CENTER FOR AEROSPACE CAMT: A slideshow …mae.mst.edu/media/academic/mae/images/research/CAMT... · • Macro-scale: residual stress • Meso-scale: melt pool model • Micro-scale:

Dr. Ming C. Leu Keith and Pat Bailey Missouri Distinguished Professor

Director, Center for Aerospace Manufacturing Technologies

Director, Intelligent Systems Center

[email protected]

Dr. Douglas A. Bristow Associate Professor

Associate Director, Center for Aerospace Manufacturing Technologies

[email protected]

http://camt.mst.edu/

Missouri University of Science and Technology

Rolla, Missouri

CAMT: A slideshow celebrating 10 years of manufacturing research at Missouri S&T

CENTER FOR AEROSPACE MANUFACTURING TECHNOLOGIES


mailto:[email protected]



Havener Center-Missouri University of Science and Technology

The Center for Aerospace Manufacturing Technology 10 Year Anniversary Celebration

October 20, 2014

Agenda

7:30-8:30 Registration and Breakfast

8:30-9:00 Opening Remarks and Introductions

9:00-9:40 Keynote Speaker: Ricky Martin, Boeing Manager Metals and Ceramic Technology

9:40-10:00 Break

10:00-11:30 CAMT: 10 Years of Manufacturing Innovation

11:30-1:00 Lunch

1:00-2:00 Industry Panel

2:00-4:30 Breakout Sessions: CAMT Research Capabilities and Lab Tours

4:30-5:30 Happy Hour/Poster Session

6:00-8:00 Dinner



• CAMT Overview History, Current Projects, and Consortia Membership

• Research Activities Highlighted manufacturing research projects in CAMT and at Missouri S&T

• Research Facilities Manufacturing research facilities at Missouri S&T

• Contact Information

Table of Contents



• The Center for Aerospace Manufacturing Technologies (CAMT) was established in May 2004 at the Missouri University of Science and Technology (Missouri S&T).

• Major initial funding for CAMT was through the Air Force Research Laboratories. The Center received AFRL funding totaling over $20 million.

• Boeing has been the main industrial partner of CAMT. The Center has also been collaborating with over 20 industrial companies since its inception.

• CAMT Industrial Consortium was established in 2007. The Consortium currently has nine industrial members.

The History of CAMT



CAMT Objectives

• Research, develop, evaluate, demonstrate and transfer advanced technologies of critical importance to the aerospace manufacturing industries in the United States.

• Create knowledge, methodologies and tools to improve affordability, productivity, rapidity, quality, reliability, and safety in aerospace manufacturing.

• Disseminate the generated R&D results to the aerospace manufacturing supply chain through direct technology transfer as well as education, training and outreach activities.

• Serve as a role model of university-industry-government collaborative relationship.



Current Projects Supported by the CAMT Industrial Consortium

• Direct Metal Deposition of IN625 and Ti64 Functionally Gradient Materials.

• Automated Repair of Metal Defect Rework.

• Practical On-Machine Inspection Equipment (PROMISE) for Metal Deposition Processes.

• Sparse-Build Tooling FDM for Autoclave Processing.

• Manufacturing of Carbon/BMI Sandwich Composite using Out-of-Autoclave Process.

• Cryogenic Machining.

• Quality of Composite Edges Finished with Abrasive Waterjets.

• Volumetric Error Compensation – Machine Tools.

• Volumetric Error Compensation – Robots.

• Adaptive Control of Laser Trackers.



CAMT Leveraged Projects Funded by Federal Sources

• Fabrication of Advanced Materials for Space Applications (NASA).

• Sparse-Build Rapid Tooling by Fused Depositing Modeling for Composite Manufacturing and Hydroforming (America Makes, public information only).

• Additive Manufacturing of Smart Parts with Embedded Sensors for In-Situ Monitoring in Advanced Power Generation Systems (DOE).

• GOALI: Volumetric Error Analysis of Machine Tools (NSF).

• SBIR Phase I: Practical On-Machine Inspection Equipment (PROMISE) for Metal Deposition Processes (NSF).

• Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials (NASA).

• Bio-inspired Design, Fabrication and Testing of Bipolar Plates for PEM Fuel Cells (NSF).

• Iterative Process Control for Laser Metal Deposition (NSF).

• REU Site: Additive Manufacturing (NSF).

• GAANN: Doctoral Research and Training in Direct Digital Manufacturing (DE).



Gold Member $200,000 Annual Fee

Full Member $50,000 Annual Fee

Associate Member $15,000 Annual Fee

CAMT Industrial Consortium Memberships

• Representative on the Industrial Advisory Board

• Five hundred voting points in project selection

• Right to one proprietary (company-specific) project with up to $50,000 value

• On-campus office space available for research

• Representative on the Industrial Advisory Board

• One hundred voting points in project selection

• Intended for small businesses and non-profit organizations



Gold Members

Full Members

Associate Members

Current CAMT Industrial Consortium Membership



http://www.stratasys.com/

Research Activities Additive Manufacturing • Automated Repair of Metal Defect

• Multi-Physics, Multi-Scale Modeling of Metal Additive Manufacturing Processes

• A Novel Dual-Laser Additive Manufacturing Technology

• Freeze-form Extrusion Fabrication (FEF) of Ceramics and Gradient Materials

• Selective Laser Sintering (SLS) of Ceramics and Composites

• Sparse-Build Fused Deposition Modeling

• Additive Manufacturing of GRIN Optics

• Control of Additive Manufacturing Processes

Materials • Direct Metal Deposition of IN625 and Ti64 Functionally

Gradient Materials

• Rare-Earth Based (Non-Chrome) Anti-Corrosion Coatings

• Ultra-High Temperature Ceramics

Machining • Volumetric Error Compensation of

Large 5-Axis Machine Tools

• Volumetric Error Compensation for Robotic Machining

• Cryogenic Machining

• Machining Thin Titanium Components

• Laser Micro-hole Drilling and Breakthrough Detection

• Laser Micromachining for Micro Sensors and Detectors

Composites • Composite Manufacturing Using Out-of -Autoclave Process

• Process Modeling of Cavity Molded Composites

• Fiber-reinforced Transparent Composites

Joining • Modeling the Transport Phenomena in Gas Metal Arc

Welding

• Bonding of Glass to Metal Via Lasers

NanoManufacturing • Scalable Nanomanufacturing of Metasurfaces

• Directed Templating of Semiconductor Nanocrystals Through Laser Melting

Assembly Simulation • Assembly Simulation and Ergonomic Analysis with Motion

Capture

Research Facilities (click here)

Research Thrust: Additive Manufacturing

Automated Repair of Metal Defect Rework Frank Liou

Industry Collaborators: GKN Aerospace

Objective: The objective of this project is to explore approaches for automated repair of Ti64 parts.

Status: Active, Nov. 2011-present. Repair methods are transitioning to Spartan Light Metal Products, Product Innovation and Engineering, and GKN Aerospace

Funding: CAMT, NSF SBIR (IIP-1046492)

Methods

Parts machined from high performance metals are very expensive, especially large precision parts. Many high performance metal parts users, such as the aerospace industry, mold/die casting industry, heavy machinery consumer etc., extend the service of these damaged parts by employing repair technology. While traditional manual welding is not reliable, hybrid additive manufacturing has shown good promise in repairing quality and speed.

Project Motivation

Results and Accomplishments to Date

Currently transitioning to Spartan Light Metal Products, Product Innovation and Eng., and GKN Aerospace.


Multi-Physics, Multi-Scale Modeling of Metal Additive Manufacturing

Processes Frank Liou and Joe Newkirk

Industry Collaborators: Boeing, Rolls Royce

Objective: The objective of this project is to explore a predictive model for metal additive manufacturing.

