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- Creators: Materials Science and Engineering Program
- Member of: Barrett, The Honors College Thesis/Creative Project Collection
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
A novel approach, the Invariant Based Theory of Composites and the "Trace" method it proposes, has the potential to reduce aerospace composite development times and costs by over 30% thus reinvigorating the development process and encouraging composite technology growth. The "trace" method takes advantage of inherent stiffness properties of laminates, specifically carbon fiber, to make predictions of material properties used to derive design allowables. The advantages of the "trace" theory may not necessarily be specific to the aerospace industry, however many automotive manufacturers are facing environmental, social and political pressure to increase the gas mileage in their vehicles and reduce their carbon footprint. Therefore, the use of lighter materials, such as carbon fiber composites, to replace heavier metals in cars is inevitable yet as of now few auto manufacturers implement composites in their cars. The high material, testing and development costs, much like the aerospace industry, have been prohibitive to widespread use of these materials but progress is being made in overcoming those challenges. The "trace" method, while initially intended for quasi-isotropic, aerospace grade carbon-fiber laminates, still yields reasonable, and correctable, results for types of laminates as well such as with woven fabrics and thermoplastic matrices, much of which are being used in these early stages of automotive composite development. Despite the varying use of materials, the "trace" method could potentially boost automotive composites in a similar way to the aerospace industry by reducing testing time and costs and perhaps even playing a role in establishing emerging simulations of these materials.
ContributorsBrown, William Ross (Author) / Adams, James (Thesis director) / Anwar, Shahriar (Committee member) / Krause, Stephen (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
Formula SAE is a student design competition where students design and fabricate a formula-style racecar to race in a series of events against schools from around the world. It gives students of all majors the ability to use classroom theory and knowledge in a real world application. The general guidelines for the prototype racecars is for the students to use four-stroke, Otto cycle piston engines with a displacement of no greater than 610cc. A 20mm air restrictor downstream the throttle limits the power of the engines to under 100 horsepower. A 178-page rulebook outlines the remaining restrictions as they apply to the various vehicle systems: vehicle dynamics, driver interface, aerodynamics, and engine. Vehicle dynamics is simply the study of the forces which affect wheeled vehicles in motion. Its primary components are the chassis and suspension system. Driver interface controls everything that the driver interacts with including steering wheel, seat, pedals, and shifter. Aerodynamics refers to the outside skin of the vehicle which controls the amount of drag and downforce on the vehicle. Finally, the engine consists of the air intake, engine block, cooling system, and the exhaust. The exhaust is one of the most important pieces of an engine that is often overlooked in racecar design. The purpose of the exhaust is to control the removal of the combusted air-fuel mixture from the engine cylinders. The exhaust as well as the intake is important because they govern the flow into and out of the engine's cylinders (Heywood 231). They are especially important in racecar design because they have a great impact on the power produced by an engine. The higher the airflow through the cylinders, the larger amount of fuel that can be burned and consequently, the greater amount of power the engine can produce. In the exhaust system, higher airflow is governed by several factors. A good exhaust design gives and engine a higher volumetric efficiency through the exhaust scavenging effect. Volumetric efficiency is also affected by frictional losses. In addition, the system should ideally be lightweight, and easily manufacturable. Arizona State University's Formula SAE racecar uses a Honda F4i Engine from a CBR 600 motorcycle. It is a four cylinder Otto cycle engine with a 600cc displacement. An ideal or tuned exhaust system for this car would maximize the negative gauge pressure during valve overlap at the ideal operating rpm. Based on the typical track layout for the Formula SAE design series, an ideal exhaust system would be optimized for 7500 rpm and work well in the range
ContributorsButterfield, Brandon Michael (Author) / Huang, Huei-Ping (Thesis director) / Trimble, Steven (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05