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Optical Metrology for Near-Net-Shaped Additively Manufactured Ceramic Components presented at the 45th International Conference and Exposition on Advanced Ceramics and Composites
This chapter focuses on material extrusion additive manufacturing (AM) processes for polymers and composite materials. Different extrusion AM platforms, along with their operating mechanism concepts, processing capabilities, and limitations, are discussed here. This chapter also covers state-of-the-art developments in new areas such as hybrid systems, integrated systems, and automation, which facilitate the integration of extrusion-based AM processes into smart manufacturing or Industry 4.0. Following this, a comprehensive discussion on materials development, criteria for successful printing of different materials (thermoplastics, thermosets, and their composites), key factors influencing printing, and material-related challenges in extrusion AM is presented. Finally, a brief overview of current and future potential applications of material extrusion AM technology is provided.
The processing of refractory metals via additive manufacturing (AM) presents an opportunity to fabricatecomponents not possible through traditional powder metallurgy techniques. However, processing via AM isextremely challenging and there exist a host of technological limitations still unaddressed. Molybdenumand tungsten are two materials of particular interest for nuclear energy generation applications. Themajority of existing work on the processing of these materials is focused on laser powder bed fusion whereasa smaller body of work exists for electron beam melting AM. In general, material with acceptable densitycan be obtained via both routes however cracking is much more difficult to mitigate against. Strongcrystallographic fiber textures have been observed across a range of refractory systems. In this work wepresent our recent findings on electron beam melting AM of pure tungsten and molybdenum. Wedemonstrate that defect-free material can be obtained in both systems with appropriate processing. Strongbuild direction crystallographic texture fibers are observed in both systems. In molybdenum the fibertexture has direct impact on the resulting tensile behavior. These results demonstrate that electron beamAM is a suitable technology for processing these difficult to fabricate materials.
A feedstock material for use in an additive manufacturing apparatus is prepared from a first material and a metal organic framework (MOF). The MOF comprises a plurality of nodes and a plurality of linkers, the plurality of linkers coupled to the plurality of nodes, thereby forming a framework. The MOF has a lower coefficient of thermal expansion than a coefficient of thermal expansion for the first material. As a result, the feedstock material has a reduced coefficient of thermal expansion as compared to the first material alone and thus exhibits low thermal expansion as its temperature is increased. The coefficient of thermal expansion for the MOF may be modified by using a different plurality of nodes and/or a different plurality of linkers, as well as by incorporating guest molecules or atoms into the framework of the MOF.
Oral Presentation entitled Materials Evaluation of Additively Manufactured Fuel Injector Candidates at 2023 UTSR and Advanced Turbines Program Review
This research program involved the development of improved gas turbine cooling by optimizing the combined internal and film cooling configurations used for turbine blades and vanes. Improved cooling of turbine airfoils allows the gas turbines to be operated at higher temperatures which improves efficiency for gas turbine-based power generation. This also facilitates operation with hydrogen-based fuels which inherently generate higher operating temperatures. Designs of the new cooling configurations were based on the added geometric flexibility that is available when using metal additive manufacturing techniques. When making these designs, adjustments were made to account for imperfections occurring in the metal additive manufacturing process. New designs for film cooling holes were developed using computational adjoint gradient optimization techniques which generated a unique film cooling hole with 70% greater film cooling effectiveness compared to conventional shaped film cooling holes. A major factor in improving the film cooling effectiveness were small external protrusions on either side of the new hole which generated vortices that pushed coolant towards the surface and increased the lateral spreading of the coolant. Our studies also included optimization of film cooling holes that can be built with conventional manufacturing techniques and optimizing the internal coolant channels that supply coolant to the film cooling holes. Various internal coolant channel shapes were investigated and designs that maximized the cooling of the airfoil while minimizing pressure losses in the channel flows were identified. Testing and verification of the performance of the final configurations was done with a transonic wind tunnel facility which allowed testing at engine realistic high velocities. Final testing of the combined internal and film cooling configurations was done by incorporating the configurations in Penn State’s National Experimental Turbine (NExT) vane. These tests confirmed the enhanced overall cooling effectiveness provided by the new cooling configuration designs.
