder-bed-based metal additive manufacturing (AM) processes is that the powder can be reused. The powder reuse or recycling times directly affect the affordability of the additively manufactured parts, especially for the AM of titanium parts. This study examines the influence of powder reuse times on the characteristics of Ti-6Al-4V powder, including powder composition, particle size distribution (PSD), apparent density, tap density, flowability, and particle morphology. In addition, tensile samples were manufactured and evaluated with respect to powder reuse times and sample locations in the powder bed. The following findings were made from reusing the same batch of powder 21 times for AM by selective electron beam melting: (i) the oxygen (O) content increased progressively with increasing reuse times but both the Al content and the V content remained generally stable (a small decrease only); (ii) the powder became less spherical with increasing reuse times and some particles showed noticeable distortion and rough surfaces after being reused 16 times; (iii) the PSD became narrower and few satellite particles were observed after 11 times of reuse; (iv) reused powder showed improved flowability; and (v) reused powder showed no measurable undesired influence on the AM process and the samples exhibited highly consistent tensile properties, irrespective of their locations in the powder bed. The implications of these findings were discussed.

  2. Synchrotron X-ray CT characterization of titanium parts fabricated by additive manufacturing. Part II. Defects.

    PubMed

    Scarlett, Nicola Vivienne Yorke; Tyson, Peter; Fraser, Darren; Mayo, Sheridan; Maksimenko, Anton

    2016-07-01

    Synchrotron X-ray tomography (SXRT) has been applied to the study of defects within three-dimensional printed titanium parts. These parts were made using the Arcam EBM(®) (electron beam melting) process which uses powdered titanium alloy, Ti64 (Ti alloy with approximately 6%Al and 4%V) as the feed and an electron beam for the sintering/welding. The experiment was conducted on the Imaging and Medical Beamline of the Australian Synchrotron. The samples represent a selection of complex shapes with a variety of internal morphologies. Inspection via SXRT has revealed a number of defects which may not otherwise have been seen. The location and nature of such defects combined with detailed knowledge of the process conditions can contribute to understanding the interplay between design and manufacturing strategy. This fundamental understanding may subsequently be incorporated into process modelling, prediction of properties and the development of robust methodologies for the production of defect-free parts. PMID:27359151

  3. Microstructure and mechanical behavior of Ti-6Al-4V produced by rapid-layer manufacturing, for biomedical applications.

    PubMed

    Murr, L E; Quinones, S A; Gaytan, S M; Lopez, M I; Rodela, A; Martinez, E Y; Hernandez, D H; Martinez, E; Medina, F; Wicker, R B

    2009-01-01

    The microstructure and mechanical behavior of simple product geometries produced by layered manufacturing using the electron beam melting (EBM) process and the selective laser melting (SLM) process are compared with those characteristic of conventional wrought and cast products of Ti-6Al-4V. Microstructures are characterized utilizing optical metallography (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM), and included alpha (hcp), beta (bcc) and alpha(') (hcp) martensite phase regimes which give rise to hardness variations ranging from HRC 37 to 57 and tensile strengths ranging from 0.9 to 1.45 GPa. The advantages and disadvantages of layered manufacturing utilizing initial powders in custom building of biomedical components by EBM and SLM in contrast to conventional manufacturing from Ti-6Al-4V wrought bar stock are discussed. PMID:19627804

  4. Differences in Rat and Human Erythrocytes Following Blood Component Manufacturing: The Effect of Additive Solutions

    PubMed Central

    da SilveiraCavalcante, Luciana; Acker, Jason P.; Holovati, Jelena L.

    2015-01-01

    Background Small animal models have been previously used in transfusion medicine studies to evaluate the safety of blood transfusion products. Although there are multiple studies on the effects of blood banking practices on human red blood cells (RBCs), little is known about the effect of blood component manufacturing on the quality of rat RBCs. Methods Blood from Sprague-Dawley rats and human volunteers (n = 6) was collected in CPD anticoagulant, resuspended in SAGM or AS3, and leukoreduced. In vitro quality was analyzed, including deformability, aggregation, microvesiculation, phosphatidylserine (PS) expression, percent hemolysis, ATP, 2,3-DPG, osmotic fragility, and potassium concentrations. Results Compared to human RBCs, rat RBCs had decreased deformability, membrane rigidity, aggregability, and microvesiculation after component manufacturing process. Rat RBCs in SAGM showed higher hemolysis compared to human RBCs in SAGM (rat 4.70 ± 0.83% vs. human 0.34 ± 0.07%; p = 0.002). Rat RBCs in AS3 had greater deformability and rigidity than in SAGM. The number of microparticles/µl and the percentage PS expression were lower in rat RBCs in AS3 than in rat RBCs in SAGM. Hemolysis was also significantly lower in AS3 compared to SAGM (2.21 ± 0.68% vs. 0.87 ± 0.39%; p = 0.028). Conclusion Rat RBCs significantly differ from human RBCs in metabolic and membrane-related aspects. SAGM, which is commonly used for human RBC banking, causes high hemolysis and is not compatible with rat RBCs. PMID:26195928

  5. Physical verification and manufacturing of contact/via layers using grapho-epitaxy DSA processes

    NASA Astrophysics Data System (ADS)

    Torres, J. Andres; Sakajiri, Kyohei; Fryer, David; Granik, Yuri; Ma, Yuansheng; Krasnova, Polina; Fenger, Germain; Nagahara, Seiji; Kawakami, Shinichiro; Rathsack, Benjamen; Khaira, Gurdaman; de Pablo, Juan; Ryckaert, Julien

    2014-03-01

    This paper extends the state of the art by describing the practical material's challenges, as well as approaches to minimize their impact in the manufacture of contact/via layers using a grapho-epitaxy directed self assembly (DSA) process. Three full designs have been analyzed from the point of view of layout constructs. A construct is an atomic and repetitive section of the layout which can be analyzed in isolation. Results indicate that DSA's main benefit is its ability to be resilient to the shape of the guiding pattern across process window. The results suggest that directed self assembly can still be guaranteed even with high distortion of the guiding patterns when the guiding patterns have been designed properly for the target process. Focusing on a 14nm process based on 193i lithography, we present evidence of the need of DSA compliance methods and mask synthesis tools which consider pattern dependencies of adjacent structures a few microns away. Finally, an outlook as to the guidelines and challenges to DSA copolymer mixtures and process are discussed highlighting the benefits of mixtures of homo polymer and diblock copolymer to reduce the number of defects of arbitrarily placed hole configurations.

  6. Effect of pore size on bone ingrowth into porous titanium implants fabricated by additive manufacturing: An in vivo experiment.

    PubMed

    Taniguchi, Naoya; Fujibayashi, Shunsuke; Takemoto, Mitsuru; Sasaki, Kiyoyuki; Otsuki, Bungo; Nakamura, Takashi; Matsushita, Tomiharu; Kokubo, Tadashi; Matsuda, Shuichi

    2016-02-01

    Selective laser melting (SLM) is an additive manufacturing technique with the ability to produce metallic scaffolds with accurately controlled pore size, porosity, and interconnectivity for orthopedic applications. However, the optimal pore structure of porous titanium manufactured by SLM remains unclear. In this study, we evaluated the effect of pore size with constant porosity on in vivo bone ingrowth in rabbits into porous titanium implants manufactured by SLM. Three porous titanium implants (with an intended porosity of 65% and pore sizes of 300, 600, and 900μm, designated the P300, P600, and P900 implants, respectively) were manufactured by SLM. A diamond lattice was adapted as the basic structure. Their porous structures were evaluated and verified using microfocus X-ray computed tomography. Their bone-implant fixation ability was evaluated by their implantation as porous-surfaced titanium plates into the cortical bone of the rabbit tibia. Bone ingrowth was evaluated by their implantation as cylindrical porous titanium implants into the cancellous bone of the rabbit femur for 2, 4, and 8weeks. The average pore sizes of the P300, P600, and P900 implants were 309, 632, and 956μm, respectively. The P600 implant demonstrated a significantly higher fixation ability at 2weeks than the other implants. After 4weeks, all models had sufficiently high fixation ability in a detaching test. Bone ingrowth into the P300 implant was lower than into the other implants at 4weeks. Because of its appropriate mechanical strength, high fixation ability, and rapid bone ingrowth, our results indicate that the pore structure of the P600 implant is a suitable porous structure for orthopedic implants manufactured by SLM. PMID:26652423

  7. Linking process, structure, property, and performance for metal-based additive manufacturing: computational approaches with experimental support

    NASA Astrophysics Data System (ADS)

    Smith, Jacob; Xiong, Wei; Yan, Wentao; Lin, Stephen; Cheng, Puikei; Kafka, Orion L.; Wagner, Gregory J.; Cao, Jian; Liu, Wing Kam

    2016-04-01

    Additive manufacturing (AM) methods for rapid prototyping of 3D materials (3D printing) have become increasingly popular with a particular recent emphasis on those methods used for metallic materials. These processes typically involve an accumulation of cyclic phase changes. The widespread interest in these methods is largely stimulated by their unique ability to create components of considerable complexity. However, modeling such processes is exceedingly difficult due to the highly localized and drastic material evolution that often occurs over the course of the manufacture time of each component. Final product characterization and validation are currently driven primarily by experimental means as a result of the lack of robust modeling procedures. In the present work, the authors discuss primary detrimental hurdles that have plagued effective modeling of AM methods for metallic materials while also providing logical speculation into preferable research directions for overcoming these hurdles. The primary focus of this work encompasses the specific areas of high-performance computing, multiscale modeling, materials characterization, process modeling, experimentation, and validation for final product performance of additively manufactured metallic components.

  8. Additive manufacturing of scaffolds with sub-micron filaments via melt electrospinning writing.

    PubMed

    Hochleitner, Gernot; Jüngst, Tomasz; Brown, Toby D; Hahn, Kathrin; Moseke, Claus; Jakob, Franz; Dalton, Paul D; Groll, Jürgen

    2015-09-01

    The aim of this study was to explore the lower resolution limits of an electrohydrodynamic process combined with direct writing technology of polymer melts. Termed melt electrospinning writing, filaments are deposited layer-by-layer to produce discrete three-dimensional scaffolds for in vitro research. Through optimization of the parameters (flow rate, spinneret diameter, voltage, collector distance) for poly-ϵ-caprolactone, we could direct-write coherent scaffolds with ultrafine filaments, the smallest being 817 ± 165 nm. These low diameter filaments were deposited to form box-structures with a periodicity of 100.6 ± 5.1 μm and a height of 80 μm (50 stacked filaments; 100 overlap at intersections). We also observed oriented crystalline regions within such ultrafine filaments after annealing at 55 °C. The scaffolds were printed upon NCO-sP(EO-stat-PO)-coated glass slide surfaces and withstood frequent liquid exchanges with negligible scaffold detachment for at least 10 days in vitro. PMID:26065373

  9. Microstructural Development and Technical Challenges in Laser Additive Manufacturing: Case Study with a 316L Industrial Part

    NASA Astrophysics Data System (ADS)

    Marya, Manuel; Singh, Virendra; Marya, Surendar; Hascoet, Jean Yves

    2015-08-01

    Additive manufacturing (AM) brings disruptive changes to the ways parts, and products are designed, fabricated, tested, qualified, inspected, marketed, and sold. These changes introduce novel technical challenges and concerns arising from the maturity and diversity of today's AM processes, feedstock materials, and process parameter interactions. AM bears a resemblance with laser and electron beam welding in the so-called conduction mode, which involves a multitude of dynamic physical events between the projected feedstock and a moving heat source that eventually influence AM part properties. For this paper, an air vent was selected for its thin-walled, hollow, and variable cross section, and limited size. The studied air vents, randomly selected from a qualification batch, were fabricated out of 316L stainless steel using a 4 kW fiber laser powder-fed AM system, referred to as construction laser additive direct (CLAD). These were systematically characterized by microhardness indentation, visual examination, optical and scanning electron microscopy, and electron-back-scattering diffraction in order to determine AM part suitability for service and also broadly discuss metallurgical phenomena. The paper then briefly expands the discussion to include additional engineering alloys and further analyze relationships between AM process parameters and AM part properties, consistently utilizing past experience with the same powder-fed CLAD 3D printer, the well-established science and technology of welding and joining, and recent publications on additive manufacturing.

  10. From lab to industrial: PZT nanoparticles synthesis and process control for application in additive manufacturing

    NASA Astrophysics Data System (ADS)

    Huang, Hsien-Lin

    Lead Zirconate Titanate (PZT) nanoparticles hold many promising current and future applications, such as PZT ink for 3-D printing or seeds for PZT thick films. One common method is hydrothermal growth, in which temperature, duration time, or mineralizer concentrations are optimized to produce PZT nanoparticles with desired morphology, controlled size and size distribution. A modified hydrothermal process is used to fabricate PZT nanoparticles. The novelty is to employ a high ramping rate (e.g., 20 deg C/min) to generate abrupt supersaturation so as to promote burst nucleation of PZT nanoparticles as well as a fast cooling rate (e.g., 5 deg C/min) with a controlled termination of crystal growth. As a result, PZT nanoparticles with a size distribution ranging from 200 nm to 800 nm are obtained with cubic morphology and good crystallinity. The identification of nanoparticles is confirmed through use of X-ray diffractometer (XRD). XRD patterns are used to compare sample variations in their microstructures such as lattice parameter. A cubic morphology and particle size are also examined via SEM images. The hydrothermal process is further modified with excess lead (from 20% wt. to 80% wt.) to significantly reduce amorphous phase and agglomeration of the PZT nanoparticles. With a modified process, the particle size still remains within the 200 nm to 800 nm. Also, the crystal structures (microstructure) of the samples show little variations. Finally, a semi-continuous hydrothermal manufacturing process was developed to substantially reduce the fabrication time and maintained the same high quality as the nanoparticles prepared in an earlier stage. In this semi-continuous process, a furnace is maintained at the process temperature (200 deg C), whereas autoclaves containing PZT sol are placed in and out of the furnace to control the ramp-up and cooling rates. This setup eliminates an extremely time-consuming step of cooling down the furnace, thus saving tremendous amount of

  11. Polymer/Perovskite-type nanoparticle multilayers with multielectric properties prepared from ligand addition-induced layer-by-layer assembly.

    PubMed

    Kim, Younghoon; Kook, Kyungyun; Hwang, Sun Kak; Park, Cheolmin; Cho, Jinhan

    2014-03-25

    We introduce an adsorption mechanism for a layer-by-layer (LbL) assembly (i.e., a ligand addition-induced LbL assembly) and demonstrate that the (polymer/perovskite nanoparticle (NP))n nanocomposite films based on the ligand addition LbL exhibit ferroelectric and resistive switching properties. Oleic acid (OA)-stabilized BaTiO3 NPs (OA-BTO NPs) with a size of approximately 8 nm were LbL-assembled with amine-functionalized dendrimers (NH2-dendrimers) using the high affinity between NH2 moieties and Ti ions. The ferroelectric properties of the (NH2-dendrimer/OA-BTO NP)n multilayers were generated by the Ti disorder in the OA-BTO NP unit cell despite the use of sub-10 nm OA-BTO NPs (i.e., OA-BTO NPs), which are near the critical size for ferroelectric properties. Additionally, the (NH2-dendrimer/OA-BTO NP)n multilayers sandwiched between the bottom (platinum) and top (silver or tungsten) electrodes exhibited a resistive switching memory at a relatively low operating voltage below 2 V with a switching speed of approximately 100 ns and an ON/OFF current ratio of approximately 10(4). Furthermore, the ferroelectric and resistive switching properties could be further improved by controlling the bilayer number (n). We believe that our approach can provide a basis for designing and exploiting multifunctional memory electronics based on a variety of perovskite NPs with ferroelectric properties. PMID:24571293

  12. Freeform manufacturing of a progressive addition lens by use of a voice coil fast tool servo

    NASA Astrophysics Data System (ADS)

    Li, Yi Yu; Chen, Jiao Jie; Feng, Hai Hua; Li, Chaohong; Qu, Jia; Chen, Hao

    2014-08-01

    The back surface of progressive addition lens (PAL) is a non-rotationally symmetric freeform surface. The local radius varies progressively from the far zone to the near zone along the intermediate zone to give the addition power. Numerical simulation method is performed to calculate the discrete points on the freeform surface in polar coordinate and generate the data files containing the trajectory of diamond tool tip for surface machining. The fabrication of PAL is accomplished by using self-developed single-point diamond turning machine with voice coil fast tool servo. The polished freeform surface profile measured by a 3-axes coordinate measuring machine shows little deviation to the simulation result. Surface power and cylinder of the fabricated PAL is also measured for comparison with theoretical design.

