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The aerospace industry has been conducting research on the additive manufacturing (AM) process since the 1980's, but companies have recently just begun to apply AM in hopes that this new technology will meet or exceed the requirements met by previous manufacturing methods, as well as producing more cost effective, geometrically-complex

The aerospace industry has been conducting research on the additive manufacturing (AM) process since the 1980's, but companies have recently just begun to apply AM in hopes that this new technology will meet or exceed the requirements met by previous manufacturing methods, as well as producing more cost effective, geometrically-complex products. This investigation evaluated the performance of 3D-printed aerospace test specimens made by Powder Bed Fusion Technologies, and compared them to forged specimens. A design of experiments varying build parameters was conducted in order to determine AM component porosity. Factors such as powder post-processing, directionality of the build, and fractology of the samples were evaluated through tensile strength testing and hardness testing of Inconel 718 wrought and EBM printed materials. Using electron microsopy, the responses to these factors were analyzed for stress fractures, grain boundaries, and other defects that occurred in the testing process. The comparison determined which metallurgical process provides the most effective material for aircraft usage.
ContributorsNez, Brittany Amber (Author) / Parsey, John (Thesis director) / Hsu, Keng (Committee member) / Godfrey, Donald (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / School of Earth and Space Exploration (Contributor) / Barrett, The Honors College (Contributor)
Created2017-05
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Description
Automobiles can advance greatly with the introduction of metal additive manufactured components. Additive tooling is slowly becoming additive manufacturing and someday the technology will be advanced enough that high volume can be supported. This research was conducted in order to show the advantages metal additive manufacturing has in the automobile

Automobiles can advance greatly with the introduction of metal additive manufactured components. Additive tooling is slowly becoming additive manufacturing and someday the technology will be advanced enough that high volume can be supported. This research was conducted in order to show the advantages metal additive manufacturing has in the automobile industry. One large advantage to metal additive manufacturing is mass reduction. Components can be designed for production with different geometries than other manufacturing methods. The change in geometry can significantly reduce the product volume and therefore mass. Overall, mass reduction in the automotive industry is beneficial. Mass reduction can increase performance and fuel economy of the car. Once metal additive manufacturing becomes capable of higher production, metal additive manufacturing will play a major role in automobile manufacturing. Research was conducted to design and produce an optimized AC compressor bracket. The bracket was designed to the specifications of the OEM component, and the mass was reduced by more than half.
ContributorsSawyer, Brenton James (Author) / Hsu, Keng (Thesis director) / Parsey, John (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2017-05
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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

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.
Created2018-05
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Description
This research was intended to investigate the effects of various motivational variables on high school students' declaration of a STEM major in college, focusing on PSEM majors. It made use of data from the High School Longitudinal Study of 2009, including the first and second follow-up years (2011 and 2013).

This research was intended to investigate the effects of various motivational variables on high school students' declaration of a STEM major in college, focusing on PSEM majors. It made use of data from the High School Longitudinal Study of 2009, including the first and second follow-up years (2011 and 2013). The advantage of this study over others is due to this data set, which was designed to be a representative sample of the national population of US high school students. Effects of motivational factors were considered in the context of demographic groups, with the analysis conducted on PSEM declaration illuminating a problem in the discrepancy between male and female high school students. In general, however, PSEM retention from intention to declaration is abysmal, with only 35% of those students who intended towards PSEM actually enrolling.
ContributorsMangu, Daniel Matei (Author) / Middleton, James (Thesis director) / Ganesh, Tirupalavanam (Committee member) / School of International Letters and Cultures (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2017-12
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Description
A method has been developed that employs both procedural and optimization algorithms to adaptively slice CAD models for large-scale additive manufacturing (AM) applications. AM, the process of joining material layer by layer to create parts based on 3D model data, has been shown to be an effective method for quickly

A method has been developed that employs both procedural and optimization algorithms to adaptively slice CAD models for large-scale additive manufacturing (AM) applications. AM, the process of joining material layer by layer to create parts based on 3D model data, has been shown to be an effective method for quickly producing parts of a high geometric complexity in small quantities. 3D printing, a popular and successful implementation of this method, is well-suited to creating small-scale parts that require a fine layer resolution. However, it starts to become impractical for large-scale objects due to build volume and print speed limitations. The proposed layered manufacturing technique builds up models from layers of much thicker sheets of material that can be cut on three-axis CNC machines and assembled manually. Adaptive slicing techniques were utilized to vary layer thickness based on surface complexity to minimize both the cost and error of the layered model. This was realized as a multi-objective optimization problem where the number of layers used represented the cost and the geometric difference between the sliced model and the CAD model defined the error. This problem was approached with two different methods, one of which was a procedural process of placing layers from a set of discrete thicknesses based on the Boolean Exclusive OR (XOR) area difference between adjacent layers. The other method implemented an optimization solver to calculate the precise thickness of each layer to minimize the overall volumetric XOR difference between the sliced and original models. Both methods produced results that help validate the efficiency and practicality of the proposed layered manufacturing technique over existing AM technologies for large-scale applications.
ContributorsStobinske, Paul Anthony (Author) / Ren, Yi (Thesis director) / Bucholz, Leonard (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
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Description
This study examines the effectiveness of two modes of exercise on self-efficacy (SE) in adolescents with Down syndrome (DS). Thirty-nine participants were randomly divided into a voluntary cycling group (VC) (i.e., self-selected cadence), an assisted cycling group (ACT) (i.e., at least 30% faster than self-selected cadence accomplished by a motor),

