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Ryan B Wicker - One of the best experts on this subject based on the ideXlab platform.

  • Joining of Inconel 718 and 316 Stainless Steel using electron beam melting Additive Manufacturing Technology
    Materials and Design, 2016
    Co-Authors: Alejandro Hinojos, Ashley Reichardt, Pedro Frigola, Peter Hosemann, Jorge Mireles, Lawrence E Murr, Ryan B Wicker
    Abstract:

    Joining of dissimilar metals using high energy-density beams such as lasers and electron beams offer several advantages including precision, narrow fusion zones, and narrow heat affected zones (HAZ) that consequently result in reduced part distortion when compared to traditional joining processes. When high energy-density beams are combined with the design freedom offered by Additive Manufacturing (AM), or a layer-by-layer part fabrication process, it becomes possible to manufacture complex multi-material parts with improved joint characteristics resulting from controlled process parameters. Complex multi-material parts can be achieved that have tremendous impact on applications ranging from nuclear power plant components to repair applications. This research explores the feasibility of joining Inconel 718 with 316L Stainless Steel, and vice versa, by utilizing electron beam melting (EBM) Additive Manufacturing, a class of powder bed fusion Technology. The use of this process can help avoid the use of filler materials, provides an evacuated processing environment resulting in limited contamination of oxides and nitrides, and can provide a high quality metallurgical joint while minimizing the thermal damage to surrounding material. Multi-material components were fabricated and the joint interfaces were characterized. Assessments of the interfaces revealed minimized thermal effects from the process and finer weld joints.

  • Fabrication of smart parts using powder bed fusion Additive Manufacturing Technology
    Additive Manufacturing, 2016
    Co-Authors: Mohammad Shojib Hossain, Ricardo Martinez Hernandez, Mohammad Arif Ishtiaque Shuvo, Ahsan Choudhuri, Jose A Gonzalez, Yirong Lin, Jorge Mireles, Ryan B Wicker
    Abstract:

    Energy system components with embedded sensors, or smart parts, can be a pathway in obtaining real-time system performance feedback and in situ monitoring during operation. Traditional surface contact or cavity placed sensors increase the possibility of disturbing the normal operation of energy systems due to changes in part design required for sensor placement. The fabrication of smart parts using Additive Manufacturing (AM) Technology can allow the flexibility of embedding a sensor within a structure without compromising the structure and/or functionality. The embedding of a sensor within a desired location allows an end user the ability to monitor specific critical regions that are of interest such as high temperature and pressure (e.g., combustor inlet conditions that can reach up to 810 K and 2760 kPa). In addition, the non-intrusive placement of the sensor within a part's body can increase the sensor's life span by isolating the sensor from the aforementioned harsh operating environments. This paper focuses on the fabrication of smart parts using electron beam melting (EBM) AM Technology as well as the characterization of the sensor's functionality. The development of a "stop and go" process was explored that comprised of pausing a part's fabrication process to allow the placement of piezoelectric ceramic material into pre-designed cavities within a part's body, and resuming the process to complete the final product. A compression test was performed on the smart parts fabricated using EBM to demonstrate the sensor's capability of sensing external forces. A maximum sensing voltage response of approximately 3 V was detected with a maximum pressure not exceeding 40 MPa. The sensor responses showed good agreement with the applied force in four different frequency conditions (i.e., 10 Hz, 15 Hz, 20 Hz, and 25 Hz). This research work demonstrates the feasibility of fabricating smart parts with embedded sensors without the need of post-processing (e.g., CNC machining and polishing). In addition, the sensing capability of monitoring a component's performance has been validated, leading to the possibility of fabricating other smart parts that could impact industries such as energy, aerospace, automotive, and biomedical industries for applications like air/fuel pre-mixing, pressure tubes, and turbine blades.

