Additive Manufacturing of Porous Ceramics with Foaming Agent

2021 ◽  
pp. 1-21
Author(s):  
Zipeng Guo ◽  
Lu An ◽  
Sushil Lakshmanan ◽  
Jason Armstrong ◽  
Shenqiang Ren ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Ambient Pressure ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Cost Effective ◽  
Tensile Tests ◽  
Porous Ceramics ◽  
Foaming Agent ◽  
Printing Quality ◽  
And Control

Abstract The macro-porous ceramics has promising durability and thermal insulation performance. As porous ceramics find more and more applications across many industries, a cost-effective and scalable additive manufacturing technique for fabricating macro-porous ceramics is highly desirable. Herein, we reported a facile additive manufacturing approach to fabricate porous ceramics and control the printed porosity. Several printable ceramic inks were prepared, the foaming agent was added to generate gaseous bubbles in the ink, followed by the direct ink writing and the ambient-pressure and room-temperature drying to create the three-dimensional geometries. A set of experimental studies were performed to optimize the printing quality. The results revealed the optimal process parameters for printing the foamed ceramic ink with a high spatial resolution and fine surface quality. Varying the concentration of the foaming agent enables the controllability of the structural porosity. The maximum porosity can reach 85%, with a crack-free internal porous structure. The tensile tests showed that the printed macro-porous ceramics possessed enhanced durability with the addition of fiber. With a high-fidelity 3D printing process and the precise controllability of the porosity, we showed that the printed samples exhibited a remarkably low thermal conductivity and durable mechanical strength.

Additive Manufacturing of Porous Ceramics With Foaming Agent

2021 ◽  
Author(s):  
Zipeng Guo ◽  
Lu An ◽  
Sushil Lakshmanan ◽  
Jason N. Armstrong ◽  
Shenqiang Ren ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Ambient Pressure ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Cost Effective ◽  
Tensile Tests ◽  
Porous Ceramics ◽  
Foaming Agent ◽  
Printing Process ◽  
Precise Control

Abstract The macro-porous ceramics has promising durability and thermal insulation performances. A cost-effective and scalable additive manufacturing technique for the fabrication of macro-porous ceramics, with a facile approach to control the printed porosity is reported in the paper. Several ceramic inks were prepared, the foaming agent was used to generate gaseous bubbles in the ink, followed by the direct ink writing and the ambient-pressure and room-temperature drying to create the three-dimensional geometries. The experimental studies were performed to optimize the printing quality. A set of studies revealed the optimal printing process parameters for printing the foamed ceramic ink with a high spatial resolution and fine surface quality. Varying the concentration of the foaming agent enabled the controllability of the structural porosity. The maximum porosity can reach 85%, with a crack-free internal porous structure. The tensile tests showed that the printed macro-porous ceramics have enhanced durability with the addition of fiber. With a high-fidelity 3D printing process and precise control of the porosity, the printed samples exhibited a low thermal conductivity and high mechanical strength.

Fractal Pattern Recognition of Image Profiles for Manufacturing Process Monitoring and Control

2018 ◽  
Author(s):  
Farhad Imani ◽  
Bing Yao ◽  
Ruimin Chen ◽  
Prahalada Rao ◽  
Hui Yang
Keyword(s):  
Additive Manufacturing ◽  
Process Monitoring ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Experimental Studies ◽  
Precision Machining ◽  
Monitoring And Control ◽  
Process Monitoring And Control ◽  
Ultra Precision ◽  
And Control

Nowadays manufacturing industry faces increasing demands to customize products according to personal needs. This trend leads to a proliferation of complex product designs. To cope with this complexity, manufacturing systems are equipped with advanced sensing capabilities. However, traditional statistical process control methods are not concerned with the stream of in-process imaging data. Also, very little has been done to investigate nonlinearity, irregularity, and inhomogeneity in image stream collected from manufacturing processes. This paper presents the multifractal spectrum and lacunarity measures to characterize irregular and inhomogeneous patterns of image profiles, as well as detect the hidden dynamics of the underlying manufacturing process. Experimental studies show that the proposed method not only effectively characterizes the surface finishes for quality control of ultra-precision machining but also provides an effective model to link process parameters with fractal characteristics of in-process images acquired from additive manufacturing. This, in turn, will allow a swift response to processes changes and consequently reduce the number of defective products. The proposed fractal method has strong potentials to be applied for process monitoring and control in a variety of domains such as ultra-precision machining, additive manufacturing, and biomanufacturing.

