scholarly journals Porosity Reducing Processing Stages of Additive Manufactured Molding (AMM) for Closed-Mold Composite Fabrication

Materials ◽  
2020 ◽  
Vol 13 (23) ◽  
pp. 5328
Author(s):  
Marquese Pollard ◽  
Phong Tran ◽  
Tarik Dickens
Keyword(s):  
Additive Manufacturing ◽  
Composite Structures ◽  
Low Cost ◽  
Processing Parameters ◽  
Strength Properties ◽  
Material Strength ◽  
Composite Manufacturing ◽  
Layer Height ◽  
Porosity Reduction ◽  
Final Porosity

This article aims to merge two evolving technologies, namely additive manufacturing and composite manufacturing, to achieve the production of high-quality and low-cost composite structures utilizing additive manufacturing molding technology. This work studied additive manufacturing processing parameters at various processing stages on final printed part performance, specifically how altering featured wall thickness and layer height combine to affect final porosity. Results showed that reducing the layer height yielded a 90% improvement in pristine porosity reduction. Optimal processing parameters were combined and utilized to design and print a closed additive manufacturing molding tool to demonstrate flexible composite manufacturing by fabricating a composite laminate. Non-destructive and destructive methods were used to analyze the composite structures. Compared to the well-established composite manufacturing processes of hand lay-up and vacuum-assisted resin transfer molding methods, additive manufacturing molding composites were shown to have comparable material strength properties.

scholarly journals Development of an Additive Manufacturing System for the Deposition of Thermoplastics Impregnated with Carbon Fibers

2019 ◽  
Vol 3 (2) ◽  
pp. 35 ◽  
Author(s):  
Miguel Reis Silva ◽  
António M. Pereira ◽  
Nuno Alves ◽  
Gonçalo Mateus ◽  
Artur Mateus ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Additive Manufacturing ◽  
Carbon Fibers ◽  
Low Cost ◽  
Deposition Process ◽  
Processing Parameters ◽  
Yarn Diameter ◽  
Thermoplastic Matrix ◽  
Anisotropic Mechanical Properties ◽  
Long Carbon Fiber

This work presents an innovative system that allows the oriented deposition of continuous fibers or long fibers, pre-impregnated or not, in a thermoplastic matrix. This system is used in an integrated way with the filamentary fusion additive manufacturing technology and allows a localized and oriented reinforcement of polymer components for advanced engineering applications at a low cost. To demonstrate the capabilities of the developed system, composite components of thermoplastic matrix (polyamide) reinforced with pre-impregnated long carbon fiber (carbon + polyamide), 1 K and 3 K, were processed and their tensile and flexural strength evaluated. It was demonstrated that the tensile strength value depends on the density of carbon fibers present in the composite, and that with the passage of 2 to 4 layers of fibers, an increase in breaking strength was obtained of about 366% and 325% for the 3 K and 1 K yarns, respectively. The increase of the fiber yarn diameter leads to higher values of tensile strength of the composite. The obtained standard deviation reveals that the deposition process gives rise to components with anisotropic mechanical properties and the need to optimize the processing parameters, especially those that lead to an increase in adhesion between deposited layers.

Design and Analysis of Hybrid Fused Filament Fabrication Apparatus for Fabrication of Composites

2021 ◽  
Vol 14 ◽  
Author(s):  
Aniket Yadav ◽  
Piyush Chohan ◽  
Ranvijay Kumar ◽  
Jasgurpreet Singh Chohan ◽  
Raman Kumar
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Design Process ◽  
Low Cost ◽  
Matrix Material ◽  
Fabrication Process ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Composite Manufacturing ◽  
Tool Paths

Background: Additive manufacturing is the most famous technology which requires materials or composites to be fabricated with layer by layer deposition strategy. Due to its lower cost, higher accuracy and less material wastage; this technology is used in almost every sector. But in many applications there is a need to alter the properties of a product in a certain direction with the help of some reinforcements. With the use of reinforcements, composite layers can be fabricated using additive manufacturing technique which will enhance the directional properties. A novel apparatus is designed to spray the reinforcement material into the printed structures in a very neat and precise manner. This spray nozzle is fully automated, which works according to tool-paths generated by slicing software. The alternate deposition of layers of reinforcement and build materials helped to fabricate customized composite products. Objective: The objective of present study is to design and analyze the working principle of novel technique which has been developed to fabricate composite materials using additive manufacturing. The apparatus is numerically controlled by computer according to CAD data which facilitates the deposition of alternate layers of reinforcement and matrix material. The major challenges during the design process and function of each component has been explored. Methods: The design process is initiated after comprehensive literature review performed to study previous composite manufacturing processes. The recent patents published by different patent offices of the world are studied in detail and analysis has been used to design a low cost composite fabrication apparatus. A liquid dispensing device comprises a storage tank attached with a pump and microprocessor. The microprocessor receives the signal from the computer as per tool paths generated by slicing software which decides the spray of reinforcements on polymer layers. The spraying apparatus moves in coordination with the primary nozzle of the Fused Filament Fabrication process. Results: The hybridization of Fused Filament Fabrication [process with metal spray process has been successfully performed. The apparatus facilitates the fabrication of low cost composite materials along with flexibility of complete customization of composite manufacturing process. The anisotropic behaviour of products can be easily controlled and managed during fabrication which can be used for different applications.