This project addresses several key barriers to wide-spread adoption of additive manufacturing (AM) technology as applied to solid state lighting luminaires. The solution will utilize cutting edge AM approaches for integrating structure with thermal management solutions, electronic functionality, and optics. The research team (Eaton, Lighting Research Center (LRC) at Rensselaer Polytechnic Institute, Xerox Research Centre of Canada (XRCC)) utilize their AM and lighting expertise to investigate breakthrough manufacturing approaches that will significantly reduce cost, eliminate manufacturing process waste, and improve luminaire efficacy. The team has identified critical areas of research and proposed novel technical approaches to achieve these goals. Key areas of focus in Budget Period 1 (BP1) of the project quantified the impact of applying AM methodologies to the main, discrete subsystem components (Heat Sink, Housing, Optics, Electronics). Budget Period 2 (BP2) research explored similar impact on a fully integrated, AM modular luminaire concept. Final Achievement of the Target Metrics for the project are as follows: Material Reduction: achieved > 57.45% (target is 50%) Manufacturing Process: achieved > 51% reduction (target is 50%) Application Efficacy: achieved 126 lm/W (target is 130 lm/W) First Cost vs Baseline: demonstrated 49% improvement in project timing, 59% improvement in man hour savings and 89% worse BOM costs (due to deficiencies in current “state of the art” equipment). The BOM costs improve to 53% savings if state of the art processes and equipment could have been used.
This work proposes a design and development strategy of a new nickel-based superalloy for additive manufacturing. A new Ni-based superalloy has been developed by the application of the combinatorial alloy development technique coupled with CALPHAD based solidification modeling by effectively suppressing the precipitation kinetics. The suppression of precipitation during processing paved a way for prevention of cracks during deposition. The new alloy "WSU 150" revealed excellent room temperature mechanical properties with a yield strength of 867 MPa, an ultimate tensile strength of 1188 MPa, and an elongation of 27.9% in the as-deposited condition. The mechanical properties of the heat-treated alloy were improved significantly to 1114 MPa yield strength, 1396 MPa ultimate tensile strength, and an elongation of 16.1%. Improvement in the mechanical properties is attributed to the additional precipitation and coarsening of γ' and carbides during heat-treatment. Microstructural investigation of the alloy revealed spherical γ' with a rippled size distribution from the center to the interdendritic region. The average size of the γ' particles in the as-deposited condition was found to be around 48 nm in the interdendritic region. Heat-treatment promoted the coarsening of γ' which is explained in the paper.
The sensitivity of geometrical parameters on the residual stress and distortion as computed by a metal additive manufacturing simulation is presented. A nozzle-like geometry was chosen with its length, wall thickness, and outer radius varied. A Latin hypercube sampling of 300 specimens produced the combinations of the geometrical parameters. Full thermomechanical simulations predicted the residual fields. Statistical analysis including regression curves shows that there is a strong correlation between these residual fields and the geometry, hinting that it may be possible to predictably influence the residual displacements and residual stresses by varying the overall geometry.
The goal of this work is to compare the outcome of a design for additive manufacturing (DfAM) heuristics lesson conducted in a virtual learning environment to the same in an in-person learning environment. Prior work revealed that receiving DfAM heuristics at different points in the design process impacts the quality and novelty of designs produced afterward, but this work may have been limited by the solely virtual format. In this work, an identical experiment was performed in a face-to-face learning environment. Results indicate that neither learning format presents an advantage over the other when it comes to the quality of designs produced during the intervention. Participants across all experimental groups reported an increase in self-efficacy after the intervention, with improved performance on quiz-type questions. Furthermore, the novelty and variety of the designs produced by the in-person experimental groups were significantly lower than that of the virtual experimental groups. In addition to validating the effectiveness of virtual instruction as a teaching method, these results also support the authors’ hypothesis that the priming effect is stronger in an in-person classroom than in a virtual classroom.