scholarly journals The Examination of Restrained Joints Created in the Process of Multi-Material FFF Additive Manufacturing Technology

Materials ◽  
2020 ◽  
Vol 13 (4) ◽  
pp. 903 ◽  
Author(s):  
Janusz Kluczyński ◽  
Lucjan Śnieżek ◽  
Alexander Kravcov ◽  
Krzysztof Grzelak ◽  
Pavel Svoboda ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Tensile Tests ◽  
Lower Amount ◽  
Internal Quality ◽  
Experimental Production ◽  
Destructive Testing ◽  
Non Destructive

The paper is focused on the examination of the internal quality of joints created in a multi-material additive manufacturing process. The main part of the work focuses on experimental production and non-destructive testing of restrained joints of modified PLA (polylactic acid) and ABS (Acrylonitrile butadiene styrene) three-dimensional (3D)-printed on RepRap 3D device that works on the “open source” principle. The article presents the outcomes of a non-destructive materials test in the form of the data from the Laser Amplified Ultrasonography, microscopic observations of the joints area and tensile tests of the specially designed samples. The samples with designed joints were additively manufactured of two materials: Specially blended PLA (Market name—PLA Tough) and conventionally made ABS. The tests are mainly focused on the determination of the quality of material connection in the joints area. Based on the results obtained, the samples made of two materials were compared in the end to establish which produced material joint is stronger and have a lower amount of defects.

Finite Element Modeling of Hard Roller Burnishing: An Analysis on the Effects of Process Parameters Upon Surface Finish and Residual Stresses

2007 ◽  
Vol 129 (4) ◽  
pp. 705-716 ◽  
Author(s):  
Partchapol Sartkulvanich ◽  
Taylan Altan ◽  
Francisco Jasso ◽  
Ciro Rodriguez
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Process Parameters ◽  
Surface Finish ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Cost Effective ◽  
Machined Surface ◽  
Fem Model ◽  
Roller Burnishing

Hard roller burnishing is a cost-effective finishing and surface enhancement process where a ceramic ball rolls on the machined surface to flatten the roughness peaks. The ball is supported and lubricated by hydrostatic fluid in a special tool holder. The process not only improves surface finish but also imposes favorable compressive residual stresses in functional surfaces, which can lead to long fatigue life. Most research in the past focused on experimental studies. There is still a special need for a reliable finite element method (FEM) model that provides a fundamental understanding of the process mechanics. In this study, two-dimensional (2D) and three-dimensional FEM models for hard roller burnishing were established. The developed 2D FEM model was used to study the effects of process parameters (i.e., burnishing pressure, feed rate) on surface finish and residual stresses. The simulation results were evaluated and compared to the experimental data. Results show that the established FEM model could predict the residual stresses and provided useful information for the effect of process parameters. Both FEM and experiments show that burnishing pressure is the most influence, where high burnishing pressure produces less roughness and more compressive residual stress at the surface.

Computer Simulation of Three-Dimensional Mechanical Assemblies: Part II — Computer Simulation

1993 ◽  
Author(s):  
T. C. Chou ◽  
F. W. Liou
Keyword(s):  
Computer Simulation ◽  
Three Dimensional ◽  
Cost Effective ◽  
Test Bed ◽  
Joint Models ◽  
Mechanical Assemblies ◽  
Final Design ◽  
Multi Body ◽  
And Control ◽  
Mating Conditions

Abstract Computer simulation of the kinematic and dynamic behaviors of mechanical assemblies has become a very important tool in design and manufacturing, because the designer can foresee how a product is going to perform before the product is actually fabricated. However, up to now, the most current simulation modules are based on analysis from another kinematic or dynamic module by specifying the mating conditions between components, and then displaying the motion on the screen. This computer simulation actually performs similarly to a movie, and can only provide visual checking. The drawback of this simulation approach is that designers are forced to use the available joint models, and may lose their creativity. In part I of this paper, general mathematical modeling of the multi-body system is presented, while part II of this paper, a prototype convex-feature modeling system is presented with which a designer can interactively create an assembly of mechanical components ready for dynamic analysis. It can provide a state-of-the-art technology for real simulation of any mechanical systems, and act as a cost-effective test bed for concepts, final design, and control algorithms.