This study examines the effectiveness of two modes of exercise on self-efficacy (SE) in adolescents with Down syndrome (DS). Thirty-nine participants were randomly divided into a voluntary cycling group (VC) (i.e., self-selected cadence), an assisted cycling group (ACT) (i.e., at least 30% faster than self-selected cadence accomplished by a motor), or a no exercise group (NC). In each cycling intervention the participant completed 30 minute cycling sessions, three times per week for a total of eight weeks. Two subsets of the Physical Activity and Self Efficacy Survey were administered prior to cycling (i.e., pretest) and after the eight week intervention (i.e., post-test). The results were consistent with the hypothesis that self-efficacy would improve after ACT, however there was not improvement after the VC condition as hypothesized. It was also hypothesized that exercise perception would improve following the ACT intervention; execise perception showed a trend of improvement after ACT, but the data did not reach significance. Limitations include the wide variability of the DS population. This limitation is responsible for the variation in mental age seen in the intervention groups and could be responsible for the non-significance of the exercise perception data. To generalize our results for parents, therapists, teachers, etc., our recommendation is for persons with DS to participate in physical activity that is easy for them at first \u2014 a simplified sport or active game, assisted cycling, brisk walking \u2014 so that they have a positive experience with exercise. Showing individuals with DS that they can be proficient exercisers will likely improve their self-efficacy and motivate them to engage in more PA over time. In conclusion, eight weeks of moderate ACT exercise demonstrated a significant trend for improved self-efficacy in adolescents with DS.
ContributorsWallace, Kellie Carter (Author) / Ringenbach, Shannon (Thesis director) / Youngstedt, Shawn (Committee member) / Hoffner, Kristin (Committee member) / School of Nutrition and Health Promotion (Contributor) / Barrett, The Honors College (Contributor)
Created2015-12
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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

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
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Description

This study investigated how mindset intervention in freshman engineering courses influenced students’ implicit intelligence and self-efficacy beliefs. An intervention which bolsters students’ beliefs that they possess the cognitive tools to perform well in their classes can be the deciding factor in their decision to continue in their engineering major. Treatment

This study investigated how mindset intervention in freshman engineering courses influenced students’ implicit intelligence and self-efficacy beliefs. An intervention which bolsters students’ beliefs that they possess the cognitive tools to perform well in their classes can be the deciding factor in their decision to continue in their engineering major. Treatment was administered across four sections of an introductory engineering course where two professors taught two sections. Across three survey points, one course of each professor received the intervention while the other remained neutral, but the second time point switched this condition, so all students received intervention. Robust efficacy and mindset scales quantitatively measured the strength of their beliefs in their abilities, general and engineering, and if they believed they could change their intelligence and abilities. Repeated measures ANOVA and linear regressions revealed that students who embody a growth mindset tended to have stronger and higher self-efficacy beliefs. With the introduction of intervention, the relationship between mindset and self-efficacy grew stronger and more positive over time.

ContributorsFulginiti, Alexander Ellis (Author) / Middleton, James (Thesis director) / Grewal, Anoop (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2021-05
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Description

Titanium has been and continues to be a popular metal across any form of manufacturing and production because of its extremely favorable properties. In important circumstances, it finds itself outclassing many metals by being lighter and less dense than comparably strong metals like steel. Relative to other metals it has

Titanium has been and continues to be a popular metal across any form of manufacturing and production because of its extremely favorable properties. In important circumstances, it finds itself outclassing many metals by being lighter and less dense than comparably strong metals like steel. Relative to other metals it has a noteworthy corrosion resistance as it is stable when it oxidizes, and due to the inert nature of the metal, it is famously hypoallergenic and as a result used in a great deal of aviation and medical fields, including being used to produce replacement joints, with the notable limitation of the material being its cost of manufacturing. Among the variants of the metal and alloys used, Ti6Al4V alloy is famous for being the most reliable and popular combination for electron beam manufacturing(EBM) as a method of additive manufacturing. <br/>Developed by the Swedish Arcam, AB, EBM is one of the more recent methods of additive manufacturing, and is notable for its lack of waste by combining most of the material into the intended product due to its precision. This method, much like the titanium it is used to print in this case, is limited mostly by time and value of production. <br/>For this thesis, nine different simulations of a dogbone model were generated and analyzed in Ansys APDL using finite element analysis at various temperature and print conditions to create a theoretical model based on experimentally produced values.

ContributorsKauffman, Jordan Michael (Author) / Ladani, Leila (Thesis director) / Razmi, Jafar (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2021-05
Description

This thesis paper outlines the Ctrl+P print store business, an honors thesis project conducted through the Founder’s Lab program at Arizona State University. The project is an online store for 3D printed items, operated by a team of four students with backgrounds in engineering and finance. Three team members have

This thesis paper outlines the Ctrl+P print store business, an honors thesis project conducted through the Founder’s Lab program at Arizona State University. The project is an online store for 3D printed items, operated by a team of four students with backgrounds in engineering and finance. Three team members have experience in computer-aided design (CAD) and can design products to print and sell, while the fourth member is responsible for the financial side of the business. The project began with a broader scope but later focused on the niche community of pool. In the spring semester, the team conducted customer discovery with over 600 ASU students; and in the fall semester, reached out to several pool halls to facilitate feedback on designs of custom pool racks. The team currently has a pending business deal with Mill’s Modern Social, a pool hall and bar in Tempe. The team's goal was to be revenue-earning by the end of the project, and they have already made a profit as a business.

ContributorsBolick, Ryne (Author) / Bouslog, Craig (Co-author) / Sauerman, Luke (Co-author) / Valentine, John (Co-author) / Byrne, Jared (Thesis director) / Balven, Rachel (Committee member) / Kneer, Danny (Committee member) / Barrett, The Honors College (Contributor) / Mechanical and Aerospace Engineering Program (Contributor)
Created2023-05