scholarly journals Study of the Mechanism of a Stable Deposited Height During GMAW-Based Additive Manufacturing

2020 ◽  
Vol 10 (12) ◽  
pp. 4322
Author(s):  
Hongyao Shen ◽  
Rongxin Deng ◽  
Bing Liu ◽  
Sheng Tang ◽  
Shun Li
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Gas Metal Arc Welding ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Deposition Process ◽  
High Deposition Rate ◽  
Thin Wall ◽  
Forming Process ◽  
Layer Height

Gas metal arc welding (GMAW)-based additive manufacturing has the advantages of a high deposition rate, low cost, the production of a compact and dense microstructure in the cladding layer, and good mechanical properties, but the forming process is unstable. The shape of the welding bead critically affects the layer height and dimensional accuracy of the parts manufactured, and it is difficult to control. A series of experiments were designed and the results indicated that when the value of the predefined layer height is set in a certain range and other parameters are held constant, the height of the thin wall produced by GMAW-based additive manufacturing is almost equal to the predefined layer height multiplied by the number of layers. This research work shows that during the GMAW process, the changes in the distance between the torch and the top surface of the part cause a variety of dry extensions of the electrode; furthermore, the changes lead to a variety in the heat input into the molten pool. Therefore, the dry extension of the electrode is the key factor influencing the geometry of the welding bead, especially the layer height, and it has a compensating effect that makes the actual layer height close to the predefined value. A three-dimensional numerical model was established to study the influence of the predefined layer height to the fluid flow and heat transfer behaviors during the weld-deposition process.

3D printing: a critical review of current development and future prospects

2019 ◽  
Vol 25 (6) ◽  
pp. 1108-1126 ◽  
Author(s):  
Md. Hazrat Ali ◽  
Shaheidula Batai ◽  
Dastan Sarbassov
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Low Cost ◽  
Processing Parameters ◽  
Optimization Techniques ◽  
Future Research ◽  
Modern Trend ◽  
Content Type ◽  
Shape Structure ◽  
Mechanical Performances

Purpose This study highlights the demand for low-cost and high accuracy products through the design and development of new 3D printing technologies. Besides, significant progress has been made in this field. A comparative study helps to understand the latest development in materials and future prospect of this technology. Design/methodology/approach Nevertheless, a large amount of progress still remains to be made. While some of the works have focused on the performances of the materials, the rest have focused on the development of new methods and techniques in additive manufacturing. Findings This paper critically evaluates the current 3D printing technologies, including the development and optimizations made to the printing methods, as well as the printed objects. Meanwhile, previous developments in this area and contributions to the modern trend in manufacturing technology are summarized briefly. Originality/value The paper can be summarized in three sections. Firstly, the existing printing methods along with the frequently used printing materials, as well as the processing parameters, and the factors which influence the quality and mechanical performances of the printed objects are discussed. Secondly, the optimization techniques, such as topology, shape, structure and mechanical property, are described. Thirdly, the latest development and applications of additive manufacturing are depicted, and the scope of future research in the relevant area is put forward.

Causes of gear pump fails and methods for their elimination

2020 ◽  
pp. 98-107
Author(s):  
Vitaliy A. Zuyevskiy ◽  
Daniil O. Klimyuk ◽  
Ivan A. Shemberev
Keyword(s):  
Adhesion Strength ◽  
Production Systems ◽  
Low Cost ◽  
High Strength ◽  
Strength Properties ◽  
Research Purpose ◽  
Working Fluid ◽  
Gear Pump ◽  
Repair Service ◽  
Recovery Method

Gear pumps are an important element of many production systems and their replacement in case of failure can be quite expensive, so it is important to have a modern and well-tuned technology for their recovery. There are many methods for restoring the pump's performance, depending on the reason that led to its failure. (Research purpose) The research purpose is in determining what causes most often lead to loss of pump performance, and developing a recovery method that provides the greatest post-repair service life of the pump and low cost of repair. (Materials and methods) Authors took into account that the applied coatings must have sufficient adhesion strength and resistance to mechanical, thermal and corrosion loads during operation. It was found that most often significant leaks of the working fluid, leading to failure, occur due to an increase in the gap between the inner surface of the housing and the gears due to active wear of the housing wells. Authors determined that the method of electric spark treatment of worn-out housing wells is best suited to perform the task (a large post-repair resource and low costs). (Results and discussion) It was found by laboratory studies of the adhesion strength of electric spark coatings with various electrodes that the best transfer of the material to the substrate is provided by bronze electrodes BrMKts3-1. It was noted that the coatings applied using the BrMKts3-1 electrode have high strength properties. (Conclusions) Research conducted in the center for collective use "Nano-Center" VIM confirmed the possibility of effective recovery of the gear pump by electric spark treatment.

