Validation of a low-cost selective powder deposition process through the characterization of tin bronze specimens

2021 ◽  
pp. 146442072110319
Author(s):  
Samuel Magalhães ◽  
Manuel Sardinha ◽  
Carlos Vicente ◽  
Marco Leite ◽  
Relógio Ribeiro ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Low Cost ◽  
Deposition Process ◽  
Metal Powders ◽  
Tin Bronze ◽  
Powder Deposition ◽  
Manufacturing Technologies ◽  
The Cost

Additive manufacturing technologies are becoming increasingly popular due to their advantages over traditional subtracting manufacturing technologies. Despite advances in this field, fixed and maintenance costs for additive manufacturing with metals remain high. The introduction of low-cost metal machines in the additive manufacturing market considerably reduces the cost of acquiring and maintaining this type of equipment. This work aims to establish the process requirements for a low-cost selective powder deposition process, and validate it through the production of specimens in the laboratory and evaluate their mechanical properties. Tin bronze specimens were produced under different manufacturing conditions, namely powder dimensions, type of crucible and coke, firing segments and casting strategy. The morphology and chemical composition of the specimens were carried out combining the scanning electron microscopy and energy dispersive X-Ray spectroscopy techniques, respectively. It was observed that crucibles and coke with impurities that react with the metal powders and infill in a reducing atmosphere have influence in the final quality of parts. Tested samples displayed high variability of results which can be correlated with different manufacturing conditions. The selection of the appropriate print parameters led to the manufacture of tin bronze specimens with mechanical properties comparable to those reported in the literature. Overall, low-cost selective powder deposition is a promising technology, if identified manufacturing issues are addressed.

scholarly journals Processing of Sr2+ Containing Poly L-Lactic Acid-Based Hybrid Composites for Additive Manufacturing of Bone Scaffolds

2020 ◽  
Vol 7 ◽  
Author(s):  
Priscila Melo ◽  
Raasti Naseem ◽  
Ilaria Corvaglia ◽  
Giorgia Montalbano ◽  
Carlotta Pontremoli ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Lactic Acid ◽  
Additive Manufacturing ◽  
Hybrid Composites ◽  
Homogeneous Distribution ◽  
Fused Filament Fabrication ◽  
Rheological Characterization ◽  
Biodegradable Composite ◽  
Manufacturing Technologies

Biodegradable composite materials represent one of the major areas of investigation for bone tissue engineering due to their tuneable compositional and mechanical properties, which can potentially mimic those of bone and potentially avoid the removal of implants, mitigating the risks for the patient and reducing the overall clinical costs. In addition, the introduction of additive manufacturing technologies enables a strict control over the final morphological features of the scaffolds. In this scenario, the optimisation of 3D printable resorbable composites, made of biocompatible polymers and osteoinductive inorganic phases, offers the potential to produce a chemically and structurally biomimetic implant, which will resorb over time. The present work focuses on the development and process optimisation of two hybrid composite filaments, to be used as feedstock for the fused filament fabrication 3D printing process. A Poly L-lactic acid matrix was blended with either rod-like nano-hydroxyapatite (nano-HA) or nanoparticles of mesoporous bioactive glasses, both partially substituted with strontium (Sr2+), due to the well-known pro-osteogenic effect of this ion. Both inorganic phases were incorporated into Poly L-lactic acid using an innovative combination of processes, obtaining a homogeneous distribution throughout the polymer whilst preserving their ability to release Sr2+. The filament mechanical properties were not hindered after the incorporation of the inorganic phases, resulting in tensile strengths and moduli within the range of cancellous bone, 50 ± 10 MPa and 3 ± 1 GPa. Finally, the rheological characterization of the hybrid composites indicated a shear thinning behaviour, ideal for the processing with fused filament fabrication, proving the potential of these materials to be processed into 3D structures aiming bone regeneration.

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.

Open Uniaxial Test Machine (OpenUTM): Part 1 — A Low-Cost Electrohydraulic Test Frame for Additive Manufacturing Part Qualification

2018 ◽  
Author(s):  
John C. Steuben ◽  
Athanasios P. Iliopoulos ◽  
John G. Michopoulos
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Test Machine ◽  
Mechanical Stiffness ◽  
Uniaxial Test ◽  
Bill Of Materials ◽  
Test Frame ◽  
Force Displacement

A wide variety of scientific and engineering activities require the use of testing machines in order to acquire data regarding the response of materials subjected to mechanical loads. This is particularly applicable to the domain of Additive Manufacturing (AM), where mechanical qualification is essential. Such machinery should be capable of applying loads at required levels and exhibit high mechanical stiffness. Accurate force, displacement, and strain measurements are also required. As a consequence, such testing machines are typically very costly. In the present paper we introduce the Open Uniaxial Test Machine (OpenUTM) project, aimed at providing a low-cost (less than $2500.00) material testing hardware/software framework. This paper will focus on the engineering design and hardware aspects of the OpenUTM project, with particular attention paid to the use of an electrohydraulic actuator (EHA) to provide test loads. A full bill of materials and drawings package is provided, in order to enable the use of the OpenUTM framework by research groups with minimal machine tooling. We introduce several case studies demonstrating the successful use of the OpenUTM frame in AM research efforts, including the testing and characterization of AM polymers and ceramics. We conclude with discussion of the software aspects of the OpenUTM framework, which will be elaborated upon in a follow-up paper (part two). We also present a series of potential avenues towards the improvement of the OpenUTM frame in future hardware iterations.

