Mechanics of Additive and Advanced Manufacturing, Volume 9: Proceedings of the 2017 Annual Conference on Experimental and Applied Mechanics

105 Pages·2018·10.66 MB·English

by  Junlan Wang et al. (eds.)

Conference Proceedings of the Society for Experimental Mechanics Series
Junlan Wang · Bonnie Antoun · Eric Brown · Weinong Chen
Ioannis Chasiotis · Emily Huskins-Retzlaff
Sharlotte Kramer · Piyush R. Thakre Editors
Mechanics of Additive and
Advanced Manufacturing,
Volume 9
Proceedings of the 2017 Annual Conference on
Experimental and Applied Mechanics
Conference Proceedings of the Society for Experimental Mechanics Series
Series Editor
Kristin B. Zimmerman, Ph. D.
Society for Experimental Mechanics, Inc.,
Bethel,CT,USA
More information about this series at http://www.springer.com/series/8922
Junlan Wang (cid:129) Bonnie Antoun (cid:129) Eric Brown (cid:129) Weinong Chen
Ioannis Chasiotis (cid:129) Emily Huskins-Retzlaff (cid:129) Sharlotte Kramer
Piyush R. Thakre
Editors
Mechanics of Additive and Advanced
Manufacturing, Volume 9
Proceedings of the 2017 Annual Conference on Experimental
and Applied Mechanics
Editors
JunlanWang BonnieAntoun
MechanicalEngineering SandiaNationalLaboratories
UniversityofWashington Livermore,CA,USA
Seattle,WA,USA
WeinongChen
EricBrown NeilArmstrongHall
LosAlamosNationalLaboratory PurdueUniversity
LosAlamos,NM,USA WestLafayette,IN,USA
IoannisChasiotis EmilyHuskins-Retzlaff
UniversityofIllinois UnitedStatesNavalAcademy
Urbana-Champaign,IL,USA Annapolis,MD,USA
SharlotteKramer PiyushR.Thakre
SandiaNationalLaboratories DowChemicalCompany
Albuquerque,NM,USA LakeJackson,TX,USA
ISSN2191-5644 ISSN2191-5652 (electronic)
ConferenceProceedingsoftheSocietyforExperimentalMechanicsSeries
ISBN978-3-319-62833-2 ISBN978-3-319-62834-9 (eBook)
DOI10.1007/978-3-319-62834-9
LibraryofCongressControlNumber:2017953418
#TheSocietyforExperimentalMechanics,Inc.2018
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Preface
Mechanics of Additive and Advanced Manufacturing represents one of nine volumes of technical papers presented at the
2017 SEM Annual Conference and Exposition on Experimental and Applied Mechanics organized by the Society for
ExperimentalMechanicsandheldinIndianapolis,IN,June12–15,2017.ThecompleteProceedingsalsoincludesvolumes
on: Dynamic Behavior of Materials; Challenges In Mechanics of Time-Dependent Materials; Advancement of Optical
Methods in Experimental Mechanics; Mechanics of Biological Systems, Materials and other topics in Experimental and
AppliedMechanics;Micro-andNanomechanics;MechanicsofComposite,HybridandMultifunctionalMaterials;Fracture,
Fatigue,FailureandDamageEvolution;andResidualStress,ThermomechanicsandInfraredImaging,HybridTechniques
andInverseProblems.
Mechanics of additive and advanced manufacturing is an emerging area due to the unprecedented design and
manufacturingpossibilitiesofferedbynewandevolvingadvancedmanufacturingprocessesandtherichmechanicsissues
thatemerge.TechnicalinterestwithinthesocietyspansseveralotherSEMtechnicaldivisionssuchas:composites,hybrids
andmultifunctionalmaterials,dynamicbehaviorofmaterials,fractureandfatigue,residualstress,time-dependentmaterials,
andtheresearchcommittee.
In this inaugural track in SEM 2017, the topic of mechanics of additive and advanced manufacturing included in
thisvolume coversdesign,optimization, experiments,computations,andmaterialsfor advanced manufacturing processes
(3D printing, micro- and nano-manufacturing, powder bed fusion, directed energy deposition, etc.) with particular focus
on mechanics aspects (e.g., mechanical properties, residual stress, deformation, failure, rate-dependent mechanical
behavior,etc.).
