Big Area Additive Manufacturing and Hardware-in-the-Loop for Rapid Vehicle Powertrain Prototyping: A Case Study on the Development of a 3-D-Printed Shelby Cobra
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Curran, Scott↗
Engineering topics
Love, Lonnie J
Publications and source records attributed to Love, Lonnie J.
The Economics of Big Area Addtiive Manufacturing
Case studies on the economics of Additive Manufacturing (AM) suggest that processing time is the dominant cost in manufacturing. Most additive processes have similar performance metrics: small part sizes, low production rates and expensive feedstocks. Big Area Additive Manufacturing is based on transitioning polymer extrusion technology from a wire to a pellet feedstock. Utilizing pellets significantly increases deposition speed and lowers material cost by utilizing low cost injection molding feedstock. The use of carbon fiber reinforced polymers eliminates the need for a heated chamber, significantly reducing machine power requirements and size constraints. We hypothesize that the increase in productivity coupled with decrease in feedstock and energy costs will enable AM to become more competitive with conventional manufacturing processes for many applications. As a test case, we compare the cost of using traditional fused deposition modeling (FDM) with BAAM for additively manufacturing composite tooling.
additive manufacturing↗
THE DURABILITY OF LARGE-SCALE ADDITIVE MANUFACTURING COMPOSITE MOLDS
Oak Ridge National Laboratory s Big Area Additive Manufacturing (BAAM) technology permits the rapid production of thermoplastic composite molds using a carbon fiber filled Acrylonitrile-Butadiene-Styrene (ABS) thermoplastic. Demonstration tools (i.e. 0.965 m X 0.559 m X 0.152 m) for composite part fabrication have been printed, coated, and finished with a traditional tooling gel. We present validation results demonstrating the stability of thermoplastic printed molds for room temperature Vacuum Assisted Resin Transfer Molding (VARTM) processes. Arkema s Elium thermoplastic resin was investigated with a variety of reinforcement materials. Experimental results include dimensional characterization of the tool surface using laser scanning technique following demolding of 10 parts. Thermoplastic composite molds offer rapid production compared to traditionally built thermoset molds in that near-net deposition allows direct digital production of the net geometry at production rate of 45 kg/hr.
Post, Brian K↗
OPERATOR BURDEN IN METAL ADDITIVE MANUFACTURING
Additive manufacturing (AM) is an emerging manufacturing process that creates usable machine parts via layer-by-layer joining of a stock material. With this layer-wise approach, high-performance geometries can be created which are impossible with traditional manufacturing methods. Metal AM technology has the potential to significantly reduce the manufacturing burden of developing custom hardware; however, a major consideration in choosing a metal AM system is the required amount of operator involvement (i.e., operator burden) in the manufacturing process. The operator burden not only determines the amount of operator training and specialization required but also the usability of the system in a facility. As operators of several metal AM processes, the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Labs is uniquely poised to provide insight into requirements for operator involvement in each of the three major metal AM processes. The paper covers an overview of each of the three metal AM technologies, focusing on the burden on the operator to complete the build cycle, process the part for final use, and reset the AM equipment for future builds.
Elliott, Amy M↗
Big Area Additive Manufacturing Applied To Buildings
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Biswas, Kaushik↗
INVESTIGATION OF IN-AUTOCLAVE ADDITIVE MANUFACTURING COMPOSITE TOOLING
The autoclave is a crucial piece of equipment for fabricating Tier 1 polymer composite aerospace structural components with very low void content (i.e. < 5 %). The essential component in this composite manufacturing process is the rigid mold that defines the final shape of the fabricated composite component. The Big Area Additive Manufacturing (BAAM) system located at Oak Ridge National Laboratory s (ORNL) Manufacturing Demonstration Facility (MDF) has been used to manufacture a new generation of in-autoclave tools that can be used to fabricate various aerospace composite parts. Different tools made form Polyphenylene sulfide (PPS) with 50 % by weight carbon fiber and Polyphenylsulfone (PPSU) with 25 % carbon fiber are investigated in this study. The behavior of the printed tools under different temperature ramp rates for the autoclave cycles was observed and analyzed.
