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- Creators: Arizona State University
- Creators: Bouslog, Craig
The objective of the research is to test the use of 3D printed thermoplastic to produce fixtures which affix instrumentation to asphalt concrete samples used for Simple Performance Testing (SPT). The testing is done as part of materials characterization to obtain properties that will help in future pavement designs. Currently, these fixtures (mounting studs) are made of expensive brass and cumbersome to clean with or without chemicals.
Three types of thermoplastics were utilized to assess the effect of temperature and applied stress on the performance of the 3D printed studs. Asphalt concrete samples fitted with thermoplastic studs were tested according to AASHTO & ASTM standards. The thermoplastics tested are: Polylactic acid (PLA), the most common 3D printing material; Acrylonitrile Butadiene Styrene (ABS), a typical 3D printing material which is less rigid than PLA and has a higher melting temperature; Polycarbonate (PC), a strong, high temperature 3D printing material.
A high traffic volume Marshal mix design from the City of Phoenix was obtained and adapted to a Superpave mix design methodology. The mix design is dense-graded with nominal maximum aggregate size of ¾” inch and a PG 70-10 binder. Samples were fabricated and the following tests were performed: Dynamic Modulus |E*| conducted at five temperatures and six frequencies; Flow Number conducted at a high temperature of 50°C, and axial cyclic fatigue test at a moderate temperature of 18°C.
The results from SPT for each 3D printed material were compared to results using brass mounting studs. Validation or rejection of the concept was determined from statistical analysis on the mean and variance of collected SPT test data.
The concept of using 3D printed thermoplastic for mounting stud fabrication is a promising option; however, the concept should be verified with more extensive research using a variety of asphalt mixes and operators to ensure no bias in the repeatability and reproducibility of test results. The Polycarbonate (PC) had a stronger layer bonding than ABS and PLA while printing. It was recommended for follow up studies.
In this research, the additive manufacturing technology and the heat exchanger design are explored to find a unique solution to improve the efficiency of heat exchangers. This includes creating a Triply Periodic Minimal Surface (TPMS) geometry, Schwarz-D in this case, using Mathematica with a flexibility to control the cell size of the models generated. This model is then encased in a closed cubical surface with manifolds for fluid inlets and outlets before 3D printed using the polymer nylon for thermal evaluation.
In the extent of this study, the heat exchanger developed is experimentally evaluated. The data obtained are used to derive a relationship between the heat transfer effectiveness and the Number of Transfer Units (NTU).The pressure loss across a fluid channel of the Schwarz D geometry is also studied.
The data presented in this study are part of initial experimental evaluation of 3D printed TPMS heat exchangers.Among heat exchangers with similar performance, the Schwarz D geometry is 32% smaller compared to a shell-and-tube heat exchanger.
This work introduces dissolvable supports to single- and multi-material metals AM. The multi-material approach uses material choice to design a functionally graded material where corrosion is the functionality being varied. The single-material approach is the primary focus of this thesis, leveraging already common post-print heat treatments to locally alter the microstructure near the surface. By including a sensitizing agent in the ageing heat treatment, carbon is diffused into the part decreasing the corrosion resistance to a depth equal to at least half the support thickness. In a properly chosen electrolyte, this layer is easily chemically, or electrochemically removed. Stainless steel 316 (SS316) and Inconel 718 are both investigated to study this process using two popular alloys. The microstructure evolution and corrosion properties are investigated for both. For SS316, the effect of applied electrochemical potential is investigated to describe the varying corrosion phenomena induced, and the effect of potential choice on resultant roughness. In summary, a new approach to remove supports from metal AM parts is introduced to decrease costs and further the field of metals AM by expanding the design space.
In cases where surgical repair is insufficient to return the heart to normal function, a patient may proceed to advanced heart failure, and a heart transplant may be required. Unfortunately, a finite number of available donor hearts are available. A mechanical circulatory support (MCS) device can be used to bridge the time between heart failure and reception of a donor heart. These MCS devices are typically constructed for the adult population. Accordingly, the size associated to the device is a limiting factor for small adults or pediatric patients who often have smaller thoracic measurements. While current eligibility criteria are based on correlative measurements, the aforementioned 3D visualization capabilities can be leveraged to accomplish patient-specific fit analysis.
The main objectives of the work presented in this dissertation were 1) to develop and evaluate an optimized process for 3D printing cardiovascular anatomy for surgical planning and medical education and 2) to develop and evaluate computational tools to assess MCS device fit in specific patients. The evaluations for objectives 1 and 2 were completed with a collection of qualitative and quantitative validations. These validations include case studies to illustrate meaningful, qualitative results as well as quantitative results from surgical outcomes. The latter results present the first quantitative supporting evidence, beyond anecdotal case studies, regarding the efficacy of 3D printing for pre-procedural planning; this data is suitable as pilot data for clinical trials. The products of this work were used to plan 200 cardiovascular procedures (including 79 cardiothoracic surgeries at Phoenix Children's Hospital), via 3D printed heart models and assess MCS device fit in 29 patients across 6 countries.
This study is a broad stroke at discovering possible alternate microstructures developing in Direct-Metal-Laser-Sintering (DMLS) processed IN718 compared to those in conventional wrought IN718. The main inspiration for this study came from creep test results from several DMLS IN718 samples at Honeywell that showed a significant
improvement in creep capabilities for DMLS718 compared to cast and wrought IN718 (Honeywell).
From this data the steady-state creep rates were evaluated and fitted to current creep models in order to identify active creep mechanisms in conventional and DMLS IN718 and illuminate the potential factors responsible for the improved creep behavior in DMSL processed IN718.
Because rapid heating and cooling can introduce high internal stress and impact microstructural development, such as gamma double prime formations (Oblak et al.), leading to differences in material behavior, DMLS and conventional IN718 materials are studied using SEM and TEM characterization to investigate sub-micron and/or nano-scale
microstructural differences developed in the DMLS samples as a result of their complex thermal history and internal stress.
The preliminary analysis presented in this body of work is an attempt to better understand the effect of DMLS processing in quest for development of optimization techniques for DMLS as a whole. A historical sketch of nickel alloys and the development of IN718 is given. A literature review detailing the microstructure of IN718 is presented. Creep data analysis and identification of active creep mechanisms are evaluated. High-resolution microstructural characterization of DMLS and wrought IN718 are discussed in detail throughout various chapters of this thesis. Finally, an initial effort in developing a processing model that would allow for parameter optimization is presented.
Ctrl+P is an online store for 3D printed items, founded by four members with experience in computer-aided design (CAD) and financial management. They initially started with a broader scope but later focused on designing custom pool racks for the pool community. They conducted customer discovery with over 634 ASU students and landed an ongoing business deal with Mill’s Modern Social, a pool hall and bar in Tempe. The team has already made a profit and aims to be revenue-earning by the end of the project. The financial plan includes potential expenses for website development, printer filament, and 3D printers. Ctrl+P's brand mission is to print products desired by customers that consult Ctrl+P. The long-term goal of the team is to continue to gain customers and expand the business to a larger customer base.
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.