Browsing by Author "Ayeni, Oyedotun Isaac"

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    Microstructure and Phase Analysis of 3D-Printed Components Using Bronze Metal Filament
    (Springer, 2020-03) Lu, Zhe; Ayeni, Oyedotun Isaac; Yang, Xuehui; Park, Hye-Yeong; Jung, Yeon-Gil; Zhang, Jing; Mechanical and Energy Engineering, School of Engineering and Technology
    Typical metal 3D printing processes with powders require either a laser or electron beam as the heating source. In this work, an alternative non-expensive metal 3D printing process based on the fused deposition modeling process using metal filled filament is studied. Using bronze filament as a feedstock, the microstructures, phases, compositions of the filament, as-printed, and sintered specimens are analyzed. The 3D printing process basically does not modify the morphology and phases of the filament. Sintering temperature below 832 °C is recommended. Above 832 °C, there are substantial oxidation reactions leading to the formation of copper oxide and cassiterite shell structure around the bronze core. The mechanical properties of the 3D-printed sample are measured using the three-point bending test. The measured flexural strength is 27.9 MPa, and the modulus of elasticity is 1.2 GPa. This study provides important information for applying the bronze filament in future engineering applications.
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    Sintering and Characterizations of 3D Printed Bronze Metal Filament
    (2018-12) Ayeni, Oyedotun Isaac; Zhang, Jing; Hazim, El-Mounayri; Xiaoliang, Wei
    Metal 3D printing typically requires high energy laser or electron sources. Recently, 3D printing using metal filled filaments becomes available which uses PLA filaments filled with metal powders (such as copper, bronze, brass, and stainless steel). Although there are some studies on their printability, the detailed study of their sintering and characterizations is still missing. In this study, the research is focused on 3D printing of bronze filaments. Bronze is a popular metal for many important uses. The objectives of this research project are to study the optimal processing conditions (like printer settings, nozzle, and bed temperatures) to print bronze metal filament, develop the sintering conditions (temperature and duration), and characterization of the microstructure and mechanical properties of 3D printed specimens to produce strong specimens. The thesis includes three components: (1) 3D printing and sintering at selected conditions, following a design of experiment (DOE) principle; (2) microstructure and compositional characterizations; and (3) mechanical property characterization. The results show that it is feasible to print using bronze filaments using a typical FDM machine with optimized printing settings. XRD spectrums show that there is no effect of sintering temperature on the composition of the printed parts. SEM images illustrate the porous structure of the printed and sintered parts, suggesting the need to optimize the process to improve the density. The micro hardness and three-point bending tests show that the mechanical strengths are highly related to the sintering conditions. This study provides important information of applying the bronze filament in future engineering applications.