Kunc, Vlastimil↗
Breaking Barriers in Polymer Additive Manufacturing
Additive Manufacturing (AM) enables the creation of complex structures directly from a computer-aided design (CAD). There are limitations that prevent the technology from realizing its full potential. AM has been criticized for being slow and expensive with limited build size. Oak Ridge National Laboratory (ORNL) has developed a large scale AM system that improves upon each of these areas by more than an order of magnitude. The Big Area Additive Manufacturing (BAAM) system directly converts low cost pellets into a large, three-dimensional part at a rate exceeding 25 kg/h. By breaking these traditional barriers, it is possible for polymer AM to penetrate new manufacturing markets.
additive manufacturing↗
Stack sampling apparatus
An apparatus for obtaining samples from a structure includes a support member, at least one stabilizing member, and at least one moveable member. The stabilizing member has a first portion coupled to the support member and a second portion configured to engage with the structure to restrict relative movement between the support member and the structure. The stabilizing member is radially expandable from a first configuration where the second portion does not engage with a surface of the structure to a second configuration where the second portion engages with the surface of the structure.
47 OTHER INSTRUMENTATION↗
The Importance of Carbon Fiber to Polymer Additive Manufacturing
Additive manufacturing holds tremendous promise in terms of revolutionizing manufacturing. However, fundamental hurdles limit mass adoption of the technology. First, production rates are extremely low. Second, the physical size of parts is generally small, less than a cubic foot. Third, while there is much excitement about metal additive manufacturing, the major growth area is in polymer additive manufacturing systems. Unfortunately, the mechanical properties of the polymer parts are poor, limiting the potential for direct part replacement. To address this issue, we describe three benefits of blending carbon fiber with polymer additive manufacturing. First, development of carbon fiber reinforced polymers for additive manufacturing achieves specific strengths approaching aerospace quality aluminum. Second, carbon fiber radically changes the behavior of the material during deposition, enabling large scale, out-of-the-oven, high deposition rate manufacturing. Finally, carbon fiber technology and additive manufacturing complement each other. Merging the two manufacturing processes enables the construction of complex components that would not be possible otherwise.
additive manufacturing↗
Elucidation of Combustion Associated With A Small Volume (4 Cc) Engine and the Utilization of Thermally-Insulating Titanium as A Head Material to Improve Efficiency and Availability
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Kass, Michael D↗
Mesofluidic two stage digital valve
A mesofluidic scale digital valve system includes a first mesofluidic scale valve having a valve body including a bore, wherein the valve body is configured to cooperate with a solenoid disposed substantially adjacent to the valve body to translate a poppet carried within the bore. The mesofluidic scale digital valve system also includes a second mesofluidic scale valve disposed substantially perpendicular to the first mesofluidic scale valve. The mesofluidic scale digital valve system further includes a control element in communication with the solenoid, wherein the control element is configured to maintain the solenoid in an energized state for a fixed period of time to provide a desired flow rate through an orifice of the second mesofluidic valve.
42 ENGINEERING↗
Mesofluidic controlled robotic or prosthetic finger
A mesofluidic powered robotic and/or prosthetic finger joint includes a first finger section having at least one mesofluidic actuator in fluid communication with a first actuator, a second mesofluidic actuator in fluid communication with a second actuator and a second prosthetic finger section pivotally connected to the first finger section by a joint pivot, wherein the first actuator pivotally cooperates with the second finger to provide a first mechanical advantage relative to the joint point and wherein the second actuator pivotally cooperates with the second finger section to provide a second mechanical advantage relative to the joint point.
42 ENGINEERING↗
Scalable economic extracellular synthesis of CdS nanostructured particles by a non-pathogenic thermophile
We report microbially facilitated synthesis of cadmium sulfide (CdS) nanostructured particles (NP) using anaerobic, metal-reducing Thermoanaerobacter sp. The extracellular CdS crystallites were <10 nm in size with yields of ~3 g/L of growth medium/month with demonstrated reproducibility and scalability up to 24 L. During synthesis, Thermoanaerobacter cultures reduced thiosulfate and sulfite salts to H2S, which reacted with Cd2+ cations to produce thermodynamically favored NP in a single step at 65oC with catalytic nucleation on the cell surfaces. Photoluminescence (PL) analysis of dry CdS NP revealed an exciton-dominated PL peak at 440 nm, having a narrow full width at half maximum of 10 nm. A PL spectrum of CdS NP produced by dissimilatory sulfur reducing bacteria was dominated by features associated with radiative exciton relaxation at the surface. High reproducibility of CdS NP PL features important for scale-up conditions was confirmed from test tubes to 24L batches at a small fraction of the manufacturing cost associated with conventional inorganic NP production processes.
Moon, Ji Won↗
Real-time Process Monitoring and Temperature Mapping of the 3D Polymer Printing Process
An extended range IR camera was used to make temperature measurements of samples as they are being manufactured. The objective is to quantify the temperature variation inside the system as parts are being fabricated, as well as quantify the temperature of a part during fabrication. The IR camera was used to map the temperature within the build volume of the oven and surface temperature measurement of a part as it was being manufactured. The development of the temperature map of the oven provides insight into the global temperature variation within the oven that may lead to understanding variations in the properties of parts as a function of location. The observation of the temperature variation of a part that fails during construction provides insight into how the deposition process itself impacts temperature distribution within a single part leading to failure.