  13. Silicon carbide sintered body manufactured from silicon carbide powder containing boron, silicon and carbonaceous additive

    NASA Technical Reports Server (NTRS)

    Tanaka, Hidehiko

    1987-01-01

    A silicon carbide powder of a 5-micron grain size is mixed with 0.15 to 0.60 wt% mixture of a boron compound, i.e., boric acid, boron carbide (B4C), silicon boride (SiB4 or SiB6), aluminum boride, etc., and an aluminum compound, i.e., aluminum, aluminum oxide, aluminum hydroxide, aluminum carbide, etc., or aluminum boride (AlB2) alone, in such a proportion that the boron/aluminum atomic ratio in the sintered body becomes 0.05 to 0.25 wt% and 0.05 to 0.40 wt%, respectively, together with a carbonaceous additive to supply enough carbon to convert oxygen accompanying raw materials and additives into carbon monoxide.

  14. Additive technology of soluble mold tooling for embedded devices in composite structures: A study on manufactured tolerances

    NASA Astrophysics Data System (ADS)

    Roy, Madhuparna

    Composite textiles have found widespread use and advantages in various industries and applications. The constant demand for high quality products and services requires companies to minimize their manufacturing costs, and delivery time in order to compete in general and niche marketplaces. Advanced manufacturing methods aim to provide economical methods of mold production. Creation of molding and tooling options for advanced composites encompasses a large portion of the fabrication time, making it a costly process and restraining factor. This research discusses a preliminary investigation into the use of soluble polymer compounds and additive manufacturing to fabricate soluble molds. These molds suffer from dimensional errors due to several factors, which have also been characterized. The basic soluble mold of a composite is 3D printed to meet the desired dimensions and geometry of holistic structures or spliced components. The time taken to dissolve the mold depends on the rate of agitation of the solvent. This process is steered towards enabling the implantation of optoelectronic devices within the composite to provide sensing capability for structural health monitoring. The shape deviation of the 3D printed mold is also studied and compared to its original dimensions to optimize the dimensional quality to produce dimensionally accurate parts. Mechanical tests were performed on compact tension (CT) resin samples prepared from these 3D printed molds and revealed crack propagation towards an embedded intact optical fiber.

  15. Additives

    NASA Technical Reports Server (NTRS)

    Smalheer, C. V.

    1973-01-01

    The chemistry of lubricant additives is discussed to show what the additives are chemically and what functions they perform in the lubrication of various kinds of equipment. Current theories regarding the mode of action of lubricant additives are presented. The additive groups discussed include the following: (1) detergents and dispersants, (2) corrosion inhibitors, (3) antioxidants, (4) viscosity index improvers, (5) pour point depressants, and (6) antifouling agents.

  16. Additive manufacturing in biomedical sciences and the need for definitions and norms.

    PubMed

    Chhaya, Mohit P; Poh, Patrina S P; Balmayor, Elizabeth R; van Griensven, Martijn; Schantz, Jan-Thorsten; Hutmacher, Dietmar W

    2015-01-01

    The application of additive biomanufacturing represents one of the most rapidly advancing areas of biomedical science, in which engineers, scientists, and clinicians are contributing to the future of health care. The combined efforts of a large number of groups around the globe have developed a strong research thrust that has resulted in a large number of publications. Reviewing this body of literature, there is an increasing trend of research groups inventing their own definitions and terminology. This has made it difficult to find and compare the results. Therefore, to move the field constructively forward, it is a conditio sine qua non to clarify various terminologies and standards. Based on this background, this article advocates tightening the terminology and has the objective of penning out definitions that will ultimately allow the development of official industry standard terms, such as American Society for Testing and Materials and or International Organization for Standardization for technologies developed for Tissue Engineering and Regenerative Medicine. PMID:26305837

  17. Ion acceleration enhanced by additional neutralizing electrons in a magnetically expanding double layer plasma

    SciTech Connect

    Takahashi, Kazunori; Fujiwara, Tamiya

    2010-10-15

    Electrons neutralizing an ion beam are additionally supplied to a magnetically expanding double layer (DL) plasma from the downstream side of the DL. The rf power and the argon gas pressure are maintained at 200 W and 55 mPa, respectively, and the source magnetic field is varied in the range of about 70-550 G. It is observed that the ion beam energy corresponding to the DL potential drop increases up to 30 eV with an increase in the magnetic field when supplying the additional electrons, while it saturates at 20 eV for the case of the absence of the additional electrons. The supplied electrons are believed to be an energy source for the DL such that increasing the magnetic field is able to increase the potential drop beyond the limit found in the absence of the supplied electrons.

  18. Tribological properties of few-layer graphene oxide sheets as oil-based lubricant additives

    NASA Astrophysics Data System (ADS)

    Chen, Zhe; Liu, Yuhong; Luo, Jianbin

    2016-03-01

    The performance of a lubricant largely depends on the additives it involves. However, currently used additives cause severe pollution if they are burned and exhausted. Therefore, it is necessary to develop a new generation of green additives. Graphene oxide (GO) consists of only C, H and O and thus is considered to be environmentally friendly. So the tribological properties of the few-layer GO sheet as an additive in hydrocarbon base oil are investigated systematically. It is found that, with the addition of GO sheets, both the coefficient of friction (COF) and wear are decreased and the working temperature range of the lubricant is expanded in the positive direction. Moreover, GO sheets has better performance under higher sliding speed and the optimized concentration of GO sheets is determined to be 0.5wt%. After rubbing, GO is detected on the wear scars through Raman spectroscopy. And it is believed that, during the rubbing, GO sheets adhere to the sliding surfaces, behaving like protective films and preventing the sliding surfaces from contacting with each other directly. This paper proves that the GO sheet is an effective lubricant additive, illuminates the lubrication mechanism, and provides some critical parameters for the practical application of GO sheets in lubrication.

  19. Additive Manufacturing of a Photo-Cross-Linkable Polymer via Direct Melt Electrospinning Writing for Producing High Strength Structures.

    PubMed

    Chen, Fei; Hochleitner, Gernot; Woodfield, Tim; Groll, Juergen; Dalton, Paul D; Amsden, Brian G

    2016-01-11

    Melt electrospinning writing (MEW) is an emerging additive manufacturing technique that enables the design and fabrication of micrometer-thin fibrous scaffolds made of biocompatible and biodegradable polymers. By using a computer-aided deposition process, a unique control over pore size and interconnectivity of the resulting scaffolds is achieved, features highly interesting for tissue engineering applications. However, MEW has been mainly used to process low melting point thermoplastics such as poly(ε-caprolactone). Since this polymer exhibits creep and a reduction in modulus upon hydration, we manufactured scaffolds of poly(L-lactide-co-ε-caprolactone-co-acryloyl carbonate) (poly(LLA-ε-CL-AC)), a photo-cross-linkable and biodegradable polymer, for the first time. We show that the stiffness of the scaffolds increases significantly (up to ∼10-fold) after cross-linking by UV irradiation at room temperature, compared with un-cross-linked microfiber scaffolds. The preservation of stiffness and high average fiber modulus (370 ± 166 MPa) within the cross-linked hydrated scaffolds upon repetitive loading (10% strain at 1 Hz up to 200,000 cycles) suggests that the prepared scaffolds may be of potential interest for soft connective tissue engineering applications. Moreover, the approach can be readily adapted through manipulation of polymer properties and scaffold geometry to prepare structures with mechanical properties suitable for other tissue engineering applications. PMID:26620885

  20. Optimal welding parameters for very high power ultrasonic additive manufacturing of smart structures with aluminum 6061 matrix

    NASA Astrophysics Data System (ADS)

    Wolcott, Paul J.; Hehr, Adam; Dapino, Marcelo J.

    2014-03-01

    Ultrasonic additive manufacturing (UAM) is a recent solid state manufacturing process that combines ad- ditive joining of thin metal tapes with subtractive milling operations to generate near net shape metallic parts. Due to the minimal heating during the process, UAM is a proven method of embedding Ni-Ti, Fe-Ga, and PVDF to create active metal matrix composites. Recently, advances in the UAM process utilizing 9 kW very high power (VHP) welding has improved bonding properties, enabling joining of high strength materials previously unweldable with 1 kW low power UAM. Consequently, a design of experiments study was conducted to optimize welding conditions for aluminum 6061 components. This understanding is critical in the design of UAM parts containing smart materials. Build parameters, including weld force, weld speed, amplitude, and temperature were varied based on a Taguchi experimental design matrix and tested for me- chanical strength. Optimal weld parameters were identi ed with statistical methods including a generalized linear model for analysis of variance (ANOVA), mean e ects plots, and interaction e ects plots.

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

    SciTech Connect

    Erdemir, Ali

    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 gas

  2. Low-Friction Adsorbed Layers of a Triblock Copolymer Additive in Oil-Based Lubrication.

    PubMed

    Yamada, Shinji; Fujihara, Ami; Yusa, Shin-ichi; Tanabe, Tadao; Kurihara, Kazue

    2015-11-10

    The tribological properties of the dilute solution of an ABA triblock copolymer, poly(11-acrylamidoundecanoic acid)-block-poly(stearyl methacrylate)-block-poly(11-acrylamidoundecanoic acid (A5S992A5), in poly(α-olefin) (PAO) confined between mica surfaces were investigated using the surface forces apparatus (SFA). Friction force was measured as a function of applied load and sliding velocity, and the film thickness and contact geometry during sliding were analyzed using the fringes of equal chromatic order (FECO) in the SFA. The results were contrasted with those of confined PAO films; the effects of the addition of A5S992A5 on the tribological properties were discussed. The thickness of the A5S992A5/PAO system varied with time after surface preparation and with repetitive sliding motions. The thickness was within the range from 40 to 70 nm 1 day after preparation (the Day1 film), and was about 20 nm on the following day (the Day2 film). The thickness of the confined PAO film was thinner than 1.4 nm, indicating that the A5S992A5/PAO system formed thick adsorbed layers on mica surfaces. The friction coefficient was about 0.03 to 0.04 for the Day1 film and well below 0.01 for the Day2 film, which were 1 or 2 orders of magnitude lower than the values for the confined PAO films. The time dependent changes of the adsorbed layer thickness and friction properties should be caused by the relatively low solubility of A5S992A5 in PAO. The detailed analysis of the contact geometry and friction behaviors implies that the particularly low friction of the Day2 film originates from the following factors: (i) shrinkage of the A5S992A5 molecules (mainly the poly(stearyl methacrylate) blocks) that leads to a viscoelastic properties of the adsorbed layers; and (ii) the intervening PAO layer between the adsorbed polymer layers that constitutes a high-fluidity sliding interface. Our results suggest that the block copolymer having relatively low solubility in a lubricant base oil is

  3. Novel real function based method to construct heterogeneous porous scaffolds and additive manufacturing for use in medical engineering.

    PubMed

    Yang, Nan; Tian, Yanling; Zhang, Dawei

    2015-11-01

    Heterogeneous porous scaffolds have important applications in biomedical engineering, as they can mimic the structures of natural tissues to achieve the corresponding properties. Here, we introduce a new and easy to implement real function based method for constructing complex, heterogeneous porous structures, including hybrid structures, stochastic structures, functionally gradient structures, and multi-scale structures, or their combinations (e.g., hybrid multi-scale structures). Based on micro-CT data, a femur-mimetic structure with gradient morphology was constructed using our method and fabricated using stereolithography. Results showed that our method could generate gradient porosity or gradient specific surfaces and be sufficiently flexible for use with micro-CT data and additive manufacturing (AM) techniques. PMID:26320819

  4. Research Summary of an Additive Manufacturing Technology for the Fabrication of 3D Composites with Tailored Internal Structure

    NASA Astrophysics Data System (ADS)

    Holmes, Larry R.; Riddick, Jaret C.

    2014-01-01

    A novel additive manufacturing technology is used to create micro-composites, which can be tailored for specific end-use applications. The Field-Aided Laminar Composite (FALCom) process uses specifically focused electric fields to align nano- to micro-sized particles into chain-like structures, which are referred to as pseudo-fibers. These pseudo-fibers are then immediately frozen into place by incident ultraviolet radiation on the photopolymer matrix. The pseudo-fibers are arranged by design, and they are used to create three-dimensional composite structures. Multiple filler materials have been evaluated for use in the FALCom system; however, this report describes aluminum micro-particles that are aligned and oriented in an acrylic photopolymer matrix. A description of the technology and a review of experimental processing are shown, and conclusions, as well as, future work are discussed.

  5. The effects of material property assumptions on predicted meltpool shape for laser powder bed fusion based additive manufacturing

    NASA Astrophysics Data System (ADS)

    Teng, Chong; Ashby, Kathryn; Phan, Nam; Pal, Deepankar; Stucker, Brent

    2016-08-01

    The objective of this study was to provide guidance on material specifications for powders used in laser powder bed fusion based additive manufacturing (AM) processes. The methodology was to investigate how different material property assumptions in a simulation affect meltpool prediction and by corrolary how different material properties affect meltpool formation in AM processes. The sensitvity of meltpool variations to each material property can be used as a guide to help drive future research and to help prioritize material specifications in requirements documents. By identifying which material properties have the greatest affect on outcomes, metrology can be tailored to focus on those properties which matter most; thus reducing costs by eliminating unnecessary testing and property charaterizations. Futhermore, this sensitivity study provides insight into which properties require more accurate measurements, thus motivating development of new metrology methods to measure those properties accurately.

  6. Investigation of the HA film deposited on the porous Ti6Al4V alloy prepared via additive manufacturing

    NASA Astrophysics Data System (ADS)

    Surmeneva, M.; Chudinova, E.; Syrtanov, M.; Koptioug, A.; Surmenev, R.

    2015-11-01

    This study is focused on the use of radio frequency magnetron sputtering to modify the surface of porous Ti6Al4V alloy fabricated via additive manufacturing technology. The hydroxyapatite (HA) coated porous Ti6Al4V alloy was studied in respect with its chemical and phase composition, surface morphology, water contact angle and hysteresis, and surface free energy. Thin nanocrystalline HA film was deposited while its structure with diamond-shaped cells remained unchanged. Hysteresis and water contact angle measurements revealed an effect of the deposited HA films, namely an increased water contact angle and contact angle hysteresis. The increase of the contact angle of the coating-substrate system compared to the uncoated substrate was attributed to the multiscale structure of the resulted surfaces.

