The analysis of microstructural shapes is an underutilized tool in the field of materials science. Typical observations of morphology are qualitative, rather than quantitative, which prevents the identification of relationships between shape and the mechanical properties of a material. Recent advances in the fields of computer vision and high-dimensional analysis have made computer-based shape characterization feasible on a variety of materials. In this work, the relationship between microstructural shapes, and the properties and function of the material as a whole, is explored using moment invariants as global shape descriptors. A diifferent relationship is examined in each of three material systems: how the three-dimensional shapes of cells in the cotyledons of the plant Arabidopsis Thaliana can be used to identify cell function; the two-dimensional shapes of additive manufacturing feedstock powder and the ability to distinguish between images of powders from different samples; and the two-dimensional shapes of ' precipitates and their influence on the creep resistance of single crystal nickel-base superalloys. In the case of Arabidopsis Thaliana cotyledon cells, three-dimensional Zernike and Cartesian moment invariants were used to quantify morphology, and combined with size and orientation information. These feature sets were then analyzed using unsupervised and supervised machine learning methods. Moderate success was found using unsupervised methods, indicating that natural delineations in the data correlate to cell roles to some degree. Using supervised methods, a success rate of 90% was possible, indicating that these features can be used to identify cell function. The ability of two-dimensional Cartesian moment invariants to distinguish meaningful features in particles of additive manufacturing feedstock was tested by using these features to classify images of feedstock. Ultimately, simple histogram matching methods were unsuccessful, likely because they rely on the most common particles to draw conclusions. A bag-of-words method was used, which uses high-dimensional visualization and clustering techniques to classify individual particles by common features. Histograms of particle clusters are then used to represent each image. This method was far more successful, and a correct classification rate of up to 90% was found, and comparable rates were discovered using invariants which describe the shapes only broadly. This indicates that moment invariants are an effective measure of the morphologies of these types of particles, and can be used to classify powder shapes, which control many properties which are relevant to the additive manufacturing process. In the case of the superalloys, it has been shown that the shape distribution of ' precipitates can be tracked using second order moment invariants. In addition, several loworder moment invariants are shown to correlate to creep resistance in four alloys examined, which supports the idea that the shape of precipitates plays role in determining creep resistance in these alloys.

The potential of Additive Manufacturing (AM) for microwave and mm-wave applications is increasingly being revealed thanks to recent advancements in research. AM empowers engineers with new capabilities to manufacture complex conformal geometries quicker and at lower costs. It allows, for instance, the embedding of RF front ends into functional structures. In this dissertation, two aspects of AM are explored: (a) The development and characterization of techniques that improve the performance of AM microwave circuits and antennas, and (b) study of complex geometries, such as meshed structures, as an alternative to reduce material usage, cost, and weight of the components. Micro-dispensing of silver paste (CB028) is extensively used in this work as a viable approach for manufacturing microwave planar transmission lines. However, the performance and upper-frequency range of these lines are limited by the cross-sectional shape and electrical conductivity of the printed paste, as well as the achievable minimum feature size which is typically around 100 μm. In this work a picosecond Nd:YAG laser is used to machine slots in a 20-25 μm-thick layer of silver paste (Dupont CB028) that is micro-dispensed on a Rogers RT5870 substrate, producing coplanar waveguide transmission lines with 16-20 μm-wide slots. It is shown that the laser solidifies 2 μm wide region along the edges of the slots, thus significantly increasing the effective conductivity of the film and improving the attenuation constant of the lines. The extracted attenuation constant at 20 GHz for laser machined CB028 is 0.74 dB/cm. CPW resonators and filters show that the effective conductivity is in the range from 10 MS/m to 30 MS/m, which represents a 100x improvement when compared to the values obtained with the exclusive use of micro-dispensing. Another main aspect of this dissertation is the study of meshed structures in coplanar waveguides. For most AM processes the materials utilized for the conductive layer are the most expensive ones; hence, there is value in minimizing the conductor surface area used in a circuit. In this work, the approach of meshed ground coplanar waveguide (MGCPW) is analyzed by simulating, fabricating and measuring a broad set of meshed ground geometry sizes. Furthermore, a physical-mathematical model is presented, which predicts the characteristic impedance and the capacitance per unit length of MGCPW with less than 5.4% error compared to simulated data. A set of filters is designed and fabricated in order to demonstrate the approach. The main parameter affected by meshing the ground plane is the attenuation constant of the waveguide. It is shown that 50% mesh density in the ground plane of a MGCPW line can be used with less than 25% increase in the loss. In contrast, the loss of finite ground coplanar waveguide (FGCPW) can increase by as much as 108% when the ground size is reduced by the same factor (50%). Both 3D printing (micro-dispensing) and traditional printed circuit board manufacturing are used in this work, and most of the propagation characterization is performed at 4 GHz. A meshing technique is also applied to rectangular waveguides, and its effects are studied. It is presented as an option for high power, low loss, but also reduced weight applications. A set of meshed Ku-band waveguides was fabricated using binder jetting 3D printing technology showing that the weight can be reduced by 22% with an increase in loss of only 5%, from 0.019 dB/cm for the solid part to 0.020 dB/cm average across the band with the meshed design. Further weight reduction is possible if higher loss is allowed. To demonstrate the concept, a comparison is made between non-meshed and meshed waveguide 4 pole Chebyshev filters. Finally, the BJ technology is characterized for Ku-Band rectangular waveguide and reflector antenna applications. This technology is characterized using electron beam microscopy (SEM) and energy dispersive spectroscopy (EDS). The RF performance of the 3D printed circuits is benchmarked with Ka-band cavity resonators, waveguide sections, and a filter. An unloaded resonator Q of 616 is achieved, and the average attenuation of the WR-28 waveguide section is 4.3 dB/m. The BJ technology is tested with a meshed parabolic reflector antenna, where the illuminating horn, waveguide feed, and a filter are printed in a single piece. The antenna shows a peak gain of 24.56 dBi at 35 GHz.