Seattle,WA,USA JunlanWang
Livermore,CA,USA BonnieAntoun
LosAlamos,NM,USA EricBrown
WestLafayette,IN,USA WeinongChen
Urbana-Champaign,IL,USA IoannisChasiotis
Annapolis,MD,USA EmilyHuskins-Retzlaff
Albuquerque,NM,USA SharlotteKramer
LakeJackson,TX,USA PiyushR.Thakre
v
Contents
1 FracturePropertiesofAdditivelyManufacturedAcrylonitrile-Butadiene-StyreneMaterials. . . . . . . . 1
KevinR.HartandEricD.Wetzel
2 ComplexModulusVariationbyManipulationofMechanicalTestMethodandPrintDirection. . . . . . 5
MeganL.Liu,KatherineK.Reichl,andDanielJ.Inman
3 ANewHeatTransferSimulationModelforSelectiveLaserMeltingtoEstimatetheGeometry
ofCrossSectionofMeltPool. . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . 13
Hong-ChuongTranandYu-LungLo
4 HeatConductionandGeometryTopologyOptimizationofSupportStructureinLaser-Based
AdditiveManufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EhsanMalekipour,AndresTovar,andHazimEl-Mounayri
5 StrainEnergyDissipationMechanismsinCarbonNanotubeCompositesFabricatedby
AdditiveManufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FrankGardea,DanielCole,BryanGlaz,andJaretRiddick
6 MechanicalPropertiesof3-DLENSandPBFPrintedStainlessSteel316LPrototypes. . . . . . . . . . . . 37
Wei-YangLu,NancyYang,JoshuaYee,andKevinConnelly
7 EffectofHeatTreatmentonFrictionStirWeldedDissimilarTitaniumAlloys. . . . . . . . . . . . . . . . . . . 45
KapilGangwarandM.Ramulu
8 EffectofPorosityonThermalPerformanceofPlasticInjectionMoldsBasedonExperimental
andNumericallyDerivedMaterialProperties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SuchanaA.Jahan,TongWu,YiZhang,JingZhang,AndresTovar,andHazimEl-Mounayri
9 ODSCoatingDevelopmentUsingDEDAdditiveManufacturingforHighTemperatureTurbine
Components.. . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 65
BruceS.Kang,JaeyoonKim,EricChia,YangLi,andMinkingChyu
10 ProcessingandCharacterizationofTi64/AZ31MultilayeredStructurebyRollBonding. . . . . . . . . . . 73
ChinShihHsuandQizhenLi
11 VibrationCharacteristicsofUnitCellStructuresFabricatedbyMulti-MaterialAdditive
Manufacturing.. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. 79
ToshitakeTatenoandShogoNishie
vii
viii Contents
12 Defects,ProcessParametersandSignaturesforOnlineMonitoringandControlin
Powder-BasedAdditiveManufacturing. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . 83
EhsanMalekipourandHazimEl-Mounayri
13 TheEffectofthe3-DPrintingProcessontheMechanicalPropertiesofMaterials. . . . . . . . . . . . . . . . 91
BobbyTangDan,DanielRobertKhodos,OliverKhairallah,RichiRamlal,andYougashwarBudhoo
14 ToolWearMechanismsofPhysicalVaporDeposition(PVD)TiAlNCoatedToolsUnder
VegetableOilBasedLubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SalmanPervaizandWaelAbdelSamad
Chapter 1
Fracture Properties of Additively Manufactured
Acrylonitrile-Butadiene-Styrene Materials
KevinR.HartandEricD.Wetzel
Abstract AdditivelyManufactured(AM) partsexhibitorthotropicbehaviorwhenloadedasaresultofthelayer-by-layer
assemblycommonlyutilized.Whilepreviousauthorshavestudiedtheeffectoflayerorientationonthetensile,flexural,and
impactresponseofAMparts,theeffectoflayerorientationonthefractureresponseisnotwellestablished.Hereweexplore
the effect of layer orientation on the fracture properties of Acrylonitrile-Butadiene-Styrene (ABS) materials fabricated
through the Fused Filament Fabrication (FFF) process. Critical fracture toughness values of Single Edge Notch Bend
(SENB)specimenswithapre-crackorientedeitherparallelorperpendiculartothedirectionoflayer-by-layerassemblywere
compared. Results show that the inter-laminar fracture toughness (fracture between layers) is approximately one order of
magnitude lower than the cross-laminar toughness (fracture through layers) of similarly manufactured parts. Contrasting
brittle and ductile fracture behavior is observed for inter-laminar and cross-laminar crack propagation, respectively,
demonstrating that the elastic-plastic response of AM ABS parts is governed by the orientation of the layers with respect
tothedirectionofcrackpropagation.
Keywords Additivemanufacturing•J-integral•Fracturemechanics•Polymer•Singleedgenotchbend
SENBspecimensmeasuring100(cid:1)20(cid:1)10mmwerefabricatedusingaTaz6FFFdesktopprinter(Lulzbot;Loveland,Co),
withABSM30filament(Stratasys;EdenPrarie,MN).Printedspecimensaredescribedaslaminates,whereeachlaminaeisa
layerofmaterialconstructedparalleltotheprintbedwithanominalthicknessequaltothelayerheight(0.22mm).Samples
with variable crack-tip/laminae orientation angles, θ, were fabricated. Specimens for inter-laminar fracture testing were
fabricated with the longest part edge oriented perpendicular to the build plate (vertically) and had a crack-tip/lamina
orientation of θ ¼ 0(cid:3). Specimens for cross-laminar fracture testing were constructed with the longest part edge oriented
paralleltothebuildplate(horizontally)andhadacrack-tip/laminaorientationofθ ¼90(cid:3).Specimenstoinvestigatecrack
kinkingbehaviorwereconstructedwiththelongestedgeorientedatanobliqueangleof75(cid:3)relativetothevertical(oblique).
