Experimental calibration and compensation for the continuous effect of time, number of layers and volume of material on shape deformation in small-scale additive manufacturing of concrete

2021 ◽  
pp. 102228
Author(s):  
Negar Ashrafi ◽  
Shadi Nazarian ◽  
Nicholas A. Meisel ◽  
Jose Pinto Duarte
Keyword(s):  
Additive Manufacturing ◽  
Shape Deformation ◽  
Small Scale ◽  
Experimental Calibration ◽  
Number Of Layers

DYNAMIC MODEL OF COMBINED AGGREGATION OF ADDITIVE MANUFACTURING PROCESS

2021 ◽  
Author(s):  
A. V. Vinnichenko ◽  
Keyword(s):  
Mathematical Modeling ◽  
Additive Manufacturing ◽  
Process Model ◽  
Additive Technologies ◽  
Additive Models ◽  
Small Scale ◽  
Scale Production ◽  
Flexible Production ◽  
Optimization Criteria ◽  
Production Resources

The paper presents methods and approaches for mathematical modeling and rationalization of flexible additive manufacturing, as well as other processes by which it is possible to create additive models for their integration into the system of experimental or pilot production. The work has also formed and synthesized a process model, which includes flexible production indicators, service indicators, and a developed criterion base for their assessment. The work takes into account the optimization criteria, as well as maximizing and minimizing risks for additive manufacturing, taking into account the possible risk component when deploying new processes for experimental and small-scale production. The models and methods described in the article will make it possible to carry out mathematical modeling and subsequent improvements for the flexible production process using additive technologies, used as a means of achieving the rational use of existing production resources within the framework of existing scientific and production complexes.

scholarly journals Large-Scale Additive Manufacturing for Low Cost Small-Scale Wind Turbine Manufacturing

2020 ◽  
Author(s):  
Brian Post ◽  
Phillip Chesser ◽  
Alex Roschli ◽  
Lonnie Love ◽  
Katherine Gaul
Keyword(s):  
Additive Manufacturing ◽  
Wind Turbine ◽  
Large Scale ◽  
Low Cost ◽  
Small Scale

scholarly journals Experience of implementation in educational process modern technologies of FDM 3D printing

2021 ◽  
pp. 55-59
Author(s):  
Petr Andrienko ◽  
Vladimir Vasilevskij ◽  
Ivan Vittsivskyi
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Current Transformer ◽  
Educational Process ◽  
Small Scale ◽  
Thermoplastic Material ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Modern Technologies

Fused Deposition Modeling is an additive manufacturing technology where a temperature-controlled head extrudes a thermoplastic material onto a build platform in a predetermined path. Standard, advanced thermoplastics and composites are used for printing. Among the areas of application for FDM printing, the main ones are rapid prototyping, as well as small-scale and batch production. The purpose of the work is the implementation of FDM 3D printing technology in the educational process of students in specialty 141 "Electroenergy, electrotechnics and electromechanics". The features of the technology of additive manufacturing of electrical apparatuses parts by the method of FDM printing have been investigated. Parts of four standard sizes were printed using ABS + and PLA plastics, namely, current transformer carcasses in the amount of 110 pieces and sensor bodies in the amount of 100 pieces. For printing, an FDM 3D printer was used built on the XZ Head Y Bed kinematic scheme with an open working chamber. The analysis of defects in finished products was carried out, which showed that the main defects are deviations of the actual dimensions and geometric shape of the finished products. Ways to prevent the occurrence of these defects are considered, namely, correcting the size of the model at the stage of preparing the model for printing, minimizing the filling density of the model, using brims in models, setting the optimal temperature of the working platform and simultaneously printing several products. The results of the study o features of the technology of additive manufacturing of electrical apparatuses parts by the method of FDM printing made it possible to develop a set of laboratory works for students of the specialty 141 "Electroenergy, electrotechnics and electromechanics".

Comparing Environmental Impacts of Additive Manufacturing vs. Investment Casting for the Production of a Shroud for Gas Turbine

2021 ◽  
Author(s):  
Angela Serra ◽  
Martina Malarco ◽  
Alessandro Musacchio ◽  
Giulio Buia ◽  
Pietro Bartocci ◽  
...  
Keyword(s):  
Life Cycle ◽  
Additive Manufacturing ◽  
Environmental Impact ◽  
Investment Casting ◽  
Gas Turbines ◽  
Raw Materials ◽  
Base Material ◽  
Small Scale ◽  
Atomization Process ◽  
Traditional Manufacturing