3D Printing↗
Freeform Fluidics
This work explores the integration of miniaturized fluid power and additive manufacturing. Oak Ridge National Laboratory (ORNL) has been developing an approach to miniaturized fluidic actuation and control that enables high dexterity, low cost and a pathway towards energy efficiency. Previous work focused on mesoscale digital control valves (high pressure, low flow) and the integration of actuation and fluid passages directly with the structure, the primary application being fluid powered robotics. The fundamental challenge was part complexity. ORNL s new additive manufacturing technologies (e-beam, laser and ultrasonic deposition) enables freeform manufacturing using conventional metal alloys with excellent mechanical properties. The combination of these two technologies, miniaturized fluid power and additive manufacturing, can enable a paradigm shift in fluid power, increasing efficiency while simultaneously reducing weight, size, complexity and cost. This paper focuses on the impact additive manufacturing can have on new forms of fluid power components and systems. We begin with a description of additive manufacturing processes, highlighting the strengths and weaknesses of each technology. Next we describe fundamental results of material characterization to understand the design and mechanical limits of parts made with the e-beam process. A novel design approach is introduced that enables integration of fluid powered actuation with mechanical structure. Finally, we describe a proof-of-principle demonstration: an anthropomorphic (human-like) hydraulically powered hand with integrated power supply and actuation.
additive manufacturing↗
The Use of Additive Manufacturing for Fabrication of Multi-Function Small Satellite Structures
The use of small satellites in constellations is limited only by the growing functionality of smallsats themselves. Additive manufacturing provides exciting new design opportunities for development of multifunction CubeSat structures that integrate such functions as propulsion and thermal control into the satellite structures themselves. Manufacturing of these complex multifunction structures is now possible in lightweight, high strength, materials such as titanium by using existing electron beam melting additive manufacturing processes. However, the use of today's additive manufacturing capabilities is often cost-prohibitive for small companies due to the large capital investments required. To alleviate this impediment the U.S. Department of Energy has established a Manufacturing Demonstration Facility (MDF) at their Oak Ridge National Laboratory (ORNL) in Tennessee that provides industry access to a broad range of energy-efficient additive manufacturing equipment for collaborative use by both small and large organizations. This paper presents a notional CubeSat multifunction design that integrates the propulsion system into a three-unit (3U) CubeSat structure. The full-scale structure has been designed and fabricated at the ORNL MDF. The use of additive manufacturing for spacecraft fabrication is opening up many new possibilities in design and fabrication capabilities for what had previously been impossible structures to fabricate.
Horais, Brian J↗
Hydraulic involute cam actuator
Mechanical joints are provided in which the angle between a first coupled member and a second coupled member may be varied by mechanical actuators. In some embodiments the angle may be varied around a pivot axis in one plane and in some embodiments the angle may be varied around two pivot axes in two orthogonal planes. The joints typically utilize a cam assembly having two lobes with an involute surface. Actuators are configured to push against the lobes to vary the rotation angle between the first and second coupled member.
42 ENGINEERING↗
Magnetic properties of bio-synthesized zinc ferrite nanoparticles
The magnetic properties of zinc ferrite (Zn-substituted magnetite, Zn{sub y}Fe{sub 1-y}Fe{sub 2}O{sub 4}) formed by a microbial process compared favorably with chemically synthesized materials. A metal reducing bacterium, Thermoanaerobacter, strain TOR-39 was incubated with Zn{sub x}Fe{sub 1-x}OOH (x=0.01, 0.1, and 0.15) precursors and produced nanoparticulate zinc ferrites. Composition and crystalline structure of the resulting zinc ferrites were verified using X-ray fluorescence, X-ray diffraction, transmission electron microscopy, and neutron diffraction. The average composition from triplicates gave a value for y of 0.02, 0.23, and 0.30 with the greatest standard deviation of 0.02. Average crystallite sizes were determined to be 67, 49, and 25 nm, respectively. While crystallite size decreased with more Zn substitution, the lattice parameter and the unit cell volume showed a gradual increase in agreement with previous literature values. The magnetic properties were characterized using a superconducting quantum interference device magnetometer and were compared with values for the saturation magnetization (M{sub s}) reported in the literature. The averaged M{sub s} values for the triplicates with the largest amount of zinc (y=0.30) gave values of 100.1, 96.5, and 69.7 emu/g at temperatures of 5, 80, and 300 K, respectively indicating increased magnetic properties of the bacterially synthesized zinc ferrites.
42 ENGINEERING↗