Additive manufacturing (AM) has shown itself to be beneficial in many application areas, including product design and manufacture, medical models and prosthetics, architectural modelling and artistic endeavours. For some of these applications, coupling AM with reverse engineering (RE) enables the utilisation of data from existing 3D shapes. This thesis describes the application of AM and RE within sculpture manufacture, in order to optimise the process chains for sculpture reproduction and relic conservation and restoration. This area poses particular problems since the original artefacts can often be fragile and inaccessible, and the finishing required on the AM replicas is both complex and varied. Several case studies within both literature and practical projects are presented, which cover essential knowledge of producing large scale sculptures from an original models as well as a wide range of artefact shapes and downstream finishing techniques. The combination of digital technologies and traditional art requires interdisciplinary knowledge across engineering and fine art. Also, definitions and requirements (e.g. 'accuracy'), can be applied as both engineering and artistic terms when specifications and trade-offs are being considered. The thesis discusses the feasibility for using these technologies across domains, and explores the potential for developing new market opportunities for AM. It presents and analyses a number of case study projects undertaken by the author with a view to developing cost and time models for various processes used. These models have then been used to develop a series of "process maps", which enable users of AM in this area to decide upon the optimum process route to follow, under various circumstances. The maps were validated and user feedback obtained through the execution of two further sculpture manufacturing projects. The thesis finishes with conclusions about the feasibility of the approach, its constraints, the pros and cons of adopting AM in this area and recommendations for future research.

Energy efficiency has become a growing concern in a world driven by a fossil fuel economy. Recuperated micro-gas-turbine systems offer the possibility of high efficiency power generation for low output power systems. To this end, increasing the performance while decreasing the cost, the weight and the volume of heat exchangers such as recuperators has become a critical research focus. Recent work done by Brayton Energy Canada (BEC) has renewed interest in Wire Mesh Heat Exchangers (WMHE) by introducing a new production method that uses cells of stacked wire mesh sheets that have a thick external shell deposited by cold spray. Fins are then machined in this external shell, creating a heat exchanger. Net shaped pin fins were successfully deposited using Cold Gas Dynamic Spraying (CGDS or simply cold spray) as an additive manufacturing technique to replace the plate fin arrays currently used. This new development is envisioned to save costs while providing higher heat transfer efficiency than traditional fin arrays. Increasing the performance of such fin arrays would yield higher heat exchanger efficiencies and increase the total efficiency of the gas turbine system. The present thesis provides a description of the research performed, as well as the results thereof, with regards to the performance of pin fin arrays produced using cold spray. A review of the relevant literature is performed to establish the motivation of this study and to describe the relevant work that has been performed by other authors in this respect. The research objectives are to evaluate the thermal and hydrodynamic performance of these fin arrays and relate those to the flow structures arising from fluid motion between these extended surfaces. Furthermore, the proposed approach and the experimental equipment that will be used are described in this work. The research objectives were successfully met, with the results obtained from this work presented in the form of peer-reviewed publications.