Status: Completed, Nov. 2012-2013. Model was further developed and being evaluated by NASA

Funding: NASA (NNX11AI73A)

Methods

Additive metals are a novel robust technique to manufacture aerospace parts. However, as the additive metals process is very complex and often operating at very high temperature, the resulting material behavior is hard to predict. This proposed research is to investigate the prediction of the microstructure of the parts produced from the additive metal processes.

Project Motivation


Multi-physics, multi-scale modeling: • Macro-scale: residual

stress • Meso-scale: melt pool

model • Micro-scale:

microstructure prediction

Experimental validation Model being evaluated by NASA and available for further maturation in industry.

A Novel Dual-Laser Additive Manufacturing Technology

Hai-Lung Tsai

Objective: To develop a novel laser-based additive manufacturing technology without using powders for metal parts.

Status: Active, Oct. 2013 – present

Funding: DOE

Methods

Project Motivation


• Nano/micro powders can be hazardous to human and environment.

• Nano/micro powders are expensive and the powder recycling and operational costs are very high.

SEM images for particles -7 um (left) and -45 + 10 um (right) from SANDVIC

• Tests for welding and micromachining have been conducted. • The use of films/foils, instead of powders.

• Two lasers are used; one is CW fiber laser for welding or addition and the other is Q-switched Nd:YAG UV laser for micromachining or subtraction.

The system is operational and testing is underway.



Freeze-form Extrusion Fabrication (FEF) of Ceramics and Gradient

Materials Ming Leu, Greg Hilmas and Robert Landers

Industry Collaborators: Boeing

Objective: To develop the freeze-from extrusion process for fabricating 3D parts from ceramics and graded materials.

Status: Active, August 2009-present.

Funding: CAMT, Lockheed Martin, National Science Foundation, Department of Energy

Methods

For high-performance aerospace applications it is desirable to have the capability of fabricating 3D components from ceramics and gradient materials to provide unique thermal and mechanical properties including high-temperature resistance, minimum thermal stresses, etc. for advanced aerosystem components that require such as leading edges and nozzle throat inserts for aircraft and spacecraft.

Project Motivation


50% Al2O3-50% ZrO2

75% Al2O3-25%ZrO2

100%Al2O3

• Develop pastes with high solids loading

• Develop a freeze-form extrusion fabrication system for extrusion of multiple pastes with controlled proportions

• Develop post processing schedules

Ultra-high temperature ceramic and functionally graded 3D parts with complex geometry successfully fabricated.


Selective Laser Sintering (SLS) of Ceramics and Composites

Ming Leu and Greg Hilmas


Objective: To develop the selective laser sintering process for fabricating 3D parts from ceramics and composite materials.

Status: Active, August 2008-present.

Funding: National Science Foundation, Office of Naval Research

Methods

Selective laser sintering is an additive manufacturing process that is attractive for making 3D parts with complex geometries because of the use of powder bed. However, this process has been used only for making parts from thermoplastics in industrial practice . It is desirable to explore the use of this process for fabricating parts from ceramics and composites for aerospace and other applications.

Project Motivation

Results and Accomplishments to Date • Determine SLS process parameters for different materials • Identify suitable polymeric binder • Measure strength and density and characterize the

microstructure of the fabricated structural components • Test the fabricated components

• The fabricated ZrB2 fuel injector strut has been tested for its response to thermal stresses by applying heat fluxes with Boeing’s arc-heater facility.

• The fabricated graphite bipolar plates and bioglass scaffolds have also been tested for strength and performance.

SLS process parameters for fabricating parts from ZrB2, graphite, and 13-93 bioglass were determined.


Sparse-Build Fused Deposition Modeling

Ming Leu and K.C. Chandrashekhara

Methods

Sparse-build FDM technology can reduce the material, time and cost of making molds/dies for composites manufacturing, hydroforming, and other rapid tooling applications.

Project Motivation


• The effects of sparse-build styles and geometric parameters on the ULTEM test specimens have been obtained from compression and flexure tests.

• Finite element predictions agree well with experimentally measured strength/mass and modulus/mass ratios.

• The viability of parse-build ULTEM molds has been demonstrated for vacuum assisted resin transfer molding.

• Fabricate ULTEM test coupons with different sparse-build styles and varying parameters and compare their strength/mass and modulus/mass ratios

• Perform finite element simulations to compare the predicted strength/mass and modulus/mass ratios with the results of experimental tests.

Industry Collaborators: Boeing, Stratasys

Objective: To determine the feasibility of sparse-build tooling using the Fused Deposition Modeling (FDM) process.

Status: Active, January 2013-present.

Funding: CAMT, America Makes (public information only)

Technology in transition at Boeing and Stratasys.


Additive Manufacturing of GRIN Optics Edward Kinzel, Douglas Bristow and Robert Landers

Industry Collaborators: Lockheed Martin

Objective: Create a tool for 3D printing GRIN optics in the visible, NIR, and MIR frequencies

Status: Active, May 2013-present

Funding: Lockheed Martin

Methods

Significant reductions in size and weight of optical components can be achieved by incorporating gradient index (GRIN) elements. These differ from conventional optical elements because the material properties vary within a

Project Motivation


MATLAB simulation of GRIN lens

Thermal

Radiation

Laboratory

Creating optical quality components using traditional, powder based, AM methods is challenging because of trapped bubbles act as scattering centers. Starting with optically dense precursors simplifies the process. We have developed a wire-fed process operating in the LWIR (where glass and oxides are absorbing).

powder

bed

wire-fed

0 2 4 6 8 10

0.0

0.5

1.0

1.5

0 2 4 6 8 10

Tra

ck W

idth

[m

m]

P/V [J/mm]

0 2 4 6 8 100.0

0.5

1.0

1.5

10

20

30

40

50

Tra

ck W

idth

[m

m]

P/V [J/mm]

Power [W]

0.49 /w P V

0 2 4 6 8 100.0

0.5

1.0

1.5

10

20

30

40

50

Tra

ck W

idth

[m

m]

P/V [J/mm]

Power [W]

0.45 /w P V

1 mm

Power/Scan speed [J/mm]

Experiment

Simulation 400 600 800 1000

0

1

2

3

Optical C

onsta

nt

wavelength [nm]

n

n

k

k

λ [nm]

optical

consta

nt

experiment

model

experiment

model

θ=70°C

Model: 18.8 nm SiO2 above Si

single element. Light is bent continuously throughout the component, providing optical power beyond refraction at the interfaces. We are leveraging advances in Additive Manufacturing, specifically Functionally Graded Materials to print optical materials. Initial studies focus on glass and will produce freeform GRIN optics.

First Generation prototype system has been constructed and is successfully printing glass.


Control of Additive Manufacturing Processes

Douglas Bristow, Robert Landers, and Frank Liou

Industry Collaborators: Optomec

Objective: Develop algorithms and sensor strategies for robust and reliable additive manufacturing of parts with precise geometry and microstructure.

Status: Active, May 2013-present

Funding: National Science Foundation

Methods

Project Motivation


First Generation algorithms are ready for testing.

Unstable ripple dynamic

Control methodologies for many additive manufacturing are in their infancy. It is not clear what quantities should be measured, what sensors should be used, and what algorithms are needed to stabilize the process and produce reliable parts. This project explores these issues from a control theoretic foundation for the LAMP, metal additive manufacturing process.

dM

Powder

Released

Powder

Captured

d MPV

Laser

Melt Pool

Solid

Part

Velocity

x

v

Multi-dimensional (in-layer and layer-to-layer) control-oriented dynamic models are constructed. Suitable control algorithms are designed and analyzed in a multi-dimensional framework.

