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- All Subjects: Additive Manufacturing
Description
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
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 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
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
Advances in computational processing have made big data analysis in fields like music information retrieval (MIR) possible. Through MIR techniques researchers have been able to study information on a song, its musical parameters, the metadata generated by the song's listeners, and contextual data regarding the artists and listeners (Schedl, 2014). MIR research techniques have been applied within the field of music and emotions research to help analyze the correlative properties between the music information and the emotional output. By pairing methods within music and emotions research with the analysis of the musical features extracted through MIR, researchers have developed predictive models for emotions within a musical piece. This research has increased our understanding of the correlative properties of certain musical features like pitch, timbre, rhythm, dynamics, mel frequency cepstral coefficients (MFCC's), and others, to the emotions evoked by music (Lartillot 2008; Schedl 2014) This understanding of the correlative properties has enabled researchers to generate predictive models of emotion within music based on listeners' emotional response to it. However, robust models that account for a user's individualized emotional experience and the semantic nuances of emotional categorization have eluded the research community (London, 2001). To address these two main issues, more advanced analytical methods have been employed. In this article we will look at two of these more advanced analytical methods, machine learning algorithms and deep learning techniques, and discuss the effect that they have had on music and emotions research (Murthy, 2018). Current trends within MIR research, the application of support vector machines and neural networks, will also be assessed to explain how these methods help to address the two main issues within music and emotion research. Finally, future research within the field of machine and deep learning will be postulated to show how individuate models may be developed from a user or a pool of user's listening libraries. Also how developments of semi-supervised classification models that assess categorization by cluster instead of by nominal data, may be helpful in addressing the nuances of emotional categorization.
ContributorsMcgeehon, Timothy Makoto (Author) / Middleton, James (Thesis director) / Knowles, Kristina (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-12
Description
Due to increasing lack of resources and funding for budding student musicians, it is often not possible for this demographic to create, record, and produce their original music in the same high-budget studio environment in which music has been traditionally made. The objective of this project is to explore alternatives which are more accessible to young independent musicians and reveal the most cost-efficient routes to obtain a high-quality result. To make this comparison, the group created budget recordings of their original music in a bedroom in true DIY fashion, and then recorded the same songs in a professional music studio using the best music and recording equipment available. The DIY recordings were mixed and mastered by the group members themselves, as well as separately by a professional audio engineer. The studio recordings were also mixed and mastered by a professional audio engineer, resulting in three final products with varying costs and quality. Ultimately, the group found that without mixing and mastering experience, it is very difficult to achieve high quality results. With the same budget recorded tracks, the group found that quality of the final product vastly increased when a professional audio engineer mixed and mastered the tracks. As far as the quality of the result, the studio recorded tracks were by far the best. Not only was the quality of the sounds from the high-end music and recording equipment much higher, the band had more freedom to be creative without the responsibility of simultaneously serving as recording engineers as was the case in the low budget recordings. The group concluded that this project was highly successful and demonstrated that high quality results could be obtained on a budget. The DIY recording techniques used in this project prove that independent musicians without access to expensive equipment and resources can still produce high quality music at the cost of more effort to serve as audio engineers in addition to musicians. However, recording in a studio with the help of a producer and professional audio engineers affords creative freedom and an increase in sound quality that is simply not possible to reproduce without the equipment and expertise that money can buy.
ContributorsBonk, Alan (Co-author) / Dhuyvetter, Nicholas Alan (Co-author) / Wickham, Kevin (Co-author) / Tobias, Evan (Thesis director) / Swoboda, Deanna (Committee member) / W.P. Carey School of Business (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
The result of hundreds of hours of work is a few minutes of music. I am mechanical engineering student with a passion for music. The objective of this creative project was to learn as much as I could about music theory, composition, orchestration, notation, recording, and mixing, and to create some music of my own. I learned a great deal in my two semesters of work. My music was focused on small ensembles of strings and piano. I created over ten hours of musical audio sketches and produced notation for four pieces for the piano and strings. The finished scores fit together with similar tones and textures, all sharing a minor tonality. The first piece, "Little Machine," is a simple, methodical piano piece created in the style of second species counterpoint. The second piece, "Searching" is a duet between a piano and a cello. For most of the piece, the two instruments share a rhythmic sense of mutual independence, yet neither part can exist without the either. "Something Lost" is a piano solo written with a variety of sections and a unifying idea that pervades through the piece. Finally, "3 Strings & Piano" is a melancholy adagio written for the piano, two cellos, and a double bass. Overall, this project has helped to prepare me for a lifetime of continued learning and composition. In the future I will continue to write music, and I hope to specifically learn more about the tools and techniques used by professionals in the industry so that I can find more efficient ways to produce my own music.
ContributorsSchichtel, Jacob (Author) / Stauffer, Sandra (Thesis director) / Tobias, Evan (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
Concentrated Solar Power and Thermal Energy Storage are two technologies that are currently being explored as environmentally friendly methods of energy generation. The two technologies are often combined in an overall system to increase efficiency and reliability of the energy generation system. A collaborative group of researchers from Australia and the United States formed a project to design solar concentrators that utilize Concentrated Solar Power and Thermal Energy Storage. The collaborators from Arizona State designed a Latent Heat Thermal Energy Storage system for the project. It was initially proposed that the system utilize Dowtherm A as the Heat Transfer Fluid and a tin alloy as the storage material. Two thermal reservoirs were designed as part of the system; one reservoir was designed to be maintained at 240˚ C, while the other reservoir was designed to be maintained at 210˚ C. The tin was designed to receive heat from the hot reservoir during a charging cycle and discharge heat to the cold reservoir during a discharge cycle. From simulation, it was estimated that the system would complete a charging cycle in 17.5 minutes and a discharging cycle in 6.667 minutes [1]. After the initial design was fabricated and assembled, the system proved ineffective and did not perform as expected. Leaks occurred within the system under high pressure and the reservoirs could not be heated to the desired temperatures. After adding a flange to one of the reservoirs, it was decided that the system would be run with one reservoir, with water as the Heat Transfer Fluid. The storage material was changed to paraffin wax, because it would achieve phase change at a temperature lower than the boiling point of water. Since only one reservoir was available, charging cycle tests were performed on the system to gain insight on system performance. It was found that the paraffin sample only absorbs 3.29% of the available heat present during a charging cycle. This report discusses the tests performed on the system, the analysis of the data from these tests, the issues with the system that were revealed from the analyses, and potential design changes that would increase the efficiency of the system.
ContributorsKocher, Jordan Daniel (Author) / Wang, Robert (Thesis director) / Phelan, Patrick (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
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 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
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
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