At this unique show floor feature, event attendees view poster displays of projects or research in the areas of 3D printing, additive manufacturing, and 3D imaging. Gain additional information of interest including a glimpse into future additive manufacturing research, developments and applications.
RAPID + TCT posters will be displayed in the exhibits area and will be open to all event attendees. On Wednesday, April 25 from 1:00 pm – 6:00 pm, a special Interactive Poster Session will be held. During this time, poster presenters will be available at their respected posters to interact with guests, answer questions and discuss the technology/features of their display.
Please note that photographing posters without the permission of the presenters is prohibited.
Development of a Robotized Laser-Based Direct Metal Deposition System by Using Wire as a Feedstock
A robotized laser/based direct metal deposition system with wire as a feedstock has been developed at SMU, RCAM (Research center for advanced manufacturing). This promising technology has enabled fabrication of freeform and near net shape metal components in a higher deposition rate and cleaner environment. Since this is a demanding and hard-to-control process, a lot of parameters have to be optimized in order to ensure the stability and repeatability of the process.
Presenter: Meysam Akbari – Southern Methodist University
A Rapid Micro-Casting Hybrid Additive Manufacturing (AM) Technique for Metamaterial Phononic Crystal Devices
A metamaterial phononic crystal is artificially engineered to achieve nonreciprocal linear transmission. The shape and size of a structure and material properties are strongly related to the characteristics of the wave propagation. Which means that a specific size, or scale, and shape of the structure are required. However, there is a challenge to fabricate metamaterial phononic crystal devices using conventional manufacturing methods because the size and shape are a millimeter scale and the complicate non-symmetric cross-section, respectively. In this study, we used a rapid micro-casting hybrid additive manufacturing (AM) technique to fabricate asymmetric aluminum rods and demonstrate that the metamaterial phononic crystal can be acoustically nonreciprocal. The experiment was conducted in the water environment and the nonreciprocity was reached 10-15 dB.
Presenter: Hyeonu Heo – University of North Texas
Mini-Fatigue Testing of a Laser Additive Manufactured IN-625
Automotive and aerospace industries are some of the proponents for the development of additive manufacturing (AM) technology. AM has evolved as a vanguard technology for making intricate and complicated structures. However, the main concern regarding these technologies is the inhomogeneity of properties based on the location and build direction. In this work, microstructure and mechanical properties using mini-tensile specimens were characterized in X-Y (horizontal) and Z (build) directions. Results suggest uniform tensile properties along horizontal and built directions. Fatigue is a crucial property for structural components, hence mini-fatigue properties in the horizontal and build directions were investigated. In addition, microstructural evolution analysis during cyclic loading was performed.
Presenter: Shivakant Shukla – University of North Texas
Laser Additive Processing of Magnetic Alloys from Elemental Blends
While laser additive manufacturing is becoming increasingly important in the context of next-generation manufacturing technologies, most current research efforts focus on optimizing process parameters for the processing of mature alloys for structural applications (primarily stainless steels, titanium base, and nickel base alloys) from pre-alloyed powder feedstocks to achieve properties superior to conventionally processed counterparts. However, laser additive manufacturing or processing can also be applied to functional materials. This article focuses on the use of directed energy deposition based additive manufacturing technologies, such as the laser engineered net shaping (LENSTM) process, to deposit magnetic alloys. Three case studies are presented: Fe-30at%Ni, Permalloys of the type Ni-Fe-V and Ni-Fe-Mo, and Fe-Si-B-Cu-Nb (derived from Finemet) alloys. All these alloys have been processed from a blend of elemental powders, used as the feedstock, and their resultant microstructures, phase formation, and magnetic properties, have been discussed in this paper. Although these alloys were produced a from blend of elemental powders, they exhibited relatively uniform microstructure and comparable magnetic properties to those of their conventionally processed counterparts.
