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IMECE2022-88301 Additive manufacturing (AM) is transforming industrial production. AM can produce parts with complex geometries and functionality. However, one of the biggest challenges in the AM world is limited material options. The purpose of this research is to develop new material mixtures and determine their mechanical properties for use at the MSOE Rapid Prototyping Center and provide valuable insight into beta materials for use in AM industry. Elastomeric polyurethane (EPU 40) and Rigid polyurethane (RPU 70), resins developed by Carbon3D, are employed for this research. Initially, EPU 40 (100%) and RPU 70 (100%) were used to print tensile and hardness test specimens so that their mechanical properties could be compared to the standard values presented by Carbon3D and used as benchmarks for newly developed material. Mixtures of the two materials, EPU 40 and RPU 70, in multiple ratios were then created and used to print tensile and hardness test specimens. Data collected from tensile and hardness tests show that EPU 40 and RPU 70 can be combined in various ratios to obtain material properties that lie between the two individual components. In addition to developing these new materials, the effect of printing orientation on mechanical properties was also studied inmore »Free, publicly-accessible full text available November 1, 2023
IMECE2022-88299 Midwest Engineered Systems Inc. has created a novel laser wire metal deposition process, ADDere manufacturing. ADDere has a much higher deposition rate than powder bed fusion, making it ideal for large components. In this project, the mechanical properties of ADDere printed materials were tested and compared to typical values found in ASM publications to show the quality of materials manufactured by the ADDere printing process. A detailed material analysis was performed on samples made from Ti-6Al-4V and 17-4 PH stainless steel. This work builds upon an earlier study of samples made from 17-4 PH that were produced using a single direction pattern. In this project, the 17-4 PH samples were printed in a cross hatched pattern, and testing results were compared to existing data from single direction samples of the previous research. The Ti-6Al-4V samples were created in two builds. One using the uni-directional method and the other with the crossed pattern. Testing specimens were removed from the samples using a water jet cutter and further machined into ASTM tensile bars and metallurgic mounts to perform a thorough material evaluation. The Ti-6Al-4V sample met the expected values in the ASM literature, and the cross hatched 17-4 PH exhibited amore »Free, publicly-accessible full text available November 1, 2023