scholarly journals The Effect of Heat Treatment on the Microstructure and Mechanical Properties of the Novel Low-Cost Ti-3Al-5Mo-4Cr-2Zr-1Fe Alloy

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3798
Author(s):  
Meng Sun ◽  
Dong Li ◽  
Yanhua Guo ◽  
Ying Wang ◽  
Yuecheng Dong ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Aging Time ◽  
Volume Fraction ◽  
Low Cost ◽  
Solution Treatment ◽  
Solution Temperature ◽  
The Novel ◽  
Α Phase ◽  
The Cost

In order to reduce the cost of titanium alloys, a novel low-cost Ti-3Al-5Mo-4Cr-2Zr-1Fe (Ti-35421) titanium alloy was developed. The influence of heat treatment on the microstructure characteristics and mechanical properties of the new alloy was investigated. The results showed that the microstructure of Ti-35421 alloy consists of a lamina primary α phase and a β phase after the solution treatment at the α + β region. After aging treatment, the secondary α phase precipitates in the β matrix. The precipitation of the secondary α phase is closely related to heat treatment parameters—the volume fraction and size of the secondary α phase increase when increasing the solution temperature or aging time. At the same solution temperature and aging time, the secondary α phase became coarser, and the fraction decreased with increasing aging temperature. When Ti-35421 alloy was solution-treated at the α + β region for 1 h with aging surpassing 8 h, the tensile strength, yield strength, elongation and reduction of the area were achieved in a range of 1172.7–1459.0 MPa, 1135.1–1355.5 MPa, 5.2–11.8%, and 7.5–32.5%, respectively. The novel low-cost Ti-35421 alloy maintains mechanical properties and reduces the cost of materials compared with Ti-3Al-5Mo-5V-4Cr-2Zr (Ti-B19) alloy.

Mechanical Properties of ABS Embedded with Basalt Fiber Fillers

2016 ◽  
Vol 16 (2) ◽  
pp. 69-74 ◽  
Author(s):  
Ayman M. M. Abdelhaleem ◽  
Mohammed Y. Abdellah ◽  
Hesham I. Fathi ◽  
Montasser Dewidar
Keyword(s):  
Mechanical Properties ◽  
Mechanical Performance ◽  
Low Cost ◽  
Basalt Fiber ◽  
Acrylonitrile Butadiene Styrene ◽  
Hardness Test ◽  
Basalt Fibers ◽  
Notched Strength ◽  
The Cost ◽  
Plastic Injection

AbstractAcrylonitrile-butadiene-styrene (ABS) has great verity applications in aerospace and automobiles industries. Mechanical strength of the ABS is superior to even that of impact resistant polystyrene. In addition metallic coatings can be applied to the surface of ABS moldings. The main aim of the present work is to investigate the mechanical properties of additives of basalt fibers (BF) to ABS with (5, 10, and 15) wt% embedded into the polymer matrix by using plastic injection molding technique. This new perceptions has been done on basalt fibers that have a potential low cost with its good mechanical performance. The ultimate tensile strength that obtained from the composite with 15 wt% is 56.67 MPa with 40.52 % increase value than neat ABS, Young’s modulus gradually increases with increasing the amount of additives. Impact un-notched strength decreases with a reported increment of 24.617 KJ.m–2. A Rockwell hardness test is also used and with the increases of additives the amount of hardness of the composite increases. A scan electron microscopy (SEM) on the fracture surface is captured to check the morphologies structure of the composite comparable with a neat ABS. and it is showed a very good distribution and bonding of the B.F. with the pure ABS. As well as the cost of the ABS and BF is reduced by a percentage of 15 %.

scholarly journals Possible Applications of Additive Manufacturing Technologies in Shipbuilding: A Review

Machines ◽  
2020 ◽  
Vol 8 (4) ◽  
pp. 84
Author(s):  
Marcin Ziółkowski ◽  
Tomasz Dyl
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Weight Reduction ◽  
Maritime Industry ◽  
High Quality ◽  
Printing Technology ◽  
3D Printing Technology ◽  
Manufacturing Technologies ◽  
Very High