Production of Ceramics Reinforced Al Foams by Powder Metallurgy Techniques

2011 ◽  
Vol 672 ◽  
pp. 39-46
Author(s):  
Mehmet Turker
Keyword(s):  
Pore Structure ◽  
Volume Fraction ◽  
Linear Expansion ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Al Alloy ◽  
Compaction Process ◽  
Foaming Agent ◽  
Foaming Behavior ◽  
Al Foam

Powders metallurgy route was used to produce foams from pure Al powders and pre-alloyed Al alloy powders (Alumix 231) with or without reinforcing elements addition. Both classical Al foam and spherical Al foam were produced with various production parameters and the results obtained have been discussed. SiC particles were used as reinforcing elements and TiH2 powders were used as foaming agent. Prior to compaction process, Al powders, reinforcing element and foaming agent were mixed in a three dimensional turbula for 30 min. Mixed powders were compacted, sintered and deformed and then foamed at 690 oC for spherical foam and 710 oC for classical foam. Effect of volume fraction of reinforcing elements, foaming temperatures and foaming agent amounts on the foaming behavior, pore structure, pore distribution, linear expansion rate, density and wall thickness of the cell were investigated. Experimental studies have shown that 1% foaming agent and 4 % SiC addition was found to be the most suitable for foaming. In general foam produced from Alumix 231 powders exhibited more homogenous pore structure compared to the ones produced from pure Al powders.

scholarly journals Additive Manufacturing in the Construction Industry: The Comparative Competitiveness of 3D Concrete Printing

2021 ◽  
Vol 11 (9) ◽  
pp. 3865
Author(s):  
Siavash H. Khajavi ◽  
Müge Tetik ◽  
Ashish Mohite ◽  
Antti Peltokorpi ◽  
Mingyang Li ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Construction Industry ◽  
Positive Impact ◽  
Three Dimensional ◽  
Cost Effective ◽  
Robotic Arm ◽  
Process Time ◽  
Current State ◽  
The Cost ◽  
The Impact

The construction industry is facing increasing pressure to improve productivity and decrease its environmental impact. Additive manufacturing (AM) technologies, especially three-dimensional concrete printing (3DCP) technology, have provided many benefits for construction. However, holistic comparative studies of the competitiveness of 3DCP and conventional methods, from cost and time perspectives, are lacking. Choosing between the methods is difficult for practitioners. In this study, we investigated the current state of 3DCP in the construction industry using seven distinct scenarios. Our analysis was performed to illustrate the impact of design and supply chain configurations on performance. The results prove the notable competitiveness of 3DCP. In contrast to the conventional construction method, the more complex round design had a positive impact on the cost and process time in 3DCP scenarios. Additionally, we show that on-site 3DCP using a robotic arm was more cost-effective than off-site 3DCP.

scholarly journals Environment and Safety Impacts of Additive Manufacturing: A Review

2019 ◽  
Vol 27 (44) ◽  
pp. 9-20
Author(s):  
Eva Buranská ◽  
Ivan Buranský ◽  
Ladislav Morovič ◽  
Katarína Líška
Keyword(s):  
Additive Manufacturing ◽  
Energy Use ◽  
Three Dimensional ◽  
Cost Effective ◽  
Liquid Sheet ◽  
Raw Material ◽  
Layer By Layer ◽  
Environmental Implications ◽  
Subtractive Manufacturing ◽  
Complicated Geometries

Abstract The paper is focused on additive manufacturing (AM) which is the process of producing objects from a three-dimensional (3D) model by joining materials layer by layer, as opposed to the subtractive manufacturing methodologies [1], directly from raw material in powder, liquid, sheet, or a filament form without the need for moulds, tools, or dies. The article demonstrates potential environmental implications of additive manufacturing related to the key issues including energy use, occupational health, waste and lifecycle impact. AM provides a cost-effective and time-efficient way to fabricating products with complicated geometries, advanced material properties and functionality. Based on this review, we identified that additive manufacturing will have a significant societal impact in the near future. A critical technical review of the promises and potential issues of AM is beneficial for advancing its further development.

