This project was initiated by Dr. Sasan Dadbaksh upon listening to the requirements I presented for my master thesis. My requirements were to do a master thesis project in the field of additive manufacturing specifically fused deposition modeling that should not only involve the research work but should also present an opportunity to develop hardware and should involve experimental testing. Then Sasan came up with the idea of developing a system capable to perform 3D printing with the extruder fixed in one position and the motion required for 3D printing will be provided by the robotic arm. The title of developing green build strategies for robot assisted plastic 3D printing came into being. The main concept behind the title of developing robot assisted plastic 3D printing platform is to develop such a system that can offer additive manufacturing services, specifically of fused deposition modeling 3D printing, as an inbound process during the manufacturing of any part through subtractive processes with the help of a robotic arm along with the repair of any kind of parts with the assistance of fused deposition modeling 3D printing. The main objectives of the master thesis include building a stationary filament extrusion module to interact with a robot hand and establishing a strategy for a robot hand to move the part to appropriate locations to complete building a part on a preform without support structures. The targets that were achieved with the completion of this thesis project includes the development of the complete hardware that consists of a mechanical structure with the option of mounting the components required to run the extrusion setup, learning the basic working of the software that are able to simulate the 3D printing process with the robotic arm (Robot Studio and Robo DK), creation of the simulation of the whole process, achieving communication between the robotic arm and the microcontroller of the extruder and finally the printing of a simple part for the demonstration. The components needed to be installed on the structure includes the motor, extruder, hot end, nozzle, filament. The structure also accumulated the required electronics that includes power supply, microcontroller, and an LCD to monitor the extrusion parameters. The developed machine runs on the state-of-the-art components that belong to the few of the best manufacturers of the technology.

The work herein is, in part, motivated by the idea of creating optimized, actuating structures using additive manufacturing processes (AM). By developing a consistent, repeatable method for designing and manufacturing multi-material compliant mechanisms, significant performance improvements can be seen in application, such as increased mechanism deflection. There are three distinct categories of research that contribute to this overall motivating idea: 1) investigation of an appropriate multi-material topology optimization process for multi-material jetting, 2) understanding the role that manufacturing constraints play in the fabrication of complex, optimized structures, and 3) investigation of an appropriate process for embedding actuating elements within material jetted parts. PolyJet material jetting is the focus of this dissertation research as it is one of the only AM processes capable of utilizing multiple material phases (e.g., stiff and flexible) within a single build, making it uniquely qualified for manufacturing complex, multi-material compliant mechanisms. However, there are two limitations with the PolyJet process within this context: 1) there is currently a dearth of understanding regarding both single and multi-material manufacturing constraints in the PolyJet process and 2) there is no robust embedding methodology for the in-situ embedding of foreign actuating elements within the PolyJet process. These two gaps (and how they relate to the field of compliant mechanism design) will be discussed in detail in this dissertation. Specific manufacturing constraints investigated include 1) "design for embedding" considerations, 2) removal of support material from printed parts, 3) self-supporting angle of surfaces, 4) post-process survivability of fine features, 5) minimum manufacturable feature size, and 6) material properties of digital materials with relation to feature size. The key manufacturing process and geometric design factors that influence each of these constraints are experimentally determined, as well as the quantitative limitations that each constraint imposes on design. / Ph. D.

