Science.gov

Sample records for additive manufacturing process

  1. Energetic additive manufacturing process with feed wire

    DOEpatents

    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.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. The metallurgy and processing science of metal additive manufacturing

    DOE PAGES

    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

  8. 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.

  9. 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.

  10. Electroacoustics modeling of piezoelectric welders for ultrasonic additive manufacturing processes

    NASA Astrophysics Data System (ADS)

    Hehr, Adam; Dapino, Marcelo J.

    2016-04-01

    Ultrasonic additive manufacturing (UAM) is a recent 3D metal printing technology which utilizes ultrasonic vibrations from high power piezoelectric transducers to additively weld similar and dissimilar metal foils. CNC machining is used intermittent of welding to create internal channels, embed temperature sensitive components, sensors, and materials, and for net shaping parts. Structural dynamics of the welder and work piece influence the performance of the welder and part quality. To understand the impact of structural dynamics on UAM, a linear time-invariant model is used to relate system shear force and electric current inputs to the system outputs of welder velocity and voltage. Frequency response measurements are combined with in-situ operating measurements of the welder to identify model parameters and to verify model assumptions. The proposed LTI model can enhance process consistency, performance, and guide the development of improved quality monitoring and control strategies.

  11. 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.

  12. 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

  13. 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

  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. 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

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

    NASA Astrophysics Data System (ADS)

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

    2016-08-01

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

  17. 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.

  18. 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.

  19. 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

  20. 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

  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.

    2016-07-01

    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.

  2. 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.

  3. 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.

  4. 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.

  5. A Novel Processing Approach for Additive Manufacturing of Commercial Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Roberts, Christopher E.; Bourell, David; Watt, Trevor; Cohen, Julien

    Aluminum 6061 is of great commercial interest due to its ubiquitous use in manufacturing, advantageous mechanical properties, and its successful certification in aerospace applications. However, as an off-eutectic with accompanying large freezing range, attempts to process the material by additive manufacturing have resulted in part cracking and diminished mechanical properties. A unique approach using mixed powders is presented to process this historically difficult-to-process material. Expansion of this combined-powder approach to other materials systems not typically compatible with additive manufacturing is possible. Dense parts without solidification cracking have been produced by the SLM process, as verified using SEM and EDS. An overview of this approach is presented along with test results using an Al-Si mixture.

  6. Biocompatibility of hydroxyapatite scaffolds processed by lithography-based additive manufacturing.

    PubMed

    Tesavibul, Passakorn; Chantaweroad, Surapol; Laohaprapanon, Apinya; Channasanon, Somruethai; Uppanan, Paweena; Tanodekaew, Siriporn; Chalermkarnnon, Prasert; Sitthiseripratip, Kriskrai

    2015-01-01

    The fabrication of hydroxyapatite scaffolds for bone tissue engineering applications by using lithography-based additive manufacturing techniques has been introduced due to the abilities to control porous structures with suitable resolutions. In this research, the use of hydroxyapatite cellular structures, which are processed by lithography-based additive manufacturing machine, as a bone tissue engineering scaffold was investigated. The utilization of digital light processing system for additive manufacturing machine in laboratory scale was performed in order to fabricate the hydroxyapatite scaffold, of which biocompatibilities were eventually evaluated by direct contact and cell-culturing tests. In addition, the density and compressive strength of the scaffolds were also characterized. The results show that the hydroxyapatite scaffold at 77% of porosity with 91% of theoretical density and 0.36 MPa of the compressive strength are able to be processed. In comparison with a conventionally sintered hydroxyapatite, the scaffold did not present any cytotoxic signs while the viability of cells at 95.1% was reported. After 14 days of cell-culturing tests, the scaffold was able to be attached by pre-osteoblasts (MC3T3-E1) leading to cell proliferation and differentiation. The hydroxyapatite scaffold for bone tissue engineering was able to be processed by the lithography-based additive manufacturing machine while the biocompatibilities were also confirmed. PMID:26484553

  7. Biocompatibility of hydroxyapatite scaffolds processed by lithography-based additive manufacturing.

    PubMed

    Tesavibul, Passakorn; Chantaweroad, Surapol; Laohaprapanon, Apinya; Channasanon, Somruethai; Uppanan, Paweena; Tanodekaew, Siriporn; Chalermkarnnon, Prasert; Sitthiseripratip, Kriskrai

    2015-01-01

    The fabrication of hydroxyapatite scaffolds for bone tissue engineering applications by using lithography-based additive manufacturing techniques has been introduced due to the abilities to control porous structures with suitable resolutions. In this research, the use of hydroxyapatite cellular structures, which are processed by lithography-based additive manufacturing machine, as a bone tissue engineering scaffold was investigated. The utilization of digital light processing system for additive manufacturing machine in laboratory scale was performed in order to fabricate the hydroxyapatite scaffold, of which biocompatibilities were eventually evaluated by direct contact and cell-culturing tests. In addition, the density and compressive strength of the scaffolds were also characterized. The results show that the hydroxyapatite scaffold at 77% of porosity with 91% of theoretical density and 0.36 MPa of the compressive strength are able to be processed. In comparison with a conventionally sintered hydroxyapatite, the scaffold did not present any cytotoxic signs while the viability of cells at 95.1% was reported. After 14 days of cell-culturing tests, the scaffold was able to be attached by pre-osteoblasts (MC3T3-E1) leading to cell proliferation and differentiation. The hydroxyapatite scaffold for bone tissue engineering was able to be processed by the lithography-based additive manufacturing machine while the biocompatibilities were also confirmed.

  8. Additive manufacturing of optical components

    NASA Astrophysics Data System (ADS)

    Heinrich, Andreas; Rank, Manuel; Maillard, Philippe; Suckow, Anne; Bauckhage, Yannick; Rößler, Patrick; Lang, Johannes; Shariff, Fatin; Pekrul, Sven

    2016-08-01

    The development of additive manufacturing methods has enlarged rapidly in recent years. Thereby, the work mainly focuses on the realization of mechanical components, but the additive manufacturing technology offers a high potential in the field of optics as well. Owing to new design possibilities, completely new solutions are possible. This article briefly reviews and compares the most important additive manufacturing methods for polymer optics. Additionally, it points out the characteristics of additive manufactured polymer optics. Thereby, surface quality is of crucial importance. In order to improve it, appropriate post-processing steps are necessary (e.g. robot polishing or coating), which will be discussed. An essential part of this paper deals with various additive manufactured optical components and their use, especially in optical systems for shape metrology (e.g. borehole sensor, tilt sensor, freeform surface sensor, fisheye lens). The examples should demonstrate the potentials and limitations of optical components produced by additive manufacturing.

  9. 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.

  10. 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.

  11. 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

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

    DOE PAGES

    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

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. Measurement of powder bed density in powder bed fusion additive manufacturing processes

    NASA Astrophysics Data System (ADS)

    Jacob, G.; Donmez, A.; Slotwinski, J.; Moylan, S.

    2016-11-01

    Many factors influence the performance of additive manufacturing (AM) processes, resulting in a high degree of variation in process outcomes. Therefore, quantifying these factors and their correlations to process outcomes are important challenges to overcome to enable widespread adoption of emerging AM technologies. In the powder bed fusion AM process, the density of the powder layers in the powder bed is a key influencing factor. This paper introduces a method to determine the powder bed density (PBD) during the powder bed fusion (PBF) process. A complete uncertainty analysis associated with the measurement method was also described. The resulting expanded measurement uncertainty, U PBD (k  =  2), was determined as 0.004 g · cm‑3. It was shown that this expanded measurement uncertainty is about three orders of magnitude smaller than the typical powder bed density. This method enables establishing correlations between the changes in PBD and the direction of motion of the powder recoating arm.

  19. 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.

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

    NASA Astrophysics Data System (ADS)

    Sahasrabudhe, Himanshu

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

  1. 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.

  2. 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.

  3. 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

  4. 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.

  5. 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

  6. 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.

  7. 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

  8. Development of magnetodielectric materials to be used in additive manufacturing processes for high-frequency applications

    NASA Astrophysics Data System (ADS)

    Parsons, Paul Emerson, II

    Electrical devices for very-high frequency (VHF, 0.03 -- 0.3 GHz) and ultra-high frequency (UHF, 0.3 -- 3.0 GHz) are commonly used for communications. However, the wavelengths, lambda, of these frequency bands correspond to lengths between 10 and 0.1 m, resulting in prohibitively large devices. Materials with an index of refraction, n, greater than 1 can be used to effectively shrink these devices by a factor of 1/ n. In this thesis, magnetodielectric materials (MDM), where n ≥1, have been made to be used in additive manufacturing processes with strict particle size requirements and were developed using various methods, such as polyol reduction and conventional ceramic solid state processing. These materials were characterized using x-ray diffraction (XRD), scanning and transmission electron microscopy (SEM and TEM), vibrating sample magnetometry (VSM), to determine their crystalline, physical, and direct current (DC) magnetization properties. The techniques used to synthesize the MDM yielded particles that were chemically similar, but had drastically different physical properties which heavily influences their high-frequency electromagnetic properties. These materials were then uniformly dispersed into a non-conducting medium, such as a low-electrical loss polymer or resin, and formed into composite samples with variable volumetric loading. These composite samples were measured using several techniques to characterize the frequency-dependent electromagnetic (EM) properties, such as relative permeability, relative permittivity, and their respective losses. Finite element method (FEM) simulations were performed using these MDM-composites to design a spiral antenna to be used at approximately 585 MHz.

  9. 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.

  10. Out of bounds additive manufacturing

    DOE PAGES

    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.; et al

    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.

  11. 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

  12. 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

    Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

  13. Additive manufacturing of hybrid circuits

    DOE PAGES

    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

  14. 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

  15. 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.

  16. 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.

  17. 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).

  18. 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

  19. [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.

  20. 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.

  1. 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.

  2. 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

  3. 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.

  4. [Additive Manufacturing and Its Medical Applications].

    PubMed

    Song, Zewen; Wang, Guohui; Gao, Qin; Zhu, Shaihong

    2015-04-01

    Additive manufacturing (AM) is a collection of technologies based on the layer-by-layer manufacturing. Characterized by its direct manufacturing and rapidity, it has been regarded by the Economist Journal as one of the key techniques which will trigger the third industry reformation. The present article, beginning with a brief introduction of the history of AM and the process of its major technologies, focuses on the advantages and disadvantages and medical applications of the technique.

  5. 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.

  6. 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.

  7. 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.

  8. 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

  9. 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.

  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. 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

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. Analysis of the laser powder bed fusion additive manufacturing process through experimental measurement and finite element modeling

    NASA Astrophysics Data System (ADS)

    Dunbar, Alexander Jay

    The objective in this work is to provide rigourous experimental measurements to aid in the development of laser powder bed fusion (LPBF) additive manufacturing (AM). A specialized enclosed instrumented measurement system is designed to provide in situ experimental measurements of temperature and distortion. Experiments include comparisons of process parameters, materials and LPBF machines. In situ measurements of distortion and temperature made throughout the build process highlight inter-layer distortion effects previously undocumented for laser powder bed fusion. Results from these experiments are also be implemented in the development and validation of finite element models of the powder bed build process. Experimental analysis is extended from small-scale to larger part-scale builds where experimental post-build measurements are used in analysis of distortion profiles. Experimental results provided from this study are utilized in the validation of a finite element model capable of simulating production scale parts. The validated finite element model is then implemented in the analysis of the part to provide information regarding the distortion evolution process. A combination of experimental measurements and simulation results are used to identify the mechanism that results in the measured distortion profile for this geometry. Optimization of support structure primarily focuses on the minimization of material use and scan time, but no information regarding failure criteria for support structure is available. Tensile test samples of LPBF built support structure are designed, built, and tested to provide measurements of mechanical properties of the support structure. Experimental tests show that LPBF built support structure has only 30-40% of the ultimate tensile strength of solid material built in the same machine. Experimental measurement of LPBF built support structure provides clear failure criteria to be utilized in the future design and implementation of

  18. Porous calcium polyphosphate bone substitutes: additive manufacturing versus conventional gravity sinter processing-effect on structure and mechanical properties.

    PubMed

    Hu, Youxin; Shanjani, Yaser; Toyserkani, Ehsan; Grynpas, Marc; Wang, Rizhi; Pilliar, Robert

    2014-02-01

    Porous calcium polyphosphate (CPP) structures proposed as bone-substitute implants and made by sintering CPP powders to form bending test samples of approximately 35 vol % porosity were machined from preformed blocks made either by additive manufacturing (AM) or conventional gravity sintering (CS) methods and the structure and mechanical characteristics of samples so made were compared. AM-made samples displayed higher bending strengths (≈1.2-1.4 times greater than CS-made samples), whereas elastic constant (i.e., effective elastic modulus of the porous structures) that is determined by material elastic modulus and structural geometry of the samples was ≈1.9-2.3 times greater for AM-made samples. X-ray diffraction analysis showed that samples made by either method displayed the same crystal structure forming β-CPP after sinter annealing. The material elastic modulus, E, determined using nanoindentation tests also showed the same value for both sample types (i.e., E ≈ 64 GPa). Examination of the porous structures indicated that significantly larger sinter necks resulted in the AM-made samples which presumably resulted in the higher mechanical properties. The development of mechanical properties was attributed to the different sinter anneal procedures required to make 35 vol % porous samples by the two methods. A primary objective of the present study, in addition to reporting on bending strength and sample stiffness (elastic constant) characteristics, was to determine why the two processes resulted in the observed mechanical property differences for samples of equivalent volume percentage of porosity. An understanding of the fundamental reason(s) for the observed effect is considered important for developing improved processes for preparation of porous CPP implants as bone substitutes for use in high load-bearing skeletal sites.

  19. 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.

  20. Additive manufacturing of materials: Opportunities and challenges

    DOE PAGES

    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

  1. MEGARA optical manufacturing process

    NASA Astrophysics Data System (ADS)

    Carrasco, E.; Páez, G.; Granados, F.; Percino, E.; Castillo-Domínguez, E.; Avilés, J. L.; García-Vargas, M. L.; Gil de Paz, A.; Gallego, J.; Iglesias-Páramo, J.; Cedazo, R.

    2014-07-01

    MEGARA is the future visible integral-field and multi-object spectrograph for the GTC 10.4-m telescope located in La Palma. INAOE is a member of the MEGARA Consortium and it is in charge of the Optics Manufacturing work package. MEGARA passed the Optics Detailed Design Review in May 2013, and the blanks of the main optics have been already ordered and their manufacturing is in progress. Except for the optical fibers and microlenses, the complete MEGARA optical system will be manufactured in Mexico, shared between the workshops of INAOE and CIO. This includes a field lens, a 5-lenses collimator, a 7-lenses camera and a complete set of volume phase holographic gratings with 36 flat windows and 24 prisms, being all these elements very large and complex. Additionally, the optical tests and the complete assembly of the camera and collimator subsystems will be carried out in Mexico. Here we describe the current status of the optics manufacturing process.

  2. 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.

  3. Additive Manufacturing for Affordable Rocket Engines

    NASA Technical Reports Server (NTRS)

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

    2016-01-01

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

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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

  9. 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.

  10. 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.

  11. Weldability of Additive Manufactured Stainless Steel

    NASA Astrophysics Data System (ADS)

    Matilainen, Ville-Pekka; Pekkarinen, Joonas; Salminen, Antti

    Part size in additive manufacturing is limited by the size of building area of AM equipment. Occasionally, larger constructions that AM machines are able to produce, are needed, and this creates demand for welding AM parts together. However there is very little information on welding of additive manufactured stainless steels. The aim of this study was to investigate the weldability aspects of AM material. In this study, comparison of the bead on plate welds between AM parts and sheet metal parts is done. Used material was 316L stainless steel, AM and sheet metal, and parts were welded with laser welding. Weld quality was evaluated visually from macroscopic images. Results show that there are certain differences in the welds in AM parts compared to the welds in sheet metal parts. Differences were found in penetration depths and in type of welding defects. Nevertheless, this study presents that laser welding is suitable process for welding AM parts.

  12. 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.

  13. 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.

  14. 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

  15. Computed tomography characterisation of additive manufacturing materials.

    PubMed

    Bibb, Richard; Thompson, Darren; Winder, John

    2011-06-01

    Additive manufacturing, covering processes frequently referred to as rapid prototyping and rapid manufacturing, provides new opportunities in the manufacture of highly complex and custom-fitting medical devices and products. Whilst many medical applications of AM have been explored and physical properties of the resulting parts have been studied, the characterisation of AM materials in computed tomography has not been explored. The aim of this study was to determine the CT number of commonly used AM materials. There are many potential applications of the information resulting from this study in the design and manufacture of wearable medical devices, implants, prostheses and medical imaging test phantoms. A selection of 19 AM material samples were CT scanned and the resultant images analysed to ascertain the materials' CT number and appearance in the images. It was found that some AM materials have CT numbers very similar to human tissues, FDM, SLA and SLS produce samples that appear uniform on CT images and that 3D printed materials show a variation in internal structure.

  16. 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.

  17. 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.

  18. Numerical modeling of heat-transfer and the influence of process parameters on tailoring the grain morphology of IN718 in electron beam additive manufacturing

    DOE PAGES

    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

  19. Inspection of additive-manufactured layered components.

    PubMed

    Cerniglia, D; Scafidi, M; Pantano, A; Rudlin, J

    2015-09-01

    Laser powder deposition (LPD) is a rapid additive manufacturing process to produce, layer upon layer, 3D geometries or to repair high-value components. Currently there is no nondestructive technique that can guarantee absence of flaws in LPD products during manufacturing. In this paper a laser ultrasonic technique for in-line inspection of LPD components is proposed. Reference samples were manufactured from Inconel and machined flaws were created to establish the sensitivity of the technique. Numerical models of laser-generated ultrasonic waves have been created to gain a deeper understanding of physics, to optimize the set-up and to verify the experimental measurements. Results obtained on two sets of reference samples are shown. A proof-of-concept prototype has been demonstrated on some specific deposition samples with induced flaws, that were confirmed by an ultra-high sensitivity X-ray technique. Experimental outcomes prove that typical micro-defects due to the layer-by-layer deposition process, such as near-surface and surface flaws in a single layer deposit, can be detected.