abstract: Honeycomb sandwich panels have been used in structural applications for several decades in various industries. While these panels are lightweight and rigid, their design has not evolved much due to constraints imposed by available manufacturing processes and remain primarily two-dimensional extrusions sandwiched between facings. With the growth in Additive Manufacturing, more complex geometries can now be produced, and advanced design techniques can be implemented into end use parts to obtain further reductions in weight, as well as enable greater multi-functionality. The question therefore is: how best to revisit the design of these honeycomb panels to obtain these benefits? In this work, a Bio-Inspired Design approach was taken to answer this question, primarily since the hexagonal lattice is so commonly found in wasp and bee nests, including the well-known bee’s honeycomb that inspired these panel designs to begin with. Whereas prior honeycomb panel design has primarily focused on the hexagonal shape of the unit cell, in this work we examine the relationship between the various parameters constituting the hexagonal cell itself, specifically the wall thickness and the corner radius, and also examine out-of-plane features that have not been previously translated into panel design. This work reports findings from a study of insect nests across 70 species using 2D and 3D measurements with optical microscopy and X-ray tomography, respectively. Data from these biological nests were used to identify design parameters of interest, which were then translated into design principles. These design principles were implemented in the design of honeycomb panels manufactured with the Selective Laser Sintering process and subjected to experimental testing to study their effects on the mechanical behavior of these panels. / Dissertation/Thesis / Masters Thesis Manufacturing Engineering 2020

Increased interest in and use of additive manufacturing has made it an important component of advanced manufacturing in the last decade. Material Extrusion Additive Manufacturing (MatEx) has seen a shift from a rapid prototyping method harnessed only in parts of industry due to machine costs, to something widely available and employed at the consumer level, for hobbyists and craftspeople, and industrial level, because falling machine costs have simplified investment decisions. At the same time MatEx systems have been scaled up in size from desktop scale Fused Filament Fabrication (FFF) systems to room scale Big Area Additive Manufacturing (BAAM). Today MatEx is still used for rapid prototyping, but it has also found application in molds for fiber layup processes up to the scale of wind turbine blades. Despite this expansion in interest and use, MatEx continues to be held back by poor part performance, relative to more traditional methods such as injection molding, and lack of reliability and user expertise. In this dissertation, a previously unreported phenomenon, irreversible thermal strain (ITε), is described and explored. Understanding ITε improves our understanding of MatEx and allows for tighter dimensional control of parts over time (each of which speaks to extant challenges in MatEx adoption). It was found that ITε occurs in multiple materials: ABS, an amorphous polymer, and PLA, a semi-crystalline one, suggesting a number of polymers may exhibit it. Control over ITε was achieved by tying its magnitude back to part layer thickness and its directionality to the direction of roads within parts. This was explained in a detail by a micromechanical model for MatEx described in this document. The model also allows for better description of stress-strain response in MatEx parts broadly. Expanding MatEx into new areas, one-way shape memory in a commodity thermoplastic, ABS, was shown. Thermal history of polymers heavily influences their performance and MatEx thermal histories are difficult to measure experimentally. To this end, a finite element model of heat transfer in the part during a MatEx build was developed and validated against experimental data for a simple geometry. The application of the model to more complex geometries was also shown. Print speed was predicted to have little impact on bonds within parts, consistent with work in the literature. Thermal diffusivity was also predicted to have a small impact, though larger than print speed. Comparisons of FFF and BAAM demonstrated that, while the processes are similar, the size scale difference changes how they respond to process parameter and material property changes, such as print speed or thermal diffusivity, with FFF having a larger response to thermal diffusivity and a smaller response to print speed. From this experimental and simulation work, understanding of MatEx has been improved. New applications have been shown and rational design of both MatEx processes and materials for MatEx has been enabled.

No description available.

Sandwich panels serve many purposes in engineering applications. Additive manufacturing opened the door for easy fabrication of the sandwich panels with different core structures. In this study, additive manufacturing technique, experiments, and numerical analysis are combined to evaluate the mechanical properties of sandwich panels with different cellular core structures. The sandwich panels having honeycomb, re-entrant honeycomb, diamond, square core topologies are printed with the vat photopolymerization technique. Uniaxial compression testing is performed to determine the compressive modulus, strength, and specific strength of these lightweight panels. Elasto-plastic finite element analysis having good similarities with the experimental results provided a preview of the stress distribution of the sandwich panels under applied loading. The imaging of the tested samples showed the fractured regions of the cellular cores. Dynamic mechanical analysis of the panels provided scope to compare the performance of panels and solid materials with the variation of temperature. Sandwich panels with the diamond structure exhibit better compressive properties and specific strength while the re-entrant structure offers high energy absorption capacity. The sandwich structures provided better thermo-mechanical properties than the solid material. The findings of this study offer insights into the mechanical properties of sandwich panels printed with vat photopolymerization technique which can benefit a wide range of engineering applications.