Abstract Additive manufacturing (AM hereinafter) is revolutionizing prototyping production and even small-scale manufacturing. Usually it is assumed that AM has lower environmental impact, compared to traditional manufacturing processes, but there have been no comprehensive environmental life-cycle assessment studies confirming this, especially for the gas turbines (GT hereinafter) and turbomachinery sector. In this study the core processes performed at Baker Hughes site in Florence are considered, together with the powder production via atomization process to describe the overall environmental impact of a GT shroud produced through additive manufacturing and comparing it with traditional investment casting production process. Particular attention is given to materials production and logistics. The full component life cycle starts from the extraction of raw materials during mining, their fusion and, as said, the atomization process, the powders are transported to the gas turbines production site where they are used as base material in additive manufacturing, also machining and finishing processes are analyzed as they differ for a component produced by AM respect to one produced by traditional investment casting. From the analysis of the data obtained, it emerges that the AM process has better performances in terms of sustainability than the Investment casting (IC hereinafter), highlighted above all by a decrease in greenhouse gas emissions (GHG hereinafter) of over 40%.

Uncertainty Quantification in Metallic Additive Manufacturing Through Data-Driven Modelling Based on Multi-Scale Multi-Physics Models and Limited Experiment Data

2020 ◽  
Author(s):  
Zhuo Wang ◽  
Chen Jiang ◽  
Mark F. Horstemeyer ◽  
Zhen Hu ◽  
Lei Chen
Keyword(s):  
Temperature Field ◽  
Additive Manufacturing ◽  
Uncertainty Quantification ◽  
Surrogate Modeling ◽  
Data Driven ◽  
Modeling Framework ◽  
High Quality ◽  
Experimental Calibration ◽  
Multi Scale ◽  
Metallic Additive

Abstract One of significant challenges in the metallic additive manufacturing (AM) is the presence of many sources of uncertainty that leads to variability in microstructure and properties of AM parts. Consequently, it is extremely challenging to repeat the manufacturing of a high-quality product in mass production. A trial-and-error approach usually needs to be employed to attain a product with high quality. To achieve a comprehensive uncertainty quantification (UQ) study of AM processes, we present a physics-informed data-driven modeling framework, in which multi-level data-driven surrogate models are constructed based on extensive computational data obtained by multi-scale multi-physical AM models. It starts with computationally inexpensive metamodels, followed by experimental calibration of as-built metamodels and then efficient UQ analysis of AM process. For illustration purpose, this study specifically uses the thermal level of AM process as an example, by choosing the temperature field and melt pool as quantity of interest. We have clearly showed the surrogate modeling in the presence of high-dimensional response (e.g. temperature field) during AM process, and illustrated the parameter calibration and model correction of an as-built surrogate model for reliable uncertainty quantification. The experimental calibration especially takes advantage of the high-quality AM benchmark data from National Institute of Standards and Technology (NIST). This study demonstrates the potential of the proposed data-driven UQ framework for efficiently investigating uncertainty propagation from process parameters to material microstructures, and then to macro-level mechanical properties through a combination of advanced AM multi-physics simulations, data-driven surrogate modeling and experimental calibration.

Fabrication of Efficient Electrodes for Dye-Sensitized Solar Cells Using Additive Manufacturing

2018 ◽  
Author(s):  
Sagil James ◽  
Rinkesh Contractor ◽  
Chris Veyna ◽  
Galen Jiang
Keyword(s):  
Solar Cells ◽  
Additive Manufacturing ◽  
Liquid Medium ◽  
Experimental Studies ◽  
Dye Sensitized Solar Cells ◽  
Light Condition ◽  
Small Scale ◽  
Dye Sensitized ◽  
Si Solar Cells ◽  
Sensitized Solar Cells

Dye-Sensitized Solar Cells (DSSC) are third generation solar cells used as an alternative to c-Si solar cells. DSSC are mostly flexible, easier to handle and are less susceptible to damage compared to c-Si solar cells. Additionally, DSSC is an excellent choice for indoor application as they perform better under diverse light condition. Most DSSCs are made of liquid medium sandwiched between two conductive polymer layers. However, DSSCs have significantly lower efficiencies compared to silicon solar cells. Also, use of liquid medium resulting in leaking of liquid, and occasional freezing during cold weather, and thermal expansion during hot weather conditions. DSSC can be manufactured in small quantities using relatively inexpensive solution-phase techniques such as roll-to-roll processing and screen printing technology. However, scaling-up the DSSC manufacturing from small-scale laboratory tests to sizeable industrial production requires better and efficient manufacturing processes. This research studies the feasibility of using additive manufacturing technique to fabricate electrodes of DSSC. The study aims to overcome the limitations of DSSCs including preventing leakage and providing more customized design. Experimental studies are performed to evaluate the effects of critical process parameters affecting the quality of electrodes for DSSC. Volume resistivity test is performed to evaluate the efficiency of the electrodes. In this study, the electrodes of DSSC are successfully fabricated using Fused Disposition Modeling (FDM) 3D printing technique. The results of this study would enable additive manufacturing technology towards rapid commercialization of DSSC technology.