scholarly journals ОСОБЛИВОСТІ ТЕРМОІМПУЛЬСНОГО ОЧИЩЕННЯ ПОВЕРХОНЬ І КРОМОК ДЕТАЛЕЙ ВІД ЗАБРУДНЕНЬ ПІСЛЯ МЕХАНІЧНОЇ ОБРОБКИ

2018 ◽  
pp. 36-46
Author(s):  
Алексей Васильевич Лосев ◽  
Игорь Валерьевич Бычков ◽  
Вячеслав Викторович Коллеров ◽  
Анна Сергеевна Селезнева
Keyword(s):  
Experimental Studies ◽  
Cost Effective ◽  
Operating Conditions ◽  
Working Fluid ◽  
Body Parts ◽  
Hydraulic Systems ◽  
Cost Component ◽  
Internal Surfaces ◽  
And Control

The requirements for the quality of aviation technology are decisive in the creation of technological systems that ensure the industrial purity of products. But the cost component of the finishing and stripping technologies is also important, the value of which depends on the chosen method of removing liquids, for example, from hydraulic units of aircraft. Reliable and cost-effective manufacture of parts with specific geometric and technological properties is the main goal of industrial production. In a market economy, the production of competitive products is a necessity, and it is always the choice of a rational, stable price-quality ratio. The quality of engineering products is a multifactorial problem, depending on the complex of systemic organizational and technological measures. In the production of aircraft technology, quality assurance is associated with dependability and a guaranteed resource that is vital due to specific operating conditions. One of the most important measures to ensure the reliability and guaranteed life of aviation products is to ensure industrial cleanliness. Cleaning from microparticles, macro- and micro-hauler surfaces and edges of parts after mechanical types of processing is included in the complex of these measures. The most problematic is the cleaning of body parts with a complex configuration of external and internal surfaces. The need to remove liquids and other technological pollution is explained by functional, ergonomic and aesthetic reasons. If ergonomic and aesthetic factors do not affect the technical characteristics of products, then the functional ones are directly related to the operability of machines and mechanisms. Functional causes are the prevention of failures of hydraulic distribution and control devices, as well as the prevention of increased wear of critical parts occurring when friction pairs of solid metal particles enter the gaps, difficulties in assembling and positioning, reducing fatigue strength and so on. Burrs cause turbulence in the flow of gas or liquid, disrupting the flow uniformity. It is obvious that the mutually influencing processes occurring in the hydraulic systems of machines, in violation of working conditions, lead to an increase in negative phenomena. The peculiarity of the use of purification technologies is the need to remove liquids from 100% of the parts included in the autonomous system of mechanisms. If at least one detail is left untreated, then the working fluid, when in contact with contaminated surfaces, washes away these contaminants and spreads them throughout the system, while the most sensitive elements are damaged. The reasons for the need to clean the surface and edges of parts from technological contamination are given. A brief review of the results of modeling and research on the removal of burrs in the environment of detonating gas mixtures has been performed. The features of the thermopulse process are considered and the results of numerical and experimental studies are presented. A comparative analysis of the energy intensity of removing burrs of various metals is shown.

Additive Manufacturing: Current State, Future Potential, Gaps and Needs, and Recommendations

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Yong Huang ◽  
Ming C. Leu ◽  
Jyoti Mazumder ◽  
Alkan Donmez
Keyword(s):  
Additive Manufacturing ◽  
Research University ◽  
Three Dimensional ◽  
Cost Effective ◽  
Layer By Layer ◽  
Current State ◽  
Future Potential ◽  
Traditional Manufacturing ◽  
Research And Education ◽  
Complicated Geometries

Additive manufacturing (AM), the process of joining materials to make objects from three-dimensional (3D) model data, usually layer by layer, is distinctly a different form and has many advantages over traditional manufacturing processes. Commonly known as “3D printing,” AM provides a cost-effective and time-efficient way to produce low-volume, customized products with complicated geometries and advanced material properties and functionality. As a result of the 2013 National Science Foundation (NSF) Workshop on Frontiers of Additive Manufacturing Research and Education, this paper summarizes AM's current state, future potential, gaps and needs, as well as recommendations for technology and research, university–industry collaboration and technology transfer, and education and training.

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