<div>The work discussed in this document seeks to integrate conductive additives with energetic material systems to offer an alternative source of ignition for the energetic material. By utilizing the conductive properties of the additives, ohmic heating may serve as a method for preheating and igniting an energetic material. This would allow for controlled ignition of the energetic material without the use of a traditional ignition source, and could also result in easier system fabrication.</div><div>For ohmic heating to be a viable method of preheating or igniting these conductive energetic materials, there cannot be significant impact on the energetic properties of the energetic materials. Various mass solids loadings of graphene nanoplatelets (GNPs) were mixed with a reactive mixture of aluminum (Al)/polyvinylidene fluoride (PVDF) to test if ohmic heating ignition was feasible and to inspect the impact that these loadings had on the energetic properties of the Al/PVDF. Results showed that while ohmic heating was a plausible method for igniting the conductive energetic samples, the addition of GNPs degraded the energetic properties of the Al/PVDF. The severity of this degradation was minimized at lower solids loadings of GNPs, but this consequently resulted in larger voltage input requirements to ignite the conductive energetic material. This was attributable to the decreased conductivities of the samples at lower solids loading of GNPs.</div><div>In hopes of conserving the energetic properties of the Al/PVDF while integrating the conductive additives, additive manufacturing techniques, more specifically fused filament fabrication, was used to print two distinct materials, Al/PVDF and a conductive composite, into singular parts. A CraftBot 3 was used to selectively deposit Conductive Graphene PLA (Black Magic) filament with a reactive filament comprised of a PVDF binder with 20% mass solids loadings of aluminum. Various amounts of voltage were applied to these conductive energetic samples to quantify the time to ignition of the Al/PVDF as the applied voltage increased. A negative correlation was discovered between the applied voltage and time to ignition. This result was imperative for demonstrating that the reaction rate could be influenced with the application of higher applied voltages.</div><div>Fused filament fabrication was also used to demonstrate the scalability of the dual printed conductive energetic materials. A flexural test specimen made of the Al/PVDF was printed with an embedded strain gauge made of the Black Magic filament. This printed strain gauge was tested for dual purposes: as an igniter and as a strain sensor, demonstrating the multi-functional use of integrating conductive additives with energetic materials.</div><div>In all, the experiments in this document lay a foundation for utilizing conductive additives with energetic materials to offer an alternative form of ignition. Going forward, ohmic heating ignition may serve as a replacement to current, outdated methods of ignition for heat sensitive energetic materials.</div>

<p>The performance of solid rocket motors (SRMs) is extremely dependent on propellant formulation, operating pressure, and initial grain geometry. Traditionally, propellant grains are cast into molds, but it is difficult to remove the grains without damage if the geometry is too complex. Cracks or voids in propellant can lead to erratic burning that can break the grain apart and/or potentially overpressurize the motor. Not only is this dangerous, but the payload could be destroyed or lost. Some geometries (i.e. internal voids or intricate structures) cannot be cast and there is no consistent nor economical way to functionally grade grains made of multiple propellant formulations at fines scales (~ mm) without the risk of delamination between layers or the use of adhesives, which significantly lower performance. If one could manufacture grains in such a way, then one would have more control and flexibility over the design and performance of a SRM. However, new manufacturing techniques are required to enable innovation of new propellant grains and new analysis techniques are necessary to understand the driving forces behind the combustion of non-traditionally manufactured propellant.</p> <p>Additive manufacturing (AM) has been used in many industries to enable rapid prototyping and the construction of complex hierarchal structures. AM of propellant is an emerging research area, but it is still in its infancy since there are some large challenges to overcome. Namely, high performance propellant requires a minimum solids loading in order to combust properly and this translates into mixtures with high viscosities that are difficult to 3D print. In addition, it is important to be able to manufacture realistic propellant formulations into grains that do not deform and can be precisely functionally graded without the presence of defects from the printing process. The research presented in this dissertation identifies the effect of a specific AM process called Vibration Assisted Printing (VAP) on the combustion of propellant, as well as the development of binders that enable UV-curing to improve the final resolution of 3D printed structures. In addition, the combustion dynamics of additively manufactured layered propellant is studied with computational and experimental methods. The work presented in this dissertation lays the foundation for progress in the developing research area of additively manufactured energetic materials. </p> <p>The appendices of this dissertation presents some additional data that could also be useful for researchers. A more detailed description of the methods necessary to support the VAP process, additional viscosity measurements and micro-CT images of propellant, the combustion of Al/PVDF filament in windowed propellant at pressure, and microexplosions of propellant with an Al/Zr additive are all provided in this section. </p>