  7. Additive Manufacturing and 3D Printing in NASA: An Overview of Current Projects and Future Initiatives for Space Exploration

    NASA Technical Reports Server (NTRS)

    Clinton, R. G., Jr.

    2014-01-01

    NASA, including each Mission Directorate, is investing in, experimenting with, and/or utilizing AM across a broad spectrum of applications and projects; Centers have created and are continuing to create partnerships with industry, other Government Agencies, other Centers, and Universities; In-house additive manufacturing capability enables rapid iteration of the entire design, development and testing process, increasing innovation and reducing risk and cost to projects; For deep space exploration, AM offers significant reduction to logistics costs and risk by providing ability to create on demand; There are challenges: Overwhelming message from recent JANNAF AM for Propulsion Applications TIM was "certification."; NASA will continue to work with our partners to address this and other challenges to advance the state of the art in AM and incorporate these capabilities into an array of applications from aerospace to science missions to deep space exploration.

  8. Shape Optimization for Additive Manufacturing of Removable Partial Dentures--A New Paradigm for Prosthetic CAD/CAM.

    PubMed

    Chen, Junning; Ahmad, Rohana; Suenaga, Hanako; Li, Wei; Sasaki, Keiichi; Swain, Michael; Li, Qing

    2015-01-01

    With ever-growing aging population and demand for denture treatments, pressure-induced mucosa lesion and residual ridge resorption remain main sources of clinical complications. Conventional denture design and fabrication are challenged for its labor and experience intensity, urgently necessitating an automatic procedure. This study aims to develop a fully automatic procedure enabling shape optimization and additive manufacturing of removable partial dentures (RPD), to maximize the uniformity of contact pressure distribution on the mucosa, thereby reducing associated clinical complications. A 3D heterogeneous finite element (FE) model was constructed from CT scan, and the critical tissue of mucosa was modeled as a hyperelastic material from in vivo clinical data. A contact shape optimization algorithm was developed based on the bi-directional evolutionary structural optimization (BESO) technique. Both initial and optimized dentures were prototyped by 3D printing technology and evaluated with in vitro tests. Through the optimization, the peak contact pressure was reduced by 70%, and the uniformity was improved by 63%. In vitro tests verified the effectiveness of this procedure, and the hydrostatic pressure induced in the mucosa is well below clinical pressure-pain thresholds (PPT), potentially lessening risk of residual ridge resorption. This proposed computational optimization and additive fabrication procedure provides a novel method for fast denture design and adjustment at low cost, with quantitative guidelines and computer aided design and manufacturing (CAD/CAM) for a specific patient. The integration of digitalized modeling, computational optimization, and free-form fabrication enables more efficient clinical adaptation. The customized optimal denture design is expected to minimize pain/discomfort and potentially reduce long-term residual ridge resorption. PMID:26161878

  9. Shape Optimization for Additive Manufacturing of Removable Partial Dentures - A New Paradigm for Prosthetic CAD/CAM

    PubMed Central

    2015-01-01

    With ever-growing aging population and demand for denture treatments, pressure-induced mucosa lesion and residual ridge resorption remain main sources of clinical complications. Conventional denture design and fabrication are challenged for its labor and experience intensity, urgently necessitating an automatic procedure. This study aims to develop a fully automatic procedure enabling shape optimization and additive manufacturing of removable partial dentures (RPD), to maximize the uniformity of contact pressure distribution on the mucosa, thereby reducing associated clinical complications. A 3D heterogeneous finite element (FE) model was constructed from CT scan, and the critical tissue of mucosa was modeled as a hyperelastic material from in vivo clinical data. A contact shape optimization algorithm was developed based on the bi-directional evolutionary structural optimization (BESO) technique. Both initial and optimized dentures were prototyped by 3D printing technology and evaluated with in vitro tests. Through the optimization, the peak contact pressure was reduced by 70%, and the uniformity was improved by 63%. In vitro tests verified the effectiveness of this procedure, and the hydrostatic pressure induced in the mucosa is well below clinical pressure-pain thresholds (PPT), potentially lessening risk of residual ridge resorption. This proposed computational optimization and additive fabrication procedure provides a novel method for fast denture design and adjustment at low cost, with quantitative guidelines and computer aided design and manufacturing (CAD/CAM) for a specific patient. The integration of digitalized modeling, computational optimization, and free-form fabrication enables more efficient clinical adaptation. The customized optimal denture design is expected to minimize pain/discomfort and potentially reduce long-term residual ridge resorption. PMID:26161878

  10. Reducing metal alloy powder costs for use in powder bed fusion additive manufacturing: Improving the economics for production

    NASA Astrophysics Data System (ADS)

    Medina, Fransisco

    Titanium and its associated alloys have been used in industry for over 50 years and have become more popular in the recent decades. Titanium has been most successful in areas where the high strength to weight ratio provides an advantage over aluminum and steels. Other advantages of titanium include biocompatibility and corrosion resistance. Electron Beam Melting (EBM) is an additive manufacturing (AM) technology that has been successfully applied in the manufacturing of titanium components for the aerospace and medical industry with equivalent or better mechanical properties as parts fabricated via more traditional casting and machining methods. As the demand for titanium powder continues to increase, the price also increases. Titanium spheroidized powder from different vendors has a price range from 260/kg-450/kg, other spheroidized alloys such as Niobium can cost as high as $1,200/kg. Alternative titanium powders produced from methods such as the Titanium Hydride-Dehydride (HDH) process and the Armstrong Commercially Pure Titanium (CPTi) process can be fabricated at a fraction of the cost of powders fabricated via gas atomization. The alternative powders can be spheroidized and blended. Current sectors in additive manufacturing such as the medical industry are concerned that there will not be enough spherical powder for production and are seeking other powder options. It is believed the EBM technology can use a blend of spherical and angular powder to build fully dense parts with equal mechanical properties to those produced using traditional powders. Some of the challenges with angular and irregular powders are overcoming the poor flow characteristics and the attainment of the same or better packing densities as spherical powders. The goal of this research is to demonstrate the feasibility of utilizing alternative and lower cost powders in the EBM process. As a result, reducing the cost of the raw material to reduce the overall cost of the product produced with

  11. Low-Temperature Additive Manufacturing of Biomimic Three-Dimensional Hydroxyapatite/Collagen Scaffolds for Bone Regeneration.

    PubMed

    Lin, Kai-Feng; He, Shu; Song, Yue; Wang, Chun-Mei; Gao, Yi; Li, Jun-Qin; Tang, Peng; Wang, Zheng; Bi, Long; Pei, Guo-Xian

    2016-03-23

    Low-temperature additive manufacturing (AM) holds promise for fabrication of three-dimensional (3D) scaffolds containing bioactive molecules and/or drugs. Due to the strict technical limitations of current approaches, few materials are suitable for printing at low temperature. Here, a low-temperature robocasting method was employed to print biomimic 3D scaffolds for bone regeneration using a routine collagen-hydroxyapatite (CHA) composite material, which is too viscous to be printed via normal 3D printing methods at low temperature. The CHA scaffolds had excellent 3D structure and maintained most raw material properties after printing. Compared to nonprinted scaffolds, printed scaffolds promoted bone marrow stromal cell proliferation and improved osteogenic outcome in vitro. In a rabbit femoral condyle defect model, the interconnecting pores within the printed scaffolds facilitated cell penetration and mineralization before the scaffolds degraded and enhanced repair, compared to nonprinted CHA scaffolds. Additionally, the optimal printing parameters for 3D CHA scaffolds were investigated; 600-μm-diameter rods were optimal in terms of moderate mechanical strength and better repair outcome in vivo. This low-temperature robocasting method could enable a variety of bioactive molecules to be incorporated into printed CHA materials and provides a method of bioprinting biomaterials without compromising their natural properties. PMID:26930140

  12. Photocurable high internal phase emulsions (HIPEs) containing hydroxyapatite for additive manufacture of tissue engineering scaffolds with multi-scale porosity.

    PubMed

    Wang, Ai-Juan; Paterson, Thomas; Owen, Robert; Sherborne, Colin; Dugan, James; Li, Jun-Ming; Claeyssens, Frederik

    2016-10-01

    Porous composites containing hydroxyapatite (HA) were templated from high internal phase emulsions (HIPEs) and were further structured using direct-write UV stereolithography to produce composite scaffolds with multi-scale porosity. FTIR, TGA and SEM analyses confirmed that HA was retained after photocuring and subsequent treatments and was incorporated within the polymerised HIPE (polyHIPE). The addition of HA particles to the polyHIPE caused changes in the mechanical properties of the material. An increase in both the Young's modulus and maximum stress at yield was observed compared with the pure polyHIPE from 1.544±0.231 to 4.614±0.775 and 0.177±0.009 to 0.267±0.034MPa, respectively. Except at very high concentrations, adding HA did not adversely cause the phase separation of the HIPE or the porous microstructure of the resulting polyHIPE. In combination with a photoinitiator, the HIPE emulsion containing HA was investigated as a photocurable resin for stereolithography-based additive manufacturing. The material was readily processable into "woodpile" structures via direct-write UV stereolithography, producing scaffolds with multi-scale porosity which may be useful for medical applications such as tissue engineering. In conclusion, HA was successfully added into polyHIPEs, producing a similar porous structure to that of the pure polyHIPE whilst improving the mechanical performance. PMID:27287098

  13. Layer cathode methods of manufacturing and materials for Li-ion rechargeable batteries

    DOEpatents

    Kang, Sun-Ho; Amine, Khalil

    2008-01-01

    A positive electrode active material for lithium-ion rechargeable batteries of general formula Li.sub.1+xNi.sub..alpha.Mn.sub..beta.A.sub..gamma.O.sub.2 and further wherein A is Mg, Zn, Al, Co, Ga, B, Zr, or Ti and 0manufacturing the same. Such an active material is manufactured by employing either a solid state reaction method or an aqueous solution method or a sol-gel method which is followed by a rapid quenching from high temperatures into liquid nitrogen or liquid helium.

  14. Fatigue performance of laser additive manufactured Ti-6Al-4V in very high cycle fatigue (VHCF) regime up to 109 cycles

    NASA Astrophysics Data System (ADS)

    Wycisk, Eric; Siddique, Shafaqat; Herzog, Dirk; Walther, Frank; Emmelmann, Claus

    2015-12-01

    Additive manufacturing technologies are in the process of establishing themselves as an alternative production technology to conventional manufacturing such as casting or milling. Especially laser additive manufacturing (LAM) enables the production of metallic parts with mechanical properties comparable to conventionally manufactured components. Due to the high geometrical freedom in LAM the technology enables the production of ultra-light weight designs and therefore gains increasing importance in aircraft and space industry. The high quality standards of these industries demand predictability of material properties for static and dynamic load cases. However, fatigue properties especially in the very high cycle fatigue regime until 109 cycles have not been sufficiently determined yet. Therefore this paper presents an analysis of fatigue properties of laser additive manufactured Ti-6Al-4V under cyclic tension-tension until 107 cycles and tension-compression load until 109 cycles. For the analysis of laser additive manufactured titanium alloy Ti-6Al-4V Woehler fatigue tests under tension-tension and tension-compression were carried out in the high cycle and very high cycle fatigue regime. Specimens in stress-relieved as well as hot-isostatic-pressed conditions were analyzed regarding crack initiation site, mean stress sensitivity and overall fatigue performance. The determined fatigue properties show values in the range of conventionally manufactured Ti-6Al-4V with particularly good performance for hot-isostatic-pressed additive-manufactured material. For all conditions the results show no conventional fatigue limit but a constant increase in fatigue life with decreasing loads. No effects of test frequency on life span could be determined. However, independently of testing principle, a shift of crack initiation from surface to internal initiation could be observed with increasing cycles to failure.

  15. Enhancing coating of brushite/hydroxyapatite layer on titanium alloy implant surface with additives

    NASA Astrophysics Data System (ADS)

    Abdel-Aal, E. A.; El-Sayed, D.; Shoeib, M.; Kandil, A. T.

    2013-11-01

    Brushite (CaHPO4·2H2O) was electrodeposited on titanium alloy substrate with and without H2O2. It was converted to hydroxyapatite [Ca10(PO4)6(OH)2] by NaOH treatment. Different H2O2 and NH4OH doses ranging from 0 ppm to 2400 ppm and from 0 ppm to 7000 ppm, respectively were used. The results showed that with increasing H2O2 dose up to 600 ppm, the weight gain and the coating thickness are increased. Further increase of H2O2 dose led to decrease of the weight gain and the coating thickness. Addition of ammonia led to decrease of the weight gain and the coating thickness. Thickness and weight gain of coated brushite layer are decreased with sodium hydroxide treatment and converted totally to hydroxyapatite. Coating thickness at Ca/P ratio of 1.67 and coating time of 1 h at current density of 1.5 mA/cm2 was about 14 and 18.5 μm without and with 600 ppm H2O2, respectively. It decreased to about 8 μm with addition of 7000 ppm ammonia solution.

  16. Modeling of time dependent localized flow shear stress and its impact on cellular growth within additive manufactured titanium implants

    PubMed Central

    Zhang, Ziyu; Yuan, Lang; Lee, Peter D; Jones, Eric; Jones, Julian R

    2014-01-01

    Bone augmentation implants are porous to allow cellular growth, bone formation and fixation. However, the design of the pores is currently based on simple empirical rules, such as minimum pore and interconnects sizes. We present a three-dimensional (3D) transient model of cellular growth based on the Navier–Stokes equations that simulates the body fluid flow and stimulation of bone precursor cellular growth, attachment, and proliferation as a function of local flow shear stress. The model's effectiveness is demonstrated for two additive manufactured (AM) titanium scaffold architectures. The results demonstrate that there is a complex interaction of flow rate and strut architecture, resulting in partially randomized structures having a preferential impact on stimulating cell migration in 3D porous structures for higher flow rates. This novel result demonstrates the potential new insights that can be gained via the modeling tool developed, and how the model can be used to perform what-if simulations to design AM structures to specific functional requirements. PMID:24664988

  17. Oxygen and nitrogen plasma etching of three-dimensional hydroxyapatite/chitosan scaffolds fabricated by additive manufacturing

    NASA Astrophysics Data System (ADS)

    Myung, Sung-Woon; Kim, Byung-Hoon

    2016-01-01

    Three-dimensional (3D) chitosan and hydroxyapatite (HAp)/chitosan (CH) scaffolds were fabricated by additive manufacturing, then their surfaces were etched with oxygen (O2) and nitrogen (N2) plasma. O2 and N2 plasma etching was performed to increase surface properties such as hydrophilicity, roughness, and surface chemistry on the scaffolds. After etching, hydroxyapatite was exposed on the surface of 3D HAp/CH scaffolds. The surface morphology and chemical properties were characterized by contact angle measurement, scanning electron microscopy, X-ray diffraction, and attenuated total reflection Fourier infrared spectroscopy. The cell viability of 3D chitosan scaffolds was examined by 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide assay. The differentiation of preosteoblast cells was evaluated by alkaline phosphatase assay. The cell viability was improved by O2 and N2 plasma etching of 3D chitosan scaffolds. The present fabrication process for 3D scaffolds might be applied to a potential tool for preparing biocompatible scaffolds.

  18. Additive Manufacturing of 17-4 PH Stainless Steel: Post-processing Heat Treatment to Achieve Uniform Reproducible Microstructure

    NASA Astrophysics Data System (ADS)

    Cheruvathur, Sudha; Lass, Eric A.; Campbell, Carelyn E.

