Is this project an undergraduate, graduate, or faculty project?
Undergraduate
Project Type
individual
Campus
Daytona Beach
Authors' Class Standing
Sean Chih, Junior
Lead Presenter's Name
Sean Chih
Lead Presenter's College
DB College of Engineering
Faculty Mentor Name
Dr. Birce Dikici
Abstract
Additive manufacturing of metals is a relatively new and groundbreaking approach to manufacturing high-performance components. However, variability in mechanical properties from the process creates a barrier before this manufacturing technique can be widely applied. Understanding when and where to use this manufacturing is also important to create components with efficiency and without harmful defects. The objective of this research is to evaluate the effects of build orientation, printing parameters, internal defects, thermal history, and residual stresses, post-processing heat treatments, and fatigue behavior on additively manufactured components. Literature-based research is conducted on commonly used metals for additive manufacturing, such as stainless steel and a titanium alloy Ti-6Al-4V, and the different mechanical properties of these metals are compared. Initial research shows that the inherent anisotropy from build orientation influences defect formation and location and drastically reduces the performance of the component. However, this can be mitigated using correct printing parameters specific to the component’s geometry and application, such as laser power, print speed, and layer thickness, which will all increase the strength of the component. Post-processing techniques can also be employed to increase the strength, ductility, and reliability of the printed part, which include heat treatment and hot isostatic pressing. The overall results indicate that the performance of additively manufactured metal components relies heavily on the manufacturing techniques during creation and if not done properly can lead to part failure. The significance of this research is to identify the controllable factors that affect the consistency and reliability of additively manufactured components and understand how to optimize the process to create the best-performing parts possible. This in turn will increase the usability of additively manufactured components in areas which require extreme reliability, such as aerospace and biomedical applications.
Did this research project receive funding support (Spark, SURF, Research Abroad, Student Internal Grants, Collaborative, Climbing, or Ignite Grants) from the Office of Undergraduate Research?
No
Additive Manufacturing of Metals: Mechanical Properties and Their Implications
Additive manufacturing of metals is a relatively new and groundbreaking approach to manufacturing high-performance components. However, variability in mechanical properties from the process creates a barrier before this manufacturing technique can be widely applied. Understanding when and where to use this manufacturing is also important to create components with efficiency and without harmful defects. The objective of this research is to evaluate the effects of build orientation, printing parameters, internal defects, thermal history, and residual stresses, post-processing heat treatments, and fatigue behavior on additively manufactured components. Literature-based research is conducted on commonly used metals for additive manufacturing, such as stainless steel and a titanium alloy Ti-6Al-4V, and the different mechanical properties of these metals are compared. Initial research shows that the inherent anisotropy from build orientation influences defect formation and location and drastically reduces the performance of the component. However, this can be mitigated using correct printing parameters specific to the component’s geometry and application, such as laser power, print speed, and layer thickness, which will all increase the strength of the component. Post-processing techniques can also be employed to increase the strength, ductility, and reliability of the printed part, which include heat treatment and hot isostatic pressing. The overall results indicate that the performance of additively manufactured metal components relies heavily on the manufacturing techniques during creation and if not done properly can lead to part failure. The significance of this research is to identify the controllable factors that affect the consistency and reliability of additively manufactured components and understand how to optimize the process to create the best-performing parts possible. This in turn will increase the usability of additively manufactured components in areas which require extreme reliability, such as aerospace and biomedical applications.