  20. 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.

  1. Hybrid Additive Manufacturing Technologies - An Analysis Regarding Potentials and Applications

    NASA Astrophysics Data System (ADS)

    Merklein, Marion; Junker, Daniel; Schaub, Adam; Neubauer, Franziska

    Imposing the trend of mass customization of lightweight construction in industry, conventional manufacturing processes like forming technology and chipping production are pushed to their limits for economical manufacturing. More flexible processes are needed which were developed by the additive manufacturing technology. This toolless production principle offers a high geometrical freedom and an optimized utilization of the used material. Thus load adjusted lightweight components can be produced in small lot sizes in an economical way. To compensate disadvantages like inadequate accuracy and surface roughness hybrid machines combining additive and subtractive manufacturing are developed. Within this paper the principles of mainly used additive manufacturing processes of metals and their possibility to be integrated into a hybrid production machine are summarized. It is pointed out that in particular the integration of deposition processes into a CNC milling center supposes high potential for manufacturing larger parts with high accuracy. Furthermore the combination of additive and subtractive manufacturing allows the production of ready to use products within one single machine. Additionally actual research for the integration of additive manufacturing processes into the production chain will be analyzed. For the long manufacturing time of additive production processes the combination with conventional manufacturing processes like sheet or bulk metal forming seems an effective solution. Especially large volumes can be produced by conventional processes. In an additional production step active elements can be applied by additive manufacturing. This principle is also investigated for tool production to reduce chipping of the high strength material used for forming tools. The aim is the addition of active elements onto a geometrical simple basis by using Laser Metal Deposition. That process allows the utilization of several powder materials during one process what

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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.

  9. Beryllium Manufacturing Processes

    SciTech Connect

    Goldberg, A

    2006-06-30

    This report is one of a number of reports that will be combined into a handbook on beryllium. Each report covers a specific topic. To-date, the following reports have been published: (1) Consolidation and Grades of Beryllium; (2) Mechanical Properties of Beryllium and the Factors Affecting these Properties; (3) Corrosion and Corrosion Protection of Beryllium; (4) Joining of Beryllium; (5) Atomic, Crystal, Elastic, Thermal, Nuclear, and other Properties of Beryllium; and (6) Beryllium Coating (Deposition) Processes and the Influence of Processing Parameters on Properties and Microstructure. The conventional method of using ingot-cast material is unsuitable for manufacturing a beryllium product. Beryllium is a highly reactive metal with a high melting point, making it susceptible to react with mold-wall materials forming beryllium compounds (BeO, etc.) that become entrapped in the solidified metal. In addition, the grain size is excessively large, being 50 to 100 {micro}m in diameter, while grain sizes of 15 {micro}m or less are required to meet acceptable strength and ductility requirements. Attempts at refining the as-cast-grain size have been unsuccessful. Because of the large grain size and limited slip systems, the casting will invariably crack during a hot-working step, which is an important step in the microstructural-refining process. The high reactivity of beryllium together with its high viscosity (even with substantial superheat) also makes it an unsuitable candidate for precision casting. In order to overcome these problems, alternative methods have been developed for the manufacturing of beryllium. The vast majority of these methods involve the use of beryllium powders. The powders are consolidated under pressure in vacuum at an elevated temperature to produce vacuum hot-pressed (VHP) blocks and vacuum hot-isostatic-pressed (HIP) forms and billets. The blocks (typically cylindrical), which are produced over a wide range of sizes (up to 183 cm dia. by 61

  10. 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.

  11. 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.

  12. 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

  13. 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.

  14. 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.

  15. Collaborative Technology Assessments Of Transient Field Processing And Additive Manufacturing Technologies As Applied To Gas Turbine Components

    SciTech Connect

    Ludtka, Gerard Michael; Dehoff, Ryan R.; Szabo, Attila; Ucok, Ibrahim

    2016-01-01

    ORNL partnered with GE Power & Water to investigate the effect of thermomagnetic processing on the microstructure and mechanical properties of GE Power & Water newly developed wrought Ni-Fe-Cr alloys. Exploration of the effects of high magnetic field process during heat treatment of the alloys indicated conditions where applications of magnetic fields yields significant property improvements. The alloy aged using high magnetic field processing exhibited 3 HRC higher hardness compared to the conventionally-aged alloy. The alloy annealed at 1785 F using high magnetic field processing demonstrated an average creep life 2.5 times longer than that of the conventionally heat-treated alloy. Preliminary results show that high magnetic field processing can improve the mechanical properties of Ni-Fe-Cr alloys and potentially extend the life cycle of the gas turbine components such as nozzles leading to significant energy savings.

  16. Evolution of solidification texture during additive manufacturing.

    PubMed

    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.

  17. 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.

  18. Evolution of solidification texture during additive manufacturing

    DOE PAGES

    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

  19. 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

  20. 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.

  1. 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

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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

  9. 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.

  10. 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

  11. Printability of alloys for additive manufacturing

    DOE PAGES

    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

  12. Dielectric breakdown of additively manufactured polymeric materials

    DOE PAGES

    Monzel, W. Jacob; Hoff, Brad W.; Maestas, Sabrina S.; French, David M.; Hayden, Steven C.

    2016-01-11

    Dielectric strength testing of selected Polyjet-printed polymer plastics was performed in accordance with ASTM D149. This dielectric strength data is compared to manufacturer-provided dielectric strength data for selected plastics printed using the stereolithography (SLA), fused deposition modeling (FDM), and selective laser sintering (SLS) methods. Tested Polyjet samples demonstrated dielectric strengths as high as 47.5 kV/mm for a 0.5 mm thick sample and 32.1 kV/mm for a 1.0 mm sample. As a result, the dielectric strength of the additively manufactured plastics evaluated as part of this study was lower than the majority of non-printed plastics by at least 15% (with themore » exception of polycarbonate).« less

  13. 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.

  14. 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

  15. 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.

  16. 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

  17. Additive manufacturing: From implants to organs.

    PubMed

    Douglas, Tania S

    2014-05-12

    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. 

  18. 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.

  19. 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.

  20. Polyimide processing additives

    NASA Technical Reports Server (NTRS)

    Fletcher, James C. (Inventor); Pratt, J. Richard (Inventor); St.clair, Terry L. (Inventor); Stoakley, Diane M. (Inventor); Burks, Harold D. (Inventor)

    1992-01-01

    A process for preparing polyimides having enhanced melt flow properties is described. The process consists of heating a mixture of a high molecular weight poly-(amic acid) or polyimide with a low molecular weight amic acid or imide additive in the range of 0.05 to 15 percent by weight of additive. The polyimide powders so obtained show improved processability, as evidenced by lower melt viscosity by capillary rheometry. Likewise, films prepared from mixtures of polymers with additives show improved processability with earlier onset of stretching by TMA.

  1. Polyimide processing additives

    NASA Technical Reports Server (NTRS)

    Pratt, J. Richard (Inventor); St.clair, Terry L. (Inventor); Stoakley, Diane M. (Inventor); Burks, Harold D. (Inventor)

    1993-01-01

    A process for preparing polyimides having enhanced melt flow properties is described. The process consists of heating a mixture of a high molecular weight poly-(amic acid) or polyimide with a low molecular weight amic acid or imide additive in the range of 0.05 to 15 percent by weight of the additive. The polyimide powders so obtained show improved processability, as evidenced by lower melt viscosity by capillary rheometry. Likewise, films prepared from mixtures of polymers with additives show improved processability with earlier onset of stretching by TMA.

  2. 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.

  3. 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.

  4. Combined additive manufacturing approaches in tissue engineering.

    PubMed

    Giannitelli, S M; Mozetic, P; Trombetta, M; Rainer, A

    2015-09-01

    Advances introduced by additive manufacturing (AM) have significantly improved the control over the microarchitecture of scaffolds for tissue engineering. This has led to the flourishing of research works addressing the optimization of AM scaffolds microarchitecture to optimally trade-off between conflicting requirements (e.g. mechanical stiffness and porosity level). A fascinating trend concerns the integration of AM with other scaffold fabrication methods (i.e. "combined" AM), leading to hybrid architectures with complementary structural features. Although this innovative approach is still at its beginning, significant results have been achieved in terms of improved biological response to the scaffold, especially targeting the regeneration of complex tissues. This review paper reports the state of the art in the field of combined AM, posing the accent on recent trends, challenges, and future perspectives.

  5. Additive Manufacturing of Functional Elements on Sheet Metal

    NASA Astrophysics Data System (ADS)

    Schaub, Adam; Ahuja, Bhrigu; Butzhammer, Lorenz; Osterziel, Johannes; Schmidt, Michael; Merklein, Marion

    Laser Beam Melting (LBM) process with its advantages of high design flexibility and free form manufacturing methodology is often applied limitedly due to its low productivity and unsuitability for mass production compared to conventional manufacturing processes. In order to overcome these limitations, a hybrid manufacturing methodology is developed combining the additive manufacturing process of laser beam melting with sheet forming processes. With an interest towards aerospace and medical industry, the material in focus is Ti-6Al-4V. Although Ti-6Al-4V is a commercially established material and its application for LBM process has been extensively investigated, the combination of LBM of Ti-6Al-4V with sheet metal still needs to be researched. Process dynamics such as high temperature gradients and thermally induced stresses lead to complex stress states at the interaction zone between the sheet and LBM structure. Within the presented paper mechanical characterization of hybrid parts will be performed by shear testing. The association of shear strength with process parameters is further investigated by analyzing the internal structure of the hybrid geometry at varying energy inputs during the LBM process. In order to compare the hybrid manufacturing methodology with conventional fabrication, the conventional methodologies subtractive machining and state of the art Laser Beam Melting is evaluated within this work. These processes will be analyzed for their mechanical characteristics and productivity by determining the build time and raw material consumption for each case. The paper is concluded by presenting the characteristics of the hybrid manufacturing methodology compared to alternative manufacturing technologies.

  6. 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.

  7. 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

  8. 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

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. Characterization of Metal Powders Used for Additive Manufacturing.

    PubMed

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

    2014-01-01

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

  16. 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

  17. Mechanical characterisation of additively manufactured material having lattice microstructure

    NASA Astrophysics Data System (ADS)

    Cuan-Urquizo, E.; Yang, S.; Bhaskar, A.

    2015-02-01

    Many natural and engineered structures possess cellular and porous architecture. This paper is focused on the mechanical characterisation of additively manufactured lattice structures. The lattice consists of a stack of polylactic acid (PLA) filaments in a woodpile arrangement fabricated using a fused deposition modelling 3D printer. Some of the most promising applications of this 3D lattice material of this type include scaffolds for tissue engineering and the core for sandwich panels. While there is a significant body of work concerning the manufacture of such lattice materials, attempts to understand their mechanical properties are very limited. This paper brings together manufacturing with the need to understand the structure-property relationship for this class of materials. In order to understand the elastic response of the PLA-based lattice structures obtained from the fused deposition modelling process, single filaments manufactured using the same process were experimentally characterised first. The single PLA filaments were manufactured under different temperatures. These filaments were then characterised by using tensile testing. The stress-strain curves are presented. The variability of the measured results is discussed. The measured properties are then taken as input to a finite element model of the lattice material. This model uses simple one-dimensional elements in conjunction with a novel method achieving computational economy which precludes the use of fine meshes. Using this novel model, the apparent elastic modulus of lattice along the filaments has been obtained and is presented in this paper.

  18. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.; Meyer, J. D.

    1978-01-01

    Activities of the manufacturing applications team (MATeam) in effecting widespread transfer of NASA technology to aid in the solution of manufacturing problems in the industrial sector are described. During the program's first year of operation, 450 companies, industry associations, and government agencies were contacted, 150 manufacturing problems were documented, and 20 potential technology transfers were identified. Although none of the technology transfers has been commercialized and put in use, several are in the applications engineering phase, and others are in the early stages of implementation. The technology transfer process is described and guidelines used for the preparation of problems statements are included.

  19. 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.

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

    DOE PAGES

    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

  1. The specification of personalised insoles using additive manufacturing.

    PubMed

    Salles, André S; Gyi, Diane E

    2012-01-01

    Research has been conducted to explore a process that delivers insoles for personalised footwear for the high street using additive manufacturing (AM) and to evaluate the use of such insoles in terms of discomfort. Therefore, the footwear personalisation process was first identified: (1) foot capture; (2) anthropometric measurements; (3) insole design; and (4) additive manufacturing. In order to explore and evaluate this process, recreational runners were recruited. They had both feet scanned and 15 anthropometric measurements taken. Personalised insoles were designed from the scans and manufactured using AM. Participants were fitted with footwear under two experimental conditions: personalised and control, which were compared in terms of discomfort. The mean ratings for discomfort variables were generally low for both conditions and no significant differences were detected between conditions. In general, the personalisation process showed promise in terms of the scan data, although the foot capture position may not be considered 'gold standard'. Polyamide, the material used for the insoles, demonstrated positive attributes: visual inspection revealed no signs of breaking. The footwear personalisation process described and explored in this study shows potential and can be considered a good starting point for designer and researchers.

  2. 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.

  3. 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.

  4. Large forging manufacturing process

    DOEpatents

    Thamboo, Samuel V.; Yang, Ling

    2002-01-01

    A process for forging large components of Alloy 718 material so that the components do not exhibit abnormal grain growth includes the steps of: a) providing a billet with an average grain size between ASTM 0 and ASTM 3; b) heating the billet to a temperature of between 1750.degree. F. and 1800.degree. F.; c) upsetting the billet to obtain a component part with a minimum strain of 0.125 in at least selected areas of the part; d) reheating the component part to a temperature between 1750.degree. F. and 1800.degree. F.; e) upsetting the component part to a final configuration such that said selected areas receive no strains between 0.01 and 0.125; f) solution treating the component part at a temperature of between 1725.degree. F. and 1750.degree. F.; and g) aging the component part over predetermined times at different temperatures. A modified process achieves abnormal grain growth in selected areas of a component where desirable.

  5. 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.

  6. 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.

  7. Mechanical and Thermal Characterization of Ultrasonic Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Foster, Daniel R.

    Additive manufacturing is an emerging production technology used to create net shaped 3-D objects from a digital model. Ultrasonic Additive Manufacturing (UAM) is a relatively new type of additive manufacturing that uses ultrasonic energy to sequentially bond layers of metal foils at temperatures much lower than the melting temperature of the material. Constructing metal structures without melting allows UAM to have distinct advantages over beam based additive manufacturing and other traditional manufacturing processes. This is because solidification defects can be avoided, structures can be composed of dissimilar material and secondary materials (both metallic and non-metallic) can be successfully embedded into the metal matrix. These advantages allow UAM to have tremendous potential to create metal matrix composite structures that cannot be built using any other manufacturing technique. Although UAM has tremendous engineering potential, the effect of interfacial bonding defects on the mechanical and thermal properties have not be characterized. Incomplete interfacial bonding at the laminar surfaces due to insufficient welding energy can result in interfacial voids. Voids create discontinuities in the structure which change the mechanical and thermal properties of the component, resulting in a structure that has different properties than the monolithic material used to create it. In-situ thermal experiments and thermal modeling demonstrates that voids at partially bonded interfaces significantly affected heat generation and thermal conductivity in. UAM parts during consolidation as well as in the final components. Using ultrasonic testing, elastic properties of UAM structures were found to be significantly reduced due to the presence of voids, with the reduction being the most severe in the transverse (foil staking) direction. Elastic constants in all three material directions decreased linearly with a reduction in the interfacial bonded area. The linear trend

  8. 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.

  9. 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

  10. 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.

  11. 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.

  12. 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

  13. 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

  14. Bioceramic 3D Implants Produced by Laser Assisted Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Lusquiños, Fernando; del Val, Jesús; Arias-González, Felipe; Comesaña, Rafael; Quintero, Félix; Riveiro, Antonio; Boutinguiza, Mohamed; Jones, Julian R.; Hill, Robert G.; Pou, Juan

    Cranial defect restoration requires a suitable implant capable to fulfill protective and aesthetic functions, such as polymeric and metallic implants. Nevertheless, the former materials cannot provide osteointegration of the implant within the host bone nor implant resorption, which is also required in pediatricorthopedics for normal patient growth. Resorbable and osteoconductivebioceramics are employed, such as silicate bioactive glasses. Nevertheless, manufacturing based on conventional casting in graphite moulds is not effective for warped shape implants suitable for patient tailored treatments. In this work, we analyze the application of rapid prototyping based on laser cladding to manufacture bioactive glass implants for low load bearing bone restoration. This laser-assisted additive technique is capable to produce three-dimensional geometries tailored to patient, with reduced fabrication time and implant composition modification. The obtained samples were characterized; the relationships between the processing conditions and the measured features were studied, in addition to the biological behavior analysis.

  15. Benchmark Study of Industrial Needs for Additive Manufacturing in Finland

    NASA Astrophysics Data System (ADS)

    Lindqvist, Markku; Piili, Heidi; Salminen, Antti

    Additive manufacturing (AM) is a modern way to produce parts for industrial use. Even though the technical knowledge and research of AM processes are strong in Finland, there are only few industrial applications. Aim of this study is to collect practical knowledge of companies who are interested in industrial use of AM, especially in South-Eastern Finland. Goal of this study is also to investigate demands and requirements of applications for industrial use of AM in this area of Finland. It was concluded, that two of the reasons prohibiting wider industrial use of AM in Finland, are wrong expectations against this technology as well as lack of basic knowledge of possibilities of the technology. Especially, it was noticed that strong 3D-hype is even causing misunderstandings. Nevertheless, the high-level industrial know-how in the area, built around Finnish lumber industry is a strong foundation for the additive manufacturing technology.

  16. Investigation of an investment casting method combined with additive manufacturing methods for manufacturing lattice structures

    NASA Astrophysics Data System (ADS)

    Kodira, Ganapathy D.

