Matching Items (29)
Description
While many 3D printed structures are rigid and stationary, the potential for complex geometries offers a chance for creative and useful motion. Printing structures larger than the print bed, reducing the need for support materials, maintaining multiple states without actuation, and mimicking origami folding are some of the opportunities offered by 3D printed hinges. Current efforts frequently employ advanced materials and equipment that are not available to all users. The purpose of this project was to develop a parametric, print-in-place, self-locking hinge that could be printed using very basic materials and equipment. Six main designs were developed, printed, and tested for their strength in maintaining a locked position. Two general design types were used: 1) sliding hinges and 2) removable pin hinges. The test results were analyzed to identify and explain the causes of observed trends. The amount of interference between the pin vertex and knuckle hole edge was identified as the main factor in hinge strength. After initial testing, the designs were modified and applied to several structures, with successful results for a collapsible hexagon and a folding table. While the initial goal was to have one CAD model as a final product, the need to evaluate tradeoffs depending on the exact application made this impossible. Instead, a set of design guidelines was created to help users make strategic decisions and create their own design. Future work could explore additional scaling effects, printing factors, or other design types.
ContributorsAndreotti, Jaimee Jeannette (Author) / Bhate, Dhruv (Thesis director) / Aukes, Daniel (Committee member) / Dean, W.P. Carey School of Business (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2021-05
Description
Due to the vast increase in processing power and energy usage in computing, a need for greater heat dissipation is prevalent. With numerous applications demanding cheaper and more efficient options for thermal management, new technology must be employed. Through the use of additive manufacturing, designs and structures can be created that were not physically possible before without extensive costs. The goal is to design a system that utilizes capillary action, which is the ability for liquids to flow through narrow spaces unassisted. The level of detail required may be achieved with direct metal laser sintering (DMLS) and stereolithography (SLA) 3D printing.
ContributorsFechter, Andrew (Author) / Bhate, Dhruv (Thesis director) / Frank, Daniel (Committee member) / Engineering Programs (Contributor, Contributor) / Barrett, The Honors College (Contributor)
Created2021-05
Description
The goal of our research was to develop and validate a method for predicting the mechanical behavior of Additively Manufactured multi-material honeycomb structures. Multiple approaches already exist in the field for modeling the behavior of cellular materials, including the bulk property assumption, homogenization and strut level characterization [1]. With the bulk property approach, the structure is assumed to behave according to what is known about the material in its bulk formulation, without regard to its geometry or scale. With the homogenization technique, the specimen that is being tested is treated as a solid material within the simulation environment even if the physical specimen is not. Then, reduced mechanical properties are assigned to the specimen to account for any voids that exist within the physical specimen. This approach to mechanical behavior prediction in cellular materials is shape dependent. In other words, the same model cannot be used from one specimen to the next if the cell shapes of those lattices differ in any way. When using the strut level characterization approach, a single strut (the connecting member between nodes constituting a cellular material) is isolated and tested. With this approach, there tends to be a significant deviation in the experimental data due to the small size of the isolated struts. Yet it has the advantage of not being shape sensitive, at least in principle. The method that we developed, and chose to test lies within the latter category, and is what we have coined as the Representative Lattice Element (RLE) Method. This method is modeled after the well-established Representative Volume Element (RVE) method [2]. We define the RLE as the smallest unit over which mechanical tests can be conducted that will provide results which are representative of the larger lattice structure. In other words, the theory is that a single member (or beam in this case) of a honeycomb structure can be taken, tests can be conducted on this member to determine the mechanical properties of the representative lattice element and the results will be representative of the mechanical behavior whole structure. To investigate this theory, we designed specimens, conducted various tensile and compression tests, analyzed the recorded data, conducted a micromechanics study, and performed structural simulation work using commercial Finite Element Analysis software.