  • fabrication of barium titanate by binder jetting Additive Manufacturing Technology
    Ceramics International, 2015
    Co-Authors: S M Gaytan, Yirong Lin, Monica Cadena, Hasanul Karim, Diego Delfin, David Espalin, Eric Macdonald, Ryan B Wicker
    Abstract:

    Abstract Fabrication of barium titanate (BaTiO 3 ) specimens was accomplished with binder jetting Additive Manufacturing, and build parameters (e.g., binder saturation and layer thickness) and sintering profiles were modified to optimize the density achieved and the crystal structures obtained in the 3D printed parts. Surface and cross sectional grain morphology was characterized by scanning electron microscopy (SEM) revealing grain growth on localized areas of BTO fabricated specimens after sintering. Crystal structure was analyzed by X-ray diffraction (XRD) where the presence of a hexagonal phase was observed for BaTiO 3 only when sintered at 1400 °C. The dielectric constant of the fabricated BaTiO 3 specimens sintered at 1260 °C was obtained by using a K u -band wave-guide and vector network analyzer setup in which the relative permittivity was measured from 8.6 to 6.23 for a frequency range of 12.4–18 GHz, respectively. When sintered at 1400 °C for 4 h, a density of 3.93 g/cm 3 was obtained, which corresponds to 65.2% of the theoretical density. Piezoelectric properties exhibited a d 33 value of 74.1 for specimens also sintered at 1400 °C. Results reported in this paper demonstrate the feasibility of BTO as a binder jetting material for 3D printed dielectric structures, ceramic capacitors and gas and pressure sensors.

  • Characterization of ceramic components fabricated using binder jetting Additive Manufacturing Technology
    Ceramics International, 2015
    Co-Authors: J A Gonzalez, Jorge Mireles, Yun Lin, Ryan B Wicker
    Abstract:

    Binder jetting Additive Manufacturing is an emerging Technology with capability of processing a wide range of commercial materials, including metals and ceramics (316 SS, 420 SS, Inconel 625, Iron, Silica). In this project, aluminum oxide (Al2O3) powder was used for part fabrication. Various build parameters (e.g. layer thickness, saturation, particle size) were modified and different sintering profiles were investigated to achieve nearly full-density parts (~96%). The material's microstructure and physical properties were characterized. Full XRD, compression testing, and dielectric testing were conducted on all parts. Sintered alumina parts were achieved with an average compressive strength of 131.86MPa (16h sintering profile) and a dielectric constant of 9.47-5.65 for a frequency range of 20Hz to 1MHz. The complexity offered by Additive processing aluminum oxide can be extended to the Manufacturing of high value energy and environmental components for environmental systems (e.g. filters and membranes) or biomedical implants with integrated reticulated structures for improved osseointegration.

Jorge Mireles - One of the best experts on this subject based on the ideXlab platform.

  • Joining of Inconel 718 and 316 Stainless Steel using electron beam melting Additive Manufacturing Technology
    Materials and Design, 2016
    Co-Authors: Alejandro Hinojos, Ashley Reichardt, Pedro Frigola, Peter Hosemann, Jorge Mireles, Lawrence E Murr, Ryan B Wicker
    Abstract:

    Joining of dissimilar metals using high energy-density beams such as lasers and electron beams offer several advantages including precision, narrow fusion zones, and narrow heat affected zones (HAZ) that consequently result in reduced part distortion when compared to traditional joining processes. When high energy-density beams are combined with the design freedom offered by Additive Manufacturing (AM), or a layer-by-layer part fabrication process, it becomes possible to manufacture complex multi-material parts with improved joint characteristics resulting from controlled process parameters. Complex multi-material parts can be achieved that have tremendous impact on applications ranging from nuclear power plant components to repair applications. This research explores the feasibility of joining Inconel 718 with 316L Stainless Steel, and vice versa, by utilizing electron beam melting (EBM) Additive Manufacturing, a class of powder bed fusion Technology. The use of this process can help avoid the use of filler materials, provides an evacuated processing environment resulting in limited contamination of oxides and nitrides, and can provide a high quality metallurgical joint while minimizing the thermal damage to surrounding material. Multi-material components were fabricated and the joint interfaces were characterized. Assessments of the interfaces revealed minimized thermal effects from the process and finer weld joints.