    Cellular metals exhibit combinations of mechanical, thermal and acoustic properties that provide opportunities for various implementations and applications; light weight aerospace and automobile structures, impact and noise absorption, heat dissipation, and heat exchange. Engineered cell topologies enable one to control mechanical, thermal, and acoustic properties of the gross cell structures. A possible way to manufacture complex 3D metallic cellular solids for mass production with a relatively low cost, the investment casting (IC) method may be used by combining the rapid prototyping (RP) of wax or injection molding. In spite of its potential to produce mass products of various 3D cellular metals, the method is known to have significant casting porosity as a consequence of the complex cellular topology which makes continuous fluid's access to the solidification interface difficult. The effects of temperature on the viscosity of the fluids were studied. A comparative cost analysis between AM-IC and additive manufacturing methods is carried out. In order to manufacture 3D cellular metals with various topologies for multi-functional applications, the casting porosity should be resolved. In this study, the relations between casting porosity and processing conditions of molten metals while interconnecting with complex cellular geometries are investigated. Temperature and pressure conditions on the rapid prototyping -- investment casting (RP-IC) method are reported, thermal stresses induced are also studied. The manufactured samples are compared with those made by additive manufacturing methods.

  17. Process for manufacturing multilayer capacitors

    DOEpatents

    Lauf, Robert J.; Holcombe, Cressie E.; Dykes, Norman L.

    1996-01-01

    The invention is directed to a method of manufacture of multilayer electrical components, especially capacitors, and components made by such a method. High capacitance dielectric materials and low cost metallizations layered with such dielectrics may be fabricated as multilayer electrical components by sintering the metallizations and the dielectrics during the fabrication process by application of microwave radiation.

  18. New Skills in Process Manufacturing.

    ERIC Educational Resources Information Center

    Dumbrell, Tom; de Montfort, Rowena; Finnegan, Wendy

    Recent changes in the nature of work in Australia's process manufacturing industry and their impact on operative-level workers and vocational education and training (VET) were examined. Structured interviews were conducted with training or human resource managers in 16 firms representing a cross-section of small, medium, and large enterprises…

  19. Process for manufacturing multilayer capacitors

    DOEpatents

    Lauf, R.J.; Holcombe, C.E.; Dykes, N.L.

    1996-01-02

    The invention is directed to a method of manufacture of multilayer electrical components, especially capacitors, and components made by such a method. High capacitance dielectric materials and low cost metallizations layered with such dielectrics may be fabricated as multilayer electrical components by sintering the metallizations and the dielectrics during the fabrication process by application of microwave radiation. 4 figs.

  20. 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.

  1. 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

  2. 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.

  3. 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

  4. 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.

  5. 21 CFR 1140.12 - Additional responsibilities of manufacturers.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... SERVICES (CONTINUED) TOBACCO PRODUCTS CIGARETTES AND SMOKELESS TOBACCO Prohibition of Sale and Distribution... addition to the other responsibilities under this part, each manufacturer shall remove from each point of... 21 Food and Drugs 8 2012-04-01 2012-04-01 false Additional responsibilities of manufacturers....

  6. 21 CFR 1140.12 - Additional responsibilities of manufacturers.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... SERVICES (CONTINUED) TOBACCO PRODUCTS CIGARETTES AND SMOKELESS TOBACCO Prohibition of Sale and Distribution... addition to the other responsibilities under this part, each manufacturer shall remove from each point of... 21 Food and Drugs 8 2013-04-01 2013-04-01 false Additional responsibilities of manufacturers....

  7. 21 CFR 1140.12 - Additional responsibilities of manufacturers.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... SERVICES (CONTINUED) TOBACCO PRODUCTS CIGARETTES AND SMOKELESS TOBACCO Prohibition of Sale and Distribution... addition to the other responsibilities under this part, each manufacturer shall remove from each point of... 21 Food and Drugs 8 2014-04-01 2014-04-01 false Additional responsibilities of manufacturers....

  8. NASA OSMA NDE Program Additive Manufacturing Foundational Effort

    NASA Technical Reports Server (NTRS)

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

    2016-01-01

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

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. Manufacturing Process Applications Team (MATeam)

    NASA Technical Reports Server (NTRS)

    1978-01-01

    The activities of the Manufacturing Process Applications Team concerning the promotion of joint Industry/Federal Agency/NASA funded research and technology operating plan (RTOP) programs are reported. Direct transfers occurred in cutting tools, laser wire stripping, soldering, and portable X-ray unit technology. TROP program funding approval was obtained for the further development of the cutting tool Sialon and development of an automated nondestructive fracture toughness testing system.

  14. Additively Manufactured Main Fuel Valve Housing

    NASA Technical Reports Server (NTRS)

    Eddleman, David; Richard, Jim

    2015-01-01

    Selective Laser Melting (SLM) was utilized to fabricate a liquid hydrogen valve housing typical of those found in rocket engines and main propulsion systems. The SLM process allowed for a valve geometry that would be difficult, if not impossible to fabricate by traditional means. Several valve bodies were built by different SLM suppliers and assembled with valve internals. The assemblies were then tested with liquid nitrogen and operated as desired. One unit was also burst tested and sectioned for materials analysis. The design, test results, and planned testing are presented herein.

  15. Process for manufacturing tantalum capacitors

    DOEpatents

    Lauf, R.J.; Holcombe, C.E.; Dykes, N.L.

    1993-02-02

    A process for manufacturing tantalum capacitors in which microwave energy is used to sinter a tantalum powder compact in order to achieve higher surface area and improved dielectric strength. The process comprises cold pressing tantalum powder with organic binders and lubricants to form a porous compact. After removal of the organics, the tantalum compact is heated to 1,300 to 2,000 C by applying microwave radiation. Said compact is then anodized to form a dielectric oxide layer and infiltrated with a conductive material such as MnO[sub 2]. Wire leads are then attached to form a capacitor to said capacitor is hermetically packaged to form the finished product.

  16. Process for manufacturing tantalum capacitors

    DOEpatents

    Lauf, Robert J.; Holcombe, Cressie E.; Dykes, Norman L.

    1993-01-01

    A process for manufacturing tantalum capacitors in which microwave energy is used to sinter a tantalum powder compact in order to achieve higher surface area and improved dielectric strength. The process comprises cold pressing tantalum powder with organic binders and lubricants to form a porous compact. After removal of the organics, the tantalum compact is heated to 1300.degree. to 2000.degree. C. by applying microwave radiation. Said compact is then anodized to form a dielectric oxide layer and infiltrated with a conductive material such as MnO.sub.2. Wire leads are then attached to form a capacitor to said capacitor is hermetically packaged to form the finished product.

  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 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.

  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. Towards automatic planning for manufacturing generative processes

    SciTech Connect

    CALTON,TERRI L.

    2000-05-24

    Generative process planning describes methods process engineers use to modify manufacturing/process plans after designs are complete. A completed design may be the result from the introduction of a new product based on an old design, an assembly upgrade, or modified product designs used for a family of similar products. An engineer designs an assembly and then creates plans capturing manufacturing processes, including assembly sequences, component joining methods, part costs, labor costs, etc. When new products originate as a result of an upgrade, component geometry may change, and/or additional components and subassemblies may be added to or are omitted from the original design. As a result process engineers are forced to create new plans. This is further complicated by the fact that the process engineer is forced to manually generate these plans for each product upgrade. To generate new assembly plans for product upgrades, engineers must manually re-specify the manufacturing plan selection criteria and re-run the planners. To remedy this problem, special-purpose assembly planning algorithms have been developed to automatically recognize design modifications and automatically apply previously defined manufacturing plan selection criteria and constraints.

  20. 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.

  1. 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.

  2. 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.

  3. Adhesive materials and processing selection for environmentally conscious manufacturing

    SciTech Connect

    Tira, J.S.

    1995-06-01

    Manufacturers that use certain adhesives and related manufacturing processes must consider the impact they have on worker health, safety, and the environment. Product manufacturers must find alternate replacements for solvent-based adhesives and solvent cements. In addition, processes that use ozone-depleting solvents for hand-wipe cleaning operations as well as vapor degreasing must find suitable alternates in order to be environmentally compliant. Likewise, manufacturers that use etching solutions that contain chrome must find a replacement. This paper identifies some of the specific problems associated with using certain adhesives and manufacturing processes. Environmentally acceptable alternative adhesives and processes are presented.

  4. 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.

  5. Additive manufacturing. Continuous liquid interface production of 3D objects.

    PubMed

    Tumbleston, John R; Shirvanyants, David; Ermoshkin, Nikita; Janusziewicz, Rima; Johnson, Ashley R; Kelly, David; Chen, Kai; Pinschmidt, Robert; Rolland, Jason P; Ermoshkin, Alexander; Samulski, Edward T; DeSimone, Joseph M

    2015-03-20

    Additive manufacturing processes such as 3D printing use time-consuming, stepwise layer-by-layer approaches to object fabrication. We demonstrate the continuous generation of monolithic polymeric parts up to tens of centimeters in size with feature resolution below 100 micrometers. Continuous liquid interface production is achieved with an oxygen-permeable window below the ultraviolet image projection plane, which creates a "dead zone" (persistent liquid interface) where photopolymerization is inhibited between the window and the polymerizing part. We delineate critical control parameters and show that complex solid parts can be drawn out of the resin at rates of hundreds of millimeters per hour. These print speeds allow parts to be produced in minutes instead of hours.

  6. 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.

  7. THE DURABILITY OF LARGE-SCALE ADDITIVE MANUFACTURING COMPOSITE MOLDS

    SciTech Connect

    Post, Brian K; Love, Lonnie J; Duty, Chad; Vaidya, Uday; Pipes, R. Byron; Kunc, Vlastimil

    2016-01-01

    Oak Ridge National Laboratory s Big Area Additive Manufacturing (BAAM) technology permits the rapid production of thermoplastic composite molds using a carbon fiber filled Acrylonitrile-Butadiene-Styrene (ABS) thermoplastic. Demonstration tools (i.e. 0.965 m X 0.559 m X 0.152 m) for composite part fabrication have been printed, coated, and finished with a traditional tooling gel. We present validation results demonstrating the stability of thermoplastic printed molds for room temperature Vacuum Assisted Resin Transfer Molding (VARTM) processes. Arkema s Elium thermoplastic resin was investigated with a variety of reinforcement materials. Experimental results include dimensional characterization of the tool surface using laser scanning technique following demolding of 10 parts. Thermoplastic composite molds offer rapid production compared to traditionally built thermoset molds in that near-net deposition allows direct digital production of the net geometry at production rate of 45 kg/hr.

  8. 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.

  9. 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.

  10. Additive manufacturing of ceramic structures by laser engineered net shaping

    NASA Astrophysics Data System (ADS)

    Niu, Fangyong; Wu, Dongjiang; Ma, Guangyi; Zhang, Bi

    2015-11-01

    Ceramic is an important material with outstanding physical properties whereas impurities and porosities generated by traditional manufacturing methods limits its further industrial applications. In order to solve this problem, direct fabrication of Al2O3 ceramic structures is conducted by laser engineered net shaping system and pure ceramic powders. Grain refinement strengthening method by doping ZrO2 and dispersion strengthening method by doping SiC are proposed to suppress cracks in fabricating Al2O3 structure. Phase compositions, microstructures as well as mechanical properties of fabricated specimens are then analyzed. The results show that the proposed two methods are effective in suppressing cracks and structures of single-bead wall, arc and cylinder ring are successfully deposited. Stable phase of α-Al2O3 and t-ZrO2 are obtained in the fabricated specimens. Micro-hardness higher than 1700 HV are also achieved for both Al2O3 and Al2O3/ZrO2, which are resulted from fine directional crystals generated by the melting-solidification process. Results presented indicate that additive manufacturing is a very attractive technique for the production of high-performance ceramic structures in a single step.

  11. 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.

  12. 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.

  13. 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.

  14. Wind Turbine Manufacturing Process Monitoring

    SciTech Connect

    Waseem Faidi; Chris Nafis; Shatil Sinha; Chandra Yerramalli; Anthony Waas; Suresh Advani; John Gangloff; Pavel Simacek

    2012-04-26

    To develop a practical inline inspection that could be used in combination with automated composite material placement equipment to economically manufacture high performance and reliable carbon composite wind turbine blade spar caps. The approach technical feasibility and cost benefit will be assessed to provide a solid basis for further development and implementation in the wind turbine industry. The program is focused on the following technology development: (1) Develop in-line monitoring methods, using optical metrology and ultrasound inspection, and perform a demonstration in the lab. This includes development of the approach and performing appropriate demonstration in the lab; (2) Develop methods to predict composite strength reduction due to defects; and (3) Develop process models to predict defects from leading indicators found in the uncured composites.

  15. 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.

  16. 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.

  17. Evaluation of direct and indirect additive manufacture of maxillofacial prostheses.

    PubMed

    Eggbeer, Dominic; Bibb, Richard; Evans, Peter; Ji, Lu

    2012-09-01

    The efficacy of computer-aided technologies in the design and manufacture of maxillofacial prostheses has not been fully proven. This paper presents research into the evaluation of direct and indirect additive manufacture of a maxillofacial prosthesis against conventional laboratory-based techniques. An implant/magnet-retained nasal prosthesis case from a UK maxillofacial unit was selected as a case study. A benchmark prosthesis was fabricated using conventional laboratory-based techniques for comparison against additive manufactured prostheses. For the computer-aided workflow, photogrammetry, computer-aided design and additive manufacture (AM) methods were evaluated in direct prosthesis body fabrication and indirect production using an additively manufactured mould. Qualitative analysis of position, shape, colour and edge quality was undertaken. Mechanical testing to ISO standards was also used to compare the silicone rubber used in the conventional prosthesis with the AM material. Critical evaluation has shown that utilising a computer-aided work-flow can produce a prosthesis body that is comparable to that produced using existing best practice. Technical limitations currently prevent the direct fabrication method demonstrated in this paper from being clinically viable. This research helps prosthesis providers understand the application of a computer-aided approach and guides technology developers and researchers to address the limitations identified.

  18. 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.

  19. 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.

  20. Integrated lunar materials manufacturing process

    NASA Technical Reports Server (NTRS)

    Gibson, Michael A. (Inventor); Knudsen, Christian W. (Inventor)

    1990-01-01

    A manufacturing plant and process for production of oxygen on the moon uses lunar minerals as feed and a minimum of earth-imported, process materials. Lunar feed stocks are hydrogen-reducible minerals, ilmenite and lunar agglutinates occurring in numerous, explored locations mixed with other minerals in the pulverized surface layer of lunar soil known as regolith. Ilmenite (FeTiO.sub.3) and agglutinates contain ferrous (Fe.sup.+2) iron reducible by hydrogen to yield H.sub.2 O and metallic Fe at about 700.degree.-1,200.degree. C. The H.sub.2 O is electrolyzed in gas phase to yield H.sub.2 for recycle and O.sub.2 for storage and use. Hydrogen losses to lunar vacuum are minimized, with no net hydrogen (or any other earth-derived reagent) consumption except for small leaks. Feed minerals are surface-mined by front shovels and transported in trucks to the processing area. The machines are manned or robotic. Ilmenite and agglutinates occur mixed with silicate minerals which are not hydrogen-reducible at 700.degree.-1,200.degree. C. and consequently are separated and concentrated before feeding to the oxygen generation process. Solids rejected from the separation step and reduced solids from the oxygen process are returned to the mine area. The plant is powered by nuclear or solar power generators. Vapor-phase water electrolysis, a staged, countercurrent, fluidized bed reduction reactor and a radio-frequency-driven ceramic gas heater are used to improve thermal efficiency.

  1. Additive manufacturing method for SRF components of various geometries

    SciTech Connect

    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.

  2. Hybrid additive manufacturing of 3D electronic systems

    NASA Astrophysics Data System (ADS)

    Li, J.; Wasley, T.; Nguyen, T. T.; Ta, V. D.; Shephard, J. D.; Stringer, J.; Smith, P.; Esenturk, E.; Connaughton, C.; Kay, R.

    2016-10-01

    A novel hybrid additive manufacturing (AM) technology combining digital light projection (DLP) stereolithography (SL) with 3D micro-dispensing alongside conventional surface mount packaging is presented in this work. This technology overcomes the inherent limitations of individual AM processes and integrates seamlessly with conventional packaging processes to enable the deposition of multiple materials. This facilitates the creation of bespoke end-use products with complex 3D geometry and multi-layer embedded electronic systems. Through a combination of four-point probe measurement and non-contact focus variation microscopy, it was identified that there was no obvious adverse effect of DLP SL embedding process on the electrical conductivity of printed conductors. The resistivity maintained to be less than 4  ×  10-4 Ω · cm before and after DLP SL embedding when cured at 100 °C for 1 h. The mechanical strength of SL specimens with thick polymerized layers was also identified through tensile testing. It was found that the polymerization thickness should be minimised (less than 2 mm) to maximise the bonding strength. As a demonstrator a polymer pyramid with embedded triple-layer 555 LED blinking circuitry was successfully fabricated to prove the technical viability.

  3. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.

    1980-01-01

    Progress in the transfer of aerospace technology to solve key problems in the manufacturing sector of the economy is reported. Potential RTOP programs are summarized along with dissemination activities. The impact of transferred NASA manufacturing technology is discussed. Specific areas covered include aircraft production, robot technology, machining of alloys, and electrical switching systems.

  4. 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.

  5. Imaging requirements for medical applications of additive manufacturing.

    PubMed

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

    2014-02-01

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

  6. 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

  7. 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.

  8. Spall fracture in additive manufactured Ti-6Al-4V

    DOE PAGES

    Jones, David Robert; Fensin, Saryu Jindal; Dippo, Olivia; Beal, Roberta Ann; Livescu, Verpnica; Martinez, Daniel Tito; Trujillo, Carl Patrick; Florando, J. N.; Kumar, M.; Gray, III, George Thompson

    2016-10-04

    Here, we present a study on the spall strength of additive manufactured (AM) Ti-6Al-4V. Samples were obtained from two pieces of selective laser melted (SLM, a powder bed fusion technique) Ti-6Al-4V such that the response to dynamic tensile loading could be investigated as a function of the orientation between the build layers and the loading direction. A sample of wrought bar-stock Ti-6Al-4V was also tested to act as a baseline representing the traditionally manufactured material response. A single-stage light gas-gun was used to launch a thin flyer plate into the samples, generating a region of intense tensile stress on amore » plane normal to the impact direction. The rear free surface velocity time history of each sample was recorded with laser-based velocimetry to allow the spall strength to be calculated. The samples were also soft recovered to enable post-mortem characterization of the spall damage evolution. Results showed that when the tensile load was applied normal to the interfaces between the build layers caused by the SLM fabrication process the spall strength was drastically reduced, dropping to 60% of that of the wrought material. However, when loaded parallel to the AM build layer interfaces the spall strength was found to remain at 95% of the wrought control, suggesting that when loading normal to the AM layer interfaces, void nucleation is facilitated more readily due to weaknesses along these boundaries. Quasi-static testing of the same sample orientations revealed a much lower degree of anisotropy, demonstrating the importance of rate-dependent studies for damage evolution in AM materials.« less

  9. Spall fracture in additive manufactured Ti-6Al-4V

    NASA Astrophysics Data System (ADS)

    Jones, D. R.; Fensin, S. J.; Dippo, O.; Beal, R. A.; Livescu, V.; Martinez, D. T.; Trujillo, C. P.; Florando, J. N.; Kumar, M.; Gray, G. T.

