Search for: All records

Wire arc additive manufacturing (WAAM) has received increasing use in 3D printing because of its high deposition rates suitable for components with large and complex geometries. However, the lower forming accuracy of WAAM than other metal additive manufacturing methods has imposed limitations on manufacturing components with high precision. To resolve this issue, we herein implemented the hybrid manufacturing (HM) technique, which integrated WAAM and subtractive manufacturing (via a milling process), to attain high forming accuracy while taking advantage of both WAAM and the milling process. We describe in this paper the design of a robot-based HM platform in which the WAAM and CNC milling are integrated using two robotic arms: one for WAAM and the other for milling immediately following WAAM. The HM was demonstrated with a thin-walled aluminum 5356 component, which was inspected by X-ray micro-computed tomography (μCT) for porosity visualization. The temperature and cutting forces in the component under milling were acquired for analysis. The surface roughness of the aluminum component was measured to assess the surface quality. In addition, tensile specimens were cut from the components using wire electrical discharge machining (WEDM) for mechanical testing. Both machining quality and mechanical properties were found satisfactory; thus the robot-based HM platform was shown to be suitable for manufacturing high-quality aluminum parts. 

Nanoindentation is an optimal technique for the measurement of thin film mechanical properties. Polymers present a unique problem in that their response to loading is time-dependent. Due to this, many of the most common nanoindentation methods are not suitable for probing polymer nanoscale properties. Despite this issue being well-known for decades, poly(3-hexylthiophene) has been exclusively analyzed by time-independent mechanical properties testing methods. Herein, we present a nanoindentation technique that analyzes the materials’ time-dependent response under both constant rate loading and step loading. By determining viscoelastic functions, we are able to extract the Young’s relaxation modulus of poly(3- hexylthiophene). The average Young’s modulus acquired from viscoelastic nanoindentation is determined to be 260 ± 27 MPa. These results are in excellent agreement with specialized mechanical tests for thin 

In this paper, a novel hybrid wire arc additive manufacturing (WAAM) and ultrasonic nanocrystal surface modification (UNSM) on porosity manipulation and surface properties of aluminum 5356 alloys was studied. The goal is to improve the quality of the WAAM-built part by eliminating bigger pores and reducing its size, reducing surface roughness, and increasing surface hardness. The as-built WAAM and WAAM-UNSM-treated samples were quantitatively studied for porosity using an X-ray micro-computed tomography (μ-CT). The surface roughness was measured on the surface profile of the same samples before and after UNSM treatment. Followed by the Vickers micro-hardness tests to evaluate the hardness modified by the influence of the UNSM treatment. It was found that the bigger pores in the as-built WAAM samples were eliminated and the medium-sized pores were shrunk to almost half the size after the UNSM treatment. Further, the UNSM treatment showed a significant improvement in both surface roughness and hardness on the WAAM Al5356 samples. This experimental work demonstrates the critical advantages of hybrid WAAM-UNSM in improving the qualities of the WAAM processed parts. 

Additive manufacturing (AM) is known to generate large magnitudes of residual stresses (RS) within builds due to steep and localized thermal gradients. In the current state of commercial AM technology, manufacturers generally perform heat treatments in effort to reduce the generated RS and its detrimental effects on part distortion and in-service failure. Computational models that effectively simulate the deposition process can provide valuable insights to improve RS distributions. Accordingly, it is common to employ Computational fluid dynamics (CFD) models or finite element (FE) models. While CFD can predict geometric and thermal fluid behavior, it cannot predict the structural response (e.g., stress–strain) behavior. On the other hand, an FE model can predict mechanical behavior, but it lacks the ability to predict geometric and fluid behavior. Thus, an effectively integrated thermofluidic–thermomechanical modeling framework that exploits the benefits of both techniques while avoiding their respective limitations can offer valuable predictive capability for AM processes. In contrast to previously published efforts, the work herein describes a one-way coupled CFDFEA framework that abandons major simplifying assumptions, such as geometric steady-state conditions, the absence of material plasticity, and the lack of detailed RS evolution/accumulation during deposition, as well as insufficient validation of results. The presented framework is demonstrated for a directed energy deposition (DED) process, and experiments are performed to validate the predicted geometry and RS profile. Both single- and double-layer stainless steel 316L builds are considered. Geometric data is acquired via 3D optical surface scans and X-ray micro-computed tomography, and residual stress is measured using neutron diffraction (ND). Comparisons between the simulations and measurements reveal that the described CFD-FEA framework is effective in capturing the coupled thermomechanical and thermofluidic behaviors of the DED process. The methodology presented is extensible to other metal AM processes, including power bed fusion and wire-feed-based AM. 

The ballistic performance of edge-clamped monolithic polyimide aerogel blocks (12 mm thickness) has been studied through a series of impact tests using a helium-filled gas gun connected to a vacuum chamber and a spherical steel projectile (approximately 3 mm diameter) with an impact velocity range of 150–1300 m s⁻¹. The aerogels had an average bulk density of 0.17 g cm⁻³with high porosity of approximately 88%. The ballistic limit velocity of the aerogels was estimated to be in the range of 175–179 m s⁻¹. Moreover, the aerogels showed a robust ballistic energy absorption performance (e.g., at the impact velocity of 1283 m s⁻¹at least 18% of the impact energy was absorbed). At low impact velocities, the aerogels failed by ductile hole enlargement followed by a tensile failure. By contrast, at high impact velocities, the aerogels failed through an adiabatic shearing process. Given the substantially robust ballistic performance, the polyimide aerogels have a potential to combat multiple constraints such as cost, weight, and volume restrictions in aeronautical and aerospace applications with high blast resistance and ballistic performance requirements such as in stuffed Whipple shields for orbital debris containment application.

 

The objective of this paper is to predict the fiber/matrix interfacial debond strength in composites. Atomic force microscopy (AFM) images of the surface topography of a de-sized carbon fiber reveal that there are surface asperities present at various length scales ranging from a nanometer to several microns. These asperities are likely caused by shrinkage of the polyacrylonitrile (PAN) precursor during the graphitization process. In order to bridge the length scales, a Fourier series-decomposition covering a range of asperity wavelengths and amplitudes is necessary to effectively capture the roughness of the fiber surface at different length scales. Further, once a surface asperity profile has been resolved into individual subcomponents using Fourier-decomposition, MD simulations can then be employed to obtain the interfacial shear strength of the subcomponent asperity of a given amplitude and wavelength. Finally, by recombining the peak interfacial shear force obtained from each of these subcomponents into the overall shear force for the fiber surface profile, the length-scale -averaged shear strength can be obtained for any given asperity. The objective of this paper is to use this novel approach to determine the interfacial shear strength of de-sized carbon fiber embedded in an epoxy matrix and compare predicted results with experimental data.