Pf d sF s hf ,h x j ,h x j

1w

rF s

,x j

,Sd x j

Pd a

, 1h x j

Multi-dimensional framework

Control-oriented dynamic model of LAMP

0 10 20 30 40 50 60 700

0.2

0.4

Position (mm)

Heig

ht (m

m)

Measured Modeled

Experimental validation of model

Velocity

0 0.5 1 1.5 2-1

-0.5

0

0.5

1

Real Axis

Ima

gin

ary

Axi

s

0.9 1 1.1-0.1

0

0.1

0.2

Case I

Case II

Case III

Unit Circle

Robust control design tools developed

Theory shows that profile scanning sensors are necessary for precision control

Research Thrust: Materials

Direct Metal Deposition of IN625 and Ti64 Functionally Gradient Materials

Frank Liou and Joseph Newkirk


Objective: This project is to investigate and fabricate using laser deposition an FGM material which grades from IN625 to Ti64.

Status: Active, Dec. 2012-present. Experience has shown what constitutes a good build. Methods of transitioning from one material to the next are being developed.

Funding: CAMT, NASA

Methods

Many aerospace systems could benefit from materials with properties which are not ordinarily found in a single material. However, combining dissimilar materials can lead to incompatibilities which will destroy the system in operation. Functionally gradient materials (FGM) could meet these properties without the incompatibilities if the two materials can be slowly intermixed, either in small steps, or in a continuous fashion. Grading metal alloys can be problematic due to chemical reactions of the components.

Project Motivation

Results and Accomplishments to Date 1. Design grading schemes to optimize properties

2. Develop strategies to avoid deleterious phases

3. Grade layers using laser deposition from powders

4. Develop Measure results and properties

• Successfully built SS316 to IN625 FGM

• Successfully built Ni to Cu FGM

• Working on SS316 to Ti-6Al-4V FGM built

• More FGMs in progress

Functionally gradient parts successfully built.


Rare-Earth Based (Non-Chrome) Anti-Corrosion Coatings Matt O’Keefe and Bill Fahrenholtz

Collaborators: PPG, Boeing, USCAR

Objective: The objective of this project is to develop coatings that protect against corrosion using rare-earth based inhibitors

Status: Active, Sept. 1999-present

Funding: AFRL, SERDP, Dept of Energy, PPG, USCAR

Methods

Replace existing hexavalent chromate, Cr(VI), anti-corrosion coatings that are toxic and carcinogenic with environmentally friendly rare-earth oxide based anti-corrosion coatings

Project Motivation


Lab Scale Testing and Evaluation

Field Testing

Coating Development

Pr based epoxy polyamide primer licensed to Deft/PPG Aerospace and in use on military aircraft

Selected as SERDP 2012 Weapons Platform Project of the Year

Ce based conversion coatings being evaluated by USCAR/DOE program for vehicle applications

Courtesy of Boeing

Developed non-chrome coating widely used in industry.

Ultra-High Temperature Ceramics Greg Hilmas and Bill Fahrenholtz


Objective: The objective of this project, with past CAMT funding, was to develop next generation ultra-high temperature ceramics (UHTCs) for leading and trailing edges of hypersonic vehicles.

Status: Completed, 2005 to 2008. Successful fabrication of UHTC components transitioned to Boeing for testing in the LCAT.

Funding: NSF, AFOSR, AFRL, SMDC.

Methods

Future hypersonic vehicles, missiles, and rockets demand flight speeds in excess of Mach 5. This increase in speed results in extremely high temperatures (often >2000°C) at the leading and trailing edges of control surfaces and propulsion systems. Critical technical challenges include shape stability, thermal shock resistance, erosion resistance, and resistance to combustion gases.

Project Motivation

Results and Accomplishments to Date Many unique UHTC components developed and tested in simulated hypersonic flight environments

X-51A Hypersonic Cruise Missile

Sharp Leading

Edges

(>2000°C)

Boeing Waverider

3” discs

4” x 4” wedge

1.7” x 0.8” wedge

2” diam. mushrooms

Utilize state-of-the-art thermodynamic models, phase equilibria, and ceramic processing methods to breakdown the barriers limiting the use of UHTCs in air and aerospace applications. Breakthroughs in UHTC development have included:

Pressurelessly sintered ZrB2 and ZrB2-SiC ceramics

Coextruded UHTC composites with improved thermal shock resistance

Fiber reinforced UHTCs with improved fracture toughness

100 µm

Cell

ZrB2-SiC

Cell Boundary

C or C + ZrB2

Sintered ZrB2 mushrooms

Missouri S&T is one of the leading institutions, nationally and internationally, in UHTC development.


Research Thrust: Machining

Volumetric Error Compensation of Large 5-Axis Machine Tools

Douglas Bristow and Robert Landers


Objective: The objective of this project is to develop new methods for measuring, modeling, and compensating the volumetric error on large 5-axis machine tools.

Status: Active, Nov. 2011-present. Calibration methods are transitioning to production at Boeing and Bell Helicopter.

Funding: CAMT, National Science Foundation (CMMI-1335340), Boeing, Missouri S&T investment

Methods

Machine Tools

Calibration

Large machine tools may have complicated geometric errors that are not well described in few parameters and are difficult to directly measure with classical metrology tools. Alternatively, laser trackers can be used to measure global coordinates of the tool over the entire workspace. Methods are needed to generate high-accuracy compensation tables from these measurements.

Project Motivation


, , , ,X Y Z C BT f f f f f

,

,, ,

i i

p X Y iZ C B

f p

, 1,1,i i p

Maximum-Likelihood Estimator

Optimal Projection onto Table

Space

Machine Model

High Accuracy Comp Tables

Measurement Data

High-order basis set for kinematic

error model

Machine Stochastics

-0.2

0

0.2

f xi,m

m

-0.2

0

0.2

f yi,m

m

-0.6

0

0.6

f zi,m

m

-0.01

0

0.01

f ci,d

eg

0 5000

-0.1

0

0.1

f bi,d

eg

X,mm

0 2000

Y,mm

0 1000

Z,mm

-200 200

C,deg

-100 100

B,degX Y Z C B

B

C

Z

Y

X

Input Axis

Co

mp

ensa

tio

n V

alu

e

Mean (thou) Max (thou)

Uncompensated 22.4 53.2

Compensated 1.2 2.8

1. Tool measurements rapidly acquired using API Radian laser tracker

2. Algorithms generate machine model and comp tables in a variety of controller formats

Machine-specific high-order comp tables capture complex machine geometric errors.

Complete calibration in 1-2 days

Typical performance:

In production at Boeing and transitioning to production at Bell Helicopter.

http://www.nsf.gov/awardsearch/showAward?AWD_ID=1335340




Volumetric Error Compensation for Robotic Machining

Douglas Bristow and Robert Landers

Industry Collaborators: Bell Helicopter

Objective: The objective of this project is to extend the machine tool calibration techniques developed in CAMT to calibration of robots for low-precision machining processes.

Status: Active, Jan. 2013-present. Calibration methods are transitioning to robotic deburring at Bell Helicopter

Funding: CAMT, Bell Helicopter

Methods

Project Motivation


Although robots are significantly less precise than traditional machine tools, robots are significantly cheaper, and in some cases have a greater ability to operate on and around parts of complex geometry. Many low precision machining operations, like deburring, are within the precision of off-the-shelf industrial robots, but beyond the off-the-shelf accuracy. Improving accuracy through calibration can make these systems viable for low-precision machining operations.

φ1x0

z0

xT

x6

x4

x3

x2

x1

zT

z6

z4

z3

z2z1

a1

a2

a3

d6

d4

LT

d7d600 0

z7x7

φ6

φ5

-k45φ4

φ4

φ3

φ2

-k46φ4-k56φ5

0

x5

z5

x5’z5’

z5"

x5"

z4’

x4’

1. Tool measurements rapidly acquired using API Radian laser tracker

2. Algorithms generate machine model and corrections for off-line programming

Models incorporate internal transmission, critical to achieving best accuracy

Positioning Error

Before After VEC

VEC is the enabling technology in Bell Helicopter’s robotic automated deburring process.