    2016-10-01

    We present a study on the spall strength of additive manufactured (AM) Ti-6Al-4V. Samples were obtained from two pieces of selective laser melted (SLM, a powder bed fusion technique) Ti-6Al-4V such that the response to dynamic tensile loading could be investigated as a function of the orientation between the build layers and the loading direction. A sample of wrought bar-stock Ti-6Al-4V was also tested to act as a baseline representing the traditionally manufactured material response. A single-stage light gas-gun was used to launch a thin flyer plate into the samples, generating a region of intense tensile stress on a plane normal to the impact direction. The rear free surface velocity time history of each sample was recorded with laser-based velocimetry to allow the spall strength to be calculated. The samples were also soft recovered to enable post-mortem characterization of the spall damage evolution. Results showed that when the tensile load was applied normal to the interfaces between the build layers caused by the SLM fabrication process the spall strength was drastically reduced, dropping to 60% of that of the wrought material. However, when loaded parallel to the AM build layer interfaces the spall strength was found to remain at 95% of the wrought control, suggesting that when loading normal to the AM layer interfaces, void nucleation is facilitated more readily due to weaknesses along these boundaries. Quasi-static testing of the same sample orientations revealed a much lower degree of anisotropy, demonstrating the importance of rate-dependent studies for damage evolution in AM materials.

  10. 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...

  11. 21 CFR 1140.12 - Additional responsibilities of manufacturers.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... each point of sale all self-service displays, advertising, labeling, and other items that the... SERVICES (CONTINUED) TOBACCO PRODUCTS CIGARETTES AND SMOKELESS TOBACCO; Eff. 6-22-10 Prohibition of Sale... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Additional responsibilities of manufacturers....

  12. 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.

  13. News: Good chemical manufacturing process criteria

    EPA Science Inventory

    This news column covers topics relating to manufacturing criteria, machine to machine technology, novel process windows, green chemistry indices, business resilience, immobilized enzymes, and Bt crops.

  14. Solid-State Additive Manufacturing for Heat Exchangers

    NASA Astrophysics Data System (ADS)

    Norfolk, Mark; Johnson, Hilary

    2015-03-01

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

  15. 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.

  16. 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.

  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. 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.

  19. 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

  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. 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. 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.

  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. Encapsulation Processing and Manufacturing Yield Analysis

    NASA Technical Reports Server (NTRS)

    Willis, P. B.

    1984-01-01

    The development of encapsulation processing and a manufacturing productivity analysis for photovoltaic cells are discussed. The goals were: (1) to understand the relationships between both formulation variables and process variables; (2) to define conditions required for optimum performance; (3) to predict manufacturing yield; and (4) to provide documentation to industry.

  5. Calculation of laser absorption by metal powders in additive manufacturing.

    PubMed

    Boley, C D; Khairallah, S A; Rubenchik, A M

    2015-03-20

    We have calculated the absorption of laser light by a powder of metal spheres, typical of the powder employed in laser powder-bed fusion additive manufacturing. Using ray-trace simulations, we show that the absorption is significantly larger than its value for normal incidence on a flat surface, due to multiple scattering. We investigate the dependence of absorption on powder content (material, size distribution, and geometry) and on beam size.

  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. 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.

  8. 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.

  9. Ultra-precision processes for optics manufacturing

    NASA Astrophysics Data System (ADS)

    Martin, William R.

    1991-12-01

    The Optics MODIL (Manufacturing Operations Development and Integration Laboratory) is developing advanced manufacturing technologies for fabrication of ultra precision optical components, aiming for a ten-fold improvement in precision and a shortening of the scheduled lead time. Current work focuses on diamond single point turning, ductile grinding, ion milling, and in/on process metrology.

  10. 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.

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

    PubMed

    Hengsbach, Stefan; Lantada, Andrés Díaz

    2014-08-01

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

  12. 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.

  13. Manufacturing of Smart Structures Using Fiber Placement Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Thomas, Matthew M.; Glowasky, Robert A.; McIlroy, Bruce E.; Story, Todd A.

    1996-01-01

    Smart structures research and development, with the ultimate aim of rapid commercial and military production of these structures, are at the forefront of the Synthesis and Processing of Intelligent Cost-Effective Structures (SPICES) program. As part of this ARPA-sponsored program, MDA-E is using fiber placement processes to manufacture integrated smart structure systems. These systems comprise advanced composite structures with embedded fiber optic sensors, shape memory alloys, piezoelectric actuators, and miniature accelerometers. Cost-effective approaches and solutions to smart material synthesis in the fiber-placement process, based upon integrated product development, are discussed herein.

  14. Cost Models for MMC Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Elzey, Dana M.; Wadley, Haydn N. G.

    1996-01-01

    The quality cost modeling (QCM) tool is intended to be a relatively simple-to-use device for obtaining a first-order assessment of the quality-cost relationship for a given process-material combination. The QCM curve is a plot of cost versus quality (an index indicating microstructural quality), which is unique for a given process-material combination. The QCM curve indicates the tradeoff between cost and performance, thus enabling one to evaluate affordability. Additionally, the effect of changes in process design, raw materials, and process conditions on the cost-quality relationship can be evaluated. Such results might indicate the most efficient means to obtain improved quality at reduced cost by process design refinements, the implementation of sensors and models for closed loop process control, or improvement in the properties of raw materials being fed into the process. QCM also allows alternative processes for producing the same or similar material to be compared in terms of their potential for producing competitively priced, high quality material. Aside from demonstrating the usefulness of the QCM concept, this is one of the main foci of the present research program, namely to compare processes for making continuous fiber reinforced, metal matrix composites (MMC's). Two processes, low pressure plasma spray deposition and tape casting are considered for QCM development. This document consists of a detailed look at the design of the QCM approach, followed by discussion of the application of QCM to each of the selected MMC manufacturing processes along with results, comparison of processes, and finally, a summary of findings and recommendations.

  15. 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.

  16. Manufacturing Process Simulation of Large-Scale Cryotanks

    NASA Technical Reports Server (NTRS)

    Babai, Majid; Phillips, Steven; Griffin, Brian

    2003-01-01

    NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing

  17. A Knowledge Database on Thermal Control in Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Hirasawa, Shigeki; Satoh, Isao

    A prototype version of a knowledge database on thermal control in manufacturing processes, specifically, molding, semiconductor manufacturing, and micro-scale manufacturing has been developed. The knowledge database has search functions for technical data, evaluated benchmark data, academic papers, and patents. The database also displays trends and future roadmaps for research topics. It has quick-calculation functions for basic design. This paper summarizes present research topics and future research on thermal control in manufacturing engineering to collate the information to the knowledge database. In the molding process, the initial mold and melt temperatures are very important parameters. In addition, thermal control is related to many semiconductor processes, and the main parameter is temperature variation in wafers. Accurate in-situ temperature measurment of wafers is important. And many technologies are being developed to manufacture micro-structures. Accordingly, the knowledge database will help further advance these technologies.

  18. 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

  19. 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.

  20. 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.

  1. An evaluation of personalised insoles developed using additive manufacturing.

    PubMed

    Salles, Andre S; Gyi, Diane E

    2013-01-01

    The aim of the study was to evaluate the short and medium term use of personalised insoles, produced by combining additive manufacturing (AM) with three-dimensional (3-D) foot scanning and computer aided design (CAD) systems. For that, 38 runners (19 pairings) were recruited. The experimental conditions were: personalised and control. The personalised condition consisted of trainers fitted with personalised glove fit insoles manufactured using AM and using foot scans to match the plantar geometry of the feet. The control condition consisted of the same trainers fitted with insoles also manufactured using AM but using scans of the original insole shape. Participants were allocated to one of the experimental conditions and wore the trainers for 3 months. Over this period they attended three laboratory sessions (at months 0, 1.5 and 3) and completed an Activity Diary after each training session. The footwear was evaluated in terms of discomfort and biomechanics. Lower discomfort ratings were found in the heel area (P ≤ 0.05) and for overall fit (P ≤ 0.05), with the personalised insole. However, discomfort was reported under the arch region for both conditions. With regard to the biomechanical data, differences between conditions were detected for ankle dorsiflexion at footstrike (P ≤ 0.05), maximum ankle eversion (P ≤ 0.05) and peak mean pressure under the heel (P ≤ 0.01): the personalised condition had lower values which may reduce injury risk. The personalisation of the geometry of insoles through advances in AM together with 3-D scanning and CAD technologies can provide benefits and has potential.

  2. 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...

  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. 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.

  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. Just-in-time Design and Additive Manufacture of Patient-specific Medical Implants

    NASA Astrophysics Data System (ADS)

    Shidid, Darpan; Leary, Martin; Choong, Peter; Brandt, Milan

    Recent advances in medical imaging and manufacturing science have enabled the design and production of complex, patient-specific orthopaedic implants. Additive Manufacture (AM) generates three-dimensional structures layer by layer, and is not subject to the constraints associated with traditional manufacturing methods. AM provides significant opportunities for the design of novel geometries and complex lattice structures with enhanced functional performance. However, the design and manufacture of patient-specific AM implant structures requires unique expertise in handling various optimization platforms. Furthermore, the design process for complex structures is computationally intensive. The primary aim of this research is to enable the just-in-time customisation of AM prosthesis; whereby AM implant design and manufacture be completed within the time constraints of a single surgical procedure, while minimising prosthesis mass and optimising the lattice structure to match the stiffness of the surrounding bone tissue. In this research, a design approach using raw CT scan data is applied to the AM manufacture of femoral prosthesis. Using the proposed just-in-time concept, the mass of the prosthesis was rapidly designed and manufactured while satisfying the associated structural requirements. Compressive testing of lattice structures manufactured using proposed method shows that the load carrying capacity of the resected composite bone can be recovered by up to 85% and the compressive stiffness of the AM prosthesis is statistically indistinguishable from the stiffness of the initial bone.

  7. Manufacturing process applications team (MATeam)

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.

    1980-01-01

    The objectives and activities of an aerospace technology transfer group are outlined and programs in various stages of progress are described including the orbital tube flaring device, infrared proximity sensor for robot positioning, laser stripping magnet wire, infrared imaging as welding process tracking system, carbide coating of cutting tools, nondestructive fracture toughness testing of titanium welds, portable solar system for agricultural applications, and an anerobic methane gas generator.

  8. 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.

  9. 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

  10. 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.

  11. 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.

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

    DOE PAGES

    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

  13. 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.

  14. Computational Fluid Dynamics - Applications in Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Beninati, Maria Laura; Kathol, Austin; Ziemian, Constance

    2012-11-01

    A new Computational Fluid Dynamics (CFD) exercise has been developed for the undergraduate introductory fluid mechanics course at Bucknell University. The goal is to develop a computational exercise that students complete which links the manufacturing processes course and the concurrent fluid mechanics course in a way that reinforces the concepts in both. In general, CFD is used as a tool to increase student understanding of the fundamentals in a virtual world. A ``learning factory,'' which is currently in development at Bucknell seeks to use the laboratory as a means to link courses that previously seemed to have little correlation at first glance. A large part of the manufacturing processes course is a project using an injection molding machine. The flow of pressurized molten polyurethane into the mold cavity can also be an example of fluid motion (a jet of liquid hitting a plate) that is applied in manufacturing. The students will run a CFD process that captures this flow using their virtual mold created with a graphics package, such as SolidWorks. The laboratory structure is currently being implemented and analyzed as a part of the ``learning factory''. Lastly, a survey taken before and after the CFD exercise demonstrate a better understanding of both the CFD and manufacturing process.

  15. 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

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. 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.

  1. Developing the Manufacturing Process for VCE: Binder for Filled Elastomers

    SciTech Connect

    E.A. Eastwood

    2009-11-01

    This topical report presents work completed to re-establish the manufacturing process for poly(ethylene-co-vinyl acetate-co-vinyl alcohol) terpolymer called VCE. The new VCE formulations meet the material requirements and have lower melt viscosity, which results in improved production for the next assembly. In addition, the reaction conditions were optimized in order to achieve a satisfactory conversion rate to enable production in a single work shift. Several equipment and process changes were made to yield a manufacturing process with improved product quality, yield, efficiency, and worker safety.

  2. Modelling Of Manufacturing Processes With Membranes

    NASA Astrophysics Data System (ADS)

    Crăciunean, Daniel Cristian; Crăciunean, Vasile

    2015-07-01

    The current objectives to increase the standards of quality and efficiency in manufacturing processes can be achieved only through the best combination of inputs, independent of spatial distance between them. This paper proposes modelling production processes based on membrane structures introduced in [4]. Inspired from biochemistry, membrane computation [4] is based on the concept of membrane represented in its formalism by the mathematical concept of multiset. The manufacturing process is the evolution of a super cell system from its initial state according to the given actions of aggregation. In this paper we consider that the atomic production unit of the process is the action. The actions and the resources on which the actions are produced, are distributed in a virtual network of companies working together. The destination of the output resources is specified by corresponding output events.

  3. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 15 Commerce and Foreign Trade 2 2012-01-01 2012-01-01 false Manufacturing and processing activity... ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.31 Manufacturing and processing activity....” When evaluating zone and subzone manufacturing and processing activity, either as proposed in...

  4. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... 15 Commerce and Foreign Trade 2 2011-01-01 2011-01-01 false Manufacturing and processing activity... ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.31 Manufacturing and processing activity....” When evaluating zone and subzone manufacturing and processing activity, either as proposed in...

  5. 15 CFR 400.31 - Manufacturing and processing activity; criteria.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 15 Commerce and Foreign Trade 2 2010-01-01 2010-01-01 false Manufacturing and processing activity... ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.31 Manufacturing and processing activity....” When evaluating zone and subzone manufacturing and processing activity, either as proposed in...

  6. Counting Processes in Simple Addition.

    ERIC Educational Resources Information Center

    Svenson, Ola; Hedenborg, Maj-Lene

    1980-01-01

    The cognitive processes of seven children solving arithmetic problems were accurately classified as reconstructive or reproductive according to the child's verbal report of his thought processes. Classifications of thought processes by means of verbal reports can also be used to improve the analysis of latencies. (SB)

  7. Microeconomics of process control in semiconductor manufacturing

    NASA Astrophysics Data System (ADS)

    Monahan, Kevin M.

    2003-06-01

    Process window control enables accelerated design-rule shrinks for both logic and memory manufacturers, but simple microeconomic models that directly link the effects of process window control to maximum profitability are rare. In this work, we derive these links using a simplified model for the maximum rate of profit generated by the semiconductor manufacturing process. We show that the ability of process window control to achieve these economic objectives may be limited by variability in the larger manufacturing context, including measurement delays and process variation at the lot, wafer, x-wafer, x-field, and x-chip levels. We conclude that x-wafer and x-field CD control strategies will be critical enablers of density, performance and optimum profitability at the 90 and 65nm technology nodes. These analyses correlate well with actual factory data and often identify millions of dollars in potential incremental revenue and cost savings. As an example, we show that a scatterometry-based CD Process Window Monitor is an economically justified, enabling technology for the 65nm node.

  8. 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.

  9. 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:...

  10. 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:...

  11. 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:...

  12. 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:...

  13. Transient period process control for continuous manufacturing

    SciTech Connect

    Nembhard, H.B.; Birge, J.R.

    1994-12-31

    We develop a multiple objective nonlinear control model to optimize decision variables for correlated process characteristics during a transient phase. Given a continuous manufacturing process we show how to use the model to improve operations from startup to the end of the transient period (when steady-state is reached). We also show how to identify the end of the transient period and compare performance using the model during steady-state to traditional SPC techniques that assume the process is in statistical control.

  14. 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.

  15. 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.

  16. 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.

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

    NASA Astrophysics Data System (ADS)

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

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

  18. Cost Models for MMC Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Elzey, Dana M.; Wadley, Haydn N. G.

    1996-01-01

    Processes for the manufacture of advanced metal matrix composites are rapidly approaching maturity in the research laboratory and there is growing interest in their transition to industrial production. However, research conducted to date has almost exclusively focused on overcoming the technical barriers to producing high-quality material and little attention has been given to the economical feasibility of these laboratory approaches and process cost issues. A quantitative cost modeling (QCM) approach was developed to address these issues. QCM are cost analysis tools based on predictive process models relating process conditions to the attributes of the final product. An important attribute, of the QCM approach is the ability to predict the sensitivity of material production costs to product quality and to quantitatively explore trade-offs between cost and quality. Applications of the cost models allow more efficient direction of future MMC process technology development and a more accurate assessment of MMC market potential. Cost models were developed for two state-of-the art metal matrix composite (MMC) manufacturing processes: tape casting and plasma spray deposition. Quality and Cost models are presented for both processes and the resulting predicted quality-cost curves are presented and discussed.

  19. Big Data Analysis of Manufacturing Processes

    NASA Astrophysics Data System (ADS)

    Windmann, Stefan; Maier, Alexander; Niggemann, Oliver; Frey, Christian; Bernardi, Ansgar; Gu, Ying; Pfrommer, Holger; Steckel, Thilo; Krüger, Michael; Kraus, Robert

    2015-11-01

    The high complexity of manufacturing processes and the continuously growing amount of data lead to excessive demands on the users with respect to process monitoring, data analysis and fault detection. For these reasons, problems and faults are often detected too late, maintenance intervals are chosen too short and optimization potential for higher output and increased energy efficiency is not sufficiently used. A possibility to cope with these challenges is the development of self-learning assistance systems, which identify relevant relationships by observation of complex manufacturing processes so that failures, anomalies and need for optimization are automatically detected. The assistance system developed in the present work accomplishes data acquisition, process monitoring and anomaly detection in industrial and agricultural processes. The assistance system is evaluated in three application cases: Large distillation columns, agricultural harvesting processes and large-scale sorting plants. In this paper, the developed infrastructures for data acquisition in these application cases are described as well as the developed algorithms and initial evaluation results.