Orientationsofvertically,horizontally,andobliquelyprintedSENBsamplesaredepictedinFig.1.1a.
Three-pointSENBtestingwasperformedonabenchtoploadframe.Fractureresponseofthespecimensvarieddepending
onthecrack-tip/laminaorientationangle,θ.Verticallyprintedsampleswithθ¼0(cid:3)displayedinter-laminarfractureandhad
a load/displacement response consistent with brittle behavior (Fig. 1.2a). Horizontally printed samples with θ ¼ 90(cid:3)
displayed cross-laminar fracture and had a load/displacement response consistent with ductile behavior (Fig. 1.2a).
Obliquely printed sampleswith θ ¼75(cid:3) displayedmixed cross- andinter-laminar fracture, resulting in mixed ductileand
brittle crack propagation (Fig. 1.2a). Since fracture behavior was inconsistent across sample types, differing methods of
fracture analysis were required to determine the samples’ fracture toughness. Analysis methods are reserved for further
readinginHartetal.[1].Resultsofthefracturetoughnessanalysisrevealthatthecriticalelastic-plasticstrainenergyrelease
rates for inter-laminar and cross-laminar fracture were 256 (cid:4) 84 J/m2 and 2260 J/m2, respectively, demonstrating that
significantlymoreenergyisrequiredtopropagateacrackacrossthelaminaethanbetweenthem.
Thisstudyconfirmsthatthelowstrengthofweld-linesbetweenoramonglaminae,relativetowithinadepositedpolymer
trace, limits the toughness of the overall part. However, the likelihood of catastrophic failure due to fracture in an AM
structurecanbereducedbyconsideringanticipatedstressfieldswhendesigninglaminaeorientations.Naturallyorthotropic
materialssuchaswood,bone,andnacre,havealladaptedtocapitalizeontheincreasedtoughnessaffordedbyflaw/laminae
alignmenttoimpartglobaltoughnessinspiteofconstituentswhichmaybeindividuallybrittle[2–7].Webelievethatthere
exists considerable opportunity to engineer higher performance AM parts by exploiting these design principles to create
tailoredfractureandfailurebehaviors.
K.R.Hart(*)•E.D.Wetzel
WeaponsandMaterialsResearchDirectorate,USArmyResearchLaboratory,4600DeerCreekLoop,
AberdeenProvingGround,Aberdeen,MD21005,USA
e-mail:[email protected]
#TheSocietyforExperimentalMechanics,Inc.2018 1
J.Wangetal.(eds.),MechanicsofAdditiveandAdvancedManufacturing,Volume9,
ConferenceProceedingsoftheSocietyforExperimentalMechanicsSeries,DOI10.1007/978-3-319-62834-9_1
2 K.R.HartandE.D.Wetzel
Fig.1.1 IllustrationsofSENBfracturespecimens.(a)Orientationofvertically,horizontally,andobliquelyprintedSENBspecimenswithrespect
to the build plate. (b) Dimensions of a vertically printed SENB sample after removal from the build plate, preparation of the pre-crack, and
machiningofthearrestinghole.Herethelaminaerunparalleltothepre-crack,facilitatinginter-laminarfracture.(c)Illustrationofahorizontally
printedSENBsampleafterremovalfromthebuildplateandpreparationofthepre-crack.Herethelaminaerunperpendiculartothepre-crack,
facilitatingcross-laminarfracture.(d)IllustrationofanobliquelyprintedSENBsampleafterremovalfromthebuildplateandpreparationofthe
pre-crack. Laminae are oriented at an angle of θ with respect to the pre-crack notch. Laminae, pre-crack notches, and raster lines are not to
scale.Dashedlinesindicatepositionandorientationofweld-lines(nottoscale)betweendepositiontraceswithineachlaminae.Imageadopted
fromHartetal.[1]
1 FracturePropertiesofAdditivelyManufacturedAcrylonitrile-Butadiene-StyreneMaterials 3
Fig.1.2 Load
vs.displacementcurvesfor
SENBspecimenswithcrack-
tip/laminaorientationanglesof
θ¼0(cid:3),θ¼75(cid:3),andθ¼90(cid:3).
VerticallyprintedSENB
specimenswithθ¼0(cid:3)exhibit
brittle,inter-laminarfracture.
HorizontallyprintedSENB
specimenswithθ¼90(cid:3)exhibit
ductile,cross-laminarfracture.
ObliquelyprintedSENB
specimenswithθ¼75(cid:3)exhibit
mixedcross-/inter-laminar
fracturebehavior.Image
adoptedfromHartetal.[1]
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