Precise programming of deburring trajectories infeasible without the improved accuracy enabled by VEC.

Technology demonstrated on deburring robot and transitioning to production.


Cryogenic Machining Robert G. Landers and Dave Van Aken

Industry Collaborators: Boeing, GKN Aerospace, Spirit Aerospace

Objective: The project objective is to determine the impact cryogenic machining has on the surface microstructure and mechanical properties of machined titanium parts. The effect of cryogenic machining on microstructure and surface stress, as well as its impact to strength, fatigue and distortion of the part will be investigated.

Status: Active, Nov. 2012-present. A cryogenic machining system has been developed and several coupons have been machined.

Funding: CAMT

Methods

Cryogenic machining dramatically reduces the cutting zone temperature and has been shown to increase tool life as well as decrease burr formations, vibrations such as chatter, surface roughness, and cutting forces. However, the effect cryogenic machining on the part’s mechanical properties has not been investigated.

Project Motivation


A cryogenic machining system has been built with data acquisition system and full sensor suite. Initial cutting tests have been conducted.

A cryogenic machining system will be developed. The specimen’s mechanical properties will be tested using dynamic fracture toughness and Krouse–type bending fatigue testing. The specimen’s microstructure will be investigated with a scanning electron microscope and Philips X–pert X–ray diffraction.

Omega

5TC-TTT30120

thermocouple

pressure

regulator

(220 psi)

Beta BJ

nozzleOmega PX1005L1-250 AC

pressure sensors (250 psi)

weight

temperature

National Instruments PCI 6221

Multifunction Card

(8 double-end AI, 16 bit)

Nitrogen

Tank

Sentranllc Scale

24"x24" 1000 lb

Technifab Vacuum

Jacketed Piping

pressure

pressure

0 50 100 150 200

355

360

365

370

Tank Weight

Weig

ht

[kg

]

Time [s]0 50 100 150 200

-80

-60

-40

-20

0

20

40

60

80

Time [s]

Fo

rce [

N]

Dynamometer Measurements

Fx Fy Fz

Results will determine structural risks of cryogenic machining to finished part.


Machining Thin Titanium Components Robert G. Landers , Dave Van Aken, and Greg Galecki


Objectives: The project objectives are 1) model thin titanium machining processes, 2) develop a method for improved process plans, 3) analyze the metallurgical characteristics of thin–gauged titanium components, and 4) produce a demonstration article.

Status: Completed, Results have been transitioned into production at Boeing.

Funding: CAMT

Methods

Many titanium aircraft components do not bear structural loads and are being designed to thinner specifications to reduce weight and improve aircraft performance. A better understanding of the machining process is required and metallurgical characterization of surface changes during titanium machining for thin components was needed.

Project Motivation

Results and Accomplishments to Date Process and structural models, as well as a process optimization routine, have been developed. Elongation to failure and ultimate tensile strength was found to decrease as the machined thickness decreased below a limit.

Machining tests were conducted and, using this data, models were constructed for the machining process and structural deflections. Metallurgical characterization included metallographic examination of machined surfaces, differential calorimetry, and eddy current probes to measure changes in conductivity.

0 1000 2000 3000 4000 50000

2

4

6

8

10

12

14

frequency (Hz)

mm

/kN

experimental

model

0.24 0.245 0.25 0.255 0.26 0.265 0.27-0.6

-0.5

-0.4

-0.3

Fy (

kN

)

0.24 0.245 0.25 0.255 0.26 0.265 0.270.15

0.2

time (s)dis

pla

ce

me

nt

(mm

)

simulation experimental

d

Side View

Part

Tool

tR

z

x

Top View

Part

w

sN

y

x

Tool

ff

exen

i

Tool: bottom slice

Part

0.20.4

0.60.8

1

0.020.04

0.060.08

0.1

0.02

0.04

0.06

0.08

d (in)w (in)

F

y (kN

)

Results currently used by Boeing in production.


Laser Micro-hole Drilling and Breakthrough Detection

Hai-Lung Tsai

Objective: To develop an optical system for real-time precision measurements of hole depth and for breakthrough detection during the laser hole drilling process.

Status: Completed, Mar. 2009 – Nov. 2011

Funding: Pratt and Whiney and the Air Force

Methods

• In laser hole drilling, it is important to know the hole depth as a function of time, particularly for blind holes.

• For laser drilling holes on airfoils, laser must be stopped at the moment when hole is just through; otherwise a damage can occur on the back plate.

Project Motivation


Motion Stage I

Machining Laser

Pin Hole

Confocal Lens

1/4 Wave

Plate

Polarizing

Beam Splitter Polarizer

Collecting Lens

Photo Detector

Gain-Adjustable

Signal Amplifier

Workpiece

Focusing

Lens

Dichroic

Mirror

Motion Stage II Host

Computer

Logic

Controller

A / D

Converter

Detecting

Laser

• Currently, wax has been filled in between an airfoil before drilling and then removed after drilling which is expensive and time consuming.

2 2.5 3 3.5 4 4.5 5 5.50

1000

2000

3000

4000

5000

Pinhole position (mm)

Inte

nsi

ty (

a.u

.)

Reference

Drilled by 100 pulses

Drilled by 1,000 pulses

• The capability of the measuring system is validated to achieve a sensitivity of 0.5 µm.

• This system can be easily implemented in a laser workstation for fabrication of 3D microstructures.

Based on the confocal principle.

This patented process measures hole depth in real-time during laser micromachining.


Laser Micromachining for Micro Sensors and Detectors

Hai-Lung Tsai

Objectives: 1) To develop efficient techniques for fabricating substrates for surface-enhanced Raman scattering (SERS), 2) To design and micro-machine probes or detectors for SERS.

Status: Active, Oct. 2009 – Sept. 2014

Funding: ONR, DOE

Methods

• Optical fiber Fabry–Perot (FP) interferometric sensors is capable of measuring various parameters including temperature, pressure, strain, acoustics, and flow.

• With advantages such as small size, immunity to electromagnetic interference, and corrosion resistance, fiber FP sensors are particularly attractive for applications involving harsh environments.

• SERS has been widely employed for molecular detection owing to its capabilities of simultaneously providing the structural and quantitative information, as well as high sensitivity for single molecular detection.

Project Motivation

Results and Accomplishments to Date • Use a femtosecond laser to micro-

machine an optical fiber for temperature and pressure measurements.

• Use a femtosecond laser to micro-machine the endface of an optical fiber for SERS applications.

• Use a femtosecond laser and a nanosecond laser to fabricate nanoparticles on a substrate for SERS applications.

400 600 800 1000 1200 1400 1600 18000

1

2

3

4

5

6

x 104

Raman shift (1/cm)

Inte

nsit

y (

a.u

.)

• Different SERS substrates and detectors with enhancement factors as high as 109

have been fabricated.

• The fabrication methods are fast and can be for large areas.

0

1

2

3

4

5

6

7

8

9

10

1475 1495 1515 1535 1555 1575

Wavelength (nm)

Reflection (

%)

-28

-22

-16

-10

1475 1505 1535 1565

Wavelength (nm)

Reflection (

dB

)

1 =

1489

.1nm

2 =

1525

.1nm

High precision fiber-based miniature sensors and probes have been developed

Research Thrust: Composite

Composite Manufacturing Using Out-of -Autoclave Process

K. Chandrashekhara

Industry Collaborators: Boeing, GKN Aerospace, Spirit AeroSystems

Objective: Manufacturing of carbon fiber epoxy and Bismaleimides (BMI) composite laminates or sandwich structure using out-of-autoclave processing. The performance of the manufactured parts are evaluated.