A Reverse Compensation Framework for Shape Deformation in Additive Manufacturing

2016 ◽  
Author(s):  
Kai Xu ◽  
Tsz-Ho Kwok ◽  
Yong Chen
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Shape Deformation ◽  
Cad Model ◽  
Complex Deformation ◽  
Physical Measurements ◽  
Building Process ◽  
Aided Design ◽  
Thermal Cooling ◽  
And Control

Shape deformation is an important issue in additive manufacturing (AM) processes such as the projection-based Stereolithography. Volumetric shrinkage and thermal cooling during the photopolymerization process combined with other factors such as the layer-constrained building process lead to complex deformation that is difficult to predict and control. In this paper, a general reverse compensation method and related computation framework are presented to reduce the shape deformation of AM fabricated parts. During the reverse compensation process, the shape deformation is calculated based on physical measurements of shape deformation. A novel method for identifying the correspondence between the deformed shape and the given nominal computer-aided design (CAD) model is presented based on added markers. Accordingly, a new CAD model based on the shape deformation and related compensation is computed. The intelligently revised CAD model by going through the same building process can result in a fabricated part that is close to the nominal CAD model. Two test cases have been designed to demonstrate the effectiveness of the presented method and the related computation framework. The shape deformation in terms of L2- and L∞-norm based on measuring the geometric errors is reduced by 40–60%.

Structure and mechanical behavior of Big Area Additive Manufacturing (BAAM) materials

2017 ◽  
Vol 23 (1) ◽  
pp. 181-189 ◽  
Author(s):  
Chad E. Duty ◽  
Vlastimil Kunc ◽  
Brett Compton ◽  
Brian Post ◽  
Donald Erdman ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Performance ◽  
Research Effort ◽  
Small Scale ◽  
Second Phase ◽  
Initial Development ◽  
Imperfect Contact ◽  
Content Type ◽  
Oak Ridge ◽  
Printed Materials

Purpose This paper aims to investigate the deposited structure and mechanical performance of printed materials obtained during initial development of the Big Area Additive Manufacturing (BAAM) system at Oak Ridge National Laboratory. Issues unique to large-scale polymer deposition are identified and presented to reduce the learning curve for the development of similar systems. Design/methodology/approach Although the BAAM’s individual extruded bead is 10-20× larger (∼9 mm) than the typical small-scale systems, the overall characteristics of the deposited material are very similar. This study relates the structure of BAAM materials to the material composition, deposition parameters and resulting mechanical performance. Findings Materials investigated during initial trials are suitable for stiffness-limited applications. The strength of printed materials can be significantly reduced by voids and imperfect fusion between layers. Deposited material was found to have voids between adjacent beads and micro-porosity within a given bead. Failure generally occurs at interfaces between adjacent beads and successive layers, indicating imperfect contact area and polymer fusion. Practical implications The incorporation of second-phase reinforcement in printed materials can significantly improve stiffness but can result in notable anisotropy that needs to be accounted for in the design of BAAM-printed structures. Originality/value This initial evaluation of BAAM-deposited structures and mechanical performance will guide the current research effort for improving interlaminar strength and process control.

Structural Study of Iron Oxide Thin Films Using Pre-Edge Feature of XANES

2015 ◽  
Vol 1098 ◽  
pp. 58-62
Author(s):  
Sunil Dehipawala ◽  
Pubudu Samarasekara ◽  
Rasika Dahanayaka
Keyword(s):  
Thin Films ◽  
Magnetic Thin Films ◽  
Peak Position ◽  
Small Scale ◽  
Magnetic Storage ◽  
Energy Position ◽  
Edge Structure ◽  
Storage Devices ◽  
Number Of Layers ◽  
Edge Feature

Recently there has been a very high demand for small scale magnetic storage devices. The industry sector has consistently demanded sub micron or even nanometer scale magnets. Magnetic thin films often contain several layers of coating. For the purpose of this study, we prepared thin film magnets by spin coating a precursor containing iron into a glass substrate. The thickness of the films was controlled by the spin rate. Precursor films on the substrate were then annealed to 6000 C for 3 hours in air. The micro structure of iron in the films was investigated using the pre-edge feature that appears in the X-ray Absorption Near Edge Structure (XANES) for samples containing different iron layers. The main absorption edge peak position and pre-edge energy position were identical in all of the samples. This indicates that there was no change in the charge state of the iron regardless of the number of layers. However the intensity of the pre-edge feature decreases as number of layers increases which shows a decrease of Fe-O compounds as the number of layers increases.

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