Projects & Posters

Optimization of FDM Processing Parameters

  • Fused Deposition Modeling fabricates inferior parts compared to conventional manufacturing methods such as injection molding or thermoforming.
  • Optimizing the processing parameters is challenging due to their large number and their complex interactions.
  • Different quality attributes require different sets of processing parameters.
  • Using Design of Experiments discipline combined with data driven models a predictive model is developed.
  • Multi-objective optimization was enabled.
  • 95% accuracy was achieved using an ensemble of artificial neural networks.
  • Preliminary finite element model was proposed and verified experimentally.
  • Publication(s): Experimental Optimization 2017, FDM Taguchi 2018, FDM RSM 2020

Developing Post Processing Treatments to Improve the Performance of LPBF Parts

  • Metallic additively manufactured parts suffer from defects and high anisotropy, which can render them inferior to conventionally manufactured parts such as forged and cast parts.
  • This project aims at developing post processing heat treatments for additively manufactured Inconel 718 and 15-5PH.
  • The goal of the heat treatments is to homogenize the microstructure and reduce the anisotropy and the severity of the defects.
  • Tensile testing, SEM microscopy, fractography, X-ray diffraction, and Rietveld refinement characterization techniques were used to analyze the influence of the heat treatment.
  • Developed heat treatment succeeded in reducing the anisotropy and improved the reliability of the additively manufactured Inconel 718 and 15-5PH steel. .
  • Publication(s):Microstructure and mechanical 2019

Characterizing the Mechanical Behavior and Microstructure of As-Built LPBF parts

  • This project aimed at characterizing the microstructure and mechanical behavior of two of the most common additively manufactured alloys, Inconel 718 and 15-5PH, in their as-built condition at room temperature and elevated temperatures.
  • Specimens were fabricated in different orientations.
  • Tensile testing, SEM microscopy, and fractography characterization techniques were implemented.
  • Preliminary Bayesian inference model was implemented to predict the tensile strength for additively manufactured 15-5PH fabricated in different orientations and at different environmental temperatures.
  • Publication(s): Effect of Man 2018, Prediction of Mech 2019

Hybrid physics and data driven modeling of post processed AM parts mechanical behavior

  • Previous work showed that additively manufactured parts do not behave similar to conventionally manufactured parts.
  • In this project a hybrid approach is adopted to model the effect of post processing heat treatments on additively manufactured Inconel 718.
  • Grain growth, phase transformation, precipitation, and other thermally activated mechanisms are considered.