Status: Active, Nov. 2011-present.

Funding: CAMT, NAVMAR Applied Sciences/NAVAIR

Methods

Epoxy and Bismaleimides (BMI) are thermosetting polymers used in the aerospace industry because they exhibit good physical properties at elevated temperatures and wet environments.

Traditionally epoxy structures are cured using expensive autoclave processing. Development of out-of-autoclave processing of sandwich structure enables increased capacity and lowers costs.

BMI composites exhibit enhanced physical properties at elevated temperatures. Out-of-Autoclave processing of BMI composites is similar to epoxies but require higher cure temperatures. Post curing can be used to improve degree of cure which translates to improvement in glass transition temperature and resin dominated properties such as interlaminar shear strength.

Project Motivation


Schematic of out-of-autoclave process

The effect of post cure cycles on glass transition temperature is investigated using a dynamic mechanical analyzer.

Laminates fabricated via out-of-autoclave processing exhibited interlaminar shear strength at room temperature and elevated temperatures comparable to that of autoclave cured composites.

laminate

release film

breather

mold

laminate

release film

breather

mold

surface bleeder

vacuum bag

edge bleeder

resin dam

bagging tape

vacuum port

Short beam shear test Flexural test Recognized in SAMPE Journal feature article (2012)

Research Thrust: Composites

Process Modeling of Cavity Molded Composites

K. Chandrashekhara

Industry Collaborators: Bell Helicopter

Objective: The objective of this project is to develop three-dimensional cure and flow models for cavity-molding process.

Status: Completed, Jan. 2011 – Dec. 2013. Simulation tool for optimization of cavity molding process.

Funding: CAMT, Bell Helicopter

Methods

Project Motivation


Helicopter rotor system

• Composite rotor yokes/hubs are manufactured using prepreg cavity molding process, the heat required for the polymerization in thermoset resins causes chemical changes in the molecular structure. The objective is to develop finite element models of cavity molding process for manufacturing thermosetting composite parts.

An integrated cure and flow model

Temperature Distribution of Flex-beam

Thermal Energy Model

Chemical Model – Kinetics of Cure

Specific Heat Capacity

Density

Thermal Conductivity

Heat of Reaction

Temperature Dependent

ViscosityRheology Model

Rate of Degree of Cure

Cu

re P

roce

ssin

g

Flo

w a

nd

Co

mp

act

ion

Platen Temperature – Cure Cycle Pressure – Platen Displacement

Elastic Deformation of Preimpregnated Fibers/Prepregs

Model results in use by Bell Helicopter for composite flex beams.

Research Thrust: Composites

Fiber-reinforced Transparent Composites

K. Chandrashekhara, Ming Leu and Thomas Schuman

Industry Collaborators: General Dynamics

Objective: The objective of this project is to develop lightweight transparent armor for ballistic protection.

Status: Completed, Oct. 2007 – Sept. 2009. Manufactured transparent composites and performed ballistic simulation of armor system.

Funding: CAMT, Habsonic, LLC.

A novel fiber reinforced transparent composite has been developed using the vacuum infusion process.

Project Motivation


Transparent composite panel (left) and glass plate (right)

A numerical model has been developed and implemented in an explicit non-linear transient dynamic numerical code LS-DYNA. The material nonlinearities of glass, polycarbonate and lead core are considered in the simulation.

A traditional transparent armor panel consists of several layers of soda lime float glass. However, glass has poor mechanical properties and cannot withstand high threat levels. Several layers of glass bonded using inter-layers such as polyurethane and PVB can increase both threat and multi-hit protection. A transparent armor system consisting of different materials like glass, polycarbonate, and transparent composite is required to withstand high velocity projectiles.

Time = 200 s

Silica float glass of 1.50 in –fails.

Silica float glass (1.25 in) + PC (0.25 in.) panel –survives

Time = 200 s

PC Glass

Methods

Multilayered transparent panels are enabling technology for new lightweight transparent armor systems.

http://upload.wikimedia.org/wikipedia/commons/7/7c/7,62mm_G3_oder_MG3.jpg

Research Thrust: Joining

Modeling the Transport Phenomena in Gas Metal Arc Welding

Hai-Lung Tsai

Methods

Project Motivation


Objective: (1) To obtain a fundamental understanding of gas metal arc welding (GMAW) through the development of high fidelity numerical models and (2) To improve the weld quality and productivity of GMAW by parametric study of many welding conditions.

Status: Completed, April 1995 – Dec. 2005

Funding: ARO, GM, TRW

• GMAW has been widely employed for jointing metals due to its high productivity, low cost, and simple to use.

Numerical models: • The PDEs governing the conservation

of mass, momentum, energy, and species based on the continuum formulation for the metal domain.

• The arc plasma and its interaction between metal droplets was handled by the two domain method.

• The VOF method was used to track the dynamic geometry of the free surfaces.

Contact Tube

to Workpiece

Distance

Arc length

Gas Nozzle

Contact Tube

Workpiece

Electrode

Weld Pool

1 mm 1 mm Simulation Experiment

Simulation Experiment

• Welding conditions, including the welding current, droplet impingement, and travel speed , on the formation and final appearance of ripples for a moving GMAW were studied.

• Transient distributions of the melt flow velocity, temperature and species, as well as the weld pool dynamics and possible porosity formation in the solidified weld bead were predicted.

3 mm

cracking

• GMAW involves very complex transport phenomena, including the arc plasma, the melting of electrode, metal transfer, and weld pool dynamics.

• With the increasing requirement of mechanization and automation, the selection of optimum operating parameters for GMAW becomes essential for high weld quality and productivity.

Five patents related to this project were obtained.

Methods

Project Motivation


Bonding of Glass to Metal Via Lasers Hai-Lung Tsai and Richard Brow

Objective: To demonstrate the feasibility of hermetic seals of glass to metal by direct laser local heating Status: Completed, Feb. 2013 – Oct. 2013. Funding: DOE

• Hermetic seals of glass to metal has many important applications.

• Glass and metal have very different thermal expansion coefficients and thermal physical properties (thermal conductivity, melting temperature, etc.).

• The existing technique using furnace heating is slow and requires heating for the entire assembly.

• The existing furnace heating cannot repair local cracking.

Two types of laser were used in this project:

• Fiber Laser

CW, 1067 nm wavelength, 100 W, IPG YLR-100

• CO2 Laser

CW, 10600 nm wavelength, 1700 W,

Convergent Energy, ARROW

A numerical model was also developed to assist the selection of optimal parameters.

The Top (a) and bottom (b) view of the bonded glass to metal.

• The new method takes only about 5 minutes of processing time, as compared to more than 10 hours by furnace heating.

• The method can also be used for repairing local cracking.

A new technology using CO2 laser has been successfully developed for hermetic sealing of glass to metal.

Research Thrust: Joining

Scalable Nanomanufacturing of Metasurfaces

Edward Kinzel and Manashi Nath

Industry Collaborators: Plasmonics Inc.

Objective: Create a tool for large scale manufacturing of metasurfaces to control thermal transport.

