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Effect of Powder Reuse on DMLS (Direct Metal Laser Sintering) Product Integrity: Why Honeywell Believes the Future is Additive Manufacturing

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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.…

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

The Impact of Implementing an Invariant-Based Theory of Composites on the Automotive Industry

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,…

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
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StreetWise: A skill service for students by students

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Stress for college students is nothing new and as more kids go to college the number of cases are on the rise. This issue is apparent at colleges across the nation including Arizona State University. StreetWise aims to help students prevent or appropriately deal with stress through interactive lessons teaching…

Stress for college students is nothing new and as more kids go to college the number of cases are on the rise. This issue is apparent at colleges across the nation including Arizona State University. StreetWise aims to help students prevent or appropriately deal with stress through interactive lessons teaching students life skills, social skills, and emotional intelligence.<br/>In order to prove the value of our service, StreetWise conducted a survey that asked students about their habits, thoughts on stress, and their future. Students from Arizona State University were surveyed with questions on respondent background, employment, number one stressor, preferred learning method, and topics that students were interested in learning. We found that students’ number one stressor was school but was interested in learning skills that would prepare them for their future after graduation. We used the results to make final decisions so that StreetWise could offer lessons that students would get the most value out of. This led to us conducting a second survey which included mock ups of the website, examples of interactive lesson plans, and an overview of the app. Students from the first survey were surveyed in addition to new respondents. This survey was intended for us to ensure that our service would maintain its value to students with the aesthetic and interface that we envisioned.
ContributorsWard, William Henry (Co-author) / Ahir, Hiral (Co-author) / Compton, Katherine (Co-author) / Byrne, Jared (Thesis director) / Hall, Rick (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2021-05
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StreetWise: A Skill Service for Students by Students

Description

Stress for college students is nothing new and as more kids go to college the number of cases are on the rise. This issue is apparent at colleges across the nation including Arizona State University. StreetWise aims to help students prevent or appropriately deal with stress through interactive lessons teaching…

Stress for college students is nothing new and as more kids go to college the number of cases are on the rise. This issue is apparent at colleges across the nation including Arizona State University. StreetWise aims to help students prevent or appropriately deal with stress through interactive lessons teaching students life skills, social skills, and emotional intelligence.<br/>In order to prove the value of our service, StreetWise conducted a survey that asked students about their habits, thoughts on stress, and their future. Students from Arizona State University were surveyed with questions on respondent background, employment, number one stressor, preferred learning method, and topics that students were interested in learning. We found that students’ number one stressor was school but was interested in learning skills that would prepare them for their future after graduation. We used the results to make final decisions so that StreetWise could offer lessons that students would get the most value out of. This led to us conducting a second survey which included mock ups of the website, examples of interactive lesson plans, and an overview of the app. Students from the first survey were surveyed in addition to new respondents. This survey was intended for us to ensure that our service would maintain its value to students with the aesthetic and interface that we envisioned.
ContributorsAhir, Hiral V (Co-author) / Compton, Katherine (Co-author) / Ward, William (Co-author) / Byrne, Jared (Thesis director) / Hall, Rick (Committee member) / School of Life Sciences (Contributor) / Barrett, The Honors College (Contributor)
Created2021-05