The effect of annealing on the tribological and corrosion properties of Al–12Si samples produced by selective laser melting (SLM) is evaluated via sliding and fretting wear tests and weight loss experiments and compared to the corresponding material processed by conventional casting. Sliding wear shows that the as-prepared SLM material has the least wear rate compared to the cast and heat-treated SLM samples with abrasive wear as the major wear mechanism along with oxidation. Similar trend has also been observed for the fretting wear experiments, where the as-prepared SLM sample displays the minimum wear loss. On the other hand, the acidic corrosion behavior of the as-prepared SLM material as well as of the cast samples is similar and the corrosion rate is accelerated by increasing the heat treatment temperature. This behavior is due to the microstructural changes induced by the heat treatment, where the continuous network of Si characterizing the as-prepared SLM sample transforms to isolated Si particles in the heat-treated SLM specimens. This shows that both the wear and corrosion behaviors are strongly associated with the change in microstructure of the SLM samples due to the heat-treatment process, where the size of the hard Si particles increases, and their density decreases with increasing annealing temperature.

<div>The new technique of Vibration-Assisted 3D Printing (VAP) offers significant potential for leveraging the geometric flexibility of additive manufacturing (AM) into the realm of solid energetics. The first part of this work compares the print capabilities of a custom-made VAP printer to those of an established commercial direct-write printer using a polymer clay. Characterization tests were conducted and a variety of other shapes were printed comparing the two methods in their turning quality, feature resolution, unsupported overhang angle, negative space feature construction, and less-than-fully-dense self-supported 3D lattices. The porosity and regularity of the printed lattices were characterized using X-ray microtomography (MicroCT) scans. The quality of the shapes was compared using statistical methods and a MATLAB edge-finding code. The results show that the VAP printer can manufacture parts of superior resolution than the commercial printer, due to its ability to extrude highly viscous material through a smaller nozzle diameter. The VAP print speeds were also found to be as high as twenty times higher than those of the direct write printer.</div><div>Following up on this work, a second study explored the possibility of modifying grain geometry through variation of printed infill design using an ammonium perchlorate composite propellant (APCP). In the propellant formulation, a polymer that cures under ultra-violet (UV) light was used instead of the more common hydroxyl-terminated polybutadiene (HTPB). Although this formulation is a less-effective fuel than HTPB, its use enables layer-by-layer curing for improved structural strength during printing. Using VAP, cylindrical propellant charges were prepared using a gyroidal infill design with a range of internal porosities (infill amounts). Some additional propellant grains were prepared with both vertical and concentric layering of different infill amounts. These grains were then burned beginning at atmospheric pressure in a constant-volume Parr cell to measure the resulting pressure output. Analysis of the pressure trace data shows that a less-dense infill increases the maximum pressurization rate, due to the presence of small voids spaced roughly uniformly throughout the grain that increase the burning surface area. We show that additive manufacturing-based propellant grain modification can be used to tailor the pressure-time trace through adjustment of the number and size of small voids. Specifically, this study shows that, using a graded functional geometry, the duration of gas generation can be controlled. This work represents a preliminary effort to explore the possibilities to propellant</div><div>12</div><div>manufacture offered by additive manufacturing and to begin to address the challenges inherent in making it practical.</div>

<div>Aluminum 6061 is extensively used in industry and welding and additive manufacturing (AM) of Al6061 offer flexibility in manufacturing. Solid-state welding and AM processes can overcome the shortcomings of fusion-based processes, such as porosity and hot cracking. In this thesis, friction stir welding and friction stir additive manufacturing, which are both based on the concepts of friction stir processing (solid-state), were studied. The welding parameters for a sound weld during friction stir welding of Al6061-T6 alloy were determined based on the experimental and numerical analysis. Formation of tunnel defects and cavity defects was also studied. A Coupled Eulerian-Lagrangian (CEL) finite element model was established to analyze the process, where the workpiece was modeled as an Eulerian body, and the tool as Lagrangian. The model was validated by conducting experiments and correlating the force measured by a three-axis dynamometer. The experimentally validated simulation model was used to find an optimum parameter set for the sound weld case.</div><div>To demonstrate the friction stir additive manufacturing process, a 40 mm × 8 mm × 8 mm (L×B×H) material was fabricated by adding five 1.6 mm thick plates. A similar coupled Eulerian-Lagrangian based finite element model was used to predict the effects of sound process parameters, such as the tool’s rotational speed and the translational speed. The temperature predicted by the model was used to predict the microhardness distribution in the sample and to further elucidate the hardness change in the weld zone, which showed a good agreement with the experimental results. The microstructure of the samples was analyzed, and the mechanical properties of the additive manufactured samples were characterized and compared with those of other AM techniques via tensile tests and tensile shear tests.</div>