Status: Active, Sept. 2012-present

Funding: Missouri Research Board, Missouri S&T Energy Center

Methods

Metamaterials have a 10+ years of research without making significant impact. This is because they have limitations in frequency response (not broadband), loss, and cost. Thermal emitters are an application where narrowband response and loss are advantageous. The challenge is to

Project Motivation


Simple structures with features smaller than 130 nm fabricated

Thermal

Radiation

Laboratory

Nanosphere Photolithography uses microspheres as lenses to focus photonic jet in photoresist

p

h

d y z

x

p hν

Unwind

support

material

Deposit resist

Soft-

bake

NPL exposure Rinse/Dry

Deposition 1

Hard-bake Rinse/Dry

Deposition 2

Inspection

Rewind

support

material

NPL exposure

Develop

pattern

Take IR metasurface production from $1000s/cm2 (EBL) to $10s/m2 without sacrificing performance

40

I [k

W/m

2]

1000°C

750°C

500°C

2 4 6 8 100

10

20

30

40

[m]

500

750

1000

30

20

10

0 2 4 6 8 10

Ez/|E0| 4 -4 0

x

y

λ0 [μm]

produce them at low cost. Traditional VLSI methods do not scale sufficiently for applications such as thermal management coatings on satellites. We are developing low-cost, high efficiency metasurfaces for controlling thermal transport and the manufacturing methods required to produce them.

Requires innovation and design for manufacturability

50 μm

2 μm 750

nm

10 μm

Microsphere array x-tal domains

Hole arrays in photoresist created by two off-axis exposures

2 μm

Al discs

Research Thrust: NanoManufacturing

This project will create metasurfaces for thermal signature control for $10s/m2.

Research Thrust: NanoManufacturing

Directed Templating of Semiconductor Nanocrystals Through Laser Melting

Heng Pan

Objective: The objective of this project is to develop new laser processing methods for manufacturing high-quality thin films for low cost and printable electronics manufacturing.

Status: Active, June. 2014-present.

Funding: National Science Foundation

Methods

Many applications in electronic devices require high quality semiconductor crystal growth on supporting materials that are not compatible with current manufacturing processes. This project aims to acquire knowledge for achieving nanoscale control of nucleation and crystal growth processes to fabricate thin crystalline domains on inexpensive and abundant substrates.

Project Motivation


Simulations show that crystallinity can be controlled by: Cooling rate • Nano-confinement

This process, currently under development at S&T, will allow for printing high quality electronics on a wide range of materials.

Research Thrust: Assembly Simulation

Assembly Simulation and Ergonomic Analysis with Motion Capture

Ming Leu and Frank Liu

Industry Collaborators: Spirit AeroSystems

Objective: To develop a portable, low-cost turn-key motion capture system for use on the shop floor for automated assembly simulation and ergonomic analysis

Status: Completed, Jan. 2011- Dec. 2012.

Funding: CAMT

Methods

Project Motivation

Results and Accomplishments

• A low-cost motion capture system with use of Optitrack cameras has been developed for human motion capture. • Another low-cost motion capture system with use of Kinects has also been developed for human motion capture. • The developed systems include software to integrate motion tracking with ergonomic analysis software JACK. • The developed systems have been demonstrated for tracking of human arm movements in fastening of mock-up and virtual aircraft fuselages.

• Develop a portable, low-cost turn-key motion capture system using Optitrack cameras or Kinects to track an assembly operation

• Generate an assembly simulations from the captured motion data for purposes of real-time simulation and ergonomic analysis

Capturing and analyzing the movements of humans on a factory floor can provide significant insights into the human assembly operations. The captured motion data can be used in CAD model based simulation and ergonomic analysis to reduce worker injuries and improve work quality. For practical purposes the motion capture system must be a turn-key system that is low-cost and portable for use on the factory floor.

The developed technology was transitioned to Spirit AeroSystems.

Machining • Manufacturing Automation and Control

Lab

• Precision Motion Control Lab

• Laser-Based Manufacturing Laboratory

Composites • Polymer Composite Laboratory:

Manufacturing

• Polymer Composite Laboratory: Experimental testing and simulation

Joining • Friction Stir Welding & Processing Lab

NanoManufacturing • Multiscale Manufacturing Lab

Assembly Simulation • Virtual Reality Laboratory

Materials • Advanced Materials Characterization Lab

• Lasko Materials Testing Lab

• High Strain Rate Testing

• Instrumented Impact testing

• Experimental Foundry

• Automated Feature Analysis Lab

• Corrosion and Coatings Lab

Additive Manufacturing • Hybrid Manufacturing Lab

• Additive Manufacturing Modelling Lab

• Polymer and Ceramic Additive Manufacturing Laboratory

• Thermal Radiation Laboratory

Research Activities (click here)

Research Facilities

Research Facilities: Materials

Lab Focal: Matt O’Keefe, Materials Research Center

Funding Sources: Missouri S&T Investment, National Science Foundation, AFRL, AFOSR, ARL

Scanning Electron Microscopy / Focused Ion Beam

A variety of scanning electron microscopes (SEM) are available for use at MRC. The Hitachi S-4700 field emission SEM is capable of magnifications up to 500,000x. Recent acquisition of a focused-ion beam (FIB) SEM allows for up to 1 nm resolution and rapid TEM sample preparation. The FIB allows for the removal of surface layers, providing cross-sectional views of layered specimens.

X-Ray Photoelectron Spectroscopy

Atomic force microscopy (AFM) reconstructs images of surfaces using a cantilevered stylus scanned over the surface in sub-nanometer increments.

X-ray Diffraction

Two PANalytical X-ray Diffraction (XRD) instruments are available at the center. The first unit is a powder diffraction unit with 15 sample changer, PIXcel detector and high temperature stage. A PANalytical X’Pert Materials Research Diffractometer is also available for the study of thin films as well as epitaxial systems.

Thermal Analysis

Thermal analysis capability at MRC includes Differential scanning calorimetry (DSC) allowing for measurement of glass transition temperatures, specific heat, phase changes, etc… Simultaneous Thermogravimetric analysis and Differential Thermal Analysis (TGA/DTA) is also available providing information on transition temperatures and exothermic/endothermic nature of reaction processes

Transmission Electron Microscopy

Transmisssion Electron Microscopy (TEM) is available, allowing for subnanometer resolution as well as crystallographic orientation and symmetry information Atomic Force Microscopy

Advanced Materials Characterization Lab (AMCL)

Surface analysis is available at the center utilizing X-ray photoelectron spectroscopy (XPS). This technique allows for the elemental compositions of surfaces to be determined. XPS has sufficient sensitivity to detect chemical bonding shifts, which allows molecular species determination.


Lab Focal: David Van Aken, Greg Hilmas

Funding Sources: Army Research Lab, Air Force Research Lab, CAMT, Peaslee Steel Manufacturing Center, Nucor Steel, Caterpillar, Boeing, Air Force Office of Scientific Research

Lasko Materials Testing Lab

650

700

750

800

850

900

950

1000

1,000 10,000 100,000 1,000,000 10,000,000Cycles to Failure

Str

ess R

an

ge

(M

Pa

)

0.030" Thick - Machined

0.080" Thick - Machined

0.0415" Thick - Sheet

The Lasko Materials Testing Laboratory is endowed with operating funds to keep the instruments NIST qualified.

