Browsing by Author "Zhang, Yi"

Now showing 1 - 10 of 37
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    Additive Manufacturing of Metallic Materials: A Review
    (Springer, 2017) Zhang, Yi; Wu, Linmin; Guo, Xingye; Kane, Stephen; Deng, Yifan; Jung, Yeon-Gil; Lee, Je-Hyun; Zhang, Jing; Mechanical Engineering, School of Engineering and Technology
    In this review article, the latest developments of the four most common additive manufacturing methods for metallic materials are reviewed, including powder bed fusion, direct energy deposition, binder jetting, and sheet lamination. In addition to the process principles, the microstructures and mechanical properties of AM-fabricated parts are comprehensively compared and evaluated. Finally, several future research directions are suggested.
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    Albumin Deficiency Reduces Hepatic Steatosis and Improves Glucose Metabolism in a Mouse Model of Diet-Induced Obesity
    (MDPI, 2023-04-25) Abdollahi, Afsoun; Narayanan, Sanjeev K.; Frankovich, Alexandra; Lai, Yen-Chun; Zhang, Yi; Henderson, Gregory C.; Anatomy, Cell Biology and Physiology, School of Medicine
    Serum albumin facilitates the transport of free fatty acids (FFAs) from adipose tissue to other organs. It was not known if impeding this process could protect from hepatic steatosis and metabolic dysfunction in obesity. We tested whether albumin knockout (Alb−/−) mice would exhibit a reduction in plasma FFA concentration, reduced hepatic lipid accumulation, and improved glucoregulation as compared to wild-type (WT) mice. Male homozygous albumin knockout mice (Alb−/−) and WT controls were fed a low-fat diet (LFD) or high-fat diet (HFD). Alb−/− mice exhibited a similar body weight gain and body composition as WT on both diets. Despite HFD-induced obesity, Alb−/− mice were protected from various comorbidities. Compared to WT mice on the HFD, Alb−/− exhibited lower plasma FFA levels, lower blood glucose levels during glucose tolerance and insulin tolerance tests, and lower hepatic steatosis and inflammation. Alb−/− mice on HFD also exhibited elevated expression of multiple genes in the liver and adipose tissues, such as peroxisome proliferator-activated receptor α in both tissues, as well as glucose transporter-4 and adiponectin in adipose tissues. The results indicate that albumin’s FFA transport function may be involved in the development of hepatic lipid accumulation and dysregulated glucose metabolism in obesity.
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    Atomistic and finite element modeling of zirconia for thermal barrier coating applications
    (2014) Zhang, Yi; Zhang, Jing; El-Mounayri, Hazim; Tovar, Andrés; Anwar, Sohel
    Zirconia (ZrO2) is an important ceramic material with a broad range of applications. Due to its high melting temperature, low thermal conductivity, and high-temperature stability, zirconia based ceramics have been widely used for thermal barrier coatings (TBCs). When TBC is exposed to thermal cycling during real applications, the TBC may fail due to several mechanisms: (1) phase transformation into yttrium-rich and yttrium-depleted regions, When the yttrium-rich region produces pure zirconia domains that transform between monoclinic and tetragonal phases upon thermal cycling; and (2) cracking of the coating due to stress induced by erosion. The mechanism of erosion involves gross plastic damage within the TBC, often leading to ceramic loss and/or cracks down to the bond coat. The damage mechanisms are related to service parameters, including TBC material properties, temperature, velocity, particle size, and impact angle. The goal of this thesis is to understand the structural and mechanical properties of the thermal barrier coating material, thus increasing the service lifetime of gas turbine engines. To this end, it is critical to study the fundamental properties and potential failure mechanisms of zirconia. This thesis is focused on investigating the structural and mechanical properties of zirconia. There are mainly two parts studied in this paper, (1) ab initio calculations of thermodynamic properties of both monoclinic and tetragonal phase zirconia, and monoclinic-to-tetragonal phase transformation, and (2) image-based finite element simulation of the indentation process of yttria-stabilized zirconia. In the first part of this study, the structural properties, including lattice parameter, band structure, density of state, as well as elastic constants for both monoclinic and tetragonal zirconia have been computed. The pressure-dependent phase transition between tetragonal (t-ZrO2) and cubic zirconia (c-ZrO2) has been calculated using the density function theory (DFT) method. Phase transformation is defined by the band structure and tetragonal distortion