  20. A simulation study on garment manufacturing process

    NASA Astrophysics Data System (ADS)

    Liong, Choong-Yeun; Rahim, Nur Azreen Abdul

    2015-02-01

    Garment industry is an important industry and continues to evolve in order to meet the consumers' high demands. Therefore, elements of innovation and improvement are important. In this work, research studies were conducted at a local company in order to model the sewing process of clothes manufacturing by using simulation modeling. Clothes manufacturing at the company involves 14 main processes, which are connecting the pattern, center sewing and side neating, pockets sewing, backside-sewing, attaching the front and back, sleeves preparation, attaching the sleeves and over lock, collar preparation, collar sewing, bottomedge sewing, buttonholing sewing, removing excess thread, marking button, and button cross sewing. Those fourteen processes are operated by six tailors only. The last four sets of processes are done by a single tailor. Data collection was conducted by on site observation and the probability distribution of processing time for each of the processes is determined by using @Risk's Bestfit. Then a simulation model is developed using Arena Software based on the data collected. Animated simulation model is developed in order to facilitate understanding and verifying that the model represents the actual system. With such model, what if analysis and different scenarios of operations can be experimented with virtually. The animation and improvement models will be presented in further work.

  1. Process and control systems for composites manufacturing

    NASA Technical Reports Server (NTRS)

    Tsiang, T. H.; Wanamaker, John L.

    1992-01-01

    A precise control of composite material processing would not only improve part quality, but it would also directly reduce the overall manufacturing cost. The development and incorporation of sensors will help to generate real-time information for material processing relationships and equipment characteristics. In the present work, the thermocouple, pressure transducer, and dielectrometer technologies were investigated. The monitoring sensors were integrated with the computerized control system in three non-autoclave fabrication techniques: hot-press, self contained tool (self heating and pressurizing), and pressure vessel). The sensors were implemented in the parts and tools.

  2. 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.

  3. 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.

  4. 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.

  5. Thermal imaging for assessment of electron-beam freeform fabrication (EBF3) additive manufacturing deposits

    NASA Astrophysics Data System (ADS)

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

    2013-05-01

    Additive manufacturing is a rapidly growing field where 3-dimensional parts can be produced layer by layer. NASA's electron beam freeform fabrication (EBF3) technology is being evaluated to manufacture metallic parts in a space environment. The benefits of EBF3 technology are weight savings to support space missions, rapid prototyping in a zero gravity environment, and improved vehicle readiness. The EBF3 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 deposit, 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 deposit assessment metrics.

  6. 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

  7. 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.

  8. 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.

  9. 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

  10. Precision replenishable grinding tool and manufacturing process

    DOEpatents

    Makowiecki, D.M.; Kerns, J.A.; Blaedel, K.L.; Colella, N.J.; Davis, P.J.; Juntz, R.S.

    1998-06-09

    A reusable grinding tool consisting of a replaceable single layer of abrasive particles intimately bonded to a precisely configured tool substrate, and a process for manufacturing the grinding tool are disclosed. The tool substrate may be ceramic or metal and the abrasive particles are preferably diamond, but may be cubic boron nitride. The manufacturing process involves: coating a configured tool substrate with layers of metals, such as titanium, copper and titanium, by physical vapor deposition (PVD); applying the abrasive particles to the coated surface by a slurry technique; and brazing the abrasive particles to the tool substrate by alloying the metal layers. The precision control of the composition and thickness of the metal layers enables the bonding of a single layer or several layers of micron size abrasive particles to the tool surface. By the incorporation of an easily dissolved metal layer in the composition such allows the removal and replacement of the abrasive particles, thereby providing a process for replenishing a precisely machined grinding tool with fine abrasive particles, thus greatly reducing costs as compared to replacing expensive grinding tools. 11 figs.

  11. Precision replenishable grinding tool and manufacturing process

    DOEpatents

    Makowiecki, Daniel M.; Kerns, John A.; Blaedel, Kenneth L.; Colella, Nicholas J.; Davis, Pete J.; Juntz, Robert S.

    1998-01-01

    A reusable grinding tool consisting of a replaceable single layer of abrasive particles intimately bonded to a precisely configured tool substrate, and a process for manufacturing the grinding tool. The tool substrate may be ceramic or metal and the abrasive particles are preferably diamond, but may be cubic boron nitride. The manufacturing process involves: coating a configured tool substrate with layers of metals, such as titanium, copper and titanium, by physical vapor deposition (PVD); applying the abrasive particles to the coated surface by a slurry technique; and brazing the abrasive particles to the tool substrate by alloying the metal layers. The precision control of the composition and thickness of the metal layers enables the bonding of a single layer or several layers of micron size abrasive particles to the tool surface. By the incorporation of an easily dissolved metal layer in the composition such allows the removal and replacement of the abrasive particles, thereby providing a process for replenishing a precisely machined grinding tool with fine abrasive particles, thus greatly reducing costs as compared to replacing expensive grinding tools.

  12. 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

  13. Monitoring of an antigen manufacturing process.

    PubMed

    Zavatti, Vanessa; Budman, Hector; Legge, Raymond; Tamer, Melih

    2016-06-01

    Fluorescence spectroscopy in combination with multivariate statistical methods was employed as a tool for monitoring the manufacturing process of pertactin (PRN), one of the virulence factors of Bordetella pertussis utilized in whopping cough vaccines. Fluorophores such as amino acids and co-enzymes were detected throughout the process. The fluorescence data collected at different stages of the fermentation and purification process were treated employing principal component analysis (PCA). Through PCA, it was feasible to identify sources of variability in PRN production. Then, partial least square (PLS) was employed to correlate the fluorescence spectra obtained from pure PRN samples and the final protein content measured by a Kjeldahl test from these samples. In view that a statistically significant correlation was found between fluorescence and PRN levels, this approach could be further used as a method to predict the final protein content.

  14. Defective Reduction in Automotive Headlining Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Rittichai, Saranya; Chutima, Parames

    2016-05-01

    In an automobile parts manufacturing company, currently the headlining process has a lot of wastes resulting in a high cost of quality per year. In this paper, the Six Sigma method is used to reduce the defects in the headlining process. Cause-and-effect matrix and failure mode and effect analysis (FMEA) were adopted to screen the factors that affect the quality of headlining. The 2k-1 fractional factorials design was also use to determine the potential preliminary root causes. The full factorial experiments was conducted to identify appropriate settings of the significant factors. The result showed that the process can reduce the defects of headlining from 12.21% to 6.95%

  15. Closed Loop Welding Controller for Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Bonaccorso, F.; Bruno, C.; Cantelli, L.; Longo, D.; Muscato, G.; Rapisarda, S.

    2011-12-01

    The aim of this paper is to investigate on the closed loop welding controller of a rapid manufacturing Shaped Metal Deposition (SMD) process. SMD was developed and patented by Rolls-Royce in order to produce mechanical parts directly from a CAD model. A simplified SMD plant has been set up in order to investigate the welding dynamics and parameters and to develop a SMD automatic controller. On the basis of the experience acquired, some basic control laws have been developed, and a closed loop controller has been implemented. This controller permits to find and to maintain the process stability condition, so that the final process results totally automatic. The control is performed adjusting the welding conditions on the basis of arc voltage information obtained from the welding machine during the deposition. The experimental results reported confirm the validity of the proposed strategy.

  16. Monitoring of an antigen manufacturing process.

    PubMed

    Zavatti, Vanessa; Budman, Hector; Legge, Raymond; Tamer, Melih

    2016-06-01

    Fluorescence spectroscopy in combination with multivariate statistical methods was employed as a tool for monitoring the manufacturing process of pertactin (PRN), one of the virulence factors of Bordetella pertussis utilized in whopping cough vaccines. Fluorophores such as amino acids and co-enzymes were detected throughout the process. The fluorescence data collected at different stages of the fermentation and purification process were treated employing principal component analysis (PCA). Through PCA, it was feasible to identify sources of variability in PRN production. Then, partial least square (PLS) was employed to correlate the fluorescence spectra obtained from pure PRN samples and the final protein content measured by a Kjeldahl test from these samples. In view that a statistically significant correlation was found between fluorescence and PRN levels, this approach could be further used as a method to predict the final protein content. PMID:26879644

  17. Incorporating manufacturability constraints into the design process of heterogeneous objects

    NASA Astrophysics Data System (ADS)

    Hu, Yuna; Blouin, Vincent Y.; Fadel, Georges M.

    2004-11-01

    Rapid prototyping (RP) technology, such as Laser Engineering Net Shaping (LENSTM), can be used to fabricate heterogeneous objects with gradient variations in material composition. These objects are generally characterized by enhanced functional performance. Past research on the design of such objects has focused on representation, modeling, and functional performance. However, the inherent constraints in RP processes, such as system capability and processing time, lead to heterogeneous objects that may not meet the designer's original intent. To overcome this situation, the research presented in this paper focuses on the identification and implementation of manufacturing constraints into the design process. A node-based finite element modeling technique is used for the representation and analysis and the multicriteria design problem corresponds to finding the nodal material compositions that minimize structural weight and maximize thermal performance. The optimizer used in this research is a real-valued Evolutionary Strategies (ES), which is well suited for this type of multi-modal problem. Two limitations of the LENS manufacturing process, which have an impact on the design process, are identified and implemented. One of them is related to the manufacturing time, which is considered as an additional criterion to be minimized in the design problem for a preselected tool path. A brake disc rotor made of two materials, aluminum for lightweight and steel for superior thermal characteristics, is used to illustrate the tradeoff between manufacturability and functionality.

  18. 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...

  19. 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.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. Effect of bovine lactoferrin addition to milk in yogurt manufacturing.

    PubMed

    Franco, I; Castillo, E; Pérez, M D; Calvo, M; Sánchez, L

    2010-10-01

    The aim of this work was to study the effect of milk supplementation with lactoferrin of different iron saturation on the manufacturing and characteristics of yogurt. Bovine lactoferrin was added at concentrations of 0.5, 1, and 2 mg/mL in the holo (iron saturated) and apo (without iron) forms. Some physicochemical properties, such as pH, concentration of lactic acid, and texture of supplemented yogurts, were determined throughout the shelf-life period storage (28 d) at 4°C. We also evaluated the stability of lactoferrin in supplemented yogurt throughout the storage time. The supplementation of milk with bovine lactoferrin did not greatly affect the physical properties of the yogurt, though apo-lactoferrin slightly delayed the decrease of pH. This could be attributed to the partial inhibition observed on the growth of Streptococcus thermophilus. The integrity and immunoreactive concentration of lactoferrin, determined by Western blotting and noncompetitive ELISA, respectively, remained constant throughout the shelf life of yogurt.

  5. Scaling up of manufacturing processes of recycled carpet based composites

    NASA Astrophysics Data System (ADS)

    Lakshminarayanan, Krishnan

    2011-12-01

    In this work, feasibility of recycling post-consumer carpets using a modified vacuum assisted resisted molding process into large-scale components was successfully demonstrated. The scale up also included the incorporation of nano-clay films in the carpet composites. It is expected that the films will enhance the ability of the composite to withstand environmental degradation and also serve as a fire retardant. Low-cost resins were used to fabricate the recycled carpet-based composites. The scale up in terms of process was achieved by manufacturing composites without a hot press and thereby saving additional equipment cost. Mechanical and physical properties were evaluated. Large-scale samples demonstrated mechanical properties that were different from results from small samples. Acoustic tests indicate good sound absorption of the carpet composite. Cost analysis of the composite material based on the cost of the raw materials and the manufacturing process has been presented.

  6. 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.

  7. 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.

  8. 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

    ... 16, 2009 (74 FR 3055), FDA announced the availability of the draft guidance of the same title dated... Additional Requirements for Manufacturers of Human Cells, Tissues, and Cellular and Tissue-Based Products... Tissue Practice (CGTP) and Additional Requirements for Manufacturers of Human Cells, Tissues,...

  9. Modeling the VARTM Composite Manufacturing Process

    NASA Technical Reports Server (NTRS)

    Song, Xiao-Lan; Loos, Alfred C.; Grimsley, Brian W.; Cano, Roberto J.; Hubert, Pascal

    2004-01-01

    A comprehensive simulation model of the Vacuum Assisted Resin Transfer Modeling (VARTM) composite manufacturing process has been developed. For isothermal resin infiltration, the model incorporates submodels which describe cure of the resin and changes in resin viscosity due to cure, resin flow through the reinforcement preform and distribution medium and compaction of the preform during the infiltration. The accuracy of the model was validated by measuring the flow patterns during resin infiltration of flat preforms. The modeling software was used to evaluate the effects of the distribution medium on resin infiltration of a flat preform. Different distribution medium configurations were examined using the model and the results were compared with data collected during resin infiltration of a carbon fabric preform. The results of the simulations show that the approach used to model the distribution medium can significantly effect the predicted resin infiltration times. Resin infiltration into the preform can be accurately predicted only when the distribution medium is modeled correctly.

  10. 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.

  11. 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.

  12. 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

    2015-01-01

    Additive manufacturing techniques are becoming more prominent and cost-effective as 3D printing becomes higher quality and more inexpensive. The idea of 3D printed prosthetics components promises affordable, customizable devices, but these systems currently have major shortcomings in durability and function. In this paper, we propose a fabrication method for custom composite prostheses utilizing additive manufacturing, allowing for customizability, as well the durability of professional prosthetics. The manufacturing process is completed using 3D printed molds in a multi-stage molding system, which creates a custom finger or palm with a lightweight epoxy foam core, a durable composite outer shell, and soft urethane gripping surfaces. The composite material was compared to 3D printed and aluminum materials using a three-point bending test to compare stiffness, as well as gravimetric measurements to compare weight. The composite finger demonstrates the largest stiffness with the lowest weight compared to other tested fingers, as well as having customizability and lower cost, proving to potentially be a substantial benefit to the development of upper-limb prostheses. PMID:26737367

  13. 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.

  14. 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.

  15. 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

    2015-01-01

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

  16. Manufacturability improvements in EUV resist processing toward NXE:3300 processing

    NASA Astrophysics Data System (ADS)

    Kuwahara, Yuhei; Matsunaga, Koichi; Shimoaoki, Takeshi; Kawakami, Shinichiro; Nafus, Kathleen; Foubert, Philippe; Goethals, Anne-Marie; Shimura, Satoru

    2014-03-01

    As the design rule of semiconductor process gets finer, extreme ultraviolet lithography (EUVL) technology is aggressively studied as a process for 22nm half pitch and beyond. At present, the studies for EUV focus on manufacturability. It requires fine resolution, uniform, smooth patterns and low defectivity, not only after lithography but also after the etch process. In the first half of 2013, a CLEAN TRACKTM LITHIUS ProTMZ-EUV was installed at imec for POR development in preparation of the ASML NXE:3300. This next generation coating/developing system is equipped with state of the art defect reduction technology. This tool with advanced functions can achieve low defect levels. This paper reports on the progress towards manufacturing defectivity levels and latest optimizations towards the NXE:3300 POR for both lines/spaces and contact holes at imec.

  17. 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.

  18. 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.

  19. 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

  20. [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.

  1. 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.

  2. Simulating the Composite Propellant Manufacturing Process

    NASA Technical Reports Server (NTRS)

    Williamson, Suzanne; Love, Gregory

    2000-01-01

    There is a strategic interest in understanding how the propellant manufacturing process contributes to military capabilities outside the United States. The paper will discuss how system dynamics (SD) has been applied to rapidly assess the capabilities and vulnerabilities of a specific composite propellant production complex. These facilities produce a commonly used solid propellant with military applications. The authors will explain how an SD model can be configured to match a specific production facility followed by a series of scenarios designed to analyze operational vulnerabilities. By using the simulation model to rapidly analyze operational risks, the analyst gains a better understanding of production complexities. There are several benefits of developing SD models to simulate chemical production. SD is an effective tool for characterizing complex problems, especially the production process where the cascading effect of outages quickly taxes common understanding. By programming expert knowledge into an SD application, these tools are transformed into a knowledge management resource that facilitates rapid learning without requiring years of experience in production operations. It also permits the analyst to rapidly respond to crisis situations and other time-sensitive missions. Most importantly, the quantitative understanding gained from applying the SD model lends itself to strategic analysis and planning.

  3. Additive manufacturing of patient-specific tubular continuum manipulators

    NASA Astrophysics Data System (ADS)

    Amanov, Ernar; Nguyen, Thien-Dang; Burgner-Kahrs, Jessica

    2015-03-01

    Tubular continuum robots, which are composed of multiple concentric, precurved, elastic tubes, provide more dexterity than traditional surgical instruments at the same diameter. The tubes can be precurved such that the resulting manipulator fulfills surgical task requirements. Up to now the only material used for the component tubes of those manipulators is NiTi, a super-elastic shape-memory alloy of nickel and titan. NiTi is a cost-intensive material and fabrication processes are complex, requiring (proprietary) technology, e.g. for shape setting. In this paper, we evaluate component tubes made of 3 different thermoplastic materials (PLA, PCL and nylon) using fused filament fabrication technology (3D printing). This enables quick and cost-effective production of custom, patient-specific continuum manipulators, produced on site on demand. Stress-strain and deformation characteristics are evaluated experimentally for 16 fabricated tubes of each thermoplastic with diameters and shapes equivalent to those of NiTi tubes. Tubes made of PCL and nylon exhibit properties comparable to those made of NiTi. We further demonstrate a tubular continuum manipulator composed of 3 nylon tubes in a transnasal, transsphenoidal skull base surgery scenario in vitro.