Current Lab Capabilities • Static and fatigue testing to 55,000 lbs • High speed fatigue testing under load control (1000Hz) • Extreme environments -129°C to 2500°C • Corrosion testing


Lab Focal: David C. Van Aken

Current Lab Utilization • Students: 3 PhD • Projects:

• Development of steel armor • Crash worthiness of AHSS automotive steels • High temperature deformation behavior

Funding Sources: Army Research Lab, Peaslee Steel Manufacturing Research Center

High Strain Rate Testing

Direct tension split Hopkinson test bar

• High strain rates >103/s - Suitable for simulating

forging and finish rolling

• Temperature control - Induction coil with infrared

optical pyrometer

Compression split Hopkinson test bar


Lab Focal: David C. Van Aken


• Development of high toughness steel castings

Funding Sources: Army Research Lab, Steel Founders Society of America, Eglin Air

Instrumented Impact testing

• Dynamic fracture toughness testing

• Loading rate: >105 MPa√m /s

• Single specimen test → pre-cracked

10x10x55 mm fracture bars

• Proposed ASTM E 1820 A17

• Instrumented impact machine

• Dynamic load vs displacement curve


Lab Focal: Von Richards, Ron O’Malley, Simon Lekakh


• Engineering graphitic iron microstructure • Development of new automotive steels • Inclusion engineering and cleanliness in steel • Trace element contamination from refractories

Funding Sources: Army Research Lab, Ford, Peaslee Steel Manufacturing Center, Nucor Steel, Caterpillar

Experimental Foundry

• 4 Induction melting furnaces - Vacuum (10lb) 30lb 100 lb or 200 lb

• Hereaus Electronite Celox oxygen probe • Verichek Foundry-Master UV arc spectrometer • LECO TC 500 Nitrogen/Oxygen analyzer • LECO CS6000 carbon/sulfur analyzer • ASPEX-PICA 1020 inclusion particle analysis system • Green sand, no-bake, lost foam and investment molding systems • Magma filling/solidification modeling • Thermal analysis and data acquisition systems


Lab Focal: Ron O’Malley, Simon Lekakh


• Development of AHSS steels and armor • Inclusion engineering and cleanliness in steel • Development of creep resistant alloys

Funding Sources: Army Research Lab, Ford, Peaslee Steel Manufacturing Center, Nucor Steel, Caterpillar

Automated Feature Analysis Lab

ASPEX-PICA 1020 Automated SEM

Spatial mapping of M23C6 carbides in cast steel after homogenization for 11 hours at 2250°F, quench, and aging.

Second phase characterization • Minimum diameter 0.5 µm • particles detected using

back-scattered electron detector


Lab Focal: Matt O’Keefe

Funding Sources: PRCI, USCAR, PPG Aerospace

Electronics • EG&G Potentiostats/Galvanostats • PARSTAT 2273 Potentiostat/Galvanostat • Solatron 1255B Frequency Analayzers

Corrosion and Coatings Lab Salt Spray Corrosion Cabinet

Electrochemical Impedance Test System Rare-Earth Coatings on Al and Mg Alloy Substrates

Research Facilities: Additive Manufacturing

Lab Focal: Frank Liou

Current Lab Utilization • Students: 7 PhD, 3 MS, 2 UG • Projects:

• 5 projects on Ti64 and tool steel repairs • 6 projects on process planning and part building

Funding Sources: Boeing, GKN Aerospace, National Science Foundation, Product Innovation and Engineering, Spartan Light Metal Products.

Hybrid Systems

1. 5X machining with direct diode laser deposition

2. Fiber laser deposition + 5X high speed machining center for precision fabrication and repair

3. 7X robot for large scale parts

Hybrid Manufacturing Active Target

• ~10% stronger than the traditional manufactured parts • Repaired a part better than its original • Accuracy and repeatability

Nachi 7-X deposition robot

• 7 DoF industrial robot • ± 0.02 in repeatability • 660 lb load • 16’ by 20’ work envelop

Spatial Hardware/Software

• Metal additive manufacturing + CNC machining

• Integration hardware and software

Hybrid (Additive/Subtractive) Manufacturing Lab


Lab Focal: Frank Liou


• 4 projects on various models

Funding Sources: Boeing, National Aeronautics and Space Administration, National Science Foundation, Rolls Royce, Titanova

Mini-Tensile Test System

• EDM Facility to cut mini samples

• Strain resolution: 0.001mm

• Multiple samples for multiple locations and orientations

• Design for additive manufacturing tensile testing

Modeling Research Active Target

• Qualification of additive manufacturing processes • Sensor development for in-situ monitoring of additive

manufacturing processes • In situ monitoring and control of additive manufacturing

processes

Various parallel computers

• GPUs • 32 core CPU

Sensor validation: sensor hardware and software for model validation Additive Manufacturing Modelling Lab

Lab Focal: Ming Leu


• 2 projects on Freeze-form Extrusion Fabrication • 1 project on Selective Laser Sintering • 1 project on Fused Deposition Modeling

Funding Sources: CAMT, NSF, DOE, AFRL, America Makes

Fortus 400mc

• Fabricates a 3D part by Fused Deposition Modeling (FDM)

• Covers thermoplastics including ABS, ULTEM, PC, and PPSF

Freeze-form Extrusion Fabrication machine

• Fabricates a 3D part by extrusion of aqueous pastes

• Can build a part with functionally graded materials

DTM 2000

• Fabricates a 3D part by Selective Laser Sintering

• Flexibility in material coverage

Polymer and Ceramic Additive Manufacturing Laboratory



Lab Focal: Edward Kinzel

Current Lab Utilization • Students: 3 PhD, 3 MS • Projects:

• Additive manufacturing of optics • Scalable nanomanufacturing of metasurfaces • Spatial/temporal varying radiation source

thermography for NDT • Microwave FSS based strain sensing/health

monitoring

Funding Sources: Lockheed, Missouri S&T Investment

Variable Angle Spectroscopic Ellipsometer

• JA Woollam M-VASE system • Measures optical properties

from 190-1100 nm

Additive Manufacturing of glass/oxides for optics

• 100 W CO2 laser • Dual wire fed system • 3-axis brushless DC motors • High-temp substrate heating

E-beam Evaporator

• 6-pocket CHA system • Long throw with large cooled

chamber • Access to MRCs FIB/SEM

Tunable CO2 Laser Range

• Property measurements including high temp emissivity

• Sensor calibration

Thermal Cameras

• FLIR SC500 & 2 DRS Cameras • Blackbody calibration source • Novel DMD based thermal

loading

Multiphysics Modeling

• ANSYS/FLUENT/HFSS

Scalable Nanomanufacturing of Metasurfaces

• Self-assembled microsphere masks

• Selective emitters

Metasurface Enabled Structural Sensing

• Embeddable FSS based sensors remotely measure strain tensor

Thermal

Radiation

Laboratory

2 μm

20 mm

Thermal Radiation Laboratory

Research Facilities: Machining

Lab Focal: Robert G. Landers


• 1 project on cryogenic machining of thin titanium • 1 project on hierarchical machining control

Funding Sources: Boeing, National Science Foundation, Society of Manufacturing Engineers, Missouri S&T Investment

Extender

(b) (c) (d)

(a)

Mitutoyo MT 505 Toolmaker’s

Microscope and Camera

Mitutoyo SJ–201P

Surface Roughness

Tester

Lion Precision ECL 100–

U5B Eddy Current

Displacement Sensor

PCB Piezotronics HT356A63

Triaxial Accelerometer PCB Piezotronics 086C03

Impact Hammer

NI PCI High–Speed Data

Acquisition System

Kistler 9257BA 3–Axis

High–Bandwidth

Dynamometer

Cincinnati V–CNC 750 Vertical Machining Center

Reconfigurable

Machine Tool in

Parallel Turning

Configuration

Reconfigurable

Machine Tool in

Parallel Milling/Drilling

Configuration

Manufacturing Automation and Control Lab


Lab Focal: Douglas Bristow

Current Lab Utilization • Students: 3 PhD, 1 UG • Projects:

• 3 projects on Volumetric Error Compensation • 1 project on precision motion control of laser

trackers

Funding Sources: Boeing, Bell Helicopter, API, National Science Foundation, CAMT, Missouri S&T Investment

API Radian Laser Tracker

• Range • 100m Linear • 640° Azimuth • 138° Elevation

• Accuracy • 5 ppm (1 thou over 5m)

