Anisotropic Mechanical Properties of ABS Parts Fabricated by Fused Deposition Modelling

In recent years, layered manufacturing (LM) processes have begun to progress from rapid prototyping techniques towards rapid manufacturing methods, where the objective is now to produce finished components for potential end use in a product (Caulfield et al., 2007). LM is especially promising for the fabrication of specific need, low volume products such as replacement parts for larger systems. This trend accentuates the need for a thorough understanding of the associated mechanical properties and the resulting behavior of parts produced by layered methods. Not only must the base material be durable, but the mechanical properties of the layered components must be sufficient to meet in-service loading and operational requirements, and be reasonably comparable to parts produced by more traditional manufacturing techniques. This chapter presents the details of a study completed to quantitatively analyze the potential of fused deposition modelling to fully evolve into a rapid manufacturing tool. The project objective is to develop an understanding of the dependence of the mechanical properties of FDM parts on raster orientation and to assess whether these parts are capable of maintaining their integrity while under service loading. The study examines the effect of fiber orientation, i.e. the direction of the polymer beads relative to the loading direction of the part, on a variety of important mechanical properties of ABS components fabricated by fused deposition modeling. Tensile, compressive, flexural, impact, and fatigue strength properties of FDM specimens are examined, evaluated, and placed in context in comparison with the properties of injection molded ABS parts.

Investigation of the Design of a Bistable Micro-Chemical-Mechanical Device Utilizing Lateral Buckling

The Gracias Laboratory at Johns Hopkins University has developed microgrippers which utilize chemically-actuated joints to be used in micro-surgery. These grippers, however, take up to thirty minutes to close fully when activated biochemicals in the human body. This is very problematic and could limit the use of the devices in surgery. It is the goal of this research to develop a gripper that uses theGracias Laboratory's existing joints in conjunction with mechanical components to decrease the closing time. The purpose of including the mechanical components is to induce a state of instability at which time a small perturbation would cause the joint to close fully.The main concept of the research was to use the lateral buckling of a triangular gripper geometry and use a toggle mechanism to decrease the closure time of the device. This would create a snap-action device mimicking the quick closure of a Venus flytrap. All developed geometries were tested using finite element analysis to determine ifloading conditions produced the desired buckled shape. This research examines lateral buckling on the micro-scale and the possibility ofusing this phenomenon in a micro-gripper. Although a final geometry with the required deformed shaped was not found, this document contains suggestions for future geometries that may produce the correct deformed shape. It was determined through this work that in order to obtain the desired deformed shape, polymeric sections need to be added to the geometry. This simplifies the analysis and allows the triangular structure to buckle in the appropriate way due to the added joints. Future work for this project will be completed by undergraduate students at Bucknell University. Fabrication and testing of devices will be done at Johns Hopkins University in the Gracias Laboratory.

Corrosion Characteristics And Mechanical Properties Of Aluminum Coatings Applied By The Cold Spray Process

Aluminum coatings were applied to 2024-T3 and 7075-T6 aluminum alloys via the Cold Spray process. The coatings were applied to substrateswith various surface preparation and Cold Spray carrier gas combinations. Some samples were coated with an additional sealant with and without a chromate conversion layer. An exhaustive corrosion analysis was then performed which utilized a number of long termand accelerated tests in order to characterize the corrosion protection of the coatings.