  4. Coaxial additive manufacture of biomaterial composite scaffolds for tissue engineering.

    PubMed

    Cornock, R; Beirne, S; Thompson, B; Wallace, G G

    2014-06-01

    An inherent difficulty associated with the application of suitable bioscaffolds for tissue engineering is the incorporation of adequate mechanical characteristics into the materials which recapitulate that of the native tissue, whilst maintaining cell proliferation and nutrient transfer qualities. Biomaterial composites fabricated using rapid prototyping techniques can potentially improve the functionality and patient-specific processing of tissue engineering scaffolds. In this work, a technique for the coaxial melt extrusion printing of core-shell scaffold structures was designed, implemented and assessed with respect to the repeatability, cell efficacy and scaffold porosity obtainable. Encapsulated alginate hydrogel/thermoplastic polycaprolactone (Alg-PCL) cofibre scaffolds were fabricated. Selective laser melting was used to produce a high resolution stainless steel 316 L coaxial extrusion nozzle, exhibiting diameters of 300 μm/900 μm for the inner and outer nozzles respectively. We present coaxial melt extrusion printed scaffolds of Alg-PCL cofibres with ~0.4 volume fraction alginate, with total fibre diameter as low as 600 μm and core material offset as low as 10% of the total diameter. Furthermore the tuneability of scaffold porosity, pore size and interconnectivity, as well as the preliminary inclusion, compatibility and survival of an L-929 mouse fibroblast cell-line within the scaffolds were explored. This preliminary cell work highlighted the need for optimal material selection and further design reiteration in future research. PMID:24658021

  5. 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.

  6. 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.

  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. 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.

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

    DOE PAGES

    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

  10. 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.

  11. Hydrodynamic Instability in High-speed Direct Laser Deposition for Additive Manufacturing

    NASA Astrophysics Data System (ADS)

    Turichin, Gleb; Zemlyakov, Evgeny; Klimova, Olga; Babkin, Konstantin

    High speed direct laser deposition, when product forms from metal powder, transferred by gas-powder jet, supplied coaxially or non-coaxially to focused laser beam, in one of most prospective additive technologies for production parts for aircraft engines. The limit of process productivity is connected with development of hydrodynamic instability of the melt pool in conditions of high power laser action and material supply by gas-powder jet. Theoretical analysis and experiments allowed clarified a physical nature of instability appearance, determine a stability conditions and invent a methods which allow avoid instability in deposition process. Nozzles for direct laser deposition, designed with consideration of stability conditions, allow get a level of process productivity more then 2 kg/h. The developed technology of deposition and technological equipment, based on high power fiber laser, has been used for manufacturing of parts for "high temperature" unit of aircraft engine.

  12. 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.

  13. 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.

  14. 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.

  15. 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

  16. 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.

  17. Auxetic polyurethane foam: Manufacturing and processing analysis

    NASA Astrophysics Data System (ADS)

    Jahan, Md Deloyer

    Materials with negative Poisson's ratio are referred to as auxetic materials. They are different from conventional materials in their deformation behavior when responding to external stresses. The cross-section of the materials widens in the lateral direction when being stretched in the longitudinal direction and becomes narrower when being compressed longitudinally. While a number of natural auxetic materials exist, most auxetic materials are synthetic. They show interesting properties and have potential in several important applications. Auxetic materials exhibit better mechanical properties than conventional materials such as enhanced indentation resistance, shear resistance, toughness, damping and energy absorption capacity, sound absorption, variable permeability and capability of producing complex curvature. These properties are beneficial in a wide range of applications including personal protective equipments, sound absorbers, packaging, smart filtration, drug delivery, tissue scaffolding, seat cushioning, etc. A wide range of auxetic materials has been synthesized. They include different polymers, metals, composites and ceramics. Among these, auxetic polyurethane (PU) foam is one of the most widely studied types of auxetic materials. Auxetic PU foams are usually fabricated by altering the microstructure of conventional foams and the unusual mechanical properties originate from the deformation characteristics of the microstructures. Three most important processing parameters in fabricating auxetic PU foam that dictate auxetic behavior are processing temperature, heating time and volumetric compression ratio. This study addresses several important issues in the manufacturing and characterization of auxetic PU foam. First, an improved automatic measuring technique has been developed to determine Poisson's ratio of auxetic PU foam. The technique involves development of a Matlab based image processing program. The second part of the study includes an

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

    DOE PAGES

    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

  19. Friction Stir Processing for Efficient Manufacturing

    SciTech Connect

    Mr. Christopher B. Smith; Dr. Oyelayo Ajayi

    2012-01-31

    Friction at contacting surfaces in relative motion is a major source of parasitic energy loss in machine systems and manufacturing processes. Consequently, friction reduction usually translates to efficiency gain and reduction in energy consumption. Furthermore, friction at surfaces eventually leads to wear and failure of the components thereby compromising reliability and durability. In order to reduce friction and wear in tribological components, material surfaces are often hardened by a variety of methods, including conventional heat treatment, laser surface hardening, and thin-film coatings. While these surface treatments are effective when used in conjunction with lubrication to prevent failure, they are all energy intensive and could potentially add significant cost. A new concept for surface hardening of metallic materials and components is Friction Stir Processing (FSP). Compared to the current surface hardening technologies, FSP is more energy efficient has no emission or waste by products and may result in better tribological performance. FSP involves plunging a rotating tool to a predetermined depth (case layer thickness) and translating the FSP tool along the area to be processed. This action of the tool produces heating and severe plastic deformation of the processed area. For steel the temperature is high enough to cause phase transformation, ultimately forming hard martensitic phase. Indeed, FSP has been used for surface modification of several metals and alloys so as to homogenize the microstructure and refine the grain size, both of which led to improved fatigue and corrosion resistance. Based on the effect of FSP on near-surface layer material, it was expected to have beneficial effects on friction and wear performance of metallic materials. However, little or no knowledge existed on the impact of FSP concerning friction and wear performance the subject of the this project and final report. Specifically for steel, which is the most dominant

  20. 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

  1. Developing the Manufacturing Process for Hylene MP Curing Agent

    SciTech Connect

    Eastwood, Eric

    2009-02-16

    This report details efforts to scale-up and re-establish the manufacturing process for the curing agent known as Hylene MP. First, small scale reactions were completed with varying conditions to determine key drivers for yielding high quality product. Once the optimum conditions were determined on the small scale, the scaled-up process conditions were determined. New equipment was incorporated into the manufacturing process to create a closed production system and improve chemical exposure controls and improve worker safety. A safe, efficient manufacturing process was developed to manufacture high quality Hylene MP in large quantities.

  2. Printing Processes Used to Manufacture Photovoltaic Solar Cells

    ERIC Educational Resources Information Center

    Rardin, Tina E.; Xu, Renmei

    2011-01-01

    There is a growing need for renewable energy sources, and solar power is a good option in many instances. Photovoltaic solar panels are now being manufactured via various methods, and different printing processes are being incorporated into the manufacturing process. Screen printing has been used most prevalently in the printing process to make…

  3. Hope versus hype: what can additive manufacturing realistically offer trauma and orthopedic surgery?

    PubMed

    Gibbs, David M R; Vaezi, Mohammad; Yang, Shoufeng; Oreffo, Richard O C

    2014-01-01

    Additive manufacturing (AM) is a broad term encompassing 3D printing and several other varieties of material processing, which involve computer-directed layer-by-layer synthesis of materials. As the popularity of AM increases, so to do expectations of the medical therapies this process may offer. Clinical requirements and limitations of current treatment strategies in bone grafting, spinal arthrodesis, osteochondral injury and treatment of periprosthetic joint infection are discussed. The various approaches to AM are described, and the current state of clinical translation of AM across these orthopedic clinical scenarios is assessed. Finally, we attempt to distinguish between what AM may offer orthopedic surgery from the hype of what has been promised by AM.

  4. 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.

  5. Additive manufacturing of a monolithic optical force sensor based on polarization modulation.

    PubMed

    Nierenberger, Mathieu; Lecler, Sylvain; Pfeiffer, Pierre; Geiskopf, François; Guilhem, Mathieu; Renaud, Pierre

    2015-08-01

    One of the specific interests of optical sensors is their compatibility with harsh environments. The polarization modulated force sensor we propose offers this advantage, in addition to low cost and ease of manufacturing thanks to its acrylate 3D printed monolithic design. All the polarization control is indeed achieved using the geometry of a single component making unnecessary future alignments. The complex geometry of the transducer is obtained thanks to the 3D printing process. This process and the resulting material optical properties are described. The sensor concept and the fabrication method are experimentally investigated. A monolithic force sensor in the required range of 20 N is exhibited for application in the field of MR-compatible robotics. The potentiality of 3D printing for optical application in the design of the force sensor is illustrated.

  6. 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

  7. Hope versus hype: what can additive manufacturing realistically offer trauma and orthopedic surgery?

    PubMed

    Gibbs, David M R; Vaezi, Mohammad; Yang, Shoufeng; Oreffo, Richard O C

    2014-01-01

    Additive manufacturing (AM) is a broad term encompassing 3D printing and several other varieties of material processing, which involve computer-directed layer-by-layer synthesis of materials. As the popularity of AM increases, so to do expectations of the medical therapies this process may offer. Clinical requirements and limitations of current treatment strategies in bone grafting, spinal arthrodesis, osteochondral injury and treatment of periprosthetic joint infection are discussed. The various approaches to AM are described, and the current state of clinical translation of AM across these orthopedic clinical scenarios is assessed. Finally, we attempt to distinguish between what AM may offer orthopedic surgery from the hype of what has been promised by AM. PMID:25159068

  8. 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.

  9. Laser processing for manufacturing nanocarbon materials

    NASA Astrophysics Data System (ADS)

    Van, Hai Hoang

    CNTs have been considered as the excellent candidate to revolutionize a broad range of applications. There have been many method developed to manipulate the chemistry and the structure of CNTs. Laser with non-contact treatment capability exhibits many processing advantages, including solid-state treatment, extremely fast processing rate, and high processing resolution. In addition, the outstanding monochromatic, coherent, and directional beam generates the powerful energy absorption and the resultant extreme processing conditions. In my research, a unique laser scanning method was developed to process CNTs, controlling the oxidation and the graphitization. The achieved controllability of this method was applied to address the important issues of the current CNT processing methods for three applications. The controllable oxidation of CNTs by laser scanning method was applied to cut CNT films to produce high-performance cathodes for FE devices. The production method includes two important self-developed techniques to produce the cold cathodes: the production of highly oriented and uniformly distributed CNT sheets and the precise laser trimming process. Laser cutting is the unique method to produce the cathodes with remarkable features, including ultrathin freestanding structure (~200 nm), greatly high aspect ratio, hybrid CNT-GNR emitter arrays, even emitter separation, and directional emitter alignment. This unique cathode structure was unachievable by other methods. The developed FE devices successfully solved the screening effect issue encounter by current FE devices. The laser-control oxidation method was further developed to sequentially remove graphitic walls of CNTs. The laser oxidation process was directed to occur along the CNT axes by the laser scanning direction. Additionally, the oxidation was further assisted by the curvature stress and the thermal expansion of the graphitic nanotubes, ultimately opening (namely unzipping) the tubular structure to

  10. 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.

  11. 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.

  12. 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

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. On-Site Additive Manufacturing by Selective Laser Melting of Composite Objects

    NASA Astrophysics Data System (ADS)

    Fateri, M.; Khosravi, M.

    2012-06-01

    This paper proposes a method for cost reduction of future space missions by manufacturing parts on foreign planets. The suitability of Selective Laser Melting process for on-site production of metallic, ceramic and glass products on mars is examined.

  20. 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.

  1. Nonterrestrial material processing and manufacturing of large space systems

    NASA Technical Reports Server (NTRS)

    Vontiesenhausen, G. F.

    1978-01-01

    An attempt is made to provide pertinent and readily usable information on the extraterrestrial processing of materials and manufacturing of components and elements of these planned large space systems from preprocessed lunar materials which are made available at a processing and manufacturing site in space. Required facilities, equipment, machinery, energy and manpower are defined.

  2. Integrated manufacturing and processing predoctoral fellowships. Final performance report

    SciTech Connect

    Rozzell, Thomas

    1999-10-01

    The first and fourth cohorts of U.S. Department of Energy Integrated Manufacturing and Processing Predoctoral Fellows were supported under this grant for up to three years of study leading to a PhD degree in a field related to integrated manufacturing and processing.

  3. Study on Process Planning System for Holonic Manufacturing

    NASA Astrophysics Data System (ADS)

    Rais, Suyoto; Sugimura, Nobuhiro; Kokubun, Atsushi

    New architectures of manufacturing systems have been proposed aiming at realizing more flexible control structures of manufacturing systems which can cope with dynamic changes in volume and variety of products. They are so called as holonic manufacturing systems, autonomous distributed manufacturing systems, random manufacturing systems and biological manufacturing systems. The objective of the present research is to develop an integrated process planning and scheduling system which is applicable to the holonic manufacturing systems. In the previous paper, procedures were proposed to recognize the machining features from the product model. A systematic method is proposed, in this paper, to select suitable machining sequences and sequences of machining equipment, by applying the genetic algorithm (GA) and the dynamic programming (DP) methods.

  4. Additive manufacturing of wet-spun polymeric scaffolds for bone tissue engineering.

    PubMed

    Puppi, Dario; Mota, Carlos; Gazzarri, Matteo; Dinucci, Dinuccio; Gloria, Antonio; Myrzabekova, Mairam; Ambrosio, Luigi; Chiellini, Federica

    2012-12-01

    An Additive Manufacturing technique for the fabrication of three-dimensional polymeric scaffolds, based on wet-spinning of poly(ε-caprolactone) (PCL) or PCL/hydroxyapatite (HA) solutions, was developed. The processing conditions to fabricate scaffolds with a layer-by-layer approach were optimized by studying their influence on fibres morphology and alignment. Two different scaffold architectures were designed and fabricated by tuning inter-fibre distance and fibres staggering. The developed scaffolds showed good reproducibility of the internal architecture characterized by highly porous, aligned fibres with an average diameter in the range 200-250 μm. Mechanical characterization showed that the architecture and HA loading influenced the scaffold compressive modulus and strength. Cell culture experiments employing MC3T3-E1 preosteoblast cell line showed good cell adhesion, proliferation, alkaline phosphatase activity and bone mineralization on the developed scaffolds.

  5. 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.

  6. 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.

  7. 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.

  8. Wellbore manufacturing processes for in situ heat treatment processes

    DOEpatents

    Davidson, Ian Alexander; Geddes, Cameron James; Rudolf, Randall Lynn; Selby, Bruce Allen; MacDonald, Duncan Charles

    2012-12-11

    A method includes making coiled tubing at a coiled tubing manufacturing unit coupled to a coiled tubing transportation system. One or more coiled tubing reels are transported from the coiled tubing manufacturing unit to one or more moveable well drilling systems using the coiled tubing transportation system. The coiled tubing transportation system runs from the tubing manufacturing unit to one or more movable well drilling systems, and then back to the coiled tubing manufacturing unit.

  9. 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.

  10. 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

  11. Computer simulation of gear tooth manufacturing processes

    NASA Technical Reports Server (NTRS)

    Mavriplis, Dimitri; Huston, Ronald L.

    1990-01-01

    The use of computer graphics to simulate gear tooth manufacturing procedures is discussed. An analytical basis for the simulation is established for spur gears. The simulation itself, however, is developed not only for spur gears, but for straight bevel gears as well. The applications of the developed procedure extend from the development of finite element models of heretofore intractable geometrical forms, to exploring the fabrication of nonstandard tooth forms.

  12. Systematic Classifier OF Manufacturing Processes For Medium Size Shafts

    NASA Astrophysics Data System (ADS)

    Lychagin, D. V.; Lasukov, A. A.; Walter, A. V.; Arkhipova, D. A.

    2016-04-01

    The article considers some issues of increasing efficiency of manufacturing preparation as a part of manufacturing processes design at a machine building enterprise. A tree of routing manufacturing processes for machining shafts of medium size is described as an example of clustering parts according to their structural and technological characteristics. Processing route for a certain part included into a certain group is developed through choosing machining operations for elementary surfaces of a part from the process route developed for a template representative of the group.

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

    DOE PAGES

    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

  14. 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

  15. 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.

  16. Feature based Weld-Deposition for Additive Manufacturing of Complex Shapes

    NASA Astrophysics Data System (ADS)

    Panchagnula, Jayaprakash Sharma; Simhambhatla, Suryakumar

    2016-08-01

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

  17. 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.

  18. 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.

  19. 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.

  20. Process and quality verification controls for solid propellant manufacturing

    NASA Technical Reports Server (NTRS)

    Rogers, C. J.

    1983-01-01

    It is pointed out that in-process tests to verify quality and detect discrepant propellant which could compromise motor performance are essential elements of the solid composite propellant manufacturing process. The successful performance of the 260SL-1 and 260SL-2 motors aptly verified the controls used for manufacturing the propellant. The present investigation is concerned with the selected control parameters, and their relationships to composition and final propellant properties. Control performance is evaluated by comparison with processing data experienced in the manufacture of the propellant for the 260SL-1 motor. It is found that the in-process quality verification controls utilized in the propellant manufacturing process for the 260-in. diameter motor contributed significantly to the confidence of successful and predictable motor performance.

  1. 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.

  2. 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

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

    PubMed

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

    2015-04-01

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

  4. Development of a Launch Vehicle Manufacturing Process. Chapter 4

    NASA Technical Reports Server (NTRS)

    Vickers, John; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    One of the goals of this chapter is to provide sufficient information so that you can develop a manufacturing process for a potential launch vehicle. With the variety of manufacturing options available, you might ask how this can possibly be done in the span of a single chapter. Actually, it will be quite simple because a basic manufacturing process is nothing more than a set of logical steps that are iterated until they produce a desired product. Although these statements seem simple and logical, don't let this simplicity fool you. Manufacturing problems with launch vehicles and their subassemblies have been the primary cause of project failures because the vehicle concept delivered to the manufacturing floor could not be built as designed.