  • Fabrication of smart parts using powder bed fusion Additive Manufacturing Technology
    Additive Manufacturing, 2016
    Co-Authors: Mohammad Shojib Hossain, Ricardo Martinez Hernandez, Mohammad Arif Ishtiaque Shuvo, Ahsan Choudhuri, Jose A Gonzalez, Yirong Lin, Jorge Mireles, Ryan B Wicker
    Abstract:

    Energy system components with embedded sensors, or smart parts, can be a pathway in obtaining real-time system performance feedback and in situ monitoring during operation. Traditional surface contact or cavity placed sensors increase the possibility of disturbing the normal operation of energy systems due to changes in part design required for sensor placement. The fabrication of smart parts using Additive Manufacturing (AM) Technology can allow the flexibility of embedding a sensor within a structure without compromising the structure and/or functionality. The embedding of a sensor within a desired location allows an end user the ability to monitor specific critical regions that are of interest such as high temperature and pressure (e.g., combustor inlet conditions that can reach up to 810 K and 2760 kPa). In addition, the non-intrusive placement of the sensor within a part's body can increase the sensor's life span by isolating the sensor from the aforementioned harsh operating environments. This paper focuses on the fabrication of smart parts using electron beam melting (EBM) AM Technology as well as the characterization of the sensor's functionality. The development of a "stop and go" process was explored that comprised of pausing a part's fabrication process to allow the placement of piezoelectric ceramic material into pre-designed cavities within a part's body, and resuming the process to complete the final product. A compression test was performed on the smart parts fabricated using EBM to demonstrate the sensor's capability of sensing external forces. A maximum sensing voltage response of approximately 3 V was detected with a maximum pressure not exceeding 40 MPa. The sensor responses showed good agreement with the applied force in four different frequency conditions (i.e., 10 Hz, 15 Hz, 20 Hz, and 25 Hz). This research work demonstrates the feasibility of fabricating smart parts with embedded sensors without the need of post-processing (e.g., CNC machining and polishing). In addition, the sensing capability of monitoring a component's performance has been validated, leading to the possibility of fabricating other smart parts that could impact industries such as energy, aerospace, automotive, and biomedical industries for applications like air/fuel pre-mixing, pressure tubes, and turbine blades.

  • Characterization of ceramic components fabricated using binder jetting Additive Manufacturing Technology
    Ceramics International, 2015
    Co-Authors: J A Gonzalez, Jorge Mireles, Yun Lin, Ryan B Wicker
    Abstract:

    Binder jetting Additive Manufacturing is an emerging Technology with capability of processing a wide range of commercial materials, including metals and ceramics (316 SS, 420 SS, Inconel 625, Iron, Silica). In this project, aluminum oxide (Al2O3) powder was used for part fabrication. Various build parameters (e.g. layer thickness, saturation, particle size) were modified and different sintering profiles were investigated to achieve nearly full-density parts (~96%). The material's microstructure and physical properties were characterized. Full XRD, compression testing, and dielectric testing were conducted on all parts. Sintered alumina parts were achieved with an average compressive strength of 131.86MPa (16h sintering profile) and a dielectric constant of 9.47-5.65 for a frequency range of 20Hz to 1MHz. The complexity offered by Additive processing aluminum oxide can be extended to the Manufacturing of high value energy and environmental components for environmental systems (e.g. filters and membranes) or biomedical implants with integrated reticulated structures for improved osseointegration.