<p>There has been a long-standing need in the marketplace for the economic production of small lots of components that have complex geometry. A potential solution is additive manufacturing (AM). AM is a manufacturing process that adds material bottom-up. It has the distinct advantages of low preparation cost and high geometric creation capability. Components fabricated via AM are now being selectively used for less-demanding applications in motor vehicles, consumer products, medical products, aerospace devices, and even some military projects.</p><p><br></p> <p>For engineering applications, high value-added components require consistency in the fatigue properties. However, components fabricated by AM have large variation in the fatigue properties compared to those by conventional manufacturing processes. To alleviate unpredictable catastrophic failures of components, it is essential to study and predict fatigue life. Previous study reported that fatigue crack initiation process accounts for a large portion of fatigue life, especially for low loading amplitude and high cycle fatigue. However, this major portion of fatigue life prediction is mostly ignored by main stream researchers working on fatigue modeling. For industrial applications, engineers often specify a lower stress condition to obtain a higher safety factor. Under these circumstances, fatigue crack initiation becomes even more important, so it is essential to further study of crack initiation.</p><p><br></p> <p>The objective of this research is to develop a fatigue crack initiation model for metal components produced by AM. To improve life prediction accuracy, the model must incorporate the effect of different microstructures, which are typically produced by AM due to a large number of repetitive cycles of re-heating and re-cooling processes. To fulfill this objective, the tasks are separated into three studies: (1) developing a temperature model to simulate temperature history, (2) modeling the component’s microstructure for the potential crack initiation zone, and (3) developing a fatigue crack initiation model for life estimation. A summary of each task is provided in the following.</p> <p>First, the role of temperature model is to understand the mechanism that leads to the variation of microstructures. The existing temperature models are computationally expensive to obtain an accurate prediction of the temperature history due to repetitive heating and cooling. The main reason is that these models considered entire boundary conditions of all the material points. In this section, we proposed and employed the concept of effective computation zone, which can save the computational time significantly for AM process. </p><p><br></p> <p>Second, it is critical to include the effect of microstructure in the fatigue life model since the microstructure variation at different locations within the real AM component is large. The grain size variation is modeled by using representative volume element, which is defined as a volume of heterogeneous material that is sufficiently large to be statistically representative of the real component’s microstructure. Regarding phase transformation, a continuous cooling transformation (CCT) diagram is a useful tool that can be used with a thermal model for microstructure design and manufacturing process control. However, traditional CCT diagrams are developed based on slow and monotonic cooling processes such as furnace cooling and air cooling, which are greatly different from the repetitive heating and cooling processes in AM. In this study, a new general methodology is presented to create CCT diagrams for materials fabricated by AM. We showed that the effect of the segmented duration within the critical temperature range, which induced precipitate formation, could be cumulative. </p><p><br></p> <p>Third, the existing fatigue crack initiation life model has poor accuracy. One of the reasons for the poor accuracy is the coefficients change due to the variation in microstructure is not accounted for. In this section, a semi-empirical fatigue crack initiation model is presented. The important coefficients include maximum persistent slipband width, energy efficiency coefficient, resolved shear stress and plastic slip rate per cycle. These coefficients are modeled and determined as a function of microstructure, which can improve the accuracy of life estimation.</p><p><br></p> <p>The contribution of this study is to provide a new engineering tool for designing the melting AM process based on scientific research. With this tool, the fundamental mechanism contributing to a large variation of the fatigue life of the metal components made by AM process can be understood, attributed, predicted and improved. The seemly ‘stochastic’ nature of fatigue life of the AM components can be changed to be more deterministic and predictable. This approach represents a major advance in fatigue research on AM materials. The model developed is considered as a tool for research, design, and control for laser-based AM process applications. </p>

<p>Extrusion deposition additive manufacturing (EDAM) has enabled upscaling the dimensions of the objects that can be additively manufactured from the desktop scale to the size of a full vehicle. The EDAM process consists of depositing beads of molten material in a layer-by-layer manner, thereby giving rise to temperature gradients during part manufacturing. To investigate the phenomena involved in EDAM, the Composites Additive Manufacturing Research Instrument (CAMRI) was developed as part of this project. CAMRI provided unparalleled flexibility for conducting controlled experiments with carbon fiber reinforced semi-crystalline polymers and served as a validation platform for the work presented in this dissertation. </p> <p>Since the EDAM process is highly non-isothermal, modeling heat transfer in EDAM is of paramount importance for predicting interlayer bonding and evolution of internal stresses during part manufacturing. Hence, local heat transfer mechanisms were characterized and implemented in a framework for EDAM process simulations. These include local convection conditions, heat losses in material compaction as well as heat of crystallization or melting. Numerical predictions of the temperature evolution during the printing process of a part were in great agreement with experimental measurements by only calibrating the radiation ambient temperature. </p> In the absence of fibers reinforcing the interface between adjacent layers, the bond developed through the polymer is the primary mechanisms governing the interlayer fracture properties in printed parts. Hence, a fusion bonding model was extended to predict the evolution of interlayer fracture properties in EDAM with semi-crystalline polymer composites. The fusion bonding model was characterized and implemented in the framework for EDAM process simulation. Experimental verification of numerical predictions obtained with the fusion bonding model for interlayer fracture properties is provided. Finally, this fusion bonding model bridges the gap between processing conditions and interlayer fracture properties which is extremely valuable for predicting regions with frail interlayer bond within a part.

<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>