The purpose of this research was to measure the equation of state for additively manufactured (AM) and forged 304L stainless steel using a novel experimental technique. An understanding of the dynamic behavior of AM metals is integral to their timely adoption into various applications. The Hugoniot of the AM 304L was compared to that of the forged 304L at particle velocities where the material retains a two-wave structure. This comparison enabled us to determine the sensitivity of the equation of state to microstructure as varied due to processing. Our results showed that there was a measurable difference in the measured shock velocity between the AM and forged 304L. The shock wave velocities for the AM 304L were found to be ~3% slower than those for the forged 304L at similar particle velocities. To understand these differences, properties such as densities, sound speeds, and texture were measured and compared between the forged and AM materials. Our results showed that no measurable difference was found in these properties. Additionally, it is possible that differing elastic wave amplitudes may influence shock velocity.
The purpose of this research was to measure the equation of state for additively manufactured (AM) and forged 304L stainless steel using a novel experimental technique. An understanding of the dynamic behavior of AM metals is integral to their timely adoption into various applications. The Hugoniot of the AM 304L was compared to that of the forged 304L at particle velocities where the material retains a two-wave structure. This comparison enabled us to determine the sensitivity of the equation of state to microstructure as varied due to processing. Our results showed that there was a measurable difference in the measured shock velocity between the AM and forged 304L. The shock wave velocities for the AM 304L were found to be ~3% slower than those for the forged 304L at similar particle velocities. To understand these differences, properties such as densities, sound speeds, and texture were measured and compared between the forged and AM materials. Our results showed that no measurable difference was found in these properties. Additionally, it is possible that differing elastic wave amplitudes may have an effect on shock velocity.
With anticipated increases in global energy use and their associated emissions, there are many efforts to improve the emissions and efficiency of many industrial processes through waste heat recovery (WHR). To maximize improvements, the heat exchangers in WHR power cycles must be designed and optimized for a given heat source. Meanwhile, additive manufacturing (AM) is a single part manufacturing technique that provides the opportunity to develop unique and complex heat exchanger designs. Consequently, this work centers on the modeling, design, optimization, and testing of AM shell and tube heat exchangers for WHR. Specifically, a modified one-dimensional (1+1-D) and three-dimensional (3-D) heat exchanger models were developed and validated, with the 1+1-D model serving as the basis for design optimization. After modifications to the design to allow for AM, heat exchanger geometry optimizations were completed, targeting increased effectiveness across a range of physical parameters. Of the designs considered, nine were additively manufactured using Ti5553, and then tested using an external heat source and working fluid. Experimentally, the nineteen-tube, zero-baffle heat exchanger displayed the best overall performance, with the effects of dimensional accuracy, surface roughness, and baffles in the other designs also indicated. Next, the experimental results were used as inputs for the 1+1-D model. Although the original model was able to predict fluid outlet temperatures within 5% differences, larger variations in the heat exchanger performance parameters, temperature differences, and pressure drop necessitated optimizing the pressure drop and heat transfer calculations within the model. Thus, the resulting improved model was able to predict the heat transfer rates, heat source temperature difference, and effectiveness within 15% differences, while showing improvements in the pressure drops and working fluid temperature differences. The improved model serves as the foundation for future work to improve the design and performance of AM heat exchangers.