    2016-03-01

    17-4 precipitation hardenable (PH) stainless steel is a useful material when a combination of high strength and good corrosion resistance up to about 315°C is required. In the wrought form, this steel has a fully martensitic structure that can be strengthened by precipitation of fine Cu-rich face-centered cubic phase upon aging. When fabricated via additive manufacturing (AM), specifically laser powder-bed fusion, 17-4 PH steel exhibits a dendritic structure containing a substantial fraction of nearly 50% of retained austenite along with body centered cubic/martensite and fine niobium carbides preferentially aligned along interdendritic boundaries. The effect of post-build thermal processing on the material microstructure is studied in comparison to that of conventionally produced wrought 17-4 PH with the intention of creating a more uniform, fully martensitic microstructure. The recommended stress relief heat treatment currently employed in industry for post-processing of AM 17-4 PH steel is found to have little effect on the as-built dendritic microstructure. It is found that, by implementing the recommended homogenization heat treatment regimen of Aerospace Materials Specification 5355 for CB7Cu-1, a casting alloy analog to 17-4 PH, the dendritic solidification structure is eliminated, resulting in a microstructure containing about 90% martensite with 10% retained austenite.

  19. Thickness management in three-dimensional laser manufacturing of suspended structures in a single SU-8 layer

    NASA Astrophysics Data System (ADS)

    Li, Biao; Gueit, Aurelien; Sharon, Andre

    2006-06-01

    Cantilevers, embedded channels, microcavities, and other high-aspect-ratio geometries requiring gaps between layers are essential to microfluidic components used for biotech/biomedical applications. Intensive efforts have been expanded in the development of novel approaches for efficiently manufacturing suspended structures. We have recently demonstrated a three-dimensional (3D) fabrication technique for rapid processing of microfluidic structures using a scanning laser system [B. Li et al. Appl. Phys. Lett. 85, 2426 (2004)]. This technique enables spot-by-spot laser pulsing for both in-plane and in-depth (parallel to film thickness) processing. Its maskless feature allows rapid prototyping of multilevel microfluidic structures at low cost. This article describes our latest results in thickness management using the 3D laser manufacturing technique. Suspended beams of various thicknesses have been fabricated by modifying grid size, laser energy, and degree of focus. Towards this end, we have demonstrated a microfluidic system with a functional microvalve in a single SU-8 layer.

  20. Effect of build geometry on the β-grain structure and texture in additive manufacture of Ti-6Al-4V by selective electron beam melting

    SciTech Connect

    Antonysamy, A.A.; Meyer, J.; Prangnell, P.B.

    2013-10-15

    With titanium alloys, the solidification conditions in Additive Manufacturing (AM) frequently lead to coarse columnar β-grain structures. The effect of geometry on the variability in the grain structure and texture, seen in Ti-6Al-4V alloy components produced by Selective Electron Beam Melting (SEBM), has been investigated. Reconstruction of the primary β-phase, from α-phase EBSD data, has confirmed that in bulk sections where in-fill “hatching” is employed growth selection favours columnar grains aligned with an <001> {sub β} direction normal to the deposited powder layers; this results in a coarse β-grain structure with a strong < 001 > {sub β} fibre texture (up 8 x random) that can oscillate between a near random distribution around the fibre axis and cube reinforcement with build height. It is proposed that this behaviour is related to the highly elongated melt pool and the raster directions alternating between two orthogonal directions every layer, which on average favours grains with cube alignment. In contrast, the outline, or “contour”, pass produces a distinctly different grain structure and texture resulting in a skin layer on wall surfaces, where nucleation occurs off the surrounding powder and growth follows the curved surface of the melt pool. This structure becomes increasingly important in thin sections. Local heterogeneities have also been found within different section transitions, resulting from the growth of skin grain structures into thicker sections. Texture simulations have shown that the far weaker α-texture (∼ 3 x random), seen in the final product, arises from transformation on cooling occurring with a near random distribution of α-plates across the 12 variants possible from the Burgers relationship. - Highlights: • Distinctly different skin and bulk structures are produced by the contour and hatching passes. • Bulk sections contain coarse β-grains with a < 001 > fibre texture in the build direction. • This

  1. The Influence of As-Built Surface Conditions on Mechanical Properties of Ti-6Al-4V Additively Manufactured by Selective Electron Beam Melting

    NASA Astrophysics Data System (ADS)

    Sun, Y. Y.; Gulizia, S.; Oh, C. H.; Fraser, D.; Leary, M.; Yang, Y. F.; Qian, M.

    2016-03-01

    Achieving a high surface finish is a major challenge for most current metal additive manufacturing processes. We report the first quantitative study of the influence of as-built surface conditions on the tensile properties of Ti-6Al-4V produced by selective electron beam melting (SEBM) in order to better understand the SEBM process. Tensile ductility was doubled along with noticeable improvements in tensile strengths after surface modification of the SEBM-fabricated Ti-6Al-4V by chemical etching. The fracture surfaces of tensile specimens with different surface conditions were characterised and correlated with the tensile properties obtained. The removal of a 650- μm-thick surface layer by chemical etching was shown to be necessary to eliminate the detrimental influence of surface defects on mechanical properties. The experimental results and analyses underline the necessity to modify the surfaces of SEBM-fabricated components for structural applications, particularly for those components which contain complex internal concave and convex surfaces and channels.

  2. Manufacture of silicon-based devices having disordered sulfur-doped surface layers

    DOEpatents

    Carey, III; James Edward; Mazur, Eric

    2008-04-08

    The present invention provides methods of fabricating a radiation-absorbing semiconductor wafer by irradiating at least one surface location of a silicon substrate, e.g., an n-doped crystalline silicon, by a plurality of temporally short laser pulses, e.g., femtosecond pulses, while exposing that location to a substance, e.g., SF.sub.6, having an electron-donating constituent so as to generate a substantially disordered surface layer (i.e., a microstructured layer) that incorporates a concentration of that electron-donating constituent, e.g., sulfur. The substrate is also annealed at an elevated temperature and for a duration selected to enhance the charge carrier density in the surface layer. For example, the substrate can be annealed at a temperature in a range of about 700 K to about 900 K.

  3. Additive Routes to Action Learning: Layering Experience Shapes Engagement of the Action Observation Network

    PubMed Central

    Kirsch, Louise P.; Cross, Emily S.

    2015-01-01

    The way in which we perceive others in action is biased by one's prior experience with an observed action. For example, we can have auditory, visual, or motor experience with actions we observe others perform. How action experience via 1, 2, or all 3 of these modalities shapes action perception remains unclear. Here, we combine pre- and post-training functional magnetic resonance imaging measures with a dance training manipulation to address how building experience (from auditory to audiovisual to audiovisual plus motor) with a complex action shapes subsequent action perception. Results indicate that layering experience across these 3 modalities activates a number of sensorimotor cortical regions associated with the action observation network (AON) in such a way that the more modalities through which one experiences an action, the greater the response is within these AON regions during action perception. Moreover, a correlation between left premotor activity and participants' scores for reproducing an action suggests that the better an observer can perform an observed action, the stronger the neural response is. The findings suggest that the number of modalities through which an observer experiences an action impacts AON activity additively, and that premotor cortical activity might serve as an index of embodiment during action observation. PMID:26209850

  4. Enhanced erythrocyte suspension layer stability achieved by surface tension lowering additives

    NASA Technical Reports Server (NTRS)

    Omenyi, S. N.; Snyder, R. S.; Absolom, D. R.; Van Oss, C. J.; Neumann, A. W.

    1982-01-01

    In connection with a fractionation procedure involving the separation of particles, a dilute suspension of these particles in a liquid is carefully layered on a dense liquid. Under ideal conditions, the suspension forms a zone of finite thickness with a 'sharp' interface between the suspension layer and the supporting liquid. Under an applied field, e.g., gravitational or electrical, the particles in the suspension layer migrate to form different layers according to their size and/or density or according to their electrophoretic mobilities. However, in many cases the ideal conditions necessary for the fractionation process are not obtained. Many studies have been conducted to explore the reasons for suspension layer 'instability'. The present investigation represents an extension of a study conducted by Omenyi et al. (1981). An electrostatic repulsion-van der Waals mechanism was used to study the stability of fixed erythrocyte suspensions layered on a D2O cushion.

  5. Investigations on the influence of composition in the development of Ni-Ti shape memory alloy using laser based additive manufacturing

    NASA Astrophysics Data System (ADS)

    Shiva, S.; Palani, I. A.; Mishra, S. K.; Paul, C. P.; Kukreja, L. M.

    2015-06-01

    Among the various shaped memory alloys (SMA), nitinol (Ni-Ti alloy) finds applications in automotive, aerospace, biomedical and robotics. The conventional route of fabrication of SMA has several limitations, like formation of stable secondary phases, fabrication of simple geometries, etc. This paper reports a novel method of fabricating SMA using a laser based additive manufacturing technique. Three different compositions of Ni and Ti powders (Ni-45% Ti-55%; Ni-50% Ti-50%; Ni-55% Ti45%) were pre-mixed using ball-milling and laser based additive manufacturing system was employed to fabricate circular rings. The material properties of fabricated rings were evaluated using Scanning Electron Microscopy (SEM), Differential scanning calorimeter (DSC), X-ray diffraction (XRD) system and micro-hardness test. All the characterized results showed that SMA could be manufactured using the laser based additive manufacturing process. The properties of laser additive manufactured SMA (Ni-50% Ti-50%) were found to be close to that of conventionally processed SMA.

  6. Effects of anodizing parameters and heat treatment on nanotopographical features, bioactivity, and cell culture response of additively manufactured porous titanium.

    PubMed

    Amin Yavari, S; Chai, Y C; Böttger, A J; Wauthle, R; Schrooten, J; Weinans, H; Zadpoor, A A

    2015-06-01

    Anodizing could be used for bio-functionalization of the surfaces of titanium alloys. In this study, we use anodizing for creating nanotubes on the surface of porous titanium alloy bone substitutes manufactured using selective laser melting. Different sets of anodizing parameters (voltage: 10 or 20V anodizing time: 30min to 3h) are used for anodizing porous titanium structures that were later heat treated at 500°C. The nanotopographical features are examined using electron microscopy while the bioactivity of anodized surfaces is measured using immersion tests in the simulated body fluid (SBF). Moreover, the effects of anodizing and heat treatment on the performance of one representative anodized porous titanium structures are evaluated using in vitro cell culture assays using human periosteum-derived cells (hPDCs). It has been shown that while anodizing with different anodizing parameters results in very different nanotopographical features, i.e. nanotubes in the range of 20 to 55nm, anodized surfaces have limited apatite-forming ability regardless of the applied anodizing parameters. The results of in vitro cell culture show that both anodizing, and thus generation of regular nanotopographical feature, and heat treatment improve the cell culture response of porous titanium. In particular, cell proliferation measured using metabolic activity and DNA content was improved for anodized and heat treated as well as for anodized but not heat-treated specimens. Heat treatment additionally improved the cell attachment of porous titanium surfaces and upregulated expression of osteogenic markers. Anodized but not heat-treated specimens showed some limited signs of upregulated expression of osteogenic markers. In conclusion, while varying the anodizing parameters creates different nanotube structure, it does not improve apatite-forming ability of porous titanium. However, both anodizing and heat treatment at 500°C improve the cell culture response of porous titanium. PMID

  7. A 10-kW SiC Inverter with A Novel Printed Metal Power Module With Integrated Cooling Using Additive Manufacturing

    SciTech Connect

    Chinthavali, Madhu Sudhan; Ayers, Curtis William; Campbell, Steven L; Wiles, Randy H; Ozpineci, Burak

    2014-01-01

    With efforts to reduce the cost, size, and thermal management systems for the power electronics drivetrain in hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs), wide band gap semiconductors including silicon carbide (SiC) have been identified as possibly being a partial solution. This paper focuses on the development of a 10-kW all SiC inverter using a high power density, integrated printed metal power module with integrated cooling using additive manufacturing techniques. This is the first ever heat sink printed for a power electronics application. About 50% of the inverter was built using additive manufacturing techniques.

  8. Nanostructured and layered lithium manganese oxide and method of manufacturing the same

    NASA Technical Reports Server (NTRS)

    Singhal, Amit (Inventor); Skandan, Ganesh (Inventor)

    2005-01-01

    Nanostructured and layered lithium manganese oxide powders and methods of producing same. The powders are represented by the chemical formula, LixMn1-yMyO2, where 0.5

  9. Ultrasonic Additive Manufacturing: Weld Optimization for Aluminum 6061, Development of Scarf Joints for Aluminum Sheet Metal, and Joining of High Strength Metals

    NASA Astrophysics Data System (ADS)

    Wolcott, Paul J.

    Ultrasonic additive manufacturing (UAM) is a low temperature, solid-state manufacturing process that enables the creation of layered, solid metal structures with designed anisotropies and embedded materials. As a low temperature process, UAM enables the creation of active composites containing smart materials, components with embedded sensors, thermal management devices, and many others. The focus of this work is on the improvement and characterization of UAM aluminum structures, advancing the capabilities of ultrasonic joining into sheet geometries, and examination of dissimilar material joints using the technology. Optimized process parameters for Al 6061 were identified via a design of experiments study indicating a weld amplitude of 32.8 synum and a weld speed of 200 in/min as optimal. Weld force and temperature were not significant within the levels studied. A methodology of creating large scale builds is proposed, including a prescribed random stacking sequence and overlap of 0.0035 in. (0.0889 mm) for foils to minimize voids and maximize mechanical strength. Utilization of heat treatments is shown to significantly increase mechanical properties of UAM builds, within 90% of bulk material. The applied loads during the UAM process were investigated to determine the stress fields and plastic deformation induced during the process. Modeling of the contact mechanics via Hertzian contact equations shows that significant stress is applied via sonotrode contact in the process. Contact modeling using finite element analysis (FEA), including plasticity, indicates that 5000 N normal loads result in plastic deformation in bulk aluminum foil, while at 3000 N no plastic deformation occurs. FEA studies on the applied loads during the process, specifically a 3000 N normal force and 2000 N shear force, show that high stresses and plastic deformation occur at the edges of a welded foil, and base of the UAM build. Microstructural investigations of heat treated foils confirms

  10. A SnO2-samarium doped ceria additional anode layer in a direct carbon fuel cell

    NASA Astrophysics Data System (ADS)

    Yu, Baolong; Zhao, Yicheng; Li, Yongdan

    2016-02-01

    The role of a SnO2-samarium doped ceria (SDC) additional anode layer in a direct carbon fuel cell (DCFC) with SDC-(Li0.67Na0.33)2CO3 composite electrolyte and lithiated NiO-SDC-(Li0.67Na0.33)2CO3 composite cathode is investigated and compared with a NiO-SDC extra anode layer. Catalytic grown carbon fiber mixed with (Li0.67Na0.33)2CO3 is used as a fuel. At 750 °C, the maximum power outputs of 192 and 143 mW cm-2 are obtained by the cells with SnO2-SDC and NiO-SDC layers, respectively. In the SnO2-SDC layer, the reduction of SnO2 and the oxidation of Sn happen simultaneously during the cell operation, and the Sn/SnO2 redox cycle provides an additional route for fuel conversion. The formation of an insulating dense interlayer between the anode and electrolyte layers, which usually happens in DCFCs with metal anodes, is avoided in the cell with the SnO2-SDC layer, and the stability of the cell is improved consequently.

  11. Numerical modeling of heat-transfer and the influence of process parameters on tailoring the grain morphology of IN718 in electron beam additive manufacturing

    DOE PAGESBeta

    Raghavan, Narendran; Dehoff, Ryan; Pannala, Sreekanth; Simunovic, Srdjan; Kirka, Michael; Turner, John; Carlson, Neil; Babu, Sudarsanam S.