changes. The results predict a transition from a monoclinic structure to a fluorite-type cubic structure at the pressure of 37 GPa. Thermodynamic property calculations of monoclinic zirconia (m-ZrO2) were also carried out. Temperature-dependent heat capacity, entropy, free energy, Debye temperature of monoclinic zirconia, from 0 to 1000 K, were computed, and they compared well with those reported in the literature. Moreover, the atomistic simulations correctly predicted the phase transitions of m-ZrO2 under compressive pressures ranging from 0 to 70 GPa. The phase transition pressures of monoclinic to orthorhombic I (3 GPa), orthorhombic I to orthorhombic II (8 GPa), orthorhombic II to tetragonal (37 GPa), and stable tetragonal phases (37-60 GPa) are in excellent agreement with experimental data. In the second part of this study, the mechanical response of yttria-stabilized zirconia under Rockwell superficial indentation was studied. The microstructure image based finite element method was used to validate the model using a composite cermet material. Then, the finite element model of Rockwell indentation of yttria-stabilized zirconia was developed, and the result was compared with experimental hardness data.
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    Atomistic modeling of resistivity evolution of copper nanoparticle in intense pulsed light sintering process
    (Elsevier, 2019-02) Meng, Lingbin; Zhang, Yi; Yang, Xuehui; Zhang, Jing; Mechanical and Energy Engineering, School of Engineering and Technology
    In this work, the intense pulsed light (IPL) sintering process of copper nanoparticle ink is simulated using molecular dynamics (MD) method. First, the neck size growth between the two copper nanoparticles during the IPL sintering process is computed. The resultant electrical resistivity is then calculated by substituting the neck size into the Reimann-Weber formula. Overall, a rapid decrease of electric resistivity is observed in the beginning of the sintering, which is caused by quick neck size growth, followed by a gradually decrease of resistivity. In addition, the correlation of the simulated temperature dependent resistivity is similar to that of the experimentally measured resistivity. The MD model is an effective tool for designers to optimize the IPL sintering process.
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    Characterization of Microstructure and Mechanical Properties of Direct Metal Laser Sintered 15–5 PH1 Stainless Steel Powders and Components
    (Springer, 2016) Zhang, Jing; Zhang, Yi; Guo, Xingye; Lee, Weng Hoh; Hu, Bin; Lu, Zhe; Jung, Yeon-Gil; Lee, Je-Hyun; Department of Mechanical Engineering, School of Engineering and Technology
    15–5 PH1 stainless steel powder is one of the common materials used for the DMLS process. In this study, both the powder and parts fabricated via DMLS have been characterized. The microstructure and elemental composition have been examined. The microhardness and surface roughness have also been measured. The results show that most powder particle are in spherical with a particle size of 5 ~ 60 μm. Chemical compositions of the powder compare well with the literature data. The thickness of rough surface is about 1 μm. The measured Rockwell hardness is HRC 42.9±0.3, which is also in good agreement with literature.
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    Design Optimization of Injection Molds with Conformal Cooling for Additive Manufacturing
    (Office of the Vice Chancellor for Research, 2015-04-17) Wu, Tong; Jahan, Suchana A.; Kumaar, Praveen; Tovar, Andres; El-Mounayri, Hazim; Zhang, Yi; Zhang, Jing; Acheson, Doug; Nalim, M. Razi
    Abstract This is a framework for optimizing additive manufacturing of plastic injection molds. The proposed system consists of three modules, namely process and material modeling, multi-scale topology optimization, and experimental testing, calibration and validation. Advanced numerical simulation is implemented for a typical die with conformal cooling channels to predict cycle time, part quality and tooling life. A thermo-mechanical topology optimization algorithm is being developed to minimize the die weight and enhance its thermal performance. The technique is implemented for simple shapes for validation before it is applied to dies with conformal cooling in future work. A method for designing a die with porous material which can be produced in additive manufacturing is developed. Also a comprehensive set of systemic design rules are developed and to be integrated with CAD modeling to automate the process of obtaining viable plastic injection dies with conformal cooling channels. Finally, material modeling using simulation as well as design of experiments is underway for obtaining the material properties and their variations.