<p>A variety of methods have been developed to enhance solid propellant burning rates, including adjusting oxidizer particle size, modifying metal additives, tailoring the propellant core geometry, and adding catalysts or wires. Fully consumable reactive wires embedded in propellant have been used to increase the burning rate by increasing the surface area; however, the manufacture of propellant grains and the observation of geometric effects with reactive components has been restricted by traditional manufacturing and viewing methods. In this work, a printable reactive filament was developed that is tailorable to a number of use cases spanning reactive fibers to photosensitive igniters. The filament employs aluminum fuel within a printable polyvinylidene fluoride matrix that can be tailored to a desired burning rate through stoichiometry or aluminum fuel configuration such as particle size and modified aluminum composites. The material is printable with fused filament fabrication, enabling access to more complex geometries such as spirals and branches that are inaccessible to traditionally cast reactive materials. However, additively manufacturing the reactive fluoropolymer and propellant together comes attendant with many challenges given the significantly different physical properties, particularly regarding adhesion. To circumvent the challenges posed by multiple printing techniques required for such dissimilar materials, the reactive fluoropolymer was included within a solid propellant carrier matrix as small fibers. The fibers were varied in aspect ratio (AR) and orientation, with aspect ratios greater than one exhibiting a self-alignment behavior in concordance with the prescribed extrusion direction. The effective burning rate of the propellant was improved nearly twofold with 10 wt.% reactive fibers with an AR of 7 and vertical orientation. </p> <p>The reactive wires and fibers in propellant proved difficult to image in realistic sample designs, given that traditional visible imaging techniques restrict the location and dimensions of the reactive wire due to the necessity of an intrusive window next to the wire, a single-view dynamic X-ray imaging technique was employed to analyze the evolution of the internal burning profile of propellant cast with embedded additively manufacture reactive components. To image complex branching geometries and propellant with multiple reactive components stacked within the same line of sight, the dynamic X-ray imaging technique was expanded to two views. Topographic reconstructions of propellants with multiple reactive fibers showed the evolution of the burning surface enhanced by the geometric effects caused by the faster burning fibers. These dual-view reconstructions provide a method for accurate quantitative analysis of volumetric burning rates that can improve the accessibility and viability of novel propellant grain designs.</p>

Background Companies which operate within heavy equipment are highly dependent on a continuous spare part stream to minimise their production downtime. The disruption of the pandemic known as Covid19 has brought the global supply chain to its knee, and countless companies have been affected by the global supply shortage. One of such industries is heavy equipment which comprises heavy-duty vehicles, large equipment, large-scale infrastructure, intricate or numerous processes with high operation cost and a unique set of challenges. Consequently, the demand for spare parts within heavy equipment can be extremely unpredictable and erratic, since the life cycle of machinery is connected to systems owned by the customers and its applications. Therefore, understanding the heavy equipment industry could allow for new innovative ways for managing spare part challenges. One of the methods for solving spare part challenges in other industries according to previous research has been the utilisation of additive manufacturing (AM).The AM technology is based on incremental layer-by-layer manufacturing compared to conventional manufacturing (CM) which mostly depend on subtractive manufacturing processes. Research questions RQ1: What are the challenges within the heavy equipment industry regarding spare part management? RQ2: How can the heavy equipment industry utilise additive manufacturing to overcome challenges surrounding spare parts management? Method The literature review comprised of the identification of spare part management challenges surrounding heavy equipment, the capabilities of AM surrounding spare parts as well as optimisation methods for existing parts with AM. Whereas the interviews consisted of two sets of interview groups (i.e., heavy equipment and AM based companies). Lastly, the experiment consisted of validating gathered data as well as identifying AMs capabilities based on a physical object (i.e., lifting bracket). Findings The findings show the existing spare part management challenges within heavy equipment are related to four dimensions namely: warehousing, cost, lead times and the environment.Whereas the findings surrounding AMs capabilities for mitigating spare part management challenges showed that, AM enable the production of low volume parts with low lead time replenishment. This could minimise overall waste within the heavy equipment industry, where central warehousing could be reduced as well as the total lead time for customers.

