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- Creators: Arizona State University
- Creators: Mechanical and Aerospace Engineering Program
Description
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.
ContributorsBeGell, Dirk (Author) / Kaloush, Kamil (Thesis advisor) / Mamlouk, Michael (Committee member) / Stempihar, Jeffery (Committee member) / Arizona State University (Publisher)
Created2018
Description
As additive manufacturing grows as a cost-effective method of manufacturing, lighter, stronger and more efficient designs emerge. Heat exchangers are one of the most critical thermal devices in the thermal industry. Additive manufacturing brings us a design freedom no other manufacturing technology offers. Advancements in 3D printing lets us reimagine and optimize the performance of the heat exchangers with an incredible design flexibility previously unexplored due to manufacturing constraints.
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.
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.
ContributorsChandrasekaran, Gokul (Author) / Phelan, Patrick E (Thesis advisor) / Rykaczewski, Konrad (Committee member) / Schultz, Karl U (Committee member) / Arizona State University (Publisher)
Created2018
Description
Additive manufacturing (AM) describes an array of methods used to create a 3D object layer by layer. The increasing popularity of AM in the past decade has been due to its demonstrated potential to increase design flexibility, produce rapid prototypes, and decrease material waste. Temporary supports are an inconvenient necessity in many metal AM parts. These sacrificial structures are used to fabricate large overhangs, anchor the part to the build substrate, and provide a heat pathway to avoid warping. Polymers AM has addressed this issue by using support material that is soluble in an electrolyte that the base material is not. In contrast, metals AM has traditionally approached support removal using time consuming, costly methods such as electrical discharge machining or a dremel.
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.
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.
ContributorsLefky, Christopher (Author) / Hildreth, Owen (Thesis advisor) / Chawla, Nikhilesh (Committee member) / Azeredo, Bruno (Committee member) / Rykaczewski, Konrad (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2018
Description
The objective of this project was to design an electrically driven centrifugal pump for the Daedalus Astronautics @ASU hybrid rocket engine (HRE). The pump design was purposefully simplified due to time, fabrication, calculation, and capability constraints, which resulted in a lower fidelity design, with the option to be improved later. The impeller, shroud, volute, shaft, motor, and ESC were the main focuses of the pump assembly, but the seals, bearings, lubrication methods, and flow path connections were considered as elements which would require future attention. The resulting pump design is intended to be used on the Daedalus Astronautics HRE test cart for design verification. In the future, trade studies and more detailed analyses should and will be performed before this pump is integrated into the Daedalus Astronautics flight-ready HRE.
ContributorsShillingburg, Ryan Carl (Author) / White, Daniel (Thesis director) / Brunacini, Lauren (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
This paper summarizes the [1] ideas behind, [2] needs, [3] development, and [4] testing of 3D-printed sensor-stents known as Stentzors. This sensor was successfully developed entirely from scratch, tested, and was found to have an output of 3.2*10-6 volts per RMS pressure in pascals. This paper also recommends further work to render the Stentzor deployable in live subjects, including [1] further design optimization, [2] electrical isolation, [3] wireless data transmission, and [4] testing for aneurysm prevention.
ContributorsMeidinger, Aaron Michael (Author) / LaBelle, Jeffrey (Thesis director) / Frakes, David (Committee member) / Barrett, The Honors College (Contributor) / Mechanical and Aerospace Engineering Program (Contributor)
Created2014-05
Description
In this analysis, materials capable of being 3D printed such as acrylonitrile-butadiene styrene (ABS), polyethylene terephthalate-glycol (PETG), and polylactic acid (PLA) were analyzed mathematically to determine their potential application as a fuel source for a hybrid rocket engine currently being developed by Daedalus Astronautics. By developing a 3D printed fuel option, new fuel grain geometries can be manufactured and tested that have the potential to greatly improve regression and flow characteristics of hybrid rockets. In addition, 3D printed grains have been shown to greatly reduce manufacturing time while improving grain-to-grain consistency. In the end, it was found that ABS, although the most difficult material to work with, would likely provide the best results as compared to an HTPB baseline. This is because after conducting a heat conservation analysis similar to that employed by NASA's chemical equilibrium with applications code (CEA), ABS was shown to operate at similarly high levels of specific impulse at approximately the same oxidizer-to-fuel ratio, meaning the current Daedalus test setup for HTPB would be applicable to ABS. In addition, PLA was found to require a far lower oxidizer-to-fuel ratio to achieve peak specific impulse than any of the other fuels analyzed leading to the conclusion that in a flight-ready engine it would likely require less oxidizer and pressurization mass, and therefore, less overall system mass, to achieve thrust levels similar to ABS and HTPB. By improving the thrust-to-weight ratio in this way a more efficient engine could be developed. Following these results, future works will include the hot-fire testing of the four fuel options to verify the analysis method used. Additionally, the ground work has been set for future analysis and development of complex fuel port geometries which have been shown to further improve flight characteristics.