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    Design Optimization of Plastic Injection Tooling for Additive Manufacturing
    (Elsevier, 2017) Wu, Tong; Jahan, Suchana A.; Zhang, Yi; Zhang, Jing; El-Mounayri, Hazim; Tovar, Andres; Mechanical Engineering, School of Engineering and Technology
    This work presents a systematic and practical finite element based design optimization approach for the injection tooling adaptive to additive manufacturing (AM) technology using stereo-lithography (SLA) and powder bed fusion (PBF). First a thermomechanical optimization of conformal cooling is implemented to obtain the optimal parameters associated with conformal cooling design. Then, a multiscale thermomechanical topology optimization is implemented to obtain a lightweight lattice injection tooling without compromising the thermal and mechanical performance. The design approach is implemented to optimize a real design mold and the final optimal design is prototyped in SLA and the manufacturability in PBF has been discussed.
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    Designing a Low-cost, Light-weight Electric Snowmobile
    (Office of the Vice Chancellor for Research, 2015-04-17) Baharuddin, Fatin; Chen, Guiming; Chen, Yu-Ren; Gandhi, Bhavesh Vijay; Mohammed, Samad Abdul; Wible, Grant; Wu, Linmin; Yong, Zhen Wei; Zhang, Yi; Golub, Michael; Zhang, Jing
    The Indiana University-Purdue University, Indianapolis Jaguar team is participating in the 2015 SAE Clean Snowmobile Challenge (CSC) with the aim of achieving a low-cost snowmobile that weigh less than 200 kg (441 lb). It was re-engineered to be an environmental friendly snowmobile without forgetting to improve the towing capability and less noise. We are using the Phantom Snowmobile PD250LT that is manufactured by FMC Motor Company and sold through out North America. The modified NetGain WarP 7 DC-series motor is connected directly to the sprocket shaft using a Goodyear Synchronous Belt. The belt itself is very quiet and can produce less than 59 dB.
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    Discrete Element Modeling of Powder Dispensing and Laser Heating in Direct Laser Metal Sintering Process
    (Office of the Vice Chancellor for Research, 2016-04-08) Lee, Weng Hoh; Zhang, Yi; Zhang, Jing
    ABSTRACT The growth of reliable methods to improve part created from additive manufacturing technologies greatly depend on the quantitative understanding of the mechanical properties and the microstructural behavior of the powder particles during the 3D printing procedure. To obtain a greater understanding of this process, a particle- based discrete element modeling (DEM) has incredible potential benefits in the field of manufacturing for reducing cost and control specific structures and materials of the parts created from this process. In this research, we developed a numerical tool and use it to study the powder characterization of the powder deposition process in the Direct Metal Laser Sintering (DLMS) machine. Our simulations include the modelling of particle insertion, particle spreading, and temperature distribution due to laser beam sintering process. The DEM simulation results show that the particle distribution of the powder bed after powder dispersing process. Temperature distribution after laser heating is also given.
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    Discrete element modeling of powder flow and laser heating in direct metal laser sintering process
    (Elsevier, 2017-06) Lee, Weng-Hoh; Zhang, Yi; Zhang, Jing; Department of Mechanical Engineering, School of Engineering and Technology
    A novel particle-based discrete element model (DEM) is developed to simulate the whole Direct Metal Laser Sintering (DMLS) process, which includes simplified powder deposition, recoating, laser heating, and holding stages. This model is first validated through the simulation of particle flow and heat conduction in the powder bed, and the simulated results are in good agreement with either experiment in the literature or finite element method. Then the validated model is employed to the DMLS process. The effects of laser power, laser scan speed, and hatch spacing on the temperature distributions in the powder bed are investigated. The results demonstrate that the powder bed temperature rises as the laser power is increased. Increasing laser scan speed and laser hatch spacing will not affect the average temperature increase in the powder bed since energy input is kept same. However, a large hatch spacing may cause non-uniform temperature distribution and microstructure inhomogeneity. The model developed in this study can be used as a design and optimization tool for DMLS process.