3D printing conquers new branches of production due to becoming a more reliable and professional method of manufacturing. The benefits of additive manufacturing such as part optimization, weight reduction, and ease of prototyping were factors accelerating the popularity of 3D printing. Additive manufacturing has found its niches, inter alia, in automotive, aerospace and dentistry. Although further research in those branches is still required, in some specific applications, additive manufacturing (AM) can be beneficial. It has been proven that additively manufactured parts have the potential to out perform the conventionally manufactured parts due to their mechanical properties; however, they must be designed for specific 3D printing technology, taking into account its limitations. The maritime industry has a long-standing tradition and is based on old, reliable techniques; therefore it implements new solutions very carefully. Besides, shipbuilding has to face very high classification requirements that force the use of technologies that guarantee repeatability and high quality. This paper provides information about current R&D works in the field of implementing AM in shipbuilding, possible benefits, opportunities and threats of implementation.

scholarly journals Development of a Passive Prosthetic Hand That Restores Finger Movements Made by Additive Manufacturing

2020 ◽  
Vol 10 (12) ◽  
pp. 4148
Author(s):  
Rodrigo Cézar da Silveira Romero ◽  
André Argueso Machado ◽  
Kliftom Amorim Costa ◽  
Paulo Henrique Rodriguês Guilherme Reis ◽  
Pedro Paiva Brito ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Tensile Testing ◽  
Maximum Stress ◽  
Low Cost ◽  
Human Hand ◽  
Prosthetic Hand ◽  
Plastic Deformations ◽  
Printing Parameters

This work aims to develop a low-cost human hand prosthesis manufactured through additive manufacturing. The methodology used for the development of the prosthesis used affordable and low-cost materials in the market. Tensile testing was performed to estimate the mechanical properties in order to verify the resistance of the printing material used. Afterwards, the mechanical feasibility study executed on the device was performed using finite element method. In conclusion, we can observe fundamental factors that influence the 3D printing process, especially in relation to its printing parameters and mechanical properties. Maximum stress, yield stress, modulus of elasticity, elongation, and hardness are the prominent properties that should be considered when choosing the polymeric material. The numerical simulation showed that the structure of the prosthesis did not present plastic deformations to the applied loads, proving its mechanical viability.

Additive Manufacturing of Nickel-Based Superalloys

2018 ◽  
Author(s):  
Benjamin Graybill ◽  
Ming Li ◽  
David Malawey ◽  
Chao Ma ◽  
Juan-Manuel Alvarado-Orozco ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
High Performance ◽  
Structural Integrity ◽  
Elevated Temperatures ◽  
Secondary Phases ◽  
Treatment Regimens ◽  
Operating Environments ◽  
Manufacturing Technologies

Additive manufacturing enables the design of components with intricate geometries that can be manufactured with lead times much shorter when compared with conventional manufacturing. The ability to manufacture components out of high-performance metals through additive manufacturing technologies attracts industries that wish to develop more complex parts, but require components to maintain their structural integrity in demanding operating environments. Nickel-based superalloys are of particular interest due to their excellent mechanical, creep, wear, and oxidation properties at both ambient and elevated temperatures. However, relationship between process parameters and the resulting microstructure is still not well understood. The control of the microstructure, in particular the precipitation of secondary phases, is of critical importance to the performance of nickel-based superalloys. This paper reviews the additive manufacturing methods used to process nickel-based superalloys, the influence of the process parameters on microstructure and mechanical properties, the effectiveness of various heat treatment regimens, and the addition of particles in order to further improve mechanical properties.

Development of New Low Cost Discontinuously Reinforced Titanium Composites for Commercial Applications

2007 ◽  
Vol 539-543 ◽  
pp. 763-768 ◽  
Author(s):  
M. García de Cortázar ◽  
Javier Goñi ◽  
J. Coleto ◽  
I. Agote ◽  
P. Egizabal ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Low Cost ◽  
Cost Effective ◽  
Microstructural Characteristics ◽  
Commercial Applications

A new cost effective process to produce discontinuously reinforced (TiB) TMCs has been developed. The article presents general features of the composites, microstructural characteristics and mechanical properties. The production and characterization of two potential commercial applications are also discussed.

There is Low Cost Titanium Componentry Today

2013 ◽  
Vol 551 ◽  
pp. 11-15 ◽  
Author(s):  
J.C. Withers ◽  
V. Shapovalov ◽  
R. Storm ◽  
R.O. Loutfy
Keyword(s):  
Mechanical Properties ◽  
Low Cost ◽  
Cost Component ◽  
Automotive Components ◽  
One Step ◽  
Near Net Shape ◽  
Mechanical Properties And Corrosion ◽  
The Cost ◽  
Processing Steps ◽  
Better Than

In spite of titanium’s excellent combinations of lightweight, mechanical properties, and corrosion resistance it has been excluded from many applications because of its high cost in fabricated componentry. The major cost to produce a titanium alloy component is the processing of the sponge into alloy plus the several processing steps for fabricating the final finished component. If low cost titanium is to become a reality, the cost of post sponge processing to final finished components must be dramatically reduced. Processing to convert sponge directly in one step to an alloyed near net shape low cost component has been demonstrated. The mechanical properties are equivalent to better than standard processed wrought titanium. Example, automotive components and other applications that confirm titanium componentry at substantially lower cost than standard processing will be provided.

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