On the development of a novel solidification crack test for additive manufacturing
department or school: Applied Science, Faculty of
department or school: Engineering, School of (Okanagan)
data provider: DSpace
degree campus: UBCO
creator: Wall, Andrew
issued: 2023-09-12T21:44:04Z
issued: 2023
related degree: Master of Applied Science - MASc
degree grantor: University of British Columbia
description: Additive manufacturing (AM) is an emerging manufacturing technique in which parts are ‘printed’ one layer at a time, which presents many unique opportunities for innovative and sustainable manufacturing, but also presents many challenges. By example, solidification cracking (SC) is a metallurgical defect that occurs during the solidification of alloys in processes such as welding, casting, and AM. SC can cause significant mechanical deterioration in parts in which it occurs, and SC remains a significant hurdle for AM processes. Research into the causes, effects, and mitigation strategies of SC in AM is ongoing, however strategies of analysing and quantifying SC is inconsistent across studies. This thesis presents a novel test for SC susceptibility in AM processes. A benchmark specimen has been produced in order to assess the viability of a self-restraint test that can promote cracking in a repeatable and quantifiable manner. The design aims to be simple, yet robust, in order to be applicable to a range of AM processes. Samples were printed by laser directed energy deposition using Inconel 625 powder for repeatability analysis, and a sample was produced using Inconel 718 powder as a comparative analysis to assess the ability to distinguish SC susceptibility between material compositions. It was found that the initial design was capable of producing cracks with repeatable results, and cracks formed in the Inconel 718 sample were less severe than the cracks produced in the Inconel 625 samples. However, the cracks were determined to be ductile fractures that initiated in the solid-state rather than SC. A redesign of the specimen is presented to address the issues facing the initial design. Changes to dimensions were made to improve printability and reduce stress concentrations in order to reduce the likelihood of solid-state cracking in favour of promoting SC initiation modes. The results provide a foundation for standardisation of SC in AM. Standardised testing is a ne…
aggregated CHO: https://circle.library.ubc.ca/rest/handle/2429/85892
note: ON THE DEVELOPMENT OF A NOVEL SOLIDIFICATION CRACK TEST FOR ADDITIVE MANUFACTURING by Andrew Wall A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF APPLIED SCIENCE in THE COLLEGE OF GRADUATE STUDIES (Mechanical Engineering) THE UNIVERSITY OF BRITISH COLUMBIA (Okanagan) September 2023 © Andrew Wall, 2023ii The following individuals certify that they have read, and recommend to the College of Graduate Studies for acceptance, a thesis entitled: One the Development of a Novel Solidification Crack Test for Additive Manufacturing submitted by Andrew Wall in partial fulfillment of the requirements of the degree of Master of Applied Science. Dr. Michael Benoit, School of Engineering Supervisor Dr. Mohammad Arjmand, School of Engineering Supervisory Committee Member Dr. Lukas Bichler, School of Engineering Supervisory Committee Member Dr. Shahria Alam, School of Engineering University Examiner Dr. Zheng Liu, School of Engineering Neutral Chair iii Abstract Additive manufacturing (AM) is an emerging manufacturing technique in which parts are ‘printed’ one layer at a time, which presents many unique opportunities for innovative and sustainable manufacturing, but also presents many challenges. By example, solidification cracking (SC) is a metallurgical defect that occurs during the solidification of alloys in processes such as welding, casting, and AM. SC can cause significant mechanical deterioration in parts in which it occurs, and SC remains a significant hurdle for AM processes. Research into the causes, effects, and mitigation strategies of SC in AM is ongoing, however strategies of analysing and quantifying SC is inconsistent across studies. This thesis presents a novel test for SC susceptibility in AM processes. A benchmark specimen has been produced in order to assess the viability of a self-restraint test that can promote cracking in a repeatable and quantifiable manner. The design aims to be simple, yet robust, in order to be ap…
has type: Thesis/Dissertation
date issued: 2023-11
is shown at: 10.14288/1.0435863
language: eng
degree discipline: Mechanical Engineering
provider: Vancouver : University of British Columbia Library
publisher: University of British Columbia
rights: Attribution-NonCommercial-NoDerivatives 4.0 International
rights URI: http://creativecommons.org/licenses/by-nc-nd/4.0/
scholar level: Graduate
contributor: Benoit, Michael J.
type: Text
identifier URI: http://hdl.handle.net/2429/85892