The arrival on the market of a new kind of CNC machines which can both add and remove material to an object paved the way to a new approach to the problem of repairing damaged components. The additive operation is performed by a Direct Laser Deposition (DLD) tool, while the subtractive one is a machining task. Up to now, repair operations have been carried out manually and for this reason they are errors prone, costly and time consuming. Refurbishment can extend the life of a component, saving raw materials and resources. For these reasons, using a precise and repeatable CNC machine to repair valuable objects is therefore very attractive for the sake of reliability and repeatability, but also from an economical and environmental point of view. One of the biggest obstacles to the automation of the repairing process is represented by the fact that the CAM software requires a solid CAD model of the damage to create the toolpaths needed to perform additive operations. Using a 3D scanner the geometry of the damaged component can be reconstructed without major difficulties, but figuring out the damage location is rather difficult. The present work proposes the use of octrees to automatically detect the damaged spot, starting from the 3D scan of the damaged object. A software named DUOADD has been developed to convert this information into a CAD model suitable to be used by the CAM software. DUOADD performs an automatic comparison between the 3D scanned model and the original CAD model to detect the damaged area. The detected volume is then exported as a STEP file suitable to be used directly by the CAM. The new workflow designed to perform a complete repair operation is described placing the focus on the coding part. DUOADD allows to approach the repairing problem from a new point of view which allows savings of time and financial resources. The successful application of the entire process to repair a damaged die for injection molding is reported as a case study. In the last part of this work the strategies used to apply new material on the worn area are described and discussed. This work also highlights the importance of using optimal parameters for the deposition of the new material. The procedures to find those optimal parameters are reported, underlying the pros and cons. Although the DLD process is very energy efficient, some issues as thermal stresses and deformations are also reported and investigated, in an attempt to minimize their effects.

With the rapid development of concrete 3D printing for construction projects, it is crucial to produce sustainable 3D-printed cementitious composites that meet the required fresh and hardened properties. This study investigates the application of cellulose-based nanomaterials (CN) (i.e., abundant natural polymers) that can improve the mechanical properties of cement-based materials – in 3D-printed cementitious composites of ordinary portland cement (OPC) and alkali-activated materials (AAMs). A combination of low calcium fly ash and ground granulated blast-furnace slag was used as the precursor in AAM systems. This work examines the 3D-printed mixtures with varying binders and mixture proportions and with different dosages of cellulose-based nanomaterial known as cellulose nanocrystals (CNC) to optimize the formulation for the production of sustainable high-performance 3D-printed elements. A suite of experimental techniques was applied to study the impact of CNC on the fresh and hardened properties of the 3D-printed samples. The buildability of the alkali-activated mixtures was improved by increasing the CNC content, suggesting that the CNC performs as a viscosity-modifying agent in AAMs. The inclusion of CNCs up to 1.00% (by volume of the binder) improves the overall mechanical performance and reduces the porosity of 3D-printed OPC and heat-cured AAM samples. Further, the addition of CNC (up to 0.30%) in sealed-cured AAM samples improves their flexural strength due to the crack-bridging mechanism of CNCs. The addition of CNC densifies the microstructure of OPC samples by increasing the degree of hydration, however, no significant impact on the microstructure of AAMs is noticed. The OPC sample with CNC has approximately 25% increase in the degree of hydration at inner depths which can be attributed to the internal curing potential of CNC materials. The initial water absorption rate of heat-cured AAM samples is lower than the sealed-cured AAM samples and comparable to the OPC system. The developed printable “alkali-activated-CNC” composites can provide an overall reduction in the environmental impacts of the 3D-printed cementitious composites by eliminating/reducing the need for different chemical admixtures to improve 3D-printed material consistency and stability, and replacing 100% of portland cement with fly ash and slag. / Civil Engineering

This investigation aims to understand and improve the deposition quality and rates of cold spray for additive manufacturing in a way that is economically sound and without the detrimental temperature effects seen in traditional metallic additive manufacturing processes. It focuses on materials that are desired by the additive manufacturing community and built upon the current knowledge in cold spray. This thesis is presented as a collection of published, or soon to be published, manuscripts accompanied by an introduction, literature review, and conclusion. The effect of a non-spherical particle morphology was the first objective investigated. Titanium has been shown repeatedly to require pure helium at very high temperatures and pressures to get dense coatings, however, the unique coral-like morphology resulting from the Armstrong Process was revealed as a key to successful deposition with nitrogen. Using low pressure cold spray, under conditions that would be considered mild, a deposition efficiency of 100% and a porosity of nearly 0% was achieved. This is a promising approach for cold spray as a method for additive manufacturing of titanium parts. The low powder cost and the advantages of additive manufacturing could allow for a substantial cost savings in titanium part production when compared to traditional manufacturing methods. With these cost saving advantages, additive manufacturing of titanium using Armstrong process powder and CS could lead to a paradigm shift of titanium production, allowing titanium to enter markets that under traditional methods would be far too expensive. Unfortunately, this unique powder morphology was not available in other materials. To address the low deposition efficiency of the other metals of interest, such as aluminum and stainless steel, the concept of mixing the propellant gas was introduced in the second objective. Considering the relative costs of gases, powder, electricity, and labour, the second paper focuses on the concept of optimizing the amount of helium to produce the minimum component cost. It was found that for the specific stainless steel and aluminum alloy powders discussed, costs could be reduced by 44% and 59%, respectively, using the gas mixing system. However, no cost saving was found for the most inexpensive of the powders, pure aluminum. For gas mixing to be effective, the cost of helium must be offset by the cost of the powders. Therefore, low-cost powders, such as pure aluminum, results in pure nitrogen as the least expensive option. This however doesn’t address the low deposition efficiency that is preventing its adoption in cold spray additive manufacturing. The third objective addresses just this, an improvement in deposition efficiency without the introduction of expensive helium. In this study, aluminum particles were preheated using a novel particle preheater that does not clog. This resulted in a deposition efficiency increase of 260% with a minimal increase in electrical costs. These three objectives, while studied and published separately, all relate to the purpose of this work to improve the process economics without detrimental temperature effects. These findings have been (or will be) published in international peer reviewed journals to add to the collective knowledge.

No description available.

No description available.

No description available.

No description available.

No description available.

No description available.

No description available.