  5. Process standardization for the manufacture of Thabdi Peda.

    PubMed

    Modha, H M; Patel, N M; Patel, H G; Patel, K N

    2015-06-01

    Traditional dairy products in India are manufactured using age old methods. Such methods varies from place to place. For industrial production of such products a standardized process is needed. Present study was designed to arrive at a method of manufacture for Thabdi Peda, a very popular sweet in Saurashtra region of Gujarat. Range of process parameters like fat percent of milk (4 to 8 %), rate of sugar addition (6 to 10 %) and duration of final heat desiccation (20 to 60 min) were studied and optimum values determined using Response Surface Methodology (RSM) with central composite rotatable design (CCRD). The samples obtained from trials were analyzed for sensory, physicochemical, compositional and textural attributes. The optimized process developed with 10 kg batch of milk having 6 % fat, 8.33 % rate of sugar addition and 34 min duration of heating produced most acceptable product. Standardized Thabdi Peda was found to contain on an average 16.80 % fat, 17.48 % moisture, 11.25 % protein, 20.95 % lactose, 29.99 % sucrose, 3.53 % ash and it gave 28.75 % yield. The pH, water activity and HMF (μ Mole/100 g) content were 6.42, 0.807 and 121.91 respectively. Standard plate count, Yeast and Mold counts were observed to be 3.68 log cfu/g, and 2.51 log cfu/g respectively. No coliforms were observed in Thabdi Peda.

  6. 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.

  7. 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

  8. Enhancing Manufacturing Process Education via Computer Simulation and Visualization

    ERIC Educational Resources Information Center

    Manohar, Priyadarshan A.; Acharya, Sushil; Wu, Peter

    2014-01-01

    Industrially significant metal manufacturing processes such as melting, casting, rolling, forging, machining, and forming are multi-stage, complex processes that are labor, time, and capital intensive. Academic research develops mathematical modeling of these processes that provide a theoretical framework for understanding the process variables…

  9. 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.

  10. Engineering aspects of rate-related processes in food manufacturing.

    PubMed

    Adachi, Shuji

    2015-01-01

    Many rate-related phenomena occur in food manufacturing processes. This review addresses four of them, all of which are topics that the author has studied in order to design food manufacturing processes that are favorable from the standpoint of food engineering. They include chromatographic separation through continuous separation with a simulated moving adsorber, lipid oxidation kinetics in emulsions and microencapsulated systems, kinetic analysis and extraction in subcritical water, and water migration in pasta.

  11. 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…

  12. Multiscale 3D manufacturing: combining thermal extrusion printing with additive and subtractive direct laser writing

    NASA Astrophysics Data System (ADS)

    Malinauskas, Mangirdas; Lukoševičius, Laurynas; MackevičiÅ«tÄ--, DovilÄ--; BalčiÅ«nas, Evaldas; RekštytÄ--, Sima; Paipulas, Domas

    2014-05-01

    A novel approach for efficient manufacturing of three-dimensional (3D) microstructured scaffolds designed for cell studies and tissue engineering applications is presented. A thermal extrusion (fused filament fabrication) 3D printer is employed as a simple and low-cost tabletop device enabling rapid materialization of CAD models out of biocompatible and biodegradable polylactic acid (PLA). Here it was used to produce cm- scale microporous (pore size varying from 100 to 400 µm) scaffolds. The fabricated objects were further laser processed in a direct laser writing (DLW) subtractive (ablation) and additive (lithography) manners. The first approach enables precise surface modification by creating micro-craters, holes and grooves thus increasing the surface roughness. An alternative way is to immerse the 3D PLA scaffold in a monomer solution and use the same DLW setup to refine its inner structure by fabricating dots, lines or a fine mesh on top as well as inside the pores of previously produced scaffolds. The DLW technique is empowered by ultrafast lasers - it allows 3D structuring with high spatial resolution in a great variety of photosensitive materials. Structure geometry on macro- to micro- scales could be finely tuned by combining these two fabrication techniques. Such artificial 3D substrates could be used for cell growth or as biocompatible-biodegradable implants. This combination of distinct material processing techniques enables rapid fabrication of diverse functional micro- featured and integrated devices. Hopefully, the proposed approach will find numerous applications in the field of ms, microfluidics, microoptics and many others.

  13. Analytic network process model for sustainable lean and green manufacturing performance indicator

    NASA Astrophysics Data System (ADS)

    Aminuddin, Adam Shariff Adli; Nawawi, Mohd Kamal Mohd; Mohamed, Nik Mohd Zuki Nik

    2014-09-01

    Sustainable manufacturing is regarded as the most complex manufacturing paradigm to date as it holds the widest scope of requirements. In addition, its three major pillars of economic, environment and society though distinct, have some overlapping among each of its elements. Even though the concept of sustainability is not new, the development of the performance indicator still needs a lot of improvement due to its multifaceted nature, which requires integrated approach to solve the problem. This paper proposed the best combination of criteria en route a robust sustainable manufacturing performance indicator formation via Analytic Network Process (ANP). The integrated lean, green and sustainable ANP model can be used to comprehend the complex decision system of the sustainability assessment. The finding shows that green manufacturing is more sustainable than lean manufacturing. It also illustrates that procurement practice is the most important criteria in the sustainable manufacturing performance indicator.

  14. Cost analysis of advanced turbine blade manufacturing processes

    NASA Technical Reports Server (NTRS)

    Barth, C. F.; Blake, D. E.; Stelson, T. S.

    1977-01-01

    A rigorous analysis was conducted to estimate relative manufacturing costs for high technology gas turbine blades prepared by three candidate materials process systems. The manufacturing costs for the same turbine blade configuration of directionally solidified eutectic alloy, an oxide dispersion strengthened superalloy, and a fiber reinforced superalloy were compared on a relative basis to the costs of the same blade currently in production utilizing the directional solidification process. An analytical process cost model was developed to quantitatively perform the cost comparisons. The impact of individual process yield factors on costs was also assessed as well as effects of process parameters, raw materials, labor rates and consumable items.

  15. Manufacturing process of a multifunctional composite panel with nanocharged matrix

    NASA Astrophysics Data System (ADS)

    Volponi, R.; Spena, P.; De Nicola, F.; Guadagno, L.; Raimondo, M.; Vietri, U.

    2016-05-01

    This paper proposes an effective manufacturing process developed to overcome drawbacks that can occur using a nanofilled resin as matrix in aeronautical composites. Nanoparticles embedded in epoxy resins impregnating carbon fibers are able to improve a composite with new desired functionalities. As soon as the nanoparticles are dispersed in a resin, the viscosity dizzily rises and usually, the traditional manufacturing processes are not suitable to obtain a good quality of the manufactured panels. An alternative method has been developed starting from the Resin Film Infusion (RFI) process. This method has been firstly tested on several flat panels, and then it has been transferred on a more complex shaped panel with three stringers. In this work, a flame resistant resin based on a tetrafunctional epoxy precursor filled with carbon nanotubes to increase electrical conductivity, has been used for the panel manufacturing.

  16. 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

  17. 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.

  18. Situ process for making multifunctional fuel additives

    SciTech Connect

    Carrier, R.C.; Allen, B.R.

    1984-02-28

    Disclosed is an in situ or ''one pot'' process for making a fuel additive comprising reacting an excess of at least one N-primary alkylalkylene diamine with maleic anhydride in the presence of from 20 to 36 weight percent of a mineral oil reaction diluent at a temperature ranging from ambient to about 225/sup 0/ F. and recovering a product containing a primary aliphatic hydrocarbon amino alkylene substituted asparagine, an N-primary alkylalkylene diamine in the reaction oil with the product having a by-product succinimide content not in excess of 1.0 weight percent, based on the weight of asparagine present.

  19. The Role of Laser Additive Manufacturing Methods of Metals in Repair, Refurbishment and Remanufacturing - Enabling Circular Economy

    NASA Astrophysics Data System (ADS)

    Leino, Maija; Pekkarinen, Joonas; Soukka, Risto

    Circular economy is an economy model where products, components, and materials are aimed to be kept at their highest utility and value at all times. Repair, refurbishment and remanufacturing processes are procedures aiming at returning the value of the product during its life cycle. Additive manufacturing (AM) is expected to be an enabling technology in circular economy based business models. One of AM process that enables repair, refurbishment and remanufacturing is Directed Energy Deposition. Respectively Powder Bed Fusion enables manufacturing of replacement components on demand. The aim of this study is to identify the current research findings and state of art of utilizing AM in repair, refurbishment and remanufacturing processes of metallic products. The focus is in identifying possibilities of AM in promotion of circular economy and expected environmental benefits based on the found literature. Results of the study indicate significant potential in utilizing AM in repair, refurbishment and remanufacturing activities.

  20. Encapsulation Processing and Manufacturing Yield Analysis

    NASA Technical Reports Server (NTRS)

    Willis, P.

    1985-01-01

    Evaluation of the ethyl vinyl acetate (EVA) encapsulation system is presented. This work is part of the materials baseline needed to demonstrate a 30 year module lifetime capability. Process and compound variables are both being studied along with various module materials. Results have shown that EVA should be stored rolled up, and enclosed in a plastic bag to retard loss of peroxide curing agents. The TBEC curing agent has superior shelf life and processing than the earlier Lupersol-101 curing agent. Analytical methods were developed to test for peroxide content, and experimental methodologies were formalized.

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

    DOE PAGES

    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

  2. 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.

  3. 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.

  4. Amorphous solid dispersions: Rational selection of a manufacturing process.

    PubMed

    Vasconcelos, Teófilo; Marques, Sara; das Neves, José; Sarmento, Bruno

    2016-05-01

    Amorphous products and particularly amorphous solid dispersions are currently one of the most exciting areas in the pharmaceutical field. This approach presents huge potential and advantageous features concerning the overall improvement of drug bioavailability. Currently, different manufacturing processes are being developed to produce amorphous solid dispersions with suitable robustness and reproducibility, ranging from solvent evaporation to melting processes. In the present paper, laboratorial and industrial scale processes were reviewed, and guidelines for a rationale selection of manufacturing processes were proposed. This would ensure an adequate development (laboratorial scale) and production according to the good manufacturing practices (GMP) (industrial scale) of amorphous solid dispersions, with further implications on the process validations and drug development pipeline. PMID:26826438

  5. 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.

  6. Using additive manufacturing in accuracy evaluation of reconstructions from computed tomography.

    PubMed

    Smith, Erin J; Anstey, Joseph A; Venne, Gabriel; Ellis, Randy E

    2013-05-01

    Bone models derived from patient imaging and fabricated using additive manufacturing technology have many potential uses including surgical planning, training, and research. This study evaluated the accuracy of bone surface reconstruction of two diarthrodial joints, the hip and shoulder, from computed tomography. Image segmentation of the tomographic series was used to develop a three-dimensional virtual model, which was fabricated using fused deposition modelling. Laser scanning was used to compare cadaver bones, printed models, and intermediate segmentations. The overall bone reconstruction process had a reproducibility of 0.3 ± 0.4 mm. Production of the model had an accuracy of 0.1 ± 0.1 mm, while the segmentation had an accuracy of 0.3 ± 0.4 mm, indicating that segmentation accuracy was the key factor in reconstruction. Generally, the shape of the articular surfaces was reproduced accurately, with poorer accuracy near the periphery of the articular surfaces, particularly in regions with periosteum covering and where osteophytes were apparent.

  7. 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.

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

    DOE PAGES

    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

  9. 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.

  10. Ramp Technology and Intelligent Processing in Small Manufacturing

    NASA Technical Reports Server (NTRS)

    Rentz, Richard E.

    1992-01-01

    To address the issues of excessive inventories and increasing procurement lead times, the Navy is actively pursuing flexible computer integrated manufacturing (FCIM) technologies, integrated by communication networks to respond rapidly to its requirements for parts. The Rapid Acquisition of Manufactured Parts (RAMP) program, initiated in 1986, is an integral part of this effort. The RAMP program's goal is to reduce the current average production lead times experienced by the Navy's inventory control points by a factor of 90 percent. The manufacturing engineering component of the RAMP architecture utilizes an intelligent processing technology built around a knowledge-based shell provided by ICAD, Inc. Rules and data bases in the software simulate an expert manufacturing planner's knowledge of shop processes and equipment. This expert system can use Product Data Exchange using STEP (PDES) data to determine what features the required part has, what material is required to manufacture it, what machines and tools are needed, and how the part should be held (fixtured) for machining, among other factors. The program's rule base then indicates, for example, how to make each feature, in what order to make it, and to which machines on the shop floor the part should be routed for processing. This information becomes part of the shop work order. The process planning function under RAMP greatly reduces the time and effort required to complete a process plan. Since the PDES file that drives the intelligent processing is 100 percent complete and accurate to start with, the potential for costly errors is greatly diminished.

  11. Method for controlling a laser additive process using intrinsic illumination

    NASA Astrophysics Data System (ADS)

    Tait, Robert; Cai, Guoshuang; Azer, Magdi; Chen, Xiaobin; Liu, Yong; Harding, Kevin

    2015-05-01

    One form of additive manufacturing is to use a laser to generate a melt pool from powdered metal that is sprayed from a nozzle. The laser net-shape machining system builds the part a layer at a time by following a predetermined path. However, because the path may need to take many turns, maintaining a constant melt pool may not be easy. A straight section may require one speed and power while a sharp bend would over melt the metal at the same settings. This paper describes a process monitoring method that uses the intrinsic IR radiation from the melt pool along with a process model configured to establish target values for the parameters associated with the manufacture or repair. This model is based upon known properties of the metal being used as well as the properties of the laser beam. An adaptive control technique is then employed to control process parameters of the machining system based upon the real-time weld pool measurement. Since the system uses the heat radiant from the melt pool, other previously deposited metal does not confuse the system as only the melted material is seen by the camera.

  12. 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

    2015-12-19

    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.

  13. 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

  14. 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.

  15. 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

  16. 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.

  17. 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.

  18. Ceramic component manufacturing process development. Final report

    SciTech Connect

    Robinson, S.

    1996-09-30

    Ceramic materials are well suited for applications where temperature, wear, and corrosion resistance are necessary. The toughness and wear resistance properties that make ceramics desirable, also make fabrication of parts difficult. The objective of this CRADA was to increase the grinding efficiency on Ceradyne Incorporated silicon nitride. This was to be accomplished through optimization of grinding wheel life and increasing silicon nitride material removal rates. Experiments were conducted to determine the relationship between grinding parameters, wheel wear, and material removal rates. Due to excessive, unexplained variation in the experimental results, a consistent relationship between the selected grinding parameters and wheel wear could not be established. Maximum material removal rates were limited by spindle and table drive power. Additional experiments were conducted to evaluate high speed grinding. When compared to conventional grinding speeds, the material removal rates using high speed grinding (13,000 SFM) increased by a factor of five to ten with no degradation of fracture strength.

  19. Modeling Manufacturing Processes to Mitigate Technological Risk

    SciTech Connect

    Allgood, G.O.; Manges, W.W.

    1999-10-24

    An economic model is a tool for determining the justifiable cost of new sensors and subsystems with respect to value and operation. This process balances the R and D costs against the expense of maintaining current operations and allows for a method to calculate economic indices of performance that can be used as control points in deciding whether to continue development or suspend actions. The model can also be used as an integral part of an overall control loop utilizing real-time process data from the sensor groups to make production decisions (stop production and repair machine, continue and warn of anticipated problems, queue for repairs, etc.). This model has been successfully used and deployed in the CAFE Project. The economic model was one of seven (see Fig. 1) elements critical in developing an investment strategy. It has been successfully used in guiding the R and D activities on the CAFE Project, suspending activities on three new sensor technologies, and continuing development o f two others. The model has also been used to justify the development of a new prognostic approach for diagnosing machine health using COTS equipment and a new algorithmic approach. maintaining current operations and allows for a method to calculate economic indices of performance that can be used as control points in deciding whether to continue development or suspend actions. The model can also be used as an integral part of an overall control loop utilizing real-time process data from the sensor groups to make production decisions (stop production and repair machine, continue and warn of anticipated problems, queue for repairs, etc.).

  20. Automated manufacturing process for DEAP stack-actuators

    NASA Astrophysics Data System (ADS)

    Tepel, Dominik; Hoffstadt, Thorben; Maas, Jürgen

    2014-03-01

    Dielectric elastomers (DE) are thin polymer films belonging to the class of electroactive polymers (EAP), which are coated with compliant and conductive electrodes on each side. Due to the influence of an electrical field, dielectric elastomers perform a large amount of deformation. In this contribution a manufacturing process of automated fabricated stack-actuators based on dielectric electroactive polymers (DEAP) are presented. First of all the specific design of the considered stack-actuator is explained and afterwards the development, construction and realization of an automated manufacturing process is presented in detail. By applying this automated process, stack-actuators with reproducible and homogeneous properties can be manufactured. Finally, first DEAP actuator modules fabricated by the mentioned process are validated experimentally.

  1. Planning and scheduling for agile manufacturers: The Pantex Process Model

    SciTech Connect

    Kjeldgaard, E.A.; Jones, D.A.; List, G.F.; Tumquist, M.A.

    1998-02-01

    Effective use of resources that are shared among multiple products or processes is critical for agile manufacturing. This paper describes the development and implementation of a computerized model to support production planning in a complex manufacturing system at the Pantex Plant, a US Department of Energy facility. The model integrates two different production processes (nuclear weapon disposal and stockpile evaluation) that use common facilities and personnel at the plant. The two production processes are characteristic of flow-shop and job shop operations. The model reflects the interactions of scheduling constraints, material flow constraints, and the availability of required technicians and facilities. Operational results show significant productivity increases from use of the model.

  2. 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

  3. 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

  4. 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.

  5. 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

  6. Manufacturing Squares: An Integrative Statistical Process Control Exercise

    ERIC Educational Resources Information Center

    Coy, Steven P.

    2016-01-01

    In the exercise, students in a junior-level operations management class are asked to manufacture a simple product. Given product specifications, they must design a production process, create roles and design jobs for each team member, and develop a statistical process control plan that efficiently and effectively controls quality during…

  7. 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.