• Portable for on-site measurement

• SDK for customized software

API Active Target

• Automatic tracking of laser beam for rapid robot and machine tool calibration

Fanuc LR Mate 200i

• 6 DoF industrial robot • ± 0.2 mm repeatability • 5 kg load • 700 mm reach

Spatial Analyzer Software

• Automated measurement with laser tracker

• Calibration planning • Geometric error analysis

Precision Motion Control Lab


Lab Focal: Hai-Lung Tsai, Ed Kinzel and Heng Pan

Current Lab Utilization • Students: 6 PhD, 2 MS • Projects:

• Additive Manufacturing • Micromachining of optics/sensors • Laser welding/cladding

Funding Sources: AFOSR, ARO, ONR, DOE, National Science Foundation, Missouri S&T Investment

CO2 laser • Convergent Energy Arrow

• 1700 W CW/7500 W pulsed, 10.6 μm • 4 axis motion stage • Ideal for welding/cladding/AM of ceramics

Femtosecond Laser • Coherent L-D-1K

• 1 W, 800 nm • 5-axis Aerotech motion stage • Coherent OPERA Optical Parametric Amplifier • Two-photon lithography/Precision/clean

ablation

Nd:YAG Laser • Adaptive Laser Systems

• 40 W CW/1.25 kW pulsed, 1064 nm • Galvo scanning system • Laser marking and material processing

Frequency Tripled Nd:YAG Laser • Coherent AVIA 355-X

• 10 W, 355 nm • Q-switched: nanosecond pulses

• 4-axis motion stage • Laser cutting (metals)

100 W Fiber laser • IPG Photonics YLR-100

• 100 W CW, 1100 nm • 3-axis Aerotech motion stage • Material processing/additive manufacturing

1000 W Fiber laser • IPG Photonics YLR-1000

• 1000 W CW, 1100 nm • 3-axis motion stage with integrated galvo

scanner • Material processing/additive manufacturing

Microscopes • Olympus BH2-UMA • Nikon Epiphot 200 • Meiji MTS Microscopy

• Brewer Science 200 CB Spin-coater • Ultrasonic cleaner • LECO CM-15 Cutoff Machine, 2000

Grinder/Polisher, MHT200 Hardness Tester, PR-25 Mounting Press; VC-50 Cutter;

• Fisher Scientific 650-14 programmable furnace • Optical detectors

Laser-Based Manufacturing Laboratory

• Autoclave Molding • Out-of-autoclave Process • Pultrusion Process • Filament Winding • Injection Molding • Compression Molding • Resin Transfer Molding

Composite Manufacturing:

Injection molding Pultrusion Autoclave

Lab Focal: K. Chandrashekhara

Current Lab Utilization • Students: 5 Ph.D., 3 M.S. • Projects:

• Composite manufacturing using out-of-autoclave process

• Pultruded composites

Funding Sources: ONR, NSF, DOE, AFRL, NAVAIR, CAMT

Polymer Composite Laboratory: Manufacturing

Research Facilities: Composites

Materials Testing: • Instron Mechanical Testing • Environmental Chamber • Non-destructive Testing

Modeling and Simulation:

• Thermo-mechanical Analysis • Nonlinear Analysis

Instron machine with thermal chamber

Climbing drum peel test

Elliptical crack

frontSub-modelAxial elliptical crack on composite

hydrogen cylinder liner

Composite wrap

Aluminum linerGlobal model

Hydrogen Storage Cylinder Analysis

Bird

Transparent Composite

Bird Strike Analysis

Lab Focal: K. Chandrashekhara

Current Lab Utilization • Students: 4 Ph.D., 2 M.S. • Projects:

• Composites with embedded sensors • Modeling and analysis of composite structures

Funding Sources: NAVMAR Applied Sciences, Department of Transportation, Habsonic LLC, Integrated Systems Solutions

Polymer Composite Laboratory: Experimental testing and simulation

Research Facilities: Composites

Research Facilities: Joining

Lab Focal: Joseph W Newkirk

Current Lab Utilization • Students: 2 PhD, 1 UG • Active Projects:

• Recrystallization of Ti64 Laser deposits • Welding of ODS steels

• Past Projects • Corrosion of FSW joints • Friction stir surfacing

Funding Sources: Boeing, DOE

Linear Friction Stir Welder

• Custom programming • 3-axis

Robotic Friction Stir Welder

• 6-axis of motion • Custom programming • Attached spot welder

Surface composites

• Incorporate up to 60% hard phases

• Excellent distribution • Controlled depth • Mixtures of additives for multiple

functions

Miniature testing to validate

• 17 or 9 mm long specimens • Small testing machine to match • High strength materials capable

Friction Stir Welding & Processing Lab

Research Facilities: NanoManufacturing

Lab Focal: Heng Pan


• 2 project on Laser base Electronics Manufacturing • 1 project on Scalable Nanomanufacturing

Funding Sources: National Science Foundation, UM Interdisciplinary and Intercampus research program (IDIC)

Laser Melting and Annealing

• High speed laser scanning on large area • Pulse and CW laser mode • In-situ characterization

Aerosol Printing and Nanoink Synthesis

• Various nanoink manufacturing and aerosol printing

Scalable Nanomanufacturing

• Soft-wall cleanroom • 200mm wafer scale • 100nm feature resolutions

Molecular Dynamics Simulation

• Melting and crystallization • Nanoparticle sintering modeling

Multiscale Manufacturing Lab

Lab Focal: Ming Leu

Current Lab Utilization • Students: 2 MS • Projects:

• 1 project on motion capture (both marker-based markerless) for automated assembly simulation and ergonomic analysis

Funding Sources: CAMT Consortium, NSF

Computer Automated Virtual Environment (CAVE) • Immersive 3D visualization

experiences can be obtained using the CAVE with Head Mounted Devices

• Applications have been developed for virtual assembly and a robotic workstation

Motion capture • Use inexpensive

commercial cameras or even Wiimote and Kinect

• Captured motions can be used for simulation and analysis

Haptics • Use PHANToM or Cyberglove • Increase reality with haptics

Assembly Simulation and Ergonomics Analysis • Use captured motion data

for automated CAD model based simulation

• Simulation of human movements in an assembly operation can be used to generate automated ergonomic analysis with commercial software JACK

Research Facilities: Assembly Simulation

Assembly Simulation Lab

http://en.wikipedia.org/wiki/File:KinectSensor.png

Center for Aerospace Manufacturing Technology 320 Engineering Research Lab 500 W. 16th Street Rolla, MO, 65409-0440 Phone: (573) 341-4908 Email: [email protected] Web: http://camt.mst.edu/

Director: Ming Leu, [email protected], ph: 4482 Assoc. Director: Douglas Bristow, [email protected], ph: 6559 CAMT Secretary: Lisa Winstead, [email protected], ph: 4908 Administrator: Debbie Sickler, [email protected], ph: 4350

Faculty Research Investigators: David Van Aken, [email protected], ph: 4717 Robert Landers, [email protected], ph: 4586 K.C. Chandrashekhara, [email protected], ph: 4587 Frank Liou, [email protected], ph: 4603 Bill Fahrenholtz, [email protected], ph: 6343 Joseph Newkirk, [email protected], ph: 4725 Grzegorz Galecki, [email protected], ph: 4938 Matt O’Keefe, [email protected], ph: 6764 Gregory Hilmas, [email protected], ph: 6102 Heng Pan, [email protected], ph: 4896 Edward Kinzel, [email protected], ph: 7254 Hai-Lung Tsai, [email protected], ph: 4945

IAB Chairman: James B. Castle, [email protected], ph: (314) 563-5007

*Unless specified otherwise, phone numbers are (573) 341-xxxx

Contact Information*




















Documents

CENTER FOR AEROSPACE CAMT: A slideshow …mae.mst.edu/media/academic/mae/images/research/CAMT... · • Macro-scale: residual stress • Meso-scale: melt pool model • Micro-scale: