Abstract This study proposes a new additive manufacturing (AM) based methodology to fabricate periodic metal matrix composite architectures, with a focus on titanium (Ti)-titanium boride whisker (TiB w ) composites. The manufacturing method includes binder jetting AM of the titanium matrix reinforced periodically by the extrusion of a custom-developed highly loaded resin, containing titanium di-boride (TiB 2) particles. A low-temperature pressure-less sintering method was then applied to increase the mechanical strength of green samples produced from the additive manufacturing step. The sintering process also fosters the chemical reaction between the matrix and ceramic, resulting in the growth of titanium boride whisker (TiB w ). The ceramic volume fraction and sintering protocol were studied as two main input variables in the design and fabrication steps. Investigating the influence of input parameters on the volume fraction and morphology (whisker formation) of TiB determined that the physical properties of the specimens, such as stiffness, were affected. The data analysis suggested a higher possibility for the formation and growth of TiB w as the temperature elevated in the sintering step (1400 °C). The ranges of 1.6 ± 0.2 GPa–3.7 ± 0.4 GPa and 83.9 ± 18.7 MPa–165 ± 13.2 MPa for the Young's modulus and Yield stress of the specimens were obtained, respectively. The stiffness of the samples was enhanced significantly by increasing the temperature and volume fraction. In particular, those samples sintered up to 1400 °C displayed 6.4%–15.2% improvement in the stiffness, although only a small fraction of the ceramic material was incorporated into the design: 2% and 4%, respectively. The similar trend of the improvement in density of the porous matrix was observed (i.e., 4.5%–19%). The range of mechanical and structural properties of the periodic composite developed in this study demonstrated the relevance of applying this method to the fabrication of biomedical and other lightweight titanium composite structures.
Abstract A high-accuracy progressive failure model based on continuum damage mechanics (CDM) is proposed to simulate the quasi-static axial crushing of composite corrugated beam. To predict various physical phenomena, both of the intra-ply damage and inter-ply interface damage are considered. The damages of intra-ply fiber and matrix are initiated with stress failure criteria and progressive damage propagation is modeled with a stiffness discount method and energy criteria. The deformation gradi...
Abstract Composite filaments with differing harakeke, hemp fibre or recycled gypsum contents (0-50 wt%) in pre-consumer recycled polypropylene (PP) were produced and mechanically assessed. Furthermore, a novel method of measuring shrinkage in 3D printed components was also developed and used to assess shrinkage of filaments. The most successful filaments contained 30 wt% harakeke fibre and had a tensile strength and Young's modulus of 39 MPa and 2.8 GPa respectively, providing improvements in te...
Last. Hui Wang(TTU: Texas Tech University)H-Index: 14
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Abstract Although TiB reinforced titanium matrix (TiB-Ti) composites exhibit superior wear resistance and strength, they still demonstrate severe problems resulted from lowered toughness and ductility, as compared with titanium and its alloys. To reduce these problems, this paper tailors a three-dimensional quasi-continuous network (3DQCN) microstructure within TiB-Ti composites by in-situ laser deposition-additive manufacturing process. Results show that the laser power has great impacts on the...
Last. Wai Yee Yeong(NTU: Nanyang Technological University)H-Index: 43
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Abstract Continuous fiber-reinforced polymer (FRP) composites have been used for many applications to create strong yet lightweight products due to their high strength-to-weight and stiffness-to-weight ratios. Aerospace [1] , automotive [2] , and sport [3] industries are three of the few industries that have been using FRP composites. The increasing need for prototyping and customization of fiber reinforced polymer composite parts is prompting innovations in new manufacturing processes to realiz...
Abstract To realize negative thermal expansion (NTE), porous composites made of two materials with different coefficients of thermal expansion are being actively researched. NTE can be realized by taking advantage of the thermal deformation mechanisms of a composite material's internal geometry. However, in addition to negative thermal expansion, materials with anisotropic and large positive thermal expansion are also desirable for various applications. Also, additive manufacturing provides new ...
Abstract This paper addresses a new methodology to fabricate cellular structures with embedded close pores distributed in controlled fashion. A hybrid additive manufacturing system integrating binder jetting and material extrusion was employed to selectively incorporate a sacrificial polymer into the structures followed by a post-processing step to decompose the polymer. Four different polymer compositions mixture of bisphenol-A ethoxylated diacrylate and cellulose acetate butyrate (CAB) were pr...
Abstract Over the past two decades, additive manufacturing has opened a new window of opportunities in fabricating complex porous matrix structures such as cellular solids. Several factors including design, material and process parameters can selectively be varied to tailor the porous properties of products based on the intended application. This article addresses the effect of variable throughout layer thickness configuration in the binder-jet additive manufacturing of titanium structures for o...
This article addresses the effects of glycerol (GLY) concentrations on the mechanical properties of calcium polyphosphate (CPP) bone substitute structures manufactured using binder jetting additive manufacturing. To achieve this goal, nine types of water-based binder solutions were prepared with 10, 12.5, and 15 wt % GLY liquid-binding agent, mixed, respectively, with 0, 0.75, and 1.5 wt % ethylene glycol diacetate (EGD) flow enhancer. The print quality of each of the solutions was established q...
Last. Wai Yee Yeong(NTU: Nanyang Technological University)H-Index: 43
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Abstract Unmanned aerial vehicles (UAV) are gaining popularity due to their application in military, private and public sector, especially being attractive for fields where human operator is not required. Light-weight UAVs are more desirable as they have better performance in terms of shorter take-off range and longer flight endurance. However, light weight structures with complex inner features are hard to fabricate using conventional manufacturing methods. The ability to print complex inner st...
In this work, a two-dimensional (2D) and three-dimensional (3D) integrated topology optimization (TO) parallel-computing framework, named TopADD (TOPology optimization for Arbitrary Design Domains), is developed to deal with topology optimization problems with arbitrary design domains. The parallel-computing framework is an extended work of the initial parallel-computing framework developed by Aage et al. (Struct Multidiscip Optim 51(3): 565–572, 2015). The extension is threefold: (a) a 2D imple...
Abstract As a non-beam-based additive manufacturing (AM) method, binder jet 3D printing (BJ3DP) is a process where a liquid binder is jetted on layers of powdered materials, selectively joined and then followed by densification process. Among AM technologies, binder jetting holds distinctive promise due to possibility of rapid production of complex structures to achieve isotropic properties in the 3D printed samples. By taking advantage of traditional powder metallurgy, BJ3DP machines can produc...
#2Mehdi Shahedi Asl(UMA: University of Mohaghegh Ardabili)H-Index: 68
Last. Seyed Ali Delbari(UMA: University of Mohaghegh Ardabili)H-Index: 24
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Ti–10 wt% Mo–1 wt% B4C composite samples were SPSed under the circumstances of 5 min dwell time, 50 MPa external pressure and sintering temperatures of 1150 °C, 1300 °C and 1450 °C. The role of sintering temperature on the relative density, microstructure and mechanical characteristics of as-sintered specimens were studied. Near fully dense relative density was obtained for the samples sintered at 1450 °C. The best mechanical properties including UTS, elongation, bending strength and micro/macro...
Abstract The oxidation behavior of melt-infiltrated SiC–TiB2 ceramic composites at 500–1300 °C in air for 32 h was investigated by the isothermal oxidation test. The phase composition and microstructure evolution were studied through examining the surficial and cross-sectional oxide layer by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM). The oxidized surfaces were covered by scattered TiO2 particles, a continuous B2O3 layer, a B2O3–Al2O3 l...
Last. M.J. Donough(RMIT: RMIT University)H-Index: 4
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Abstract Designing and manufacturing multi-functional, lightweight and high-performance body armour materials and assemblies have attracted intense attention recently due to fast-growing military applications. There is an urgent need to reduce the weight and increase the flexibility of body armours without compromising their ballistic protection capability. Natural/biological armour materials and assemblies offer remarkable properties that can inspire the design of lightweight, flexible and toug...
Last. Mohsen Mohammadi(UNB: University of New Brunswick)H-Index: 26
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Abstract Ti–10 wt% Mo–1 wt% B4C composites were fabricated using spark plasma sintering (SPS) technique to study the effect of sintering temperature and dwell time on their microstructure and mechanical properties. The composites were sintered at different temperature degrees (1150, 1300 and 1450 °C) with dwell time of 5 and 10 min under the external pressure of 50 MPa. The composites prepared in 10 min were hot-rolled to investigate the influence of the thermomechanical process on their mechani...
#1Xiaoyu Cao(Shaanxi University of Science and Technology)H-Index: 2
#2Miaomiao Ma(Shaanxi University of Science and Technology)H-Index: 1
Last. Jun Wu(Shaanxi University of Science and Technology)H-Index: 1
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Abstract An in situ SiC-TiB2 ceramic composites was fabricated by infiltrating the Al-Si alloy melt into pre-sintered porous preforms with different B4C/TiC weight ratios. The phase composition and microstructure of the SiC-TiB2 ceramic composites were analyzed to understand the synthesis mechanism of the composites. TiB2 and SiC were originated from the reaction among B4C, TiC and Al-Si melt. When the B4C/TiC weight ratio was 35:65, the fabricated TiB2-SiC ceramic composites but no byproduct or...
Last. David C. Dunand(NU: Northwestern University)H-Index: 82
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Abstract Titanium metal matrix composite microlattices are fabricated using 3D ink extrusion printing and sintering. The inks consist of TiH2+TiB2 or TiH2+TiC powder blends to form (i) Ti-TiB composites by dehydrogenation and in situ reaction of Ti + TiB2 to form Ti + TiB and (ii) Ti-TiC composites, where TiC remains stable during the sintering process. Rapid densification of the printed powder blend is achieved during pressureless sintering in vacuum at 1200 °C between 1 and 4 h, due to the sma...
The last few decades have seen rapid growth in additive manufacturing (AM) technologies. AM has implemented a novel method of production in design, manufacture, and delivery to end-users. Accordingly, AM technologies have given great flexibility in design for building complex components, highly customized products, effective waste minimization, high material variety, and sustainable products. This review paper addresses the evolution of engineering design to take advantage of the opportunities p...
Last. Mehdi Shahedi Asl(UMA: University of Mohaghegh Ardabili)H-Index: 68
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Abstract The spark plasma sintering process was implemented to produce four different composites, namely Ti-10 wt% Mo-(0.5, 1, 2, and 4) wt% (TiB2 + TiC). All samples were sintered at 1300 °C for 5 min under 50 MPa. A full study was carried out on the mechanical properties and the relative density of these SPSed composite samples. The best relative density of around 98.7% was related to the sample with 1 wt% (TiB2 + TiC). The role of relative density was so predominant that the best values for a...