No description available.

No description available.

<p>Additive manufacturing (AM) can be an advantageous substitute to various traditional manufacturing techniques. Due to the ability to rapidly create products, AM has been traditionally used to prototype more efficiently. As the industry has progressed, however, use cases have gone beyond prototyping into production of complex parts with unique geometries. Amongst the most popular of AM processes is fused deposition modeling (FDM). FDM fabricates products through an extrusion technique where plastic filament is heated to the glass transition temperature and extruded layer by layer onto a build platform to construct the desired part. The purpose of this research is to elaborate on the potential of this technology, while considering environmental impact as it becomes more widespread throughout industry, research, and academia.</p> <p>Although AM consumes resources more conservatively than traditional methodologies, it is not free from having environmental impacts. Several studies have shown that additive manufacturing can affect human and environmental health by emitting particles of a dynamic size range into the surrounding environment during a print. To begin this study, chapters investigate emission profiles and characterization of emissions from FDM 3D printers with the intention of developing a better understanding of the impact from such devices. Background work is done to confirm the occurrence of particle emission from FDM using acrylonitrile butadiene styrene (ABS) plastic filament. An aluminum bodied 3D printer is enclosed in a chamber and placed in a Class 1 cleanroom where measurements are conducted using high temporal resolution electrical low-pressure impactor (ELPI), scanning mobility particle sizer (SMPS), and optical particle sizer (OPS), which combined measure particles of a size range 6-500nm. Tests were done using the NIST standard test part and a honeycomb infill cube. Results from this study show that particle emissions are closely related to filament residence time in the extruder while less related to extruding speed. An initial spike of particle concentration is observed immediately after printing, which is likely a result of the long time required to heat the extruder and bed to the desired temperature. Upon conclusion of this study, it is theorized that particles may be formed through vapor condensation and coagulation after being released into the surrounding environment.</p> <p>With confirmation of FDM ultrafine particle emission at notable concentrations, an effort was consequently placed on diagnosing the primary cause of emission and energy consumption based on developed hypotheses. Experimental data suggests that particle emission is mainly the result of condensing and agglomerating semi-volatile organic compounds. The initial emission spike occurs when there is dripping of semi-liquid filament from the heated nozzle and/or residue left in the nozzle between prints; this supports the previously stated hypothesis regarding residence time. However, the study shows that while printing speed and material flow influence particle emission rate, the effects from these factors are relatively insignificant. Power profile analysis indicates that print bed heating and component temperature maintaining are the leading contributors to energy consumption for FDM printers, making time the primary variable driving energy input.</p> <p>To better understand the severity of FDM emissions, further investigation is necessary to diligence the makeup of the process output flows. By collecting exhaust discharge from a Makerbot Replicator 2x printing ABS filament and diffusing it through a type 1 water solution, we are able to investigate the chemical makeup of these compounds. Additional exploration is done by performing a filament wash to investigate emissions that may already be present before extrusion. Using solid phase micro-extraction, contaminants are studied using gas chromatography mass spectrometry (GCMS) thermal desorption. Characterization of the collected emission offers more comprehensive knowledge of the environmental and human health impacts of this AM process.</p> <p>Classification of the environmental performance of various manufacturing technologies can be achieved by analyzing their input and output material, as well as energy flows. The unit process life cycle inventory (UPLCI) is a proficient approach to developing reusable models capable of calculating these flows. The UPLCI models can be connected to estimate the total material and energy consumption of, and emissions from, product manufacturing based on a process plan. The final chapter focuses on using the knowledge gained from this work in developing UPLCI model methodology for FDM, and applying it further to the second most widely used AM process: stereolithography (SLA). The model created for the FDM study considers material input/output flows from ABS plastic filament. Energy input/output flows come from the running printer, step motors, heated build plate, and heated extruder. SLA also fabricates parts layer by layer, but by the use of a photosensitive liquid resin which solidifies when cured under the exposure of ultraviolet light. Model material input/output flows are sourced from the photosensitive liquid resin, while energy input/output flows are generated from (i) the projector used as the ultraviolet light source and (ii) the step motors. As shown in this work, energy flow is mostly time dependent; material flows, on the other hand, rely more on the nature of the fabrication process. While a focus on FDM is asserted throughout this study, the developed UPLCI models show how conclusions drawn from this work can be applied to different forms of AM processes in future work.</p>