  • approximation of absolute surface temperature measurements of powder bed fusion Additive Manufacturing Technology using in situ infrared thermography
    Additive manufacturing, 2015
    Co-Authors: Emmanuel Rodriguez, Jorge Mireles, César A. Terrazas, David Espali, Mireya A Perez, Rya Wicke
    Abstract:

    Abstract Additive Manufacturing (AM) has several possible advantages over traditional Manufacturing including increased design freedom, reduced material usage, and shorter lead-times. A noteworthy capability of AM is the ability to monitor the process during material deposition and interrupt the process during fabrication if necessary. Recently, such monitoring, feedback, and control have been made possible by implementing in situ infrared (IR) thermography in powder bed fusion AM technologies. The purpose of the current research was to investigate the acquisition of absolute surface temperatures using in situ IR imaging of the melted or solid surfaces layer-by-layer during fabrication within an electron beam melting (EBM) system. The thermal camera was synchronized with the system's signal voltages of three synchronized events (pre-heating, melting, and raking) to automatically capture images. To acquire absolute temperature values from the IR images, a calibration procedure was established to determine the solid material's emissivity and reflected temperature or mean radiant temperature of the build chamber, which are necessary input parameters for the IR camera. A blackbody radiator was fabricated via EBM and was used as a tool to determine the emissivity of Ti–6Al–4V (determined to be 0.26 in the temperature range of the current study). Furthermore, a mathematical model was developed to determine the view factors associated with the system's interior (e.g. heat shielding) that were used in calculating the mean radiant temperature of the Manufacturing environment (∼342 °C). Experimental validation of the model was performed using a thermocouple embedded during fabrication that showed a 3.77% difference in temperature. A temperature difference of ∼366 °C (1038 °C vs . 672 °C) was observed when comparing uncorrected IR temperature data with corrected temperature data. Upon validation of the IR parameters for a melted area, experimentation was conducted to also determine powder emissivity (found to be 0.50). The thermal model presented here can be modified and implemented in other AM technologies for consideration of radiation energy to acquire absolute temperatures of layered surfaces, leading to improved thermal monitoring and control of the fabrication process.

Kevin Chou - One of the best experts on this subject based on the ideXlab platform.

  • Review on powder-based electron beam Additive Manufacturing Technology
    Manufacturing Review, 2014
    Co-Authors: Xibing Gong, Ted Anderson, Kevin Chou
    Abstract:

    This paper presents a thorough literature review of the powder-based electron beam Additive Manufacturing (EBAM) Technology. EBAM, a relatively new Additive Manufacturing (AM) process, can produce full-density metallic parts directly from the electronic data of the designed part geometry. EBAM has gained broad attentions from different industries such as aerospace and biomedical, with great potential in a variety of applications. The paper first introduces the general aspects of EBAM. The unique characteristics, advantages and challenges of EBAM are then presented. Moreover, the hub of this paper includes extensive discussions of microstructures, mechanical properties, geometric attributes, which impact the application ranges of EBAM parts, with focus on commonly used titanium alloys (in particular, Ti-6Al-4V). In the end, modeling efforts and process metrology of the EBAM process are discussed as well.

  • review on powder based electron beam Additive Manufacturing Technology
    ASME ISCIE 2012 International Symposium on Flexible Automation, 2012
    Co-Authors: Xibing Gong, Ted Anderson, Kevin Chou
    Abstract:

    This paper presents a thorough literature review of the powder-based electron beam Additive Manufacturing (EBAM) Technology. EBAM, a relatively new Additive Manufacturing (AM) process, can produce full-density metallic parts directly from the electronic data of the designed part geometry. EBAM has gained broad attentions from different industries such as aerospace and biomedical, with great potential in a variety of applications. The paper first introduces the general aspects of EBAM. The unique characteristics, advantages and challenges of EBAM are then presented. Moreover, the hub of this paper includes extensive discussions of microstructures, mechanical properties, geometric attributes, which impact the application ranges of EBAM parts, with focus on commonly used titanium alloys (in particular, Ti-6Al-4V). In the end, modeling work of the EBAM process is discussed as well.Copyright © 2012 by ASME

Xibing Gong - One of the best experts on this subject based on the ideXlab platform.