ContributorsWinsryg, Benjamin Rolf (Author) / White, Daniel (Thesis director) / Brunacini, Lauren (Committee member) / Mechanical and Aerospace Engineering Program (Contributor, 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
Many industries require workers in warehouse and stockroom environments to perform frequent lifting tasks. Over time these repeated tasks can lead to excess strain on the worker's body and reduced productivity. This project seeks to develop an exoskeletal wrist fixture to be used in conjunction with a powered exoskeleton arm to aid workers performing box lifting types of tasks. Existing products aimed at improving worker comfort and productivity typically employ either fully powered exoskeleton suits or utilize minimally powered spring arms and/or fixtures. These designs either reduce stress to the user's body through powered arms and grippers operated via handheld controls which have limited functionality, or they use a more minimal setup that reduces some load, but exposes the user's hands and wrists to injury by directing support to the forearm. The design proposed here seeks to strike a balance between size, weight, and power requirements and also proposes a novel wrist exoskeleton design which minimizes stress on the user's wrists by directly interfacing with the object to be picked up. The design of the wrist exoskeleton was approached through initially selecting degrees of freedom and a ROM (range of motion) to accommodate. Feel and functionality were improved through an iterative prototyping process which yielded two primary designs. A novel "clip-in" method was proposed to allow the user to easily attach and detach from the exoskeleton. Designs utilized a contact surface intended to be used with dry fibrillary adhesives to maximize exoskeleton grip. Two final designs, which used two pivots in opposite kinematic order, were constructed and tested to determine the best kinematic layout. The best design had two prototypes created to be worn with passive test arms that attached to the user though a specially designed belt.
ContributorsGreason, Kenneth Berend (Author) / Sugar, Thomas (Thesis director) / Holgate, Matthew (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
Shape Memory Polymers (SMPs) are smart polyurethane thermoplastics that can recover their original shape after undergoing deformation. This shape recovery can be actuated by raising the SMP above its glass transition temperature, Tg. This report outlines a process for repeatedly recycling SMPs using 3D printing. Cubes are printed, broken down into pellets mechanically, and re-extruded into filament. This simulates a recycling iteration that the material would undergo in industry. The samples are recycled 0, 1, 3, and 5 times, then printed into rectangular and dog-bone shapes. These shapes are used to perform dynamic mechanical analysis (DMA) and 3-point bending for shape recovery testing. Samples will also be used for scanning electron microscopy (SEM) to characterize their microstructure.
ContributorsSweeney, Andrew Joseph (Author) / Yekani Fard, Masoud (Thesis director) / Chattopadhyay, Aditi (Committee member) / W.P. Carey School of Business (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
For those interested in the field of robotics, there are not many options to get your hands on a physical robot without paying a steep price. This is why the folks at BCN3D Technologies decided to design a fully open-source 3D-printable robotic arm. Their goal was to reduce the barrier to entry for the field of robotics and make it exponentially more accessible for people around the world. For our honors thesis, we chose to take the design from BCN3D and attempt to build their robot, to see how accessible the design truly is. Although their designs were not perfect and we were forced to make some adjustments to the 3D files, overall the work put forth by the people at BCN3D was extremely useful in successfully building a robotic arm that is programmed with ease.
ContributorsCohn, Riley (Co-author) / Petty, Charles (Co-author) / Ben Amor, Hani (Thesis director) / Yong, Sze Zheng (Committee member) / Computer Science and Engineering Program (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2017-12