Matching Items (5)
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- All Subjects: Additive Manufacturing
- Creators: Phelan, Patrick
Description
Applications such as heat exchangers, surface-based cellular structures, rotating blades, and waveguides rely on thin metal walls as crucial constituent elements of the structure. The design freedom enabled by laser powder bed fusion has led to an interest in exploiting this technology to further the performance of these components, many of which retain their as-built surface morphologies on account of their design complexity. However, there is limited understanding of how and why mechanical properties vary by wall thickness for specimens that are additively manufactured and maintain an as-printed surface finish. Critically, the contributions of microstructure and morphology to the mechanical behavior of thin wall laser powder bed fusion structures have yet to be systematically identified and decoupled. This work focuses on elucidating the room temperature quasi-static tensile and high cycle fatigue properties of as-printed, thin-wall Inconel 718 fabricated using laser powder bed fusion, with the aim of addressing this critical gap in the literature. Wall thicknesses studied range from 0.3 - 2.0 mm, and the effects of Hot Isostatic Pressing are also examined, with sheet metal specimens used as a baseline for comparison. Statistical analyses are conducted to identify the significance of the dependence of properties on wall thickness and Hot Isostatic Pressing, as well as to examine correlations of these properties to section area, porosity, and surface roughness. A thorough microstructural study is complemented with a first-of-its-kind study of surface morphology to decouple their contributions and identify underlying causes for observed changes in mechanical properties. This thesis finds that mechanical properties in the quasi-static and fatigue framework do not see appreciable declines until specimen thickness is under 0.75 mm in thickness. The added Hot Isostatic Pressing heat treatment effectively closed pores, recrystallized the grain structure, and provided a more homogenous microstructure that benefits the modulus, tensile strength, elongation, and fatigue performance at higher stresses. Stress heterogeneities, primarily caused by surface defects, negatively affected the thinner specimens disproportionately. Without the use of the Hot Isostatic Pressing, the grain structure remained much more refined and benefitted the yield strength and fatigue endurance limit.
ContributorsParadise, Paul David (Author) / Bhate, Dhruv (Thesis advisor) / Chawla, Nikhilesh (Committee member) / Azeredo, Bruno (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2022
Description
The conversion of H2S enables the recycling of a waste gas into a potential source of hydrogen at a lower thermodynamic energy cost as compared to water splitting. However, studies on the photocatalytic decomposition of H2S focus on traditional deployment of catalyst materials to facilitate this conversion, and operation only when a light source is available. In this study, the efficacy of Direct Ink Written (DIW) luminous structures for H2S conversion has been investigated, with the primary objective of sustaining H2S conversion when a light source has been terminated. Additionally, as a secondary objective, improving light distribution within monoliths for photocatalytic applications is desired. The intrinsic illumination of the 3D printed monoliths developed in this work could serve as an alternative to monolith systems that employ light transmitting fiber optic cables that have been previously proposed to improve light distribution in photocatalytic systems. The results that were obtained demonstrate that H2S favorable adsorbents, a wavelength compatible long afterglow phosphor, and a photocatalyst can form viscoelastic inks that are printable into DIW luminous monolithic contactors. Additionally, rheological, optical and porosity analyses conducted, provide design guidelines for future studies seeking to develop DIW luminous monoliths from compatible catalyst-phosphor pairs. The monoliths that were developed demonstrate not only improved conversion when exposed to light, but more significantly, extended H2S conversion from the afterglow of the monoliths when an external light source was removed. Lastly, considering growing interests in attaining a global circular economy, the techno-economic feasibility of a H2S-CO2 co-utilization plant leveraging hydrogen from H2S photocatalysis as a feed source for a downstream CO2 methanation plant has been assessed. The work provides preliminary information to guide future chemical kinetic design characteristics that are important to strive for if using H2S as a source of hydrogen in a CO2 methanation facility.
ContributorsAbdullahi, Adnan (Author) / Andino, Jean (Thesis advisor) / Phelan, Patrick (Thesis advisor) / Bhate, Dhruv (Committee member) / Wang, Robert (Committee member) / Huang, Huei-Ping (Committee member) / Arizona State University (Publisher)
Created2023
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
Additive manufacturing, also known as 3-dimensional (3-d) printing, is now a rapidly growing manufacturing technique. Innovative and complex designs in various aspects of engineering have called for more efficient manufacturing techniques and 3-d printing has been a perfect choice in that direction. This research investigates the use of additive manufacturing in fabricating polymer heat exchangers and estimate their effectiveness as a heat transfer device. Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS) and Stereolithography (SLA) are the three 3-d printing techniques that are explored for their feasibility in manufacturing heat exchangers. The research also explores a triply periodic minimal structure–the gyroid, as a heat exchanger design. The performance of the gyroid heat exchanger was studied using experiments. The main parameters considered for the experiments were heat transfer rate, effectiveness and pressure drop. From the results obtained it can be inferred that using polymers in heat exchangers helps reducing corrosion and fouling problems, but it affects the effectiveness of the heat exchangers. For our design, the maximum effectiveness achieved was 0.1. The pressure drop for the heat exchanger was observed to decrease with an increase in flow rate and the maximum pressure drop measured was 0.88 psi for a flow rate of 5 LPM.
ContributorsDanayat, Swapneel Shailesh (Author) / Phelan, Patrick (Thesis advisor) / Kwon, Beomjin (Committee member) / Azeredo, Bruno (Committee member) / Arizona State University (Publisher)
Created2019
Description
Thermal management is a critical aspect of microelectronics packaging and often centers around preventing central processing units (CPUs) and graphics processing units (GPUs) from overheating. As the need for power going into these processors increases, so too does the need for more effective thermal management strategies. One such strategy is to utilize additive manufacturing to fabricate heat sinks with bio-inspired and cellular structures and is the focus of this thesis. In this study, a process was developed for manufacturing the copper alloy CuNi2SiCr on the 100w Concept Laser Mlab laser powder bed fusion 3D printer to obtain parts that were 94% dense, while dealing with challenges of low absorptivity in copper and its high potential for oxidation. The developed process was then used to manufacture and test heat sinks with traditional pin and fin designs to establish a baseline cooling effect, as determined from tests conducted on a substrate, CPU and heat spreader assembly. Two additional heat sinks were designed, the first of these being bio-inspired and the second incorporating Triply Periodic Minimal Surface (TPMS) cellular structures, with the aim of trying to improve the cooling effect relative to commercial heat sinks. The results showed that the pure copper commercial pin-design heat sink outperformed the additive manufactured (AM) pin-design heat sink under both natural and forced convection conditions due to its approximately tenfold higher thermal conductivity, but that the gap in performance could be bridged using the bio-inspired and Schwarz-P heat sink designs developed in this work and is an encouraging indicator that further improvements could be obtained with improved alloys, heat treatments and even more innovative designs.
ContributorsYaple, Jordan Marie (Author) / Bhate, Dhruv (Thesis advisor) / Azeredo, Bruno (Committee member) / Phelan, Patrick (Committee member) / Arizona State University (Publisher)
Created2021