Tissue regeneration using in-vitro scaffold becomes a vital mean to mimic the in-vivo counterpart due to the insufficiency of animal models to predict the applicability of drug and other physiological behavior. Three-dimensional (3D) bio-printing is an emerging technology to reproduce living tissue through controlled allocation of biomaterial and cell. Due to its bio-compatibility, natural hydrogels are commonly considered as the scaffold material in bio-printing process. However, repeatable scaffold structure with good printability and shape fidelity is a challenge with hydrogel material due to weak bonding in polymer chain. Additionally, there are intrinsic limitations for bio-printing of hydrogels due to limited cell proliferation and colonization while cells are immobilized within hydrogels and don’t spread, stretch and migrate to generate new tissue. The goal of this research is to develop a bio-ink suitable for extrusion-based bio-printing process to construct 3D scaffold. In this research, a novel hybrid hydrogel, is designed and systematic quantitative characterization are conducted to validate its printability, shape fidelity and cell viability. The outcomes are measured and quantified which demonstrate the favorable printability and shape fidelity of our proposed material. The research focuses on factors associated with pre-printing, printing and post-printing behavior of bio-ink and their biology. With the proposed hybrid hydrogel, 2 cm tall acellular 3D scaffold is fabricated with proper shape fidelity. Cell viability of the proposed material are tested with multiple cell lines i.e. BxPC3, prostate stem cancer cell, HEK 293, and Porc1 cell and about 90% viability after 15-day incubation have been achieved. The designed hybrid hydrogel demonstrate excellent behavior as bio-ink for bio-printing process which can reproduce scaffold with proper printability, shape fidelity and higher cell survivability. Additionally, the outlined characterization techniques proposed here open-up a novel avenue for quantifiable bio-ink assessment framework in lieu of their qualitative evaluation.

In a push towards more environmentally friendly pyrotechnics, new greener pyrotechnic compositions need to be developed. A primary goal is to replace components such as lead, barium, and chromium in pyrotechnic compositions. Fused Deposition Modelling (FDM) is a 3D printing/additive manufacturing method whereby a thin filament is passed through a heated nozzle, and extruded onto a substrate in successive layers. This method of manufacturing could be used to produce pyrotechnic time delays based on suitable “green” polymer/fuel mixtures. Fluoropolymers are an attractive oxidising system for pyrotechnic use as fluorine is highly reactive and reacts relatively easily with common metallic fuels such as aluminium and magnesium to release a large amount of energy. Fluoropolymers are already in use as oxidisers and binders, especially in infrared decoy flares. PTFE has found wide use in the pyrotechnics industry, but is not melt-processible. A similar fluoropolymer, poly(chloro-trifluoroethylene) (PCTFE) was considered instead. PCTFE differs from PTFE in that one of the fluorine atoms in the TFE monomer has been replaced by a chlorine atom. The larger chlorine atom interferes with the packing of the polymer chains during polymerisation and, as such, may make it easier to process than PTFE. It was found that pure PCTFE degraded heavily during processing and was therefore precluded from any further study. Melt-processible copolymers containing PCTFE are available from industry. These copolymers contain vinylidene fluoride (VDF) in addition to the CTFE i.e. poly(CTFE-co-VDF). Two grades of copolymer were obtained from 3M: FK-800® resin and Dyneon® 31508 resin. These two polymers contain different ratios of CTFE to VDF. FK-800® resin was successfully extruded and showed minimal signs of degradation. Pyrotechnic films, containing aluminium powder as the fuel, were cast with both polymers using solvent techniques. Differential thermal analysis (DTA) was used to determine the ignition points of the compositions. All of the FK-800®-based compositions ignited at approximately 450 °C whilst all the Dyneon® 31508-based compositions ignited at approximately 400 °C. The energy output of the compositions was determined using bomb calorimetry. The experimental energy outputs of the FK-800®-based compositions correlated well with the predictions from the thermodynamic simulations. The maximum energy output, ~7.0 MJ∙kg1, occurred at a fuel loading between 30 – 35 wt.%. Except for one composition, the Dyneon® 31508-based compositions did not ignite in the bomb calorimeter. FK-800® was successfully extruded into a filament and showed minimal signs of degradation. In order to assess the impact of adding a solid filler on the mechanical properties and extrudability of the polymer, magnesium hydroxide was used as inactive model compound in place of aluminium. A filament of FK-800® and Mg(OH)2 was successfully compounded and produced using a filler loading of 30 wt.%. Compounding of the Dyneon 31508® with the magnesium hydroxide was unsuccessful. Addition of LFC-1® liquid fluoroelastomer improved the processibility of the Dyneon 31508® by lowering the melt viscosity. / Dissertation (MEng)--University of Pretoria, 2017. / Chemical Engineering / MEng / Unrestricted