    2016-04-26

    The fabrication of 3-D parts from CAD models by additive manufacturing (AM) is a disruptive technology that is transforming the metal manufacturing industry. The correlation between solidification microstructure and mechanical properties has been well understood in the casting and welding processes over the years. This paper focuses on extending these principles to additive manufacturing to understand the transient phenomena of repeated melting and solidification during electron beam powder melting process to achieve site-specific microstructure control within a fabricated component. In this paper, we have developed a novel melt scan strategy for electron beam melting of nickel-base superalloy (Inconel 718) andmore » also analyzed 3-D heat transfer conditions using a parallel numerical solidification code (Truchas) developed at Los Alamos National Laboratory. The spatial and temporal variations of temperature gradient (G) and growth velocity (R) at the liquid-solid interface of the melt pool were calculated as a function of electron beam parameters. By manipulating the relative number of voxels that lie in the columnar or equiaxed region, the crystallographic texture of the components can be controlled to an extent. The analysis of the parameters provided optimum processing conditions that will result in columnar to equiaxed transition (CET) during the solidification. Furthermore, the results from the numerical simulations were validated by experimental processing and characterization thereby proving the potential of additive manufacturing process to achieve site-specific crystallographic texture control within a fabricated component.« less

  12. The beneficial effect of superhydropobic layer addition on lubrication behavior in bearing application

    NASA Astrophysics Data System (ADS)

    Muchammad, Tauviqirrahman, Mohammad; Pratomo, Ariawan Wahyu; Jamari, J.; Schipper, Dirk J.

    2016-04-01

    Recently, superhydrophobic materials got a lot of attention for special applications, such as anti stiction and energy conversion. In this paper, a theoretical investigation was carried out to study the effect of adding a superhydrophobic layer on the tribological performance of bearings and further compared it to textured bearings. In doing so, different texture depths were also studied and compared to each other to find the optimal textured bearing. The superhydrophobic behaviour was characterized by the Navier slip model. The results showed that the presence of a superhydrophobic layer in a bearing could result in a significant improvement in the hydrodynamic pressure distribution as well as the shear stress compared to a textured bearing.

  13. Multilayer electronic component systems and methods of manufacture

    NASA Technical Reports Server (NTRS)

    Thompson, Dane (Inventor); Wang, Guoan (Inventor); Kingsley, Nickolas D. (Inventor); Papapolymerou, Ioannis (Inventor); Tentzeris, Emmanouil M. (Inventor); Bairavasubramanian, Ramanan (Inventor); DeJean, Gerald (Inventor); Li, RongLin (Inventor)

    2010-01-01

    Multilayer electronic component systems and methods of manufacture are provided. In this regard, an exemplary system comprises a first layer of liquid crystal polymer (LCP), first electronic components supported by the first layer, and a second layer of LCP. The first layer is attached to the second layer by thermal bonds. Additionally, at least a portion of the first electronic components are located between the first layer and the second layer.

  14. Apparatus and method of manufacture for depositing a composite anti-reflection layer on a silicon surface

    NASA Technical Reports Server (NTRS)

    Pain, Bedabrata (Inventor)

    2012-01-01

    An apparatus and associated method are provided. A first silicon layer having at least one of an associated passivation layer and barrier is included. Also included is a composite anti-reflection layer including a stack of layers each with a different thickness and refractive index. Such composite anti-reflection layer is disposed adjacent to the first silicon layer.

  15. Additive Manufacturing/Diagnostics via the High Frequency Induction Heating of Metal Powders: The Determination of the Power Transfer Factor for Fine Metallic Spheres

    SciTech Connect

    Rios, Orlando; Radhakrishnan, Balasubramaniam; Caravias, George; Holcomb, Matthew

    2015-03-11

    Grid Logic Inc. is developing a method for sintering and melting fine metallic powders for additive manufacturing using spatially-compact, high-frequency magnetic fields called Micro-Induction Sintering (MIS). One of the challenges in advancing MIS technology for additive manufacturing is in understanding the power transfer to the particles in a powder bed. This knowledge is important to achieving efficient power transfer, control, and selective particle heating during the MIS process needed for commercialization of the technology. The project s work provided a rigorous physics-based model for induction heating of fine spherical particles as a function of frequency and particle size. This simulation improved upon Grid Logic s earlier models and provides guidance that will make the MIS technology more effective. The project model will be incorporated into Grid Logic s power control circuit of the MIS 3D printer product and its diagnostics technology to optimize the sintering process for part quality and energy efficiency.

  16. Effects of Ti additives on structural and electric properties of Cr- and Ti-codoped ZnO layers

    NASA Astrophysics Data System (ADS)

    Lee, Sejoon; Lee, Youngmin; Young Kim, Deuk; Won Kang, Tae

    2013-08-01

    We investigate the effects of Ti-codoping on the structural and electrical properties of the ZnCrTiO layers grown on the Pt (111)/Ti/Al2O3 (0001) substrates by co-sputtering of ZnCrO and Ti. The ZnCrTiO layers with the Ti contents of 0.2-0.3 at. % reveal the enhanced disorder-activated Raman modes, attributing to increased lattice-displacement-induced phonon scattering due to the incorporation of Ti additives. In comparison with ZnCrO, the ZnCrTiO layers exhibit the improved ferroelectric properties with one order of magnitude-increased remnant polarization. This causes a polarization-dependent asymmetric hysteresis behavior in the Pt/ZnCrTiO/Pt top-to-bottom metal-ferroelectric-metal device, suggesting potential applications for two-terminal ferroelectric-tunneling resistive memories.

  17. Distribution and Viability of Fetal and Adult Human Bone Marrow Stromal Cells in a Biaxial Rotating Vessel Bioreactor after Seeding on Polymeric 3D Additive Manufactured Scaffolds

    PubMed Central

    Leferink, Anne M.; Chng, Yhee-Cheng; van Blitterswijk, Clemens A.; Moroni, Lorenzo

    2015-01-01

    One of the conventional approaches in tissue engineering is the use of scaffolds in combination with cells to obtain mechanically stable tissue constructs in vitro prior to implantation. Additive manufacturing by fused deposition modeling is a widely used technique to produce porous scaffolds with defined pore network, geometry, and therewith defined mechanical properties. Bone marrow-derived mesenchymal stromal cells (MSCs) are promising candidates for tissue engineering-based cell therapies due to their multipotent character. One of the hurdles to overcome when combining additive manufactured scaffolds with MSCs is the resulting heterogeneous cell distribution and limited cell proliferation capacity. In this study, we show that the use of a biaxial rotating bioreactor, after static culture of human fetal MSCs (hfMSCs) seeded on synthetic polymeric scaffolds, improved the homogeneity of cell and extracellular matrix distribution and increased the total cell number. Furthermore, we show that the relative mRNA expression levels of indicators for stemness and differentiation are not significantly changed upon this bioreactor culture, whereas static culture shows variations of several indicators for stemness and differentiation. The biaxial rotating bioreactor presented here offers a homogeneous distribution of hfMSCs, enabling studies on MSCs fate in additive manufactured scaffolds without inducing undesired differentiation. PMID:26557644

  18. Modeling the Microstructure Evolution During Additive Manufacturing of Ti6Al4V: A Comparison Between Electron Beam Melting and Selective Laser Melting

    NASA Astrophysics Data System (ADS)

    Vastola, G.; Zhang, G.; Pei, Q. X.; Zhang, Y.-W.

    2016-05-01

    Beam-based additive manufacturing (AM) is an innovative technique in which parts are built layerwise, starting from the material in powder form. As a developing manufacturing technique, achievement of excellent mechanical properties in the final part is of paramount importance for the mainstream adoption of this technique in industrial manufacturing lines. At the same time, AM offers an unprecedented opportunity to precisely control the manufacturing conditions locally within the part during build, enabling local influence on the formation of the texture and microstructure. In order to achieve the control of microstructure by tailoring the AM machine parameters, a full understanding and modeling of the heat transfer and microstructure evolution processes is needed. Here, we show the implementation of the non-equilibrium equations for phase formation and dissolution in an AM modeling framework. The model is developed for the Ti6Al4V alloy and allows us to show microstructure evolution as given by the AM process. The developed capability is applied to the cases of electron beam melting and selective laser melting AM techniques to explain the significantly different microstructures observed in the two processes.

  19. Modeling the mechanical and aging properties of silicone rubber and foam - stockpile-historical & additively manufactured materials

    SciTech Connect

    Maiti, A.; Weisgraber, T. H.; Gee, R. H.

    2014-09-30

    M97* and M9763 belong to the M97xx series of cellular silicone materials that have been deployed as stress cushions in some of the LLNL systems. Their purpose of these support foams is to distribute the stress between adjacent components, maintain relative positioning of various components, and mitigate the effects of component size variation due to manufacturing and temperature changes. In service these materials are subjected to a continuous compressive strain over long periods of time. In order to ensure their effectiveness, it is important to understand how their mechanical properties change over time. The properties we are primarily concerned about are: compression set, load retention, and stress-strain response (modulus).

  20. Effect of Ti additive on (Cr, Fe)7C3 carbide in arc surfacing layer and its refined mechanism

    NASA Astrophysics Data System (ADS)

    Zhou, Yefei; Yang, Yulin; Yang, Jian; Hao, Feifei; Li, Da; Ren, Xuejun; Yang, Qingxiang

    2012-06-01

    Arc surfacing layer of hypoeutectic high chromium cast iron (HCCI) expects refiner carbides in the microstructure to improve its mechanical properties. In this paper, Ti additive as a strong carbide forming element was added in the hypoeutectic HCCI arc surfacing layer. Microstructure of titaniferous hypoeutectic HCCI was studied by optical microscopy, X-ray diffraction and field emission scanning electronic microscopy with energy dispersive spectrometer. Furthermore, the M(M = Cr, Fe)7C3 carbide refinement mechanism was explained by the phase diagram calculation and lattice misfit theory. The results show that, the M7C3 carbide in arc surfacing microstructure of hypoeutectic HCCI has been refined with 2 wt.% Ti additive, and TiC carbide can be observed in/around the M7C3 carbide. With Ti addictive increasing, the micro-hardness along the depth in profile section of layer becomes more uniform, and the wear resistance has been improved. According to the phase diagram calculation, MC carbide precipitates prior to M7C3 carbide in Fe-Cr-C-Ti alloy. In addition, the lattice misfit between (1 1 0)TiC and (0C is 9.257%, which indicates that the TiC as heterogeneous nuclei of the M7C3 is medium effective. Therefore, the M7C3 carbide can be refined.

  1. Spin polarization and additional magneto-optical activity of nonmagnetic layers in Fe/Ag CMF

    NASA Astrophysics Data System (ADS)

    Xu, Y. B.; Zhai, H. R.; Lu, M.; Jin, Q. Y.; Miao, Y. Z.

    1992-08-01

    The experimental magneto-optical Kerr rotation spectra of Fe/Ag compositionally modulated films reported by Katayama et al. are studied theoretically. It is found that the free electrons of Ag are spin polarized. The magnitude of the polarization is about 1% with a direction opposite to that of Fe. The polarized Ag also gives rise to an additional magneto-optical activity as in Pt and Pd.

  2. Change in fatigue property and its relation to critical current for YBCO coated conductor with additional Cu layer

    NASA Astrophysics Data System (ADS)

    Yoshida, Y.; Hojo, M.; Sugano, M.; Adachi, T.; Inoue, Y.; Shikimachi, K.; Hirano, N.; Nagaya, S.

    2009-10-01

    YBa 2Cu 3O 7-δ, (YBCO) coated conductors with an additional Cu layer are expected to be applied as coils used in superconducting magnetic energy storage, SMES. In the operation of SMES, large cyclic hoop stress is applied to the coated conductor in the longitudinal direction. In the present study, we carried out fatigue tests in liquid nitrogen, LN 2, and measured the critical current, I c, after a specific number of fatigue cycles to clarify its fatigue fracture mechanism. All fatigue tests were carried out under a stress ratio (the ratio of the minimum to maximum load) of 0.5. The frequency of stress cycling was 30 Hz. Our results showed that the addition of a Cu layer increased the fatigue strength after 10 6 cycles, F, by about 19%. Decrease of I c was more than 30% of the initial critical current, I c0, without loading at the point of final overall fracture when the maximum load in the stress cycles was close to that corresponding to irreversible strain. Furthermore, microscopic observation and the change in I c showed that fatigue fracture mainly initiated from the Hastelloy C-276 substrate. Fatigue fracture also initiated from the Cu layer, but only when the maximum load was approximately F.

  3. Engineering of an MBR supernatant fouling layer by fine particles addition: a possible way to control cake compressibility.

    PubMed

    Teychene, Benoît; Guigui, Christelle; Cabassud, Corinne

    2011-02-01

    For membrane bioreactors (MBR) applied to wastewater treatment membrane fouling is still the prevalent issue. The main limiting phenomena related to fouling is a sudden jump of the transmembrane pressure (TMP) often attributed to the collapse of the fouling layer. Among existing techniques to avoid or to delay this collapse, the addition of active particles membrane fouling reducers (polymer, resins, powdered activated carbon (PAC), zeolithe...) showed promising results. Thus the main objective of this work is to determine if fouling can be reduced by inclusion of inert particles (500 nm and inert compared to other fouling reducers) and which is the impact on filtration performances of the structuring of the fouling. Those particles were chosen for their different surface properties and their capability to form well structured layer. Results, obtained at constant pressure in dead end mode, show that the presence of particles changes foulant deposition and induces non-compressible fouling (in the range of 0.5-1 bar) and higher rejection values compared to filtration done on supernatant alone. Indeed dead end filtration tests show that whatever interactions between biofluid and particles, the addition of particles leads to better filtration performances (in terms of rejection, and fouling layer compressibility). Moreover results confirm the important role played by macromolecular compounds, during supernatant filtration, creating highly compressible and reversible fouling. In conclusion, this study done at lab-scale suggests the potential benefit to engineer fouling structure to control or to delay the collapse of the fouling layer. Finally this study offers the opportunities to enlarge the choice of membrane fouling reducers by taking into consideration their ability to form more consistent fouling (i.e. rigid, structured fouling). PMID:21232780

  4. The potential application of red mud and soil mixture as additive to the surface layer of a landfill cover system.

    PubMed

    Ujaczki, Éva; Feigl, Viktória; Molnár, Mónika; Vaszita, Emese; Uzinger, Nikolett; Erdélyi, Attila; Gruiz, Katalin

    2016-06-01

    Red mud, the by-product of aluminum production, has been regarded as a problematic residue all over the world. Its storage involves risks as evidenced by the Ajka red mud spill, an accident in Hungary where the slurry broke free, flooding the surrounding areas. As an immediate remediation measure more than 5cm thick red mud layer was removed from the flooded soil surface. The removed red mud and soil mixture (RMSM) was transferred into the reservoirs for storage. In this paper the application of RMSM is evaluated in a field study aiming at re-utilizing waste, decreasing cost of waste disposal and providing a value-added product. The purpose was to investigate the applicability of RMSM as surface layer component of landfill cover systems. The field study was carried out in two steps: in lysimeters and in field plots. The RMSM was mixed at ratios ranging between 0 and 50% w/w with low quality subsoil (LQS) originally used as surface layer of an interim landfill cover. The characteristics of the LQS+RMSM mixtures compared to the subsoil (LQS) and the RMSM were determined by physical-chemical, biological and ecotoxicological methods. The addition of RMSM to the subsoil (LQS) at up to 20% did not result any ecotoxic effect, but it increased the water holding capacity. In addition, the microbial substrate utilization became about triple of subsoil (LQS) after 10months. According to our results the RMSM mixed into subsoil (LQS) at 20% w/w dose may be applied as surface layer of landfill cover systems. PMID:27266315

  5. Selective laser melting additive manufactured Inconel 718 superalloy parts: High-temperature oxidation property and its mechanisms

    NASA Astrophysics Data System (ADS)

    Jia, Qingbo; Gu, Dongdong

    2014-10-01

    This work presented a comprehensive study of high-temperature oxidation behaviors and mechanisms of Selective laser melting (SLM) processed Inconel 718 superalloy parts using different methods including isothermal oxidation testing, X-ray diffraction, scanning electron microscopy and energy dispersive X-ray spectroscopy. The experimental results revealed that the oxidation process of the tested parts processed at a lower volumetric laser energy density experienced the severe spallation. On reasonably increasing the applied volumetric laser energy density, the oxidation kinetics of the as-produced parts obeyed a parabolic law, exhibiting the significantly improved oxidation resistance performance. The constitutional phases within the oxidation film were identified and the corresponding formation mechanisms were elucidated in detail according to the thermodynamic principles. The cross-sectional morphologies of oxidized Inconel 718 parts indicated that the oxidation microstructure mainly consisted of an external oxidation layer and an internal oxidation zone. The oxidation process was controlled by the outward diffusion of oxide forming elements and inward penetration of oxygen, by which the interaction mechanisms between the microstructures and internal oxidation zones were clarified. On the basis of the experimental results and theoretical analyses, the physical oxidation mechanisms were accordingly established to illustrate the oxidation behaviors of SLM-processed Inconel 718 parts at elevated operative temperatures.