  8. Biofabrication of customized bone grafts by combination of additive manufacturing and bioreactor knowhow.

    PubMed

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

    2014-09-01

    This study reports on an original concept of additive manufacturing for the fabrication of tissue engineered constructs (TEC), offering the possibility of concomitantly manufacturing a customized scaffold and a bioreactor chamber to any size and shape. As a proof of concept towards the development of anatomically relevant TECs, this concept was utilized for the design and fabrication of a highly porous sheep tibia scaffold around which a bioreactor chamber of similar shape was simultaneously built. The morphology of the bioreactor/scaffold device was investigated by micro-computed tomography and scanning electron microscopy confirming the porous architecture of the sheep tibiae as opposed to the non-porous nature of the bioreactor chamber. Additionally, this study demonstrates that both the shape, as well as the inner architecture of the device can significantly impact the perfusion of fluid within the scaffold architecture. Indeed, fluid flow modelling revealed that this was of significant importance for controlling the nutrition flow pattern within the scaffold and the bioreactor chamber, avoiding the formation of stagnant flow regions detrimental for in vitro tissue development. The bioreactor/scaffold device was dynamically seeded with human primary osteoblasts and cultured under bi-directional perfusion for two and six weeks. Primary human osteoblasts were observed homogenously distributed throughout the scaffold, and were viable for the six week culture period. This work demonstrates a novel application for additive manufacturing in the development of scaffolds and bioreactors. Given the intrinsic flexibility of the additive manufacturing technology platform developed, more complex culture systems can be fabricated which would contribute to the advances in customized and patient-specific tissue engineering strategies for a wide range of applications.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets

    PubMed Central

    Li, Ling; Tirado, Angelica; Nlebedim, I. C.; Rios, Orlando; Post, Brian; Kunc, Vlastimil; Lowden, R. R.; Lara-Curzio, Edgar; Fredette, Robert; Ormerod, John; Lograsso, Thomas A.; Paranthaman, M. Parans

    2016-01-01

    Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic properties are: intrinsic coercivity Hci = 688.4 kA/m, remanence Br = 0.51 T, and energy product (BH)max = 43.49 kJ/m3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. The present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials. PMID:27796339

  14. 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.

  15. 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.

  16. 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

  17. 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.

  18. Investigations on Manufacturability and Process Reliability of Selective Laser Melting

    NASA Astrophysics Data System (ADS)

    Krauss, H.; Zaeh, M. F.

    Selective laser melting is a layer-wise manufacturing process that enables the use of complex geometric shapes in part design and production. An infrared laser beam is focused on a thin layer of metallic powder and selectively deflected in order to scan the cross-section of the parts being built. The process quality is dominated by the consolidation of powder particles through laser beam interaction, the part geometry itself and the arrangement of multiple parts. In this paper, the manufacturability is investigated by characterizing single melt tracks and the buildup of thin wall structures consisting of a few aligned scan tracks.

  19. Process development status report for advanced manufacturing projects

    SciTech Connect

    Brinkman, J.R.; Homan, D.A.

    1990-03-30

    This is the final status report for the approved Advanced Manufacturing Projects for FY 1989. Five of the projects were begun in FY 1987, one in FY 1988, and one in FY 1989. The approved projects cover technology areas in welding, explosive material processing and evaluation, ion implantation, and automated manufacturing. It is expected that the successful completion of these projects well result in improved quality and/or reduced cost for components produced by Mound. Those projects not brought to completion will be continued under Process development in FY 1990.

  20. A factory concept for processing and manufacturing with lunar material

    NASA Technical Reports Server (NTRS)

    Driggers, G. W.

    1977-01-01

    A conceptual design for an orbital factory sized to process 1.5 million metric tons per year of raw lunar fines into 0.3 million metric tons of manufacturing materials is presented. A conservative approach involving application of present earth-based technology leads to a design devoid of new inventions. Earth based counterparts to the factory machinery were used to generate subsystem masses and lumped parameters for volume and mass estimates. The results are considered to be conservative since technologies more advanced than those assumed are presently available in many areas. Some attributes of potential space processing technologies applied to material refinement and component manufacture are discussed.

  1. Monitoring Chlorfenapyr in Green Tea during the Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Takahashi, Atsushi; Kishi, Yasuhiro; Ogawa, Hideyuki; Nakajima, Kenta

    In order to clarify the change in the leaves of agricultural chemicals during the green tea manufacturing process, we analyzed chlorfenapyr in tea leaves obtained at each processing stage by using an immunoassay. Chlorfenapyr is a novel broad-spectrum insecticide-miticide registered in many countries for the control of various insects and mite pests. Chlorfenapyr is stable and persistent in the environment. Furthermore, it is widely applied for tea cultivation in Japan. Therefore, we selected chlorfenapyr for analysis in this study. In the unrefined tea (Aracha) manufacturing process, the highest level of chlorfenapyr was 16.5 ppm, which was obtained in tea powder separated from leaves at the secondary drying stage. However, the level at the other processing stages in tea leaves was approximately 9 ppm, and no significant difference in the chlorfenapyr level was detected between the processing stages. After Aracha processing, tea leaves are classified on the basis of their size, shape and color; this is the refined tea (Shiagecha) manufacturing process. After this process, although a high level of chlorfenapyr was detected in bud tea (8.1 ppm) and honcha (on-grade tea; 6.2 ppm), the level in the other classified teas was approximately 4.0 ppm. Thus, this paper shows the difference in the chlorfenapyr level in tea leaves obtained at each processing stage. This indicated that there are significant differences in the agricultural chemical levels between the green tea processing stages.

  2. Development of Probabilistic Structural Analysis Integrated with Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Pai, Shantaram S.; Nagpal, Vinod K.

    2007-01-01

    An effort has been initiated to integrate manufacturing process simulations with probabilistic structural analyses in order to capture the important impacts of manufacturing uncertainties on component stress levels and life. Two physics-based manufacturing process models (one for powdered metal forging and the other for annular deformation resistance welding) have been linked to the NESSUS structural analysis code. This paper describes the methodology developed to perform this integration including several examples. Although this effort is still underway, particularly for full integration of a probabilistic analysis, the progress to date has been encouraging and a software interface that implements the methodology has been developed. The purpose of this paper is to report this preliminary development.

  3. Integration of Advanced Simulation and Visualization for Manufacturing Process Optimization

    NASA Astrophysics Data System (ADS)

    Zhou, Chenn; Wang, Jichao; Tang, Guangwu; Moreland, John; Fu, Dong; Wu, Bin

    2016-05-01

    The integration of simulation and visualization can provide a cost-effective tool for process optimization, design, scale-up and troubleshooting. The Center for Innovation through Visualization and Simulation (CIVS) at Purdue University Northwest has developed methodologies for such integration with applications in various manufacturing processes. The methodologies have proven to be useful for virtual design and virtual training to provide solutions addressing issues on energy, environment, productivity, safety, and quality in steel and other industries. In collaboration with its industrial partnerships, CIVS has provided solutions to companies, saving over US38 million. CIVS is currently working with the steel industry to establish an industry-led Steel Manufacturing Simulation and Visualization Consortium through the support of National Institute of Standards and Technology AMTech Planning Grant. The consortium focuses on supporting development and implementation of simulation and visualization technologies to advance steel manufacturing across the value chain.

  4. 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

  5. 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.

  6. 21 CFR 1005.25 - Service of process on manufacturers.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Service of process on manufacturers. 1005.25 Section 1005.25 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES... Radiation Control of the Federal Food, Drug, and Cosmetic Act (formerly the Radiation Control for Health...

  7. 21 CFR 1005.25 - Service of process on manufacturers.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 21 Food and Drugs 8 2014-04-01 2014-04-01 false Service of process on manufacturers. 1005.25 Section 1005.25 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES... Subchapter C—Electronic Product Radiation Control of the Federal Food, Drug, and Cosmetic Act (formerly...

  8. Manufacturing Demonstration Facility: Roll-to-Roll Processing

    SciTech Connect

    Datskos, Panos G; Joshi, Pooran C; List III, Frederick Alyious; Duty, Chad E; Armstrong, Beth L; Ivanov, Ilia N; Jacobs, Christopher B; Graham, David E; Moon, Ji Won

    2015-08-01

    This Manufacturing Demonstration Facility (MDF)e roll-to-roll processing effort described in this report provided an excellent opportunity to investigate a number of advanced manufacturing approaches to achieve a path for low cost devices and sensors. Critical to this effort is the ability to deposit thin films at low temperatures using nanomaterials derived from nanofermentation. The overarching goal of this project was to develop roll-to-roll manufacturing processes of thin film deposition on low-cost flexible substrates for electronics and sensor applications. This project utilized ORNL s unique Pulse Thermal Processing (PTP) technologies coupled with non-vacuum low temperature deposition techniques, ORNL s clean room facility, slot dye coating, drop casting, spin coating, screen printing and several other equipment including a Dimatix ink jet printer and a large-scale Kyocera ink jet printer. The roll-to-roll processing project had three main tasks: 1) develop and demonstrate zinc-Zn based opto-electronic sensors using low cost nanoparticulate structures manufactured in a related MDF Project using nanofermentation techniques, 2) evaluate the use of silver based conductive inks developed by project partner NovaCentrix for electronic device fabrication, and 3) demonstrate a suite of low cost printed sensors developed using non-vacuum deposition techniques which involved the integration of metal and semiconductor layers to establish a diverse sensor platform technology.

  9. 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?

  10. Adaptive Process Controls and Ultrasonics for High Temperature PEM MEA Manufacture

    SciTech Connect

    Walczyk, Daniel F.

    2015-08-26

    The purpose of this 5-year DOE-sponsored project was to address major process bottlenecks associated with fuel cell manufacturing. New technologies were developed to significantly reduce pressing cycle time for high temperature PEM membrane electrode assembly (MEA) through the use of novel, robust ultrasonic (U/S) bonding processes along with low temperature (<100°C) PEM MEAs. In addition, greater manufacturing uniformity and performance was achieved through (a) an investigation into the causes of excessive variation in ultrasonically and thermally bonded MEAs using more diagnostics applied during the entire fabrication and cell build process, and (b) development of rapid, yet simple quality control measurement techniques for use by industry.

  11. 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

  12. 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.

  13. 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.

  14. Documentation of a heroin manufacturing process in Afghanistan.

    PubMed

    Zerell, U; Ahrens, B; Gerz, P

    2005-01-01

    The present article documents an authentic process of heroin manufacturing in Afghanistan: white heroin hydrochloride produced using simple equipment and a small quantity of chemicals. The quantities of chemicals actually used corresponded to the minimum needed for manufacturing heroin. The only organic solvent used was acetone, and only a very small quantity of it was used. Because the chemicals used in the demonstration were from actual seizures in Afghanistan, some of the chemicals had been disguised or repackaged by smugglers. Others had been put into labelled containers that proved to be counterfeit, and some glass containers used were not the original containers of the manufacturer displayed on the label. The brown heroin base prepared as an intermediate step in the process shares some of the characteristics of the South-West Asia type of heroin preparations often seized in Germany. The final product of the documented heroin manufacturing process was white heroin hydrochloride, which shares the key characteristics of the white heroin occasionally seized in Germany and other countries in Western Europe since 2000. The present article demonstrates that this kind of heroin can be produced in Afghanistan.

  15. 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.

  16. 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.

  17. Influence of Manufacturing Processes on the Performance of Phantom Lungs

    SciTech Connect

    Traub, Richard J.

    2008-10-01

    Chest counting is an important tool for estimating the radiation dose to individuals who have inhaled radioactive materials. Chest counting systems are calibrated by counting the activity in the lungs of phantoms where the activity in the phantom lungs is known. In the United States a commonly used calibration phantom was developed at the Lawrence Livermore National Laboratory and is referred to as the Livermore Torso Phantom. An important feature of this phantom is that the phantom lungs can be interchanged so that the counting system can be challenged by different combinations of radionuclides and activity. Phantom lungs are made from lung tissue substitutes whose constituents are foaming plastics and various adjuvants selected to make the lung tissue substitute similar to normal healthy lung tissue. Some of the properties of phantom lungs cannot be readily controlled by phantom lung manufacturers. Some, such as density, are a complex function of the manufacturing process, while others, such as elemental composition of the bulk plastic are controlled by the plastics manufacturer without input, or knowledge of the phantom manufacturer. Despite the fact that some of these items cannot be controlled, they can be measured and accounted for. This report describes how manufacturing processes can influence the performance of phantom lungs. It is proposed that a metric that describes the brightness of the lung be employed by the phantom lung manufacturer to determine how well the phantom lung approximates the characteristics of a human lung. For many purposes, the linear attenuation of the lung tissue substitute is an appropriate surrogate for the brightness.

  18. 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.

  19. Manufacturing process applications team (MATeam). [NASA/industry relations

    NASA Technical Reports Server (NTRS)

    Bangs, E. R.

    1978-01-01

    Forty additional statements were added to the list of 150 problem/opportunity statements identifying possibilities for transfer of NASA technology to various manufacturing industries. Selected statements that are considered to have a high potential for transfer in the 1978 program year are presented in the form of goals and milestones. The transfer of a flux used in the stud welding of aluminum is reported. Candidate RTOP programs are identified.

  20. 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.

  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°.

  2. 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

  3. 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

  4. 16 CFR 303.33 - Country where textile fiber products are processed or manufactured.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 16 Commercial Practices 1 2010-01-01 2010-01-01 false Country where textile fiber products are... UNDER SPECIFIC ACTS OF CONGRESS RULES AND REGULATIONS UNDER THE TEXTILE FIBER PRODUCTS IDENTIFICATION ACT § 303.33 Country where textile fiber products are processed or manufactured. (a) In addition...

  5. "Keep a low profile": pesticide residue, additives, and freon use in Australian tobacco manufacturing

    PubMed Central

    Chapman, S

    2003-01-01

    Objectives: To review the Australian tobacco industry's knowledge of pesticide residue on Australian tobacco and its policies and practices on resisting calls by tobacco control advocates that consumers should be informed about pesticide residue as well as additives. Methods: Review of previously internal industry documents relevant to pesticides and additives in Australian tobacco located from the Master Settlement Agreement websites. Results: Between 1972 and 1994 Philip Morris Australia was aware that its leaf samples were often contaminated with pesticide residue, sometimes including organochlorine levels described by PM's European laboratories as being "extremely high". Consumers were not advised of the contamination nor products withdrawn. From 1981, the industry also resisted calls to declare fully the extent of use and long term safety data on all additives used in their products. They developed standard public responses that were evasive and misleading and, in 2000, implemented voluntary additive disclosure which allowed the companies to continue to avoid disclosure of any ingredient they deemed to be a trade secret. There was extensive use of ozone depleting freon in Australian tobacco manufacturing. Again, the industry kept this information away from consumers. Conclusions: Australian smokers are unable to make informed decisions about smoking because pesticide and additive disclosure remains voluntary. The Australian government should regulate tobacco to require full disclosure including information on the likely health consequences of inhaling pesticide and additive pyrolysis products. PMID:14645948

  6. 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.

  7. 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.

  8. 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.

  9. 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

  10. 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.

  11. Influence of Manufacturing Processes and Microstructures on the Performance and Manufacturability of Advanced High Strength Steels

    SciTech Connect

    Choi, Kyoo Sil; Liu, Wenning N.; Sun, Xin; Khaleel, Mohammad A.

    2009-10-01

    Advanced high strength steels (AHSS) are performance-based steel grades and their global material properties can be achieved with various steel chemistries and manufacturing processes, leading to various microstructures. In this paper, we investigate the influence of supplier variation and resulting microstructure difference on the overall mechanical properties as well as local formability behaviors of advanced high strength steels (AHSS). For this purpose, we first examined the basic material properties and the transformation kinetics of TRansformation Induced Plasticity (TRIP) 800 steels from three different suppliers under different testing temperatures. The experimental results show that there is a significant supplier (i.e., manufacturing process) dependency of the TRIP 800 steel mechanical and microstructure properties. Next, we examined the local formability of two commercial Dual Phase (DP) 980 steels during stamping process. The two commercial DP 980 steels also exhibit noticeably different formability during stamping process in the sense that one of them shows severe tendency for shear fracture. Microstructure-based finite element analyses are carried out next to simulate the localized deformation process with the two DP 980 microstructures, and the results suggest that the possible reason for the difference in formability lies in the morphology of the hard martensite phase in the DP microstructure.

  12. 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

  13. 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.

  14. 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.

  15. 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

  16. 15 CFR 400.33 - Restrictions on manufacturing and processing activity.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 15 Commerce and Foreign Trade 2 2010-01-01 2010-01-01 false Restrictions on manufacturing and...-TRADE ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.33 Restrictions on manufacturing and processing activity. (a) In general. In approving manufacturing or processing activity for a...

  17. 15 CFR 400.33 - Restrictions on manufacturing and processing activity.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 15 Commerce and Foreign Trade 2 2012-01-01 2012-01-01 false Restrictions on manufacturing and...-TRADE ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.33 Restrictions on manufacturing and processing activity. (a) In general. In approving manufacturing or processing activity for a...

  18. 15 CFR 400.33 - Restrictions on manufacturing and processing activity.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... 15 Commerce and Foreign Trade 2 2011-01-01 2011-01-01 false Restrictions on manufacturing and...-TRADE ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.33 Restrictions on manufacturing and processing activity. (a) In general. In approving manufacturing or processing activity for a...

  19. (Development of industrial processes for manufacturing of silicon sampling hadron calorimeters)

    SciTech Connect

    Plasil, F.; Walter, J.

    1991-01-04

    The travelers attended meetings in Dubna and in Zelenograd. Discussions in Dubna centered on (1) obtaining information on USSR capabilities in silicon detector manufacture and testing and on (2) strategy regarding the development of an industrial process and the manufacture of a large quantity of silicon detectors for the SSC L* collaboration. The ELMA plant in Zelenograd was inspected, and discussions were held on production process development and on a possible detector supply time line. In addition, J. Walter participated in technical and cost estimate forecast discussions with representatives of Wacker-Chemitronic Factory (Germany) about silicon crystals for possible use in the SSC.

  20. Advanced Manufacturing Systems in Food Processing and Packaging Industry

    NASA Astrophysics Data System (ADS)

    Shafie Sani, Mohd; Aziz, Faieza Abdul

    2013-06-01

    In this paper, several advanced manufacturing systems in food processing and packaging industry are reviewed, including: biodegradable smart packaging and Nano composites, advanced automation control system consists of fieldbus technology, distributed control system and food safety inspection features. The main purpose of current technology in food processing and packaging industry is discussed due to major concern on efficiency of the plant process, productivity, quality, as well as safety. These application were chosen because they are robust, flexible, reconfigurable, preserve the quality of the food, and efficient.