Matching Items (10)
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- All Subjects: Additive Manufacturing
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Description
The purpose of this honors project is to analyze the difference between different powder separation techniques, and their suitability for my capstone project – ‘Effect of Powder Reuse on DMLS (Direct Metal Laser Sintering) Product Integrity’. Due to the nature of my capstone project, my group needs to characterize foreign contaminants in IN 718 (Ni-based superalloy) powder with a mean diameter around 40um. In order to clearly analyze the contaminants and recycle useful IN 718 powders, powder separation is favorable since the filtered samples will be much easier to characterize rather than inspect all the powders at once under microscope. By conducting literature review, I found that powder separation is commonly used in Geology, and Chemistry department. To screen which combination of techniques could be the best for my project, I have consulted several research specialists, obtained adequate knowledge about powder separation. Accordingly, I will summarize the pros and cons of each method with regard the specific project that I am working on, and further explore the impacts of each method under economical, societal, and environmental considerations. Several powder separation techniques will be discussed in details in the following sections, including water elutriation, settling column, magnetic separation and centrifugation. In addition to these methods, sieving, water tabling and panning will be briefly introduced. After detailed comparison, I found that water elutriation is the most efficient way to purity IN718 powder for reuse purpose, and recovery rate is as high as 70%, which could result in a significant reduction in the manufacturing cost for Honeywell since currently Honeywell only use virgin powders to build parts, and 90% of the leftover powders are discarded.
ContributorsLuo, Zheyu (Author) / Adams, James (Thesis director) / Tasooji, Amaneh (Committee member) / Materials Science and Engineering Program (Contributor) / School of Sustainability (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
Honeywell is currently extending the reach of additive manufacturing (AM) in its product line and expects to produce as much as 40% of its inventory through AM in five years. Additive manufacturing itself is expected to grow into a $3.1 billion dollar industry in the next 5 to 10 years. Reusing IN 718 powder, a nickel-based super alloy metal powder, is an ideal option to reduce costs as well as reduce waste because it can be used with additive manufacturing, but the main obstacles are lack of procedure standardization and product quality assurances from this process. The goal of the capstone project, "Effect of Powder Reuse on DMLS (Direct Metal Laser Sintering) Product Integrity," is to create a powder characterization protocol in order to determine if the IN 718 powder can be reused and what effect the IN 718 reused powder has on the mechanical properties of the products Honeywell fabricates. To provide context and impact of this capstone project, this paper serves to identify the benefits of AM for Honeywell and the cost effectiveness of reusing the powder versus using virgin powder every time. It was found that Honeywell's investment in AM is due to the cost effectiveness of AM, versatility in product design, and to ensure Honeywell remains competitive in the future. In terms of reducing expenses, reusing powder enables costs to be approximately 45% less than using virgin powder. With these key pieces of information, the motivations for this capstone project are understood to a fuller and more profound degree.
ContributorsQuigley, Elizabeth (Co-author) / Luo, Zheyu (Co-author) / Murella, Anoosha (Co-author) / Lee, Wey Lyn (Co-author) / Adams, James (Thesis director) / Tasooji, Amaneh (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
The objective for Under the Camper Shell was to build a prototype of a full living environment within the confines of a pickup truck bed and camper shell. The total volume available to work with is approximately 85ft3. This full living environment entails functioning systems for essential modern living, providing shelter and spaces for cooking, sleeping, eating, and sanitation. The project proved to be very challenging from the start. First, the livable space is extremely small, being only tall enough for one to sit up straight. The truck and camper shell were both borrowed items, so no modifications were allowed for either, e.g. drilling holes for mounting. The idea was to create a system that could be easily removed, transforming it from a camper to a utility truck. The systems developed for the living environment would be modular and transformative so to accommodate for different necessities when packing. The goal was to create a low-water system with sustainability in mind. Insulating the space was the largest challenge and the most rewarding, using body heat to warm the space and insulate from the elements. Comfort systems were made of high density foam cushions in sections to allow folding and stacking for different functions (sleeping, lounging, and sitting). Sanitation is necessary for healthy living and regular human function. A composting toilet was used for the design, lending to low-water usage and is sustainable over time. Saw dust would be necessary for its function, but upon composting, the unit will generate sufficient amounts of heat to act as a space heater. Showering serves the functions of exfoliation and ridding of bacteria, both of which bath wipes can accomplish, limiting massive volumes of water storage and waste. Storage systems were also designed for modularity. Hooks were installed the length of the bed for hanging or securing items as necessary. Some are available for hanging bags. A cabinetry rail also runs the length of the bed to allow movement of hard storage to accommodate different scenarios. The cooking method is called "sous-vide", a method of cooking food in air-tight bags submerged in hot water. The water is reusable for cooking and no dishes are necessary for serving. Overall, the prototype fulfilled its function as a full living environment with few improvements necessary for future use.