  6. To overcome the appearance of the efflorescences by magnesium carbonate addition in a mass for manufacture of bricks of construction

    NASA Astrophysics Data System (ADS)

    Chemani, H.

    2011-01-01

    Following the tendency of some European countries the briquetiers develop further the aesthetic aspect of their products and, the supply of colors and, aspects of surface will be further extended. The recovery of the sustainability of facades in bricks apparent, the quality of raw materials, and their determination remain a major problem. The presence of soluble salts in the field is fairly harmful for the product terracotta because they are the cause of apparitions of efflorescences. To defeat this type of default our study is on an addition of MgCO3 a mixture of two kinds of clay. The doses MgCO3 were between (0,25-0,5-0,75-1-1,5%) of the dry mass to treat. With rates of clay yellow and, gray which are respectively (40-60%). In comparison with a previous study where the addition was BaCO3. Finished products obtained with 1% MgCO3 exhibited a better aesthetic aspect, of the qualities insulating, and a mechanical resistance significantly higher than the bricks ceramics ordinary marketed at the present time.

  7. Hierarchical random additive process and logarithmic scaling of generalized high order, two-point correlations in turbulent boundary layer flow

    NASA Astrophysics Data System (ADS)

    Yang, X. I. A.; Marusic, I.; Meneveau, C.

    2016-06-01

    Townsend [Townsend, The Structure of Turbulent Shear Flow (Cambridge University Press, Cambridge, UK, 1976)] hypothesized that the logarithmic region in high-Reynolds-number wall-bounded flows consists of space-filling, self-similar attached eddies. Invoking this hypothesis, we express streamwise velocity fluctuations in the inertial layer in high-Reynolds-number wall-bounded flows as a hierarchical random additive process (HRAP): uz+=∑i=1Nzai . Here u is the streamwise velocity fluctuation, + indicates normalization in wall units, z is the wall normal distance, and ai's are independently, identically distributed random additives, each of which is associated with an attached eddy in the wall-attached hierarchy. The number of random additives is Nz˜ln(δ /z ) where δ is the boundary layer thickness and ln is natural log. Due to its simplified structure, such a process leads to predictions of the scaling behaviors for various turbulence statistics in the logarithmic layer. Besides reproducing known logarithmic scaling of moments, structure functions, and correlation function [" close="]3/2 uz(x ) uz(x +r ) >, new logarithmic laws in two-point statistics such as uz4(x ) > 1 /2, 1/3, etc. can be derived using the HRAP formalism. Supporting empirical evidence for the logarithmic scaling in such statistics is found from the Melbourne High Reynolds Number Boundary Layer Wind Tunnel measurements. We also show that, at high Reynolds numbers, the above mentioned new logarithmic laws can be derived by assuming the arrival of an attached eddy at a generic point in the flow field to be a Poisson process [Woodcock and Marusic, Phys. Fluids 27, 015104 (2015), 10.1063/1.4905301]. Taken together, the results provide new evidence supporting the essential ingredients of the attached eddy hypothesis to describe streamwise velocity fluctuations of large, momentum transporting eddies in wall-bounded turbulence, while

  8. Advanced Manufacturing Technologies

    NASA Technical Reports Server (NTRS)

    Fikes, John

    2016-01-01

    Advanced Manufacturing Technologies (AMT) is developing and maturing innovative and advanced manufacturing technologies that will enable more capable and lower-cost spacecraft, launch vehicles and infrastructure to enable exploration missions. The technologies will utilize cutting edge materials and emerging capabilities including metallic processes, additive manufacturing, composites, and digital manufacturing. The AMT project supports the National Manufacturing Initiative involving collaboration with other government agencies.

  9. The bio-gripper: a fluid-driven micro-manipulator of living tissue constructs for additive bio-manufacturing.

    PubMed

    Ip, Blanche C; Cui, Francis; Tripathi, Anubhav; Morgan, Jeffrey R

    2016-06-01

    We previously developed the Bio-Pick, Place, and Perfuse (Bio-P3) instrument to fabricate large perfusable tissue constructs by stacking and aligning scaffold-free living microtissues with integrated lumens. The Bio-P3 required an actuating mechanism to manipulate living microtissues of various sizes and shapes that are fragile, and must remain in an aqueous environment. The optical transparency of the Bio-P3 gripping device was essential to provide unobstructed visuals for accurate alignment of microtissues. We previously engineered a pilot fluid force-driven bio-gripper that can pick-and-place microtissue in planar position without causing cellular damage by pulling culture medium through track-etched membrane-integrated cell culture inserts. In this study, we invented a new flexible bio-gripper design that maximized the bio-gripper utilities. We utilized experimental approaches, multivariate analyzes, and theoretical modeling to elucidate how membrane characteristics (pore size, pore density, membrane thickness, membrane area, and surface chemistry) altered bio-gripper robustness and the flow rate (Q(c)) required for successful gripping. We devised two standardized tests and synthetic parts that mimicked microtissues, to systematically quantify bio-gripper performance. All thirteen syringe pump-driven bio-grippers except one successfully gripped and released synthetic parts with values of Q(c) that coincided with our mathematical simulation of the fluid mechanics of gripping. The bio-gripper could grip synthetic parts of various sizes, shapes and masses, demonstrating the robustness of the actuating mechanism. Multivariate analysis of experimental data indicated that both membrane porosity and thickness modulated Q(c), and in addition, revealed that membrane pore density determined membrane optical transparency. Fabricating large tissue constructs requires repeated stacking of microtissues. We showed that one bio-gripper could pick-and-place living microtissues

  10. Additive Fabrication of Conductive Patterns by a Template Transfer Process Based on Benzotriazole Adsorption As a Separation Layer.

    PubMed

    Chang, Yu; Yang, Zhen-Guo

    2016-06-01

    The traditional subtractive process to fabricate conductive patterns is environmentally harmful, wasteful, and limited in line width. The additive process, including direct printing of conductive paste or ink, direct printing of catalytic ink, laser-induced forward transfer, etc., can solve these problems. However, the current additive process also faces many difficulties such as low electrical and adhesion properties, low pattern thickness, high cost, etc. Benzotriazole (BTA), as widely used corrosion inhibitor, can be adsorbed onto a copper surface. The electroplated copper film on BTA-adsorbed copper foil shows poor adhesion. On the basis of this phenomenon, a novel template transfer process to additively fabricate conductive patterns has been developed. A permeant antiadhesive mask is printed on carrier copper foil, and then, BTA is adsorbed onto the exposed area of the carrier foil, thus forming the template. The template is electroplated to grow conductive patterns in the exposed parts, and then can be adhered to the flexible substrate. The substrate is peeled off, with the transfer of the conductive patterns to the substrate, to form the designed conductive patterns on PET. By reimmersing the template into BTA solution, the template can be used again. The mechanism of BTA adsorption and the reason for the low peeling strength are researched using Raman spectra, XPS and electrochemical impedance spectroscopy. Copper patterns more than 20 μm in thickness can be prepared on PET, the resistivity of the prepared copper patterns is 2.01 μΩ cm, which is about the same as bulk copper, and the peeling strength of the pattern on PET is measured to be 6.97 N/cm. This template transfer process, with no waste, low pollution, high electrical and adhesion properties, and low cost, shows high potential in the large scale manufacturing of electronic devices, such as RFID circuitry, FPCs, etc. PMID:27171553

  11. Additive Manufacturing of Single-Crystal Superalloy CMSX-4 Through Scanning Laser Epitaxy: Computational Modeling, Experimental Process Development, and Process Parameter Optimization

    NASA Astrophysics Data System (ADS)

    Basak, Amrita; Acharya, Ranadip; Das, Suman

    2016-06-01

    This paper focuses on additive manufacturing (AM) of single-crystal (SX) nickel-based superalloy CMSX-4 through scanning laser epitaxy (SLE). SLE, a powder bed fusion-based AM process was explored for the purpose of producing crack-free, dense deposits of CMSX-4 on top of similar chemistry investment-cast substrates. Optical microscopy and scanning electron microscopy (SEM) investigations revealed the presence of dendritic microstructures that consisted of fine γ' precipitates within the γ matrix in the deposit region. Computational fluid dynamics (CFD)-based process modeling, statistical design of experiments (DoE), and microstructural characterization techniques were combined to produce metallurgically bonded single-crystal deposits of more than 500 μm height in a single pass along the entire length of the substrate. A customized quantitative metallography based image analysis technique was employed for automatic extraction of various deposit quality metrics from the digital cross-sectional micrographs. The processing parameters were varied, and optimal processing windows were identified to obtain good quality deposits. The results reported here represent one of the few successes obtained in producing single-crystal epitaxial deposits through a powder bed fusion-based metal AM process and thus demonstrate the potential of SLE to repair and manufacture single-crystal hot section components of gas turbine systems from nickel-based superalloy powders.

  12. Additive Manufacturing of Single-Crystal Superalloy CMSX-4 Through Scanning Laser Epitaxy: Computational Modeling, Experimental Process Development, and Process Parameter Optimization

    NASA Astrophysics Data System (ADS)

    Basak, Amrita; Acharya, Ranadip; Das, Suman

    2016-08-01

    This paper focuses on additive manufacturing (AM) of single-crystal (SX) nickel-based superalloy CMSX-4 through scanning laser epitaxy (SLE). SLE, a powder bed fusion-based AM process was explored for the purpose of producing crack-free, dense deposits of CMSX-4 on top of similar chemistry investment-cast substrates. Optical microscopy and scanning electron microscopy (SEM) investigations revealed the presence of dendritic microstructures that consisted of fine γ' precipitates within the γ matrix in the deposit region. Computational fluid dynamics (CFD)-based process modeling, statistical design of experiments (DoE), and microstructural characterization techniques were combined to produce metallurgically bonded single-crystal deposits of more than 500 μm height in a single pass along the entire length of the substrate. A customized quantitative metallography based image analysis technique was employed for automatic extraction of various deposit quality metrics from the digital cross-sectional micrographs. The processing parameters were varied, and optimal processing windows were identified to obtain good quality deposits. The results reported here represent one of the few successes obtained in producing single-crystal epitaxial deposits through a powder bed fusion-based metal AM process and thus demonstrate the potential of SLE to repair and manufacture single-crystal hot section components of gas turbine systems from nickel-based superalloy powders.

  13. Data indicating temperature response of Ti–6Al–4V thin-walled structure during its additive manufacture via Laser Engineered Net Shaping

    PubMed Central

    Marshall, Garrett J.; Thompson, Scott M.; Shamsaei, Nima

    2016-01-01

    An OPTOMEC Laser Engineered Net Shaping (LENS™) 750 system was retrofitted with a melt pool pyrometer and in-chamber infrared (IR) camera for nondestructive thermal inspection of the blown-powder, direct laser deposition (DLD) process. Data indicative of temperature and heat transfer within the melt pool and heat affected zone atop a thin-walled structure of Ti–6Al–4V during its additive manufacture are provided. Melt pool temperature data were collected via the dual-wavelength pyrometer while the dynamic, bulk part temperature distribution was collected using the IR camera. Such data are provided in Comma Separated Values (CSV) file format, containing a 752×480 matrix and a 320×240 matrix of temperatures corresponding to individual pixels of the pyrometer and IR camera, respectively. The IR camera and pyrometer temperature data are provided in blackbody-calibrated, raw forms. Provided thermal data can aid in generating and refining process-property-performance relationships between laser manufacturing and its fabricated materials. PMID:27054180

  14. Data indicating temperature response of Ti-6Al-4V thin-walled structure during its additive manufacture via Laser Engineered Net Shaping.

    PubMed

    Marshall, Garrett J; Thompson, Scott M; Shamsaei, Nima

    2016-06-01

    An OPTOMEC Laser Engineered Net Shaping (LENS(™)) 750 system was retrofitted with a melt pool pyrometer and in-chamber infrared (IR) camera for nondestructive thermal inspection of the blown-powder, direct laser deposition (DLD) process. Data indicative of temperature and heat transfer within the melt pool and heat affected zone atop a thin-walled structure of Ti-6Al-4V during its additive manufacture are provided. Melt pool temperature data were collected via the dual-wavelength pyrometer while the dynamic, bulk part temperature distribution was collected using the IR camera. Such data are provided in Comma Separated Values (CSV) file format, containing a 752×480 matrix and a 320×240 matrix of temperatures corresponding to individual pixels of the pyrometer and IR camera, respectively. The IR camera and pyrometer temperature data are provided in blackbody-calibrated, raw forms. Provided thermal data can aid in generating and refining process-property-performance relationships between laser manufacturing and its fabricated materials. PMID:27054180

  15. Layered Double Hydroxide Nanoplatelets with Excellent Tribological Properties under High Contact Pressure as Water-Based Lubricant Additives

    PubMed Central

    Wang, Hongdong; Liu, Yuhong; Chen, Zhe; Wu, Bibo; Xu, Sailong; Luo, Jianbin

    2016-01-01

    High efficient and sustainable utilization of water-based lubricant is essential for saving energy. In this paper, a kind of layered double hydroxide (LDH) nanoplatelets is synthesized and well dispersed in water due to the surface modification with oleylamine. The excellent tribological properties of the oleylamine-modified Ni-Al LDH (NiAl-LDH/OAm) nanoplatelets as water-based lubricant additives are evaluated by the tribological tests in an aqueous environment. The modified LDH nanoplatelets are found to not only reduce the friction but also enhance the wear resistance, compared with the water-based cutting fluid and lubricants containing other particle additives. By adding 0.5 wt% LDH nanoplatelets, under 1.5 GPa initial contact pressure, the friction coefficient, scar diameter, depth and width of the wear track dramatically decrease by 83.1%, 43.2%, 88.5% and 59.5%, respectively. It is considered that the sufficiently small size and the excellent dispersion of NiAl-LDH/OAm nanoplatelets in water are the key factors, so as to make them enter the contact area, form a lubricating film and prevent direct collision of asperity peaks. Our investigations demonstrate that the LDH nanoplatelet as a water-based lubricant additive has a great potential value in industrial application. PMID:26951794

  16. Layered Double Hydroxide Nanoplatelets with Excellent Tribological Properties under High Contact Pressure as Water-Based Lubricant Additives.