Presenter: Srinivas Aditya Mantri – University of North Texas
Microstructure and Mechanical Behavior Characterization of Additively Manufactured Ni-Base Superalloys
Detailed microstructural, tensile, axial fatigue and Charpy impact properties of additively manufactured IN625 and IN718 alloys produced by selective laser melting technique have been evaluated. Post-heat treatment led to the removal of interdendritic segregation in both the alloys, however severe intra- and inter-grain δ phase segregation occurred in IN718. Axial fatigue properties along the build direction were similar to MMPDS-01 wrought fatigue data. In the case of IN625, Charpy impact energy values were superior to wrought data in hot-rolled condition. Fractography of both fatigue and Charpy impact tested samples was done as well to understand the effect of various microstructural features on the mechanical properties.
Presenter: Mageshwari Komarasamy – University of North Texas
Friction Stir Additive Manufacturing: Its Application to Low and High Melting Temperature Alloys
Additive manufacturing (AM) continues to emerge as a capable means for producing complex structural components and rapid prototyping of components. As a result, AM has drawn the interest of a wide-ranging of industries such as the automotive, aerospace and defense. Efforts have been made to implement AM in both low density and high strength alloy systems having significantly different melting temperatures, i.e. magnesium alloys and steels, respectively. In the recent years, friction stir additive manufacturing (FSAM) has been developed as a solid-state solution for various alloy systems to avoid cast microstructural evolution in fusion AM processes, which can result in deterioration of mechanical properties. Inspired by the potential to produce refined microstructures by FSAM, here we present its application to both low-density magnesium alloys as well as high strength steels. Microstructural evolution and site specific tensile properties were evaluated to understand the effects of FSAM parameters on mechanical behavior.
Presenter: Michael Frank – University of North Texas
Laser Additive Manufacturing of High Entropy Alloy Coatings
High entropy alloys (HEAs) are emerging class of materials containing near equiatomic concentration of multiple elements rather than a base element with smaller alloying additions. As a result, the configurational randomness of the alloy system increases its overall entropy. HEAs have shown good surface properties such as high hardness, fatigue resistance, and corrosion resistance making them suitable for surface engineering. Moreover, microstructure control in bulk synthesis of HEAs becomes difficult. Therefore, to take an advantage of their properties, HEAs can be synthesized as coatings on conventional structural materials by suitable method. In the present work, single and multi-layer HEA coatings were additively synthesized using laser surface engineering on an aluminum substrate. The dilution from the substrate minimized upon introduction of an additional coating layer. Furthermore, higher laser input energy (25 J/mm2) during processing led to uniform mixing amongst the coating components and formation of evenly distributed HEA phases. Such a microstructure showed enhanced corrosion resistance for the coatings in near neutral NaCl solution.
Presenter: Sameehan S. Joshi – University of North Texas
3D Printed Composite Tooling
Manufacturing parts with complex geometries and curves can be challenging and require metallic tooling methods which are expensive and have long lead times. A novel approach to replacing this method is using 3D printed composite tooling. The technology associated with Fused Deposition Modeling (FDM) and its applications are constantly improving. 3D printed composite tooling can be used to manufacture complex parts which are comparatively less expensive and faster to manufacture than metallic tooling. In this project, a composite winglet with ribs and a spar is manufactured. The materials are identified for the composite part, and the toolings based on their functions in this project. Since surface finish is one of the bigger challenges associated with this manufacturing method, several design considerations are made to ensure a smooth surface finish of the winglet. Some of the factors affecting surface finish and their implementation to overcome this challenge have been outlined.
Presenter: Eligius Allan – University of Texas at Arlington
A Design Methodology for Continuous Fiber Additive Manufacturing Using Advanced Computer Aided Engineering Techniques
A design methodology for Continuous Carbon Fiber Additive Manufacturing (CCFAM) developed using Computer Aided Engineering (CAE) techniques takes advantage of both the mechanical strength of composite materials and the Fused Filament Fabrication (FFF) method. By performing topology optimization and Finite Element Analysis (FEA) on a load-bearing part, engineers can design much lighter optimized parts that exhibit similar mechanical properties to those produced using FFF. This weight reduction is achieved by relying on the mechanical properties of continuous carbon fibers printed alongside a traditional thermoplastic matrix. The FFF additive manufacturing method enables the production of complex shapes which can match the load-driven, organic geometries derived from topology optimization and other advanced CAE techniques. The efficacy of this design methodology has been demonstrated in a case study of a motor mount for a vertical take-off and landing drone.
Presenter: Nicholas Venter – University of Texas at Arlington