ContributorsSalti, Ziyad Zuheir (Co-author) / Eppley, Trevor (Co-author) / Bhate, Dhruv (Thesis director) / Song, Kenan (Committee member) / Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
The purpose of the project is to study how the mechanical properties of cellular structures made by Fused Deposition Modeling (FDM) change depending on the number of unit cells and the cell geometry. Specimens with three geometries of regular hexagon, square, and equilateral triangle were produced by FDM. The number of cells was varied systematically in each of the three geometries. The samples were tested for compressive strength. The specimens were laser-scanned to determine the actual dimensions, and those values were used in calculations to reduce the dimensional errors. Based on the calculations and analysis, it was concluded that for each geometry, the material modulus converged to a limiting value as the number of unit cells approached "infinity", and the convergent values of the material modulus were approximately the same (within 10% of error) for the three geometries. The convergent values for the material modulus of the hexagon, square, and triangle geometries were 273ksi, 248ksi, and 262ksi respectively. The percentages of error of the square and triangle geometries with respect to the hexagon geometry were 4.0%, and 9.2%, respectively.
ContributorsLe, Thao Nguyen Minh (Author) / Parsey, John (Thesis director) / Bhate, Dhruv (Committee member) / School of Mathematical and Statistical Sciences (Contributor) / Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
Laser Powder Bed Fusion (LPBF) is an additive manufacturing (AM) technology that has emerged as the predominant technology for metal 3D printing. An alloy of particular interest to the aerospace industry is the nickel-based superalloy, Inconel 718 (IN718), which is widely used for its superior performance in elevated temperature conditions, particularly for gas-turbine engine blades and heat exchangers. With LPBF providing new ways of exploiting complex part geometry, the high-temperature properties of the AM version of the alloy must be understood. Of additional interest is how these properties change as a function of geometry and post-processing. This research focuses on the behavior of LPBF IN718 as a function of hot isostatic pressing (HIP) and specimen thickness at elevated temperatures. These results and behavior were compared to the behavior of IN718 sheet metal for properties such as True Ultimate Tensile Strength (UTS), Yield Strength, Young’s Modulus, percent elongation, and necking. The results showed dependence of strength on both thickness and HIP condition, and also exhibited a steep drop in UTS and yield strength at 1600 °F, linearly declining modulus, and excess dynamic strain ageing (DSA) behavior at certain temperatures.
ContributorsTemes, Samuel (Author) / Bhate, Dhruv (Thesis advisor) / Azeredo, Bruno (Committee member) / Das, Partha (Committee member) / Arizona State University (Publisher)
Created2021
Description
Additively Manufactured Thin-wall Inconel 718 specimens commonly find application in heat exchangers and Thermal Protection Systems (TPS) for space vehicles. The wall thicknesses in applications for these components typically range between 0.03-2.5mm. Laser Powder Bed Fusion (PBF) Fatigue standards assume thickness over 5mm and consider Hot Isostatic Pressing (HIP) as conventional heat treatment. This study aims at investigating the dependence of High Cycle Fatigue (HCF) behavior on wall thickness and Hot Isostatic Pressing (HIP) for as-built Additively Manufactured Thin Wall Inconel 718 alloys. To address this aim, high cycle fatigue tests were performed on specimens of seven different thicknesses (0.3mm,0.35mm, 0.5mm, 0.75mm, 1mm, 1.5mm, and 2mm) using a Servohydraulic FatigueTesting Machine. Only half of the specimen underwent HIP, creating data for bothHIP and No-HIP specimens. Upon analyzing the collected data, it was noticed that the specimens that underwent HIP had similar fatigue behavior to that of sheet metal specimens. In addition, it was also noticed that the presence of Porosity in No-HIP specimens makes them more sensitive to changes in stress. A clear decrease in fatigue strength with the decrease in thickness was observed for all specimens.
ContributorsSaxena, Anushree (Author) / Bhate, Dhruv (Thesis advisor) / Liu, Yongming (Committee member) / Kwon, Beomjin (Committee member) / Arizona State University (Publisher)
Created2021
Description
Inspired by the design of lightweight cellular structures in nature, humans have made cellular solids for a wide range of engineering applications. Cellular structures composed of solid and gaseous phases, and an interconnected network of solid struts or plates that form the cell's edges and faces. This makes them an ideal candidate for numerous energy absorption applications in the military, transportation, and automotive industries. The objective of the thesis is to study the energy-absorption of multi-material cellular structures. Cellular structures made from Acrylonitrile-Butadiene-Styrene (ABS) a thermoplastic polymer and Thermoplastic Polyurethane (TPU) a thermoplastic elastomer were manufactured using dual extrusion 3D printing. The surface-based structures were designed with partitions to allocate different materials using Matlab and nTopology. Aperiodicity was introduced to the design through perturbation. The specimens were designed for two wall thicknesses - 0.5mm and 1mm, respectively. In total, 18 specimens were designed and 3D printed. All the specimens were tested under quasi-static compression. A detailed analysis was performed to study the energy absorption metrics and draw conclusions, with emphasis on specific energy absorbed as a function of relative density, efficiency, and peak stress of the specimens to hypothesize and validate mechanisms for observed behavior. All the specimens were analyzed to draw comparisons across designs.