An Al–10Ce-8Mn (wt%) alloy was designed and fabricated by laser powder bed fusion additive manufacturing (AM). The rapid cooling rates of the AM process produced a refined microstructure with a large fraction of reinforcing intermetallic phases. The tensile properties of the alloy were characterized in the as-fabricated state and following thermal exposure. The properties of the as-fabricated microstructure showed exceptional high-temperature performance and strength retention at elevated temperatures up to 400 °C relative to benchmark wrought Al and AM Al alloy properties. Characterization of the microstructure and thermodynamic modeling of the ternary Al–Ce–Mn system rationalized the solidification and solid-state phase transformations. Finally, analysis of the relevant strengthening mechanisms for both the as-fabricated and thermally exposed conditions was performed.
The adoption of Additively Manufactured (AM) Ti-6Al-4V (Ti64) is continually increasing in the industry due to its benefits over the conventional manufacturing techniques. However, AM Ti64 parts are prone to poor surface finish, which significantly affects their fatigue performance. Therefore, AM Ti64 parts need post-processing to enhance surface finish and fatigue performance. Prior work with a sulfur-based self-terminating etching process for AM Ti64 demonstrated support removal and surface roughness reduction. To further this work, this manuscript details the impact of this sulfur-based post-processing technique on the mechanical properties and the fatigue life of AM Ti64 by characterizing the surface roughness, microstructural evolution, and fracture surfaces. Finally, this post-processing technique decreased the surface roughness parameter - S v by 55 % from 84 ± 11 µm to 38 ± 19 µm and increased the average fatigue life by 340 % from about 7000 cycles to 30,000 cycles.
The purpose of this research was to measure the equation of state for additively manufactured (AM) and forged 304L stainless steel. An understanding of the dynamic behavior of AM metals is integral to their timely adoption into industrial and governmental applications. The Hugoniot of the AM 304L was compared to that of the forged 304L. This comparison enabled us to determine the sensitivity of the equation of state to processing parameters and the resulting microstructure. Our results show that there is a measurable difference in the Hugoniot between the AM 304L and forged 304L. The shock wave velocities for the AM 304L were found to be slower than those for the forged 304L at similar particle speeds perhaps because of the presence of porosity in the AM 304L. While our measurements of density showed no distinct trend toward a measurable decrease in density in the AM 304L, there was a fair amount of scatter in these results.
Abstract —In this paper we demonstrate a fully additively manufactured packaged W-band amplifier with integrated bypass capacitors. This package was fabricated using a chip-first approach and aerosol jet printing. Package substrates (dielectrics), conductors and interconnects are printed around a bare die attached to a carrier. This package uses shaped ramp interconnects, allowing for frequency agnostic package performance of the interconnect with no impedance discontinuity, within the physical limits of the printer. High dielectric constant thin films of a polymer-matrix nanocomposite for bypass capacitors were printed using multi-material aerosol jet printing. The maximum measured packaged gain is 14.9 dB in the W-band, compared to the maximum bare die gain of 15.5 dB in the same frequency range. From 75 - 92 GHz, the average package loss is 1.1 dB including 3 mm transmission line, interconnects, and a GSG launch structure correlating to an average loss of 0.37 dB/mm.
This dataset provides sample datasets containing voxelized, three-dimensional representations of simulated grain structures and crystallographic orientations that can result from laser powder bed fusion additive manufacturing. The six microstructure files each contain approximately 1 cubic millimeter of material (1 mm x 1 mm cross-section over 26 simulated layers of deposition). Some of the microstructures have columnar grains that extend across nearly the entire simulation domain, while others have more equiaxed or truncated columnar grains. The process conditions to generate these microstructures were from the Peregrine v2023-10 dataset (10.13139/ORNLNCCS/2008021). The codes used are publicly available and released under open-source licenses. Myna (https://github.com/ORNL-MDF/Myna) was used for configuration of the cases from the Peregrine v2023-10 HDF5 dataset and to run the simulation workflow. AdditiveFOAM (https://github.com/ORNL/AdditiveFOAM) was used to simulate the melt pool and generate solidification conditions. And ExaCA (https://github.com/LLNL/ExaCA ) was used to simulate the three-dimensional microstructures.