ContributorsLimsirichai, Pimwadee (Author) / Foy, Joseph (Thesis director) / Parrish, Kristen (Committee member) / Barrett, The Honors College (Contributor) / Materials Science and Engineering Program (Contributor) / School of Sustainability (Contributor)
Created2014-12
Description
Additive Manufacturing and 3D printing are becoming important technologies in the manufacturing sector. The benefits of this technology include complex part geometry, short lead-times, low waste, and simple user interface. However, the technology does not come without its drawbacks: mainly the removal of support structures from the component. Traditional techniques that involve sawing and cutting can be expensive and take a long time, increasing the overall price of 3D printed metal components. This paper discusses two approaches taken for dissolvable support structures in 3D printed stainless steel (17-4 PH). For the first time in powder bed fusion components, with the help of Christopher Lefky and Dr. Owen Hildreth, dissolvable support capabilities are achieved in metal prints. The first approach, direct dissolution, involves direct corrosion of the entire part, leading to support removal. This approach is not self-terminating, and leads to changes in final component geometry. The second approach involves a post-build sensitization step, which physically alters the microstructure and chemical stability of the first 100-200 microns of the metal. The component is then etched at an electric potential that will readily corrode this sensitized surface, but not the underlying base metal. An electrolytic solution of HNO3/KCl/HCl paired with an anodic bias was used for the direct dissolution approach, resulting in a loss of about 120 microns of material from the components surface. For the self-limiting approach, surface sensitization was achieve through a post build annealing step (800 C for 6 hours, air cooled) with exposure to a sodium hexacynoferrate slurry. When the slurry decomposes in the furnace, carbon atoms diffuse into the surface and precipitate a chromium-carbide, which reduces the chemical stability of the stainless steel. Etching is demonstrated in an anodic bias of HNO3/KCl. To determine proper etching potentials, open circuit potential and cyclic voltammetry experiments were run to create Potentiodynamic Polarization Curves. Further testing of the self-terminating approach was performed on a 316 stainless steel interlocking ring structure with a complex geometry. In this case, 32.5 hours of etching at anodic potentials replaced days of mechanical sawing and cutting.
ContributorsZucker, Brian Nicholas (Co-author) / Lefky, Christopher (Co-author) / Hildreth, Owen (Co-author, Thesis director) / Hsu, Keng (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
This study analyzes mechanical properties of additively manufactured plastic materials produced in a conventional 3D printer. This topic has generally been studied in controlled scenarios, and this study aims to reflect the properties seen by consumers. Layered prints are inherently anisotropic due to the direction of the layers and associated weaknesses or stress concentrators. Thus, the ultimate strength and elastic modulus of plastic specimens produced using default settings are compared based on print orientation angle, and trends are observed. When a specimen is parallel to the build plate, it tends to have ultimate strength and elastic modulus near the published bulk values of 13.2MPa and 404-710MPa, but these values tend to decrease as the print angle increases.
ContributorsGarry, Allan Edward (Author) / Patel, Jay (Thesis director) / Mertz, Benjamin (Committee member) / School of Mathematical and Statistical Sciences (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
Plastics make up a large proportion of solid waste that ends up in landfills and pollute ecosystems, and do not readily decompose. Composites from fungus mycelium are a recent and promising alternative to replace plastics. Mycelium is the root-like fibers from fungi that grow underground. When fed with woody biomass, the mycelium becomes a dense mass. From there, the mycelium is placed in mold to take its shape and grow. Once the growth process is done, the mycelium is baked to end the growth, thus making a mycelium brick. The woody biomass fed into the mycelium can include materials such as sawdust and pistachio shells, which are all cheap feedstock. In comparison to plastics, mycelium bricks are mostly biodegradable and eco-friendly. Mycelium bricks are resistant to water, fire, and mold and are also lightweight, sustainable, and affordable. Mycelium based materials are a viable option to replace less eco-friendly materials. This project aims to explore growth factors of mycelium and incorporate nanomaterials into mycelium bricks to achieve strong and sustainable materials, specifically for packaging materials. The purpose of integrating nanomaterials into mycelium bricks is to add further functionality such as conductivity, and to enhance properties such as mechanical strength.
