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Mechanical & Energy Engineering Department Theses and Dissertations
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Information about the Purdue School of Engineering and Technology Graduate Degree Programs available at IUPUI can be found at: http://www.engr.iupui.edu/academics.shtml
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Browsing Mechanical & Energy Engineering Department Theses and Dissertations by Subject "3D printing"
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Item Characterization of tensile and hardness properties and microstructure of 3D printed bronze metal clay(2017) Golub, Michael; Zhang, JingBronze is a popular metal for many important uses. Currently, there are no economical 3D printers that can print Bronze powders. A recent product, Bronze Metal Clay (BMC) has arrived. Additionally, commercial metal 3D printers require laser or electron beam sources, which are expensive and not easily accessible. The objective of this research is to develop a new two-step processing technique to produce 3D printed metallic component. The processing step includes room temperature 3D printing followed by high-temperature sintering. Since no material data exists for this clay, the tensile strength and hardness properties of BMC are compared to wrought counterpart. In this research tests are completed to determine the mechanical properties of Cu89Sn11 Bronze Metal Clay. The author of this thesis compares the physical properties of the same material in two different formats: 3D printed clay and molded clay. Using measured stress-strain curves and derived mechanical properties, including Young's modulus, yield strength, and ultimate tensile strength, the two formats demonstrate inherit differences. The Ultimate tensile strength for molded BMC and 3D-printed specimens sintered at 960 C was 161.94 MPa and 157 MPa, respectively. A 3D printed specimen which was red at 843 C had 104.32 MPa tensile strength. Factory acquired C90700 specimen had an ultimate stress of 209.29 MPa. The Young's modulus for molded BMC and 3D-printed specimens sintered at 960 C was 36.41 GPa and 37.05 GPa, respectively. The 843 C 3D-printed specimen had a modulus of 22.12 GPa. C90700 had the highest modulus of 76.81 GPa. The Yield stress values for molded BMC and 3D-printed specimens sintered at 960 C was 77.81 MPa and 72.82 MPa, respectively. The 3D-printed specimen had 46.44 MPa. C90700 specimen had 115.21 MPa. Hand molded specimens had a Rockwell hardness HRB85, while printed samples had a mean of HRB69. Also, molded samples recorded a higher Young's Modulus of 43 GPa vs. 33 GPa for the printed specimens. Both samples were weaker than the wrought Cu88:8Sn11P0:2 which had a 72 GPa. Cu88:8Sn11P0:2 also was a harder material with an HRC45. The property di erence between 3D printed, molded, and wrought samples was explained by examining their micro structures. It shows that 3D printed sample had more pores than the molded one due to printing process. This study demonstrates the flexibility and feasibility of using 3D printing to produce metallic components, without laser or electron beam source.Item Characterization of tensile, creep, and fatigue properties of 3D printed Acrylonitrile Butadiene Styrene(2016-08) Zhang, Hanyin; Zhang, Jing; Ryu, Jong Eun; Jones, Alan S.; Anwar, SohelAcrylonitrile Butadiene Styrene (ABS) is the most widely used thermoplastics in 3D printing for making models, prototypes, patterns, tools and end-use parts. However, there is a lack of systematic understanding of the mechanical properties of 3D printed ABS components, including orientation-dependent tensile strength, creep, and fatigue properties. These mechanical properties are critically needed for design and application of 3D printed components. The main objective of this research is to systematically characterize key mechanical properties of 3D printed ABS components, including tensile, creep, and fatigue properties. Additionally, the eff ects of printing orientation on the mechanical prop- erties are investigated. There are two research approaches employed in the thesis: rst, experimental investigation of the tensile, creep, and fatigue properties of the 3D printed ABS components; second, laminate based finite-element modeling of tensile test to understand the stress distributions in different printing layers. The major conclusions of the thesis work are summarized as follows. The tensile test experiments show that the 0 printing orientation has the highest Young's modulus, 1.81 GPa, and ultimate strength, 224 MPa. The tensile test simulation shows a similar Young's modulus as the experiment in elastic region, indicating the robustness of laminate based finite element model. In the creep test, the 90 printing orientation has the lowest k value of 0.2 in the plastics creep model, suggesting the 90 is the most creep resistant among 0 , 45 , and 90 printing orientations. In the fatigue test, the average cycle number under load of 30 N is 3796 revolutions. The average cycle number decreases to 128 revolutions when the load is below 60N. Using the Paris Law, with the crack size of 0.75 mm long and stress intensity factor is varied from 352 to 700 MN -m^3/2 , the predicted fatigue crack growth rate is 0.0341 mm/cycle.