  • Review on powder-based electron beam Additive Manufacturing Technology
    Manufacturing Review, 2014
    Co-Authors: Xibing Gong, Ted Anderson, Kevin Chou
    Abstract:

    This paper presents a thorough literature review of the powder-based electron beam Additive Manufacturing (EBAM) Technology. EBAM, a relatively new Additive Manufacturing (AM) process, can produce full-density metallic parts directly from the electronic data of the designed part geometry. EBAM has gained broad attentions from different industries such as aerospace and biomedical, with great potential in a variety of applications. The paper first introduces the general aspects of EBAM. The unique characteristics, advantages and challenges of EBAM are then presented. Moreover, the hub of this paper includes extensive discussions of microstructures, mechanical properties, geometric attributes, which impact the application ranges of EBAM parts, with focus on commonly used titanium alloys (in particular, Ti-6Al-4V). In the end, modeling efforts and process metrology of the EBAM process are discussed as well.

  • review on powder based electron beam Additive Manufacturing Technology
    ASME ISCIE 2012 International Symposium on Flexible Automation, 2012
    Co-Authors: Xibing Gong, Ted Anderson, Kevin Chou
    Abstract:

    This paper presents a thorough literature review of the powder-based electron beam Additive Manufacturing (EBAM) Technology. EBAM, a relatively new Additive Manufacturing (AM) process, can produce full-density metallic parts directly from the electronic data of the designed part geometry. EBAM has gained broad attentions from different industries such as aerospace and biomedical, with great potential in a variety of applications. The paper first introduces the general aspects of EBAM. The unique characteristics, advantages and challenges of EBAM are then presented. Moreover, the hub of this paper includes extensive discussions of microstructures, mechanical properties, geometric attributes, which impact the application ranges of EBAM parts, with focus on commonly used titanium alloys (in particular, Ti-6Al-4V). In the end, modeling work of the EBAM process is discussed as well.Copyright © 2012 by ASME

Ted Anderson - One of the best experts on this subject based on the ideXlab platform.

  • Review on powder-based electron beam Additive Manufacturing Technology
    Manufacturing Review, 2014
    Co-Authors: Xibing Gong, Ted Anderson, Kevin Chou
    Abstract:

    This paper presents a thorough literature review of the powder-based electron beam Additive Manufacturing (EBAM) Technology. EBAM, a relatively new Additive Manufacturing (AM) process, can produce full-density metallic parts directly from the electronic data of the designed part geometry. EBAM has gained broad attentions from different industries such as aerospace and biomedical, with great potential in a variety of applications. The paper first introduces the general aspects of EBAM. The unique characteristics, advantages and challenges of EBAM are then presented. Moreover, the hub of this paper includes extensive discussions of microstructures, mechanical properties, geometric attributes, which impact the application ranges of EBAM parts, with focus on commonly used titanium alloys (in particular, Ti-6Al-4V). In the end, modeling efforts and process metrology of the EBAM process are discussed as well.

  • review on powder based electron beam Additive Manufacturing Technology
    ASME ISCIE 2012 International Symposium on Flexible Automation, 2012
    Co-Authors: Xibing Gong, Ted Anderson, Kevin Chou
    Abstract:

    This paper presents a thorough literature review of the powder-based electron beam Additive Manufacturing (EBAM) Technology. EBAM, a relatively new Additive Manufacturing (AM) process, can produce full-density metallic parts directly from the electronic data of the designed part geometry. EBAM has gained broad attentions from different industries such as aerospace and biomedical, with great potential in a variety of applications. The paper first introduces the general aspects of EBAM. The unique characteristics, advantages and challenges of EBAM are then presented. Moreover, the hub of this paper includes extensive discussions of microstructures, mechanical properties, geometric attributes, which impact the application ranges of EBAM parts, with focus on commonly used titanium alloys (in particular, Ti-6Al-4V). In the end, modeling work of the EBAM process is discussed as well.Copyright © 2012 by ASME