2023 Technical Division Student Poster Contest: MPMD 2023 Technical Division Undergraduate Student Poster Contest
Program Organizers: TMS Administration
Monday 5:30 PM
March 20, 2023
Room: Exhibit Hall G
Location: SDCC
SPU-5: A High-speed Radiography Study for Validating the Effect of Dwell Time on Melt-pool Dynamics during Laser Powder Bed Fusion: Raymond Wysmierski1; Rakesh Kamath1; Gerry Knapp2; John Coleman2; Stuart Slattery2; Sam Reeve2; Hahn Choo1; 1University of Tennessee Knoxville; 2Oak Ridge National Laboratory
Understanding the relationship between processing parameters and microstructure is key to advancing metal additive manufacturing processes. High speed synchrotron x-ray radiography was conducted at the Advanced Photon Source (Argonne National Laboratory) in tandem with the laser spot melting of Ti-6Al-4V to gain a basic understanding of the melt pool dynamics during a laser powder bed fusion process. The dwell time of the laser spot melt was varied from 2 ms to 8 ms, maintaining a constant laser power of 82 W, to observe its effect on the evolution of melt pool dimensions and the solid-liquid interface velocity. Melt pool boundaries were tracked using the resulting x-ray radiography images. Moreover, the in-situ radiography data was used to validate and improve a physics-based melt pool model based on the OpenFOAM framework. This effort will help further understanding of microstructure evolution and benefit industry by optimizing laser AM processes of the Ti-6Al-4V alloy.
SPU-6: Assessing Laser Powder Bed Additive Manufacturing Part Quality via In-Situ Monitoring & Machine Learning: Ana Love1; 1Sandia National Labs; University of New Mexico
In-situ monitoring paired with real-time data analytics has the potential to overcome challenges associated with ensuring build quality and consistency in additive manufacturing (AM). Internal flaws are expensive and time consuming to identify in a completed part, however, in-situ monitoring enables inexpensive quantification of the size and spatial distribution of defects. This work focuses on the development of a framework that feeds real-time sensor data into machine learning algorithms trained to discriminate between nominal and defective build regions. Optical imaging and analysis performed using Oak Ridge National Laboratories’ Peregrine software is used to identify spatter and balling defects in real-time. Addition of thermal and acoustic sensors enables cross-correlation between multiple data streams. Validity of in-situ analysis for AM builds is determined by testing the neural network against user-specified ground truths. Ultimately, the use of functional and accurate in-situ monitoring will increase trust in AM, expanding its use in mainstream production.
SPU-7: Burn Rate Analysis of an Energetic Initiator Ink for 3D Printing: Kayleigh Cameron1; Dr. Chelsey Hargather1; 1New Mexico Institute of Mining and Technology
Currently, the properties of energetics and the uses for them are limited by traditional manufacturing techniques like casting. Cast energetics typically must be produced in large amounts, are limited to certain geometries and properties, and are expensive to transport to the work location. Additive manufacturing expands the applications of energetics by eliminating some of the problems faced in traditional manufacturing. The end goal of this project is to create an energetic initiator ink for additive manufacturing that will have the ability to be produced in a wider range of geometries, have tailorable burn properties, and can be produced in non-specific locations. The present work focuses on the characterization of burn rate as a function of composition of the energetic system.
SPU-8: Development of a Pyrotechnic Initiator Ink for Additive Manufacturing Methodology: Benito Silva1; Chelsey Hargather1; 1New Mexico Institute of Mining and Technology
The purpose of this study is to develop a pyrotechnic initiator ink that can be used accurately in additive manufacturing. The initiator ink must be able to ignite a less sensitive energetic material and should demonstrate multi-point or simultaneous initiation. Thermites have a high thermal output with low gas emission and are the ideal energetic for the ink. Three thermite formulations are developed using barium nitrate, strontium nitrate, or manganese oxide as oxidizers and Al as fuel. The oxidizer and fuel mixture is combined with a stoichiometric mixture of Fe and S to help stabilize and control the burning of the thermite. The combustion rate and thermal output of each formulation is tested. The barium nitrate and strontium nitrate formulations were found to have the highest burn rate and thermal output. Future experiments include testing the volumetric flow rate and viscosity of the ink in an additive manufacturing application.