ContributorsVarma, Rajeshree Pawan (Author) / Bhate, Dhruv (Thesis advisor) / Shuaib, Abdelrahman (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2021
Description
Polylactic Acid (PLA), a thermoplastic polymer is well-known for its biocompatibility, making it ideal for the manufacturing of biomedical devices. However, the current applications of PLA are commonly limited by its intrinsic polymer characteristics, such as low modulus, mechanical strength, and thermal conductivity. To enhance these physical properties, a biocompatible nanodiamond enhanced PLA filament has been studied. Thermogravimetric analysis was performed to unveil the composition of nanodiamond in the composite. Four printing parameters: nozzle temperature, layer height, infill pattern and printing speed were considered and the Taguchi L9 orthogonal array was implemented for the design of experiments. Fused deposition modeling (FDM) technique was utilized to 3D print the PLA/Nanodiamond samples by altering the four printing parameters considered and were tested according to the standards for tensile strength, flexural strength, and thermal conductivity. Using the Taguchi optimization approach and analysis of variance (ANOVA), the generated experimental data was used to find the optimum set of printing parameters. Finally, cell studies were performed to demonstrate the biocompatibility of PLA/Nanodiamond. All these results could aid in determining the working ranges for FDM fabrication of PLA/Nanodiamond for biomedical applications.
ContributorsPoornabodha, Nikhitha (Author) / Nian, Qiong (Thesis advisor) / Kang, Wonmo (Committee member) / Zhuang, Houlong (Committee member) / Arizona State University (Publisher)
Created2022
Description
Achieving a viable process for advanced manufacturing of ceramics and metal-ceramic composites is a sought-after goal in a wide range of fields including electronics and sensors for harsh environments, microelectromechanical devices, energy storage materials, and structural materials, among others. In this dissertation, the processing, and manufacturing of ceramics and ceramic composites are addressed, specifically, a process for three-dimensional (3D) printing of polymer-derived ceramics (PDC), and a process for low-cost manufacturing as well as healing of metal-ceramic composites is demonstrated.Three-dimensional printing of ceramics is enabled by dispensing the preceramic polymer at the tip of a moving nozzle into a gel that can reversibly switch between fluid and solid states, and subsequently thermally cross-linking the entire printed part “at once” while still inside the same gel was demonstrated. The solid gel converts to fluid at the tip of the moving nozzle, allowing the polymer solution to be dispensed and quickly returns to a solid state to maintain the geometry of the printed polymer both during printing and the subsequent high-temperature (160 °C) cross-linking. After retrieving the cross-linked part from the gel, the green body is converted to ceramic by high-temperature pyrolysis. This scalable process opens new opportunities for low-cost and high-speed production of complex three-dimensional ceramic parts and will be widely used for high-temperature and corrosive environment applications, including electronics and sensors, microelectromechanical systems, energy, and structural applications.
Metal-ceramic composites are technologically significant as structural and functional materials and are among the most expensive materials to manufacture and repair. Hence, technologies for self-healing metal-ceramic composites are important. Here, a concept to fabricate and heal co-continuous metal-ceramic composites at room temperature were demonstrated. The composites were fabricated by infiltration of metal (here Copper) into a porous alumina preform (fabricated by freeze-casting) through electroplating; a low-temperature and low-cost process for the fabrication of such composites. Additionally, the same electroplating process was demonstrated for healing damages such as grooves and cracks in the original composite, such that the healed composite recovered its strength by more than 80%. Such technology may be expanded toward fully autonomous self-healing structures.
ContributorsMahmoudi, Mohammadreza (Author) / Minary-Jolandan, Majid (Thesis advisor) / Rajagopalan, Jagannathan (Committee member) / Cramer, Corson (Committee member) / Kang, Wonmo (Committee member) / Bhate, Dhruv (Committee member) / Arizona State University (Publisher)
Created2022
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