    PubMed

    Wang, Hongdong; Liu, Yuhong; Chen, Zhe; Wu, Bibo; Xu, Sailong; Luo, Jianbin

    2016-01-01

    High efficient and sustainable utilization of water-based lubricant is essential for saving energy. In this paper, a kind of layered double hydroxide (LDH) nanoplatelets is synthesized and well dispersed in water due to the surface modification with oleylamine. The excellent tribological properties of the oleylamine-modified Ni-Al LDH (NiAl-LDH/OAm) nanoplatelets as water-based lubricant additives are evaluated by the tribological tests in an aqueous environment. The modified LDH nanoplatelets are found to not only reduce the friction but also enhance the wear resistance, compared with the water-based cutting fluid and lubricants containing other particle additives. By adding 0.5 wt% LDH nanoplatelets, under 1.5 GPa initial contact pressure, the friction coefficient, scar diameter, depth and width of the wear track dramatically decrease by 83.1%, 43.2%, 88.5% and 59.5%, respectively. It is considered that the sufficiently small size and the excellent dispersion of NiAl-LDH/OAm nanoplatelets in water are the key factors, so as to make them enter the contact area, form a lubricating film and prevent direct collision of asperity peaks. Our investigations demonstrate that the LDH nanoplatelet as a water-based lubricant additive has a great potential value in industrial application. PMID:26951794

  17. Layered Double Hydroxide Nanoplatelets with Excellent Tribological Properties under High Contact Pressure as Water-Based Lubricant Additives

    NASA Astrophysics Data System (ADS)

    Wang, Hongdong; Liu, Yuhong; Chen, Zhe; Wu, Bibo; Xu, Sailong; Luo, Jianbin

    2016-03-01

    High efficient and sustainable utilization of water-based lubricant is essential for saving energy. In this paper, a kind of layered double hydroxide (LDH) nanoplatelets is synthesized and well dispersed in water due to the surface modification with oleylamine. The excellent tribological properties of the oleylamine-modified Ni-Al LDH (NiAl-LDH/OAm) nanoplatelets as water-based lubricant additives are evaluated by the tribological tests in an aqueous environment. The modified LDH nanoplatelets are found to not only reduce the friction but also enhance the wear resistance, compared with the water-based cutting fluid and lubricants containing other particle additives. By adding 0.5 wt% LDH nanoplatelets, under 1.5 GPa initial contact pressure, the friction coefficient, scar diameter, depth and width of the wear track dramatically decrease by 83.1%, 43.2%, 88.5% and 59.5%, respectively. It is considered that the sufficiently small size and the excellent dispersion of NiAl-LDH/OAm nanoplatelets in water are the key factors, so as to make them enter the contact area, form a lubricating film and prevent direct collision of asperity peaks. Our investigations demonstrate that the LDH nanoplatelet as a water-based lubricant additive has a great potential value in industrial application.

  18. Embedding Sensors During Additive Manufacturing

    SciTech Connect

    Sbriglia, Lexey Raylene

    2015-08-10

    This PowerPoint presentation had the following headings: Fused deposition modeling (FDM); Open source 3D printing; Objectives; Vibration analysis; Equipment; Design; Material choices; Failure causes, such as tension, bubbling; Potential solutions; Simulations; Embedding the sensors; LabView programming; Alternate data acquisition; Problem and proposed solution; and, Conclusions

  19. Manufacturing Laboratory (Fact Sheet)

    SciTech Connect

    Not Available

    2011-10-01

    This fact sheet describes the purpose, lab specifications, applications scenarios, and information on how to partner with NREL's Manufacturing Laboratory at the Energy Systems Integration Facility. The Manufacturing Laboratory at NREL's Energy Systems Integration Facility (ESIF) focuses on developing methods and technologies that will assist manufacturers of hydrogen and fuel cell technologies, as well as other renewable energy technologies, to scale up their manufacturing capabilities to volumes that meet DOE and industry targets. Specifically, the manufacturing activity is currently focused on developing and validating quality control techniques to assist manufacturers of low temperature and high temperature fuel cells in the transition from low to high volume production methods for cells and stacks. Capabilities include initial proof-of-concept studies through prototype system development and in-line validation. Existing diagnostic capabilities address a wide range of materials, including polymer films, carbon and catalyst coatings, carbon fiber papers and wovens, and multi-layer assemblies of these materials, as well as ceramic-based materials in pre- or post-fired forms. Work leading to the development of non-contact, non-destructive techniques to measure critical dimensional and functional properties of fuel cell and other materials, and validation of those techniques on the continuous processing line. This work will be supported by materials provided by our partners. Looking forward, the equipment in the laboratory is set up to be modified and extended to provide processing capabilities such as coating, casting, and deposition of functional layers, as well as associated processes such as drying or curing. In addition, continuous processes are used for components of organic and thin film photovoltaics (PV) as well as battery technologies, so synergies with these important areas will be explored.

  20. Polymelous layer chick displaying additional malformations of the hind gut: case report and in-depth review of related literature.

    PubMed

    Hirschberg, R M; Saleh, M; Kaiser, S; Lierz, M; Hafez, H M; Bragulla, H H

    2012-08-01

    A case report of a male 6-day-old male layer chick featuring incomplete polymelia of the hind limbs and hindgut malformations is presented. The chick was submitted to computed tomography (CT) examination and subsequent anatomical dissection. Apart from the two supernumerary hind limbs, the anatomical dissection revealed additional hindgut alterations: three uniform-sized caeca flanked the ileum, and the rectum branched into paired cloacae. The supernumerary hind limbs were localized caudal to the normal hind limbs in an inverted position and were attached to pelvic girdle elements and to a curtate pygostyle. They featured a prominent unpaired femur besides paired tibiotarsi, tarsometatarsi and species-specific phalanges of the toes. Additionally, two separate bones attached to the caudoventral aspect of the regular hip bones were developed. The supernumerary limbs were in part mobile and received nerve and vascular supply. Digital 3D-reconstruction based on the CT datasets revealed the osseous components of the malformed body parts. The possible morphogenesis including an in-depth literature review and the clinical implications of the reported malformations are discussed. PMID:22250842

  1. Considerations about the theoretically expected crushing strength of tablets from binary powder mixtures: double layer tablets versus arithmetic additivity rule.

    PubMed

    Belda, Petra M; Mielck, Jobst B

    2006-11-01

    The theoretically expected breaking strength of tablets from powder mixtures is often calculated by the weighted arithmetic mean from the breaking strength of the single components, which corresponds to a linear interpolation. The validity of this additivity of fracture strength shall be evaluated by the underlying model of parallel couplings. It assumes the components linked in parallel with respect to the direction of loading during diametrical strength testing. Parallel couplings were experimentally realised by the preparation of double layer tablets from crystalline and spray-dried lactose on the one hand and from maltitol and metamizol-sodium on the other. Constant total true volumes of the single substances and of layered powders in varying ratios of true volume were compressed on an eccentric tabletting machine to constant geometric mean punch force. Simulated crushing profiles of parallel couplings were derived from force-displacement profiles measured during diametrical compression of the one-component tablets. At given finely graded deformation levels, the forces exerted by the components during loading were added in the proportion of the true volume fractions of the components in the coupling. The results from the experiments and from the simulations are in good accordance. They demonstrate that a linear change of the crushing strength in dependence on the true volume fraction of the components can only be assumed if the single components deform to the same extent up to the point of fracture. This behaviour was approximately found with the parallel lactose system. In all other cases it must be expected that the crushing strength of parallel systems will be lowered beneath the weighted arithmetic mean values or even below the crushing strength of the single components. The latter was observed with the maltitol-metamizol combinations. Thus, if tablets from binary powder mixtures exhibit a crushing strength depression, this is not necessarily an indication

  2. Microstructural architecture developed in the fabrication of solid and open-cellular copper components by additive manufacturing using electron beam melting

    NASA Astrophysics Data System (ADS)

    Ramirez, Diana Alejandra

    The fabrication of Cu components were first built by additive manufacturing using electron beam melting (EBM) from low-purity, atomized Cu powder containing a high density of Cu2O precipitates leading to a novel example of precipitate-dislocation architecture. These microstructures exhibit cell-like arrays (1-3microm) in the horizontal reference plane perpendicular to the build direction with columnar-like arrays extending from ~12 to >60 microm in length and corresponding spatial dimensions of 1-3 microm. These observations were observed by the use of optical metallography, and scanning and transmission electron microscopy. The hardness measurements were taken both on the atomized powder and the Cu components. The hardness for these architectures ranged from ~HV 83 to 88, in contrast to the original Cu powder microindentation hardness of HV 72 and the commercial Cu base plate hardness of HV 57. These observations were utilized for the fabrication of open-cellular copper structures by additive manufacturing using EBM and illustrated the ability to fabricate some form of controlled microstructural architecture by EBM parameter alteration or optimizing. The fabrication of these structures ranged in densities from 0.73g/cm3 to 6.67g/cm3. These structures correspond to four different articulated mesh arrays. While these components contained some porosity as a consequence of some unmelted regions, the Cu2O precipitates also contributed to a reduced density. Using X-ray Diffraction showed the approximate volume fraction estimated to be ~2%. The addition of precipitates created in the EBM melt scan formed microstructural arrays which contributed to hardening contributing to the strength of mesh struts and foam ligaments. The measurements of relative stiffness versus relative density plots for Cu compared very closely with Ti-6Al-4V open cellular structures - both mesh and foams. The Cu reticulated mesh structures exhibit a slope of n = 2 in contrast to a slope of n = 2

  3. New Electrospinning Nozzle to Reduce Jet Instability and Its Application to Manufacture of Multi-layered Nanofibers

    PubMed Central

    Lee, Byoung-Sun; Jeon, Seung-Yeol; Park, Haedong; Lee, Geunsung; Yang, Ho-Sung; Yu, Woong-Ryeol

    2014-01-01

    A new nozzle system for the efficient production of multi-layered nanofibers through electrospinning is reported. Developed a decade ago, the commonly used coaxial nozzle system consisting of two concentric cylindrical needles has remained unchanged, despite recent advances in multi-layered, multi-functional nanofibers. Here, we demonstrate a core-cut nozzle system, in which the exit pipe of the core nozzle is removed such that the core fluid can form an envelope inside the shell solution. This configuration effectively improves the coaxial electrospinning behavior of two fluids and significantly reduces the jet instability, which was proved by finite element simulation. The proposed electrospinning nozzle system was then used to fabricate bi- and tri-layered carbon nanofibers. PMID:25342096

  4. New Electrospinning Nozzle to Reduce Jet Instability and Its Application to Manufacture of Multi-layered Nanofibers

    NASA Astrophysics Data System (ADS)

    Lee, Byoung-Sun; Jeon, Seung-Yeol; Park, Haedong; Lee, Geunsung; Yang, Ho-Sung; Yu, Woong-Ryeol

    2014-10-01

    A new nozzle system for the efficient production of multi-layered nanofibers through electrospinning is reported. Developed a decade ago, the commonly used coaxial nozzle system consisting of two concentric cylindrical needles has remained unchanged, despite recent advances in multi-layered, multi-functional nanofibers. Here, we demonstrate a core-cut nozzle system, in which the exit pipe of the core nozzle is removed such that the core fluid can form an envelope inside the shell solution. This configuration effectively improves the coaxial electrospinning behavior of two fluids and significantly reduces the jet instability, which was proved by finite element simulation. The proposed electrospinning nozzle system was then used to fabricate bi- and tri-layered carbon nanofibers.

  5. Failure mechanism of layered lithium-rich oxide/graphite cell and its solution by using electrolyte additive

    NASA Astrophysics Data System (ADS)

    Zhu, Yunmin; Luo, Xueyi; Xu, Mengqing; Zhang, Liping; Yu, Le; Fan, Weizhen; Li, Weishan

    2016-06-01

    We report a failure mechanism of layered lithium-rich oxide/graphite cell and a solution to this failure. Charge/discharge tests demonstrate that Li1.2Mn0.54Ni0.13Co0.13O2/graphite full cell fails when it is performed with cycling and this issue can be solved effectively by using an electrolyte additive, tris (trimethylsilyl) phosphite (TMSPi). Further cycling tests on Li/Li1.2Mn0.54Ni0.13Co0.13O2 and Li/graphite half-cells and physical characterizations on the cycled cathode indicate that this failure involves the increased HF concentration and the subsequent corrosion for aluminum current collector of cathode due to the electrolyte decomposition during cycling. TMSPi contributes to the formation of a protective interphase on cathode due to its preferential oxidation compared with the base electrolyte, which suppresses the electrolyte decomposition and the HF formation, preventing aluminum current collector from corrosion.

  6. Tribological performance of Mg/Al/Ce layered double hydroxides nanoparticles and intercalated products as lubricant additives

    NASA Astrophysics Data System (ADS)

    Li, Shuo; Qin, Haojing; Zuo, Ranfang; Bai, Zhimin

    2015-10-01

    Mg/Al/Ce ternary layered double hydroxides (LDHs) were synthesized via coprecipitation and intercalated by succinic acid and lauric acid through ion exchange method respectively. The LDHs products were characterized by X-ray diffraction (XRD), scanning electron microscope (SEM) and Fourier transform infrared (FT-IR). Tribological properties of LDHs as lubricant additives were evaluated by four-ball friction and air compressor test. The results indicated that Mg/Al/Ce LDHs were prepared successfully with Ce/Al molar ratio of 0.05 and crystallization temperature of 140 °C. The interlayer spacing of LDHs precursor was expanded by succinic acid and lauric acid to 8.838 and 17.519 Å respectively. All the three LDHs products can reduce friction and wear of engine lubricating oil in the tests. LDHs intercalated with lauric acid showed best tribological performance among them which was attributed to sliding each other between laminates, good dispersibility in oil medium and a protective tribofilm formed on the worn surface.

  7. Selective Laser Melting Additive Manufacturing of TiC/AlSi10Mg Bulk-form Nanocomposites with Tailored Microstructures and Properties

    NASA Astrophysics Data System (ADS)

    Gu, Dongdong; Wang, Hongqiao; Chang, Fei; Dai, Donghua; Yuan, Pengpeng; Hagedorn, Yves-Christian; Meiners, Wilhelm

    The nanoscale TiC particle reinforced AlSi10Mg nanocomposite parts were produced by selective laser melting (SLM) additive manufacturing process. The influence of laser energy density (LED) on densification behavior, microstructural evolution, microhardness and wear properties of SLM-processed TiC/AlSi10Mg nanocomposites was studied. It showed that the near fully dense nanocomposite parts (>98% theoretical density) were achieved with increasing the applied LED. The TiC reinforcement in SLM-processed parts experienced a microstructural change from the standard nanoscale particle morphology (the average size 77-93 nm) to the relatively coarsened submicron structure (the mean particle size 154 nm) as the LED increased.The sufficiently high densification rate combined with the homogeneousdistribution of nanoscale TiC reinforcement throughout the matrix led to a high microhardness of 181.2 HV0.2, a considerably low coefficient of friction (COF) of 0.36, and a reduced wear rate of 2.94×10-5 mm3N-1m-1 for SLM-processed TiC/AlSi10Mg nanocomposite parts.