ContributorsWong, Cindy (Author) / Wang, Qing Hua (Thesis director) / Green, Alexander (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2019-05
Description
The standard for hybrid fuel grains is Hydroxyl-terminated polybutadiene (HTPB). With the advances in additive manufacturing, the promise of 3D printed fuel grains has become a possibility. Yet, 3D printed grains do not have as good of a regression rate as the casted HTPB grains. However, with 3D printing, the core of these grains can be printed to maximize surface area in contact with the oxidizer. The goal of this research is to print hybrid rocket fuel grains with various core geometries and test them on a small-scale hybrid test stand. While the hot fires are still under testing at the time of this abstract, the manufacturing posed an interesting outcome, being more time intensive than expected, contradicting the initial hypothesis of faster manufacturing. Future endeavors will continue research into the cores of the 3D printed grains, possible multi-material made grains and creating core structures for HTPB grains from 3D printed materials.
ContributorsRust, Daniel William Yun Jin (Author) / Rajadas, John (Thesis director) / Taconi, Carolyn (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2019-05
Description
This project sought to analyze the effects of recycling Inconel 718 powder for Direct Metal Laser Sintering (DMSL) for additive manufacturing by testing low cycle fatigue tensile samples ranging from virgin to ten times recycled. Fracture generally occurs at the sample surface where persistent slip planes form and accumulate to cause a sudden fracture leading to signature markings for various phases of crack growth. Effects caused by contamination would be found in the first region of crack growth at the initiation site as the cause stress concentration. Tensile strength and fatigue life were compared to initiation site size found from fracture images obtained using scanning electron microscope imaging which found no significant deviations from the expected surface cracking and LCF region of slip plane buildups. Contamination was not found at any initiation site indicating that fracture life was not impacted by the amount of powder recycling. LCF life ranged from 60,000 to 250,000 which the majority experiencing fractures near 120,000 cyclic loadings. If defect effects were to be found than the low fatigue life sample would exhibit them however its fracture surface did not exhibit contamination but a slight increase in porosity found in the phase III cracking region. The In 718 powders were also analyzed to determine that the primary powder contaminates were brush fibers used to sweep away unused powders during processing however these were not seen in the final DMLS samples.
ContributorsLaws, Alec Ky (Author) / Tasooji, Amaneh (Thesis director) / Eylon, Daniel (Committee member) / Materials Science and Engineering Program (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
The environment today is facing concerns over accumulation of plastics in landfills as well as excessive CO2 emissions. Containers and packaging take up approximately 15 million tons each year, and accumulations such as the Great Pacific Garbage Patch are entering the oceans. Work has been done to alter and treat polyethylene plastic to be added to cement mixtures. This is done to increase bearing capacity and ductility of concrete in addition to decreasing carbon emissions and plastic waste.
ContributorsWestersund, Susanna (Author) / Hoover, Christian (Thesis director) / Soman, Silpa (Committee member) / Barrett, The Honors College (Contributor) / Materials Science and Engineering Program (Contributor) / Civil, Environmental and Sustainable Eng Program (Contributor)
Created2023-05
Description
Our group examined the low rate of clothing utilization in the fashion industry. Fast fashion has contributed to this low rate of utilization, as well as the high amounts of textiles that end up in landfills. Our startup, Patchwork Apparel, was designed to address this problem. Our clothes were made with fabric scraps or donated textiles that would otherwise end up in landfills. The mission of our business was to develop trendy and sustainable apparel that helped to eliminate textile waste while staying on brand with current fashion trends.
ContributorsBolas, Brandon (Author) / Schalla, Freya (Co-author) / Rebe, Breanna (Co-author) / Espinosa, Karly (Co-author) / Byrne, Jared (Thesis director) / Lee, Christopher (Committee member) / Balven, Rachel (Committee member) / Barrett, The Honors College (Contributor) / Materials Science and Engineering Program (Contributor)
Created2022-05