scholarly journals Microfabrication with Very Low-Average Power of Green Light to Produce PDMS Microchips

Polymers ◽  
2021 ◽  
Vol 13 (4) ◽  
pp. 607
Author(s):  
Lucero M. Hernandez-Cedillo ◽  
Francisco G. Vázquez-Cuevas ◽  
Rafael Quintero-Torres ◽  
Jose L. Aragón ◽  
Miguel Angel Ocampo Mortera ◽  
...  
Keyword(s):  
Low Cost ◽  
Average Power ◽  
Green Light ◽  
Microfluidic Devices ◽  
Processing Parameters ◽  
Coating Film ◽  
Two Dimensional ◽  
Dimethyl Siloxane ◽  
Visible Laser ◽  
High Absorption

In this article, we show an alternative low-cost fabrication method to obtain poly(dimethyl siloxane) (PDMS) microfluidic devices. The proposed method allows the inscription of micron resolution channels on polystyrene (PS) surfaces, used as a mold for the wanted microchip’s production, by applying a high absorption coating film on the PS surface to ablate it with a focused low-power visible laser. The method allows for obtaining micro-resolution channels at powers between 2 and 10 mW and can realize any two-dimensional polymeric devices. The effect of the main processing parameters on the channel’s geometry is presented.

Influence of Specimen Layout on 17-4PH (AISI 630) Alloys Fabricated by Low-Cost Additive Manufacturing

2021 ◽  
Author(s):  
Chanun Suwanpreecha ◽  
Phanuphak Seensattayawong ◽  
Vorawat Vadhanakovint ◽  
Anchalee Manonukul
Keyword(s):  
Additive Manufacturing ◽  
Low Cost

Printing of Low Cost Sensors by Additive Manufacturing

2021 ◽  
Author(s):  
Salman Ahmad ◽  
Muhammad Shakeel ◽  
Nadeem Iqbal ◽  
Mohsin Amin ◽  
Khalid Rahman
Keyword(s):  
Additive Manufacturing ◽  
Low Cost

scholarly journals Gold, Silver, and Electrum Electroless Plating on Additively Manufactured Laser Powder-Bed Fusion AlSi10Mg Parts: A Review

Coatings ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 422
Author(s):  
Dana Ashkenazi ◽  
Alexandra Inberg ◽  
Yosi Shacham-Diamand ◽  
Adin Stern
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Ion Beam ◽  
Surface Finishing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Finishing Process ◽  
Gold Silver ◽  
3D Printed

Additive manufacturing (AM) revolutionary technologies open new opportunities and challenges. They allow low-cost manufacturing of parts with complex geometries and short time-to-market of products that can be exclusively customized. Additive manufactured parts often need post-printing surface modification. This study aims to review novel environmental-friendly surface finishing process of 3D-printed AlSi10Mg parts by electroless deposition of gold, silver, and gold–silver alloy (e.g., electrum) and to propose a full process methodology suitable for effective metallization. This deposition technique is simple and low cost method, allowing the metallization of both conductive and insulating materials. The AlSi10Mg parts were produced by the additive manufacturing laser powder bed fusion (AM-LPBF) process. Gold, silver, and their alloys were chosen as coatings due to their esthetic appearance, good corrosion resistance, and excellent electrical and thermal conductivity. The metals were deposited on 3D-printed disk-shaped specimens at 80 and 90 °C using a dedicated surface activation method where special functionalization of the printed AlSi10Mg was performed to assure a uniform catalytic surface yielding a good adhesion of the deposited metal to the substrate. Various methods were used to examine the coating quality, including light microscopy, optical profilometry, XRD, X-ray fluorescence, SEM–energy-dispersive spectroscopy (EDS), focused ion beam (FIB)-SEM, and XPS analyses. The results indicate that the developed coatings yield satisfactory quality, and the suggested surface finishing process can be used for many AM products and applications.

scholarly journals Multiscale additive manufacturing of polymers using 3D photo-printable self-assembling ionic liquid monomers

2019 ◽  
Vol 4 (3) ◽  
pp. 580-585 ◽  
Author(s):  
Bineh G. Ndefru ◽  
Bryan S. Ringstrand ◽  
Sokhna I.-Y. Diouf ◽  
Sönke Seifert ◽  
Juan H. Leal ◽  
...  
Keyword(s):  
Ionic Liquid ◽  
Additive Manufacturing ◽  
Self Assembly ◽  
Low Cost ◽  
Low Resolution ◽  
Top Down ◽  
Bottom Up ◽  
Cost Approach ◽  
Self Assembling ◽  
Nanoscale Features

Combining bottom-up self-assembly with top-down 3D photoprinting affords a low cost approach for the introduction of nanoscale features into a build with low resolution features.

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