  8. Validating continuous digital light processing (cDLP) additive manufacturing accuracy and tissue engineering utility of a dye-initiator package.

    PubMed

    Wallace, Jonathan; Wang, Martha O; Thompson, Paul; Busso, Mallory; Belle, Vaijayantee; Mammoser, Nicole; Kim, Kyobum; Fisher, John P; Siblani, Ali; Xu, Yueshuo; Welter, Jean F; Lennon, Donald P; Sun, Jiayang; Caplan, Arnold I; Dean, David

    2014-03-01

    This study tested the accuracy of tissue engineering scaffold rendering via the continuous digital light processing (cDLP) light-based additive manufacturing technology. High accuracy (i.e., <50 µm) allows the designed performance of features relevant to three scale spaces: cell-scaffold, scaffold-tissue, and tissue-organ interactions. The biodegradable polymer poly (propylene fumarate) was used to render highly accurate scaffolds through the use of a dye-initiator package, TiO2 and bis (2,4,6-trimethylbenzoyl)phenylphosphine oxide. This dye-initiator package facilitates high accuracy in the Z dimension. Linear, round, and right-angle features were measured to gauge accuracy. Most features showed accuracies between 5.4-15% of the design. However, one feature, an 800 µm diameter circular pore, exhibited a 35.7% average reduction of patency. Light scattered in the x, y directions by the dye may have reduced this feature's accuracy. Our new fine-grained understanding of accuracy could be used to make further improvements by including corrections in the scaffold design software. Successful cell attachment occurred with both canine and human mesenchymal stem cells (MSCs). Highly accurate cDLP scaffold rendering is critical to the design of scaffolds that both guide bone regeneration and that fully resorb. Scaffold resorption must occur for regenerated bone to be remodeled and, thereby, achieve optimal strength. PMID:24429508

  9. A Closed-Form Solution for the Effect of Free Edges on Melt Pool Geometry and Solidification Microstructure in Additive Manufacturing of Thin-Wall Geometries

    NASA Astrophysics Data System (ADS)

    Gockel, Joy; Klingbeil, Nathan; Bontha, Srikanth

    2016-04-01

    Laser and electron beam-based additive manufacturing of Ti-6Al-4V are under consideration for application to aerospace components. A critical concern for these processes is the ability to obtain a consistent and desirable microstructure and corresponding mechanical properties of the deposit. Based on the Rosenthal solution for a moving point-heat source, recent work has developed simulation-based process maps for the thermal conditions controlling microstructure (grain size and morphology) in beam-based deposition of semi-infinite geometries, where a steady-state melt pool exists away from free edges. In the current study, the Rosenthal solution is modified to include the effects of free edges. This is accomplished by the superposition of two point-heat sources approaching one another, with the line of symmetry representing the free edge. The result is an exact solution for the case of temperature-independent properties. Dimensionless results for melt pool geometry are determined, and plotted as a function of distance from the free edge. Results are plotted on solidification maps to predict trends in microstructure for Ti-6Al-4V. Finite element analysis is used to verify results. Results suggest that melt pool geometry is more sensitive to free edges than solidification microstructure.

  10. Additive Manufacturing of IN100 Superalloy Through Scanning Laser Epitaxy for Turbine Engine Hot-Section Component Repair: Process Development, Modeling, Microstructural Characterization, and Process Control

    NASA Astrophysics Data System (ADS)

    Acharya, Ranadip; Das, Suman

    2015-09-01

    This article describes additive manufacturing (AM) of IN100, a high gamma-prime nickel-based superalloy, through scanning laser epitaxy (SLE), aimed at the creation of thick deposits onto like-chemistry substrates for enabling repair of turbine engine hot-section components. SLE is a metal powder bed-based laser AM technology developed for nickel-base superalloys with equiaxed, directionally solidified, and single-crystal microstructural morphologies. Here, we combine process modeling, statistical design-of-experiments (DoE), and microstructural characterization to demonstrate fully metallurgically bonded, crack-free and dense deposits exceeding 1000 μm of SLE-processed IN100 powder onto IN100 cast substrates produced in a single pass. A combined thermal-fluid flow-solidification model of the SLE process compliments DoE-based process development. A customized quantitative metallography technique analyzes digital cross-sectional micrographs and extracts various microstructural parameters, enabling process model validation and process parameter optimization. Microindentation measurements show an increase in the hardness by 10 pct in the deposit region compared to the cast substrate due to microstructural refinement. The results illustrate one of the very few successes reported for the crack-free deposition of IN100, a notoriously "non-weldable" hot-section alloy, thus establishing the potential of SLE as an AM method suitable for hot-section component repair and for future new-make components in high gamma-prime containing crack-prone nickel-based superalloys.

  11. Study on visible-light-curable polycarprolactone and poly(ethylene glycol) diacrylate for LCD-projected maskless additive manufacturing system

    NASA Astrophysics Data System (ADS)

    Cheng, Yih-Lin; Kao, Hao-Lun

    2015-09-01

    Photopolymers have been applied in many Additive Manufacturing (AM) systems and mostly are cured by UV light. Biodegradable photo-curable polymers are very limited and are not commercially available. DLP-projected maskless AM systems become more and more popular nowadays, but its working area is limited if the part resolution is required. For larger working envelope purpose, liquid crystal display (LCD) panel has great potentials, and LCD's resolution has been improved significantly in the past few years due to the smart phone application. Therefore, in this research, LCD panel is used to replace DLP for a maskless AM system to cure biodegradable materials, Polycarprolactone (PCL) and Poly(ethylene glycol) diacrylate (PEG-DA). Due to the characteristics of LCD panel, the material systems should be sensitive and photo-polymerized in visible-light range, particularly in RGB. In this study, various percentages of visiblelight photoinitiator, Irgacure 784, in the material systems were investigated. Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) were utilized to characterize cured biomaterials. Because of the use of photoinitiator, the biocompatibility of the cured materials was also concerned, and hence, MTT assay tests were performed. The preliminary tests of fabrication, using the LCD-projected maskless AM system, cured grid patterns to illustrate the feasibility. The visible-light-curable PCL and PEG-DA will be able to be adopted in tissue engineering scaffold applications in the future.

  12. Thermal evolution behavior and fluid dynamics during laser additive manufacturing of Al-based nanocomposites: Underlying role of reinforcement weight fraction

    NASA Astrophysics Data System (ADS)

    Gu, Dongdong; Yuan, Pengpeng

    2015-12-01

    In this study, a three-dimensional transient computational fluid dynamics model was established to investigate the influence of reinforcement weight fraction on thermal evolution behavior and fluid dynamics during selective laser melting (SLM) additive manufacturing of TiC/AlSi10Mg nanocomposites. The powder-to-solid transition and nonlinear variation of thermal physical properties of as-used materials were considered in the numerical model, using the Gaussian distributed volumetric heat source. The simulation results showed that the increase of operating temperature and the resultant formation of larger melt pool were caused by the increase of weight fraction of reinforcement. The Marangoni convection was intensified using a larger reinforcement content, accelerating the coupled motion of fluid and solid particles. The circular flows appeared when the TiC content reached 5.0 wt. % and the larger-sized circular flows were present as the reinforcement content increased to 7.5 wt. %. The experimental study on surface morphologies and microstructures on the polished sections of SLM-processed TiC/AlSi10Mg nanocomposite parts was performed. A considerably dense and smooth surface free of any balling effect and pore formation was obtained when the reinforcement content was optimized at 5.0 wt. %, due to the sufficient liquid formation and moderate Marangoni flow. Novel ring-structured reinforcing particulates were tailored because of the combined action of the attractive effect of centripetal force and repulsive force, which was consistent with the simulation results.

  13. A Honeycomb-Structured Ti-6Al-4V Oil-Gas Separation Rotor Additively Manufactured by Selective Electron Beam Melting for Aero-engine Applications

    NASA Astrophysics Data System (ADS)

    Tang, H. P.; Wang, Q. B.; Yang, G. Y.; Gu, J.; Liu, N.; Jia, L.; Qian, M.

    2016-03-01

    Oil -gas separation is a key process in an aero-engine lubrication system. This study reports an innovative development in oil -gas separation. A honeycomb-structured rotor with hexagonal cone-shaped pore channels has been designed, additively manufactured from Ti-6Al-4V using selective electron beam melting (SEBM) and assessed for oil -gas separation for aero-engine application. The Ti-6Al-4V honeycomb structure showed a high compressive strength of 110 MPa compared to less than 20 MPa for metal foam structures. The oil -gas separation efficiency of the honeycomb-structured separation rotor achieved 99.8% at the rotation speed of 6000 rpm with much lower ventilation resistance (17.3 kPa) than that of the separator rotor constructed using a Ni-Cr alloy foam structure (23.5 kPa). The honeycomb-structured Ti-6Al-4V separator rotor produced by SEBM provides a promising solution to more efficient oil -gas separation in the aero-engine lubrication system.

  14. Effect of additional elements on compositional modulated atomic layered structure of hexagonal Co80Pt20 alloy films with superlattice diffraction

    NASA Astrophysics Data System (ADS)

    Hinata, Shintaro; Yamane, Akira; Saito, Shin

    2016-05-01

    The effect of additional element on compositionally modulated atomic layered structure of hexagonal Co80Pt20 alloy films with superlattice diffraction was investigated. In this study it is found that the addition of Cr or W element to Co80Pt20 alloy film shows less deterioration of hcp stacking structure and compositionally modulated atomic layer stacking structure as compared to Si or Zr or Ti with Ku of around 1.4 or 1.0 × 107 erg/cm3 at 5 at.% addition. Furthermore, for O2 addition of O2 ≥ 5.0 × 10-3 Pa to CoPt alloy, compositionally modulated atomic layer stacking structure will be deteriorated with enhancement of formation of hcp stacking structure which leads higher Ku of 1.0 × 107 erg/cm3.

  15. Insight into self-discharge of layered lithium-rich oxide cathode in carbonate-based electrolytes with and without additive

    NASA Astrophysics Data System (ADS)

    Li, Jianhui; Xing, Lidan; Zhang, Liping; Yu, Le; Fan, Weizhen; Xu, Mengqing; Li, Weishan

    2016-08-01

    Self-discharge behavior of layered lithium-rich oxide as cathode of lithium ion battery in a carbonated-based electrolyte is understood, and a simple boron-containing compound, trimethyl borate (TMB), is used as an electrolyte additive to suppress this self-discharge. It is found that layered lithium-rich oxide charged under 4.8 V in additive-free electrolyte suffers severe self-discharge and TMB is an effective electrolyte additive for self-discharge suppression. Physical characterizations from XRD, SEM, TEM, XPS and ICP-MS demonstrate that the crystal structure of the layered lithium-rich oxide collapses due to the chemical interaction between the charged oxide and electrolyte. When TMB is applied, the structural integrity of the oxide is maintained due to the protective cathode film generated from the preferential oxidation of TMB.

  16. Microgravity Manufacturing

    NASA Technical Reports Server (NTRS)

    Cooper, Ken; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    Manufacturing capability in outer space remains one of the critical milestones to surpass to allow humans to conduct long-duration manned space exploration. The high cost-to-orbit for leaving the Earth's gravitational field continues to be the limiting factor in carrying sufficient hardware to maintain extended life support in microgravity or on other planets. Additive manufacturing techniques, or 'chipless' fabrication, like RP are being considered as the most promising technologies for achieving in situ or remote processing of hardware components, as well as for the repair of existing hardware. At least three RP technologies are currently being explored for use in microgravity and extraterrestrial fabrication.

  17. Integrated Processing: Quality Assurance Procedure of the Surface Layer of Machine Parts during the Manufacturing Step "Diamond Smoothing"

    NASA Astrophysics Data System (ADS)

    Skeeba, V. Yu; Ivancivsky, V. V.; Lobanov, D. V.; Zhigulev, A. K.; Skeeba, P. Yu

    2016-04-01

    The present study has found that during the integrated processing after the diamond smoothing, in the surface-hardened sample a cold-worked layer 0.01 ... 0.02 mm in thickness, the microhardness value of which reaches 868 HV, is formed. The intensity of compressive stresses on the part surface increases to στ = -678 MPa. The analysis of the experimental data has shown the relationship between the parameter Ra and the processing modes that can be used during diamond smoothing, based on the high performance and the desired surface roughness. It has been found that the minimum value of roughness Ra = 0.18±0.08 μm is reliably achieved by smoothing processing when the smoothing force Py ranges from 100 N to 150 N.

  18. Energy Use in Manufacturing

    EIA Publications

    2006-01-01

    This report addresses both manufacturing energy consumption and characteristics of the manufacturing economy related to energy consumption. In addition, special sections on fuel switching capacity and energy-management activities between 1998 and 2002 are also featured in this report.

  19. Interface-engineering additives of poly(oxyethylene tridecyl ether) for low-band gap polymer solar cells consisting of PCDTBT:PCBM₇₀ bulk-heterojunction layers.

    PubMed

    Huh, Yoon Ho; Park, Byoungchoo

    2013-01-14

    We herein report on the improved photovoltaic (PV) effects of using a polymer bulk-heterojunction (BHJ) layer that consists of a low-band gap electron donor polymer of poly(N-9'-heptadecanyl-2,7-carbazole-alt-5,5-(4',7'-di-2-thienyl-2',1',3'-benzothiadiazole)) (PCDTBT) and an acceptor of [6,6]-phenyl C₇₁ butyric acid methyl ester (PCBM₇₀), doped with an interface-engineering surfactant additive of poly(oxyethylene tridecyl ether) (PTE). The presence of an interface-engineering additive in the PV layer results in excellent performance; the addition of PTE to a PCDTBT:PCBM₇₀ system produces a power conversion efficiency (PCE) of 6.0%, which is much higher than that of a reference device without the additive (4.9%). We attribute this improvement to an increased charge carrier lifetime, which is likely to be the result of the presence of PTE molecules oriented at the interfaces between the BHJ PV layer and the anode and cathode, as well as at the interfaces between the phase-separated BHJ domains. Our results suggest that the incorporation of the PTE interface-engineering additive in the PCDTBT:PCBM₇₀ PV layer results in a functional composite system that shows considerable promise for use in efficient polymer BHJ PV cells. PMID:23389265

  20. Manufacturing of GLARE Parts and Structures

    NASA Astrophysics Data System (ADS)

    Sinke, J.

    2003-07-01

    GLARE is a hybrid material consisting of alternating layers of metal sheets and composite layers, requiring special attention when manufacturing of parts and structures is concerned. On one hand the applicable manufacturing processes for GLARE are limited, on the other hand, due to the constituents and composition of the laminate, it offers new opportunities for production. One of the opportunities is the manufacture of very large skin panels by lay-up techniques. Lay-up techniques are common for full composites, but uncommon for metallic structures. Nevertheless, large GLARE skin panels are made by lay-up processes. In addition, the sequences of forming and laminating processes, that can be selected, offer manufacturing options that are not applicable to metals or full composites. With respect to conventional manufacturing processes, the possibilities for Fibre Metal Laminates in general, are limited. The limits are partly due to the different failure modes, partly due to the properties of the constituents in the laminate. For machining processes: the wear of the cutting tools during machining operations of GLARE stems from the abrasive nature of the glass fibres. For the forming processes: the limited formability, expressed by a small failure strain, is related to the glass fibres. However, although these manufacturing issues may restrict the use of manufacturing processes for FMLs, application of these laminates in aircraft is not hindered.