SPU-9: Effects of LPBF Parameters on Fatigue Life of AlSi10Mg Alloys: Timothy Nice1; Bhaskar Majumdar1; Nathaniel Badgett1; John O’Connell1; 1New Mexico Institute of Mining & Technology
Laser powder bed fusion (LPBF) additive manufacturing is quickly becoming a sought-after process for manufacturing an increasing number of parts for the aerospace and other industry needs. Fatigue life of components is absolutely critical in the aerospace industry and therefore the catalyst driving this research. For this research tensile and fatigue bars were printed using LPBF at various print parameters to investigate their effects on tensile strength and fatigue life of AlSi10Mg. The mechanical results, microstructure and fracture faces of LPBF additive manufactured samples are compared to published experimental data.
SPU-10: Mechanochemistry for Creation of Functional Surface Treatments: Jennifer Johnson1; Jon Kellar1; William Cross1; 1South Dakota School of Mines and Technology
This research explores mechanochemistry to create functional surface treatments. A planetary centrifugal mixer was used to modify BAM particles (aluminum magnesium boride, Al3Mg3B56) and fluorite (CaF2) surfaces. Native BAM particles do not flow easily, inhibiting their use for additive manufacturing; therefore, organic surface treatments are explored to create better flowability. (3-Aminoproply)triethoxysilane was used to create a more hydrophilic BAM surface. Fluorite particles were treated with oleic acid to increase hydrophobicity, and to aid in mineral beneficiation. Both systems were evaluated using Fourier-transform infrared spectroscopy and contact angle goniometry to determine the effectiveness of mixing and surface reactivity. After treatment BAM has shown improved flowability, and the fluorite became more hydrophobic. Mechanochemical processing has proven successful in transforming surface properties, and holds promise for surface engineering in areas of additive manufacturing and mineral processing.
SPU-11: Study of the Pyrometallurgical Recycling Process to the Recovery of Zinc and Manganese Oxide from Spent Alkaline and Zn-C Batteries: Seoung-Uk Bae1; Kyoung-Tae Park2; Jae Hong Shin2; Junghoon Lee3; 1Incheon National University; 2Korea Institute of Industrial Technology; 3Other
In this study, research was conducted to develop a technology for recovery of zinc and manganese oxide powder through a high temperature pyrometallurgical recycling process from black powder of alkaline and Zn-C batteries. In order to remove chlorides such as potassium chloride present in the black powder, the black powder was washed using deionized water, and the washed black powder was used as a material for recovering zinc and manganese. Pre-thermodynamic calculations were performed using a FactSage program to set the process temperature. Zinc oxide present in the black powder reacted with residual carbon and was reduced to zinc gas, and zinc powder could be obtained by rapidly condensing the generated zinc gas. In addition, it was confirmed that only the manganese oxide phase was present in the black powder residue in the crucible.
SPU-12: Viscosity Characterization of an Energetic Initiator Ink for 3D Printing: Hannah Morgan-Smith Myers1; Chelsey Hargather1; 1New Mexico Institute of Mining and Technology
Additive manufacturing (AM) is a useful tool yet to be thoroughly applied to the manufacturing of energetic materials. A material with high viscosity and yield stress is required for the AM of energetics. This project focuses on characterizing the viscosity of an energetic initiator ink using a rotational viscometer. The end product is an energetic initiator ink with easily customizable parameters such as composition and print speed. Changes to the particle size ratios, binder system, and catalyst concentration will be done to optimize printability for given applications. In the present work, experimental viscosity procedures have been established for curing and non-curing energetic systems and preliminary data has been collected. So far, the data indicates that viscosity is dramatically changed with particle size ratios. Additionally, catalyst concentration is shown to significantly impact the cure rate, which is linear. Viscosity data is validated against the current scientific literature when available.