Elucidating the Powder Flow Mechanics of Additive Manufacturing

In an effort to create an innovation-driven manufacturing sector that delivers huge cost-savings without sacrificing part strength, the addition of materials like metals and ceramics to Additive Manufacturing (AM) has emerged as a game changer. AM presents the opportunity to achieve mass customization and the manufacturing of complex internal geometries by simply printing a three-dimensional computer aided design (CAD) file slice by slice. This project focuses on elucidating the powder mechanics involved in creating complex geometries without sacrificing strength and speed. Using in-house modeling and fundamental powder experiments, the PFTL is working with the world's leading AM machines and consumable providers to advance the state-of-the-art.
powder flow mechanics
Photo: extremetech.com
PFTL Research Assistant(s):   Deepak Patil, Randyka Pudjoprawoto, Patrick S. M. Dougherty
Method(s) Employed:   Electron Beam Sintering, Powder Flow Analysis, in situ data acquisition, ex situ optical interferometry, Powder Processing;
Rig(s) and/or Software(s) Employed:   ARCAM 3D Printer; Zygo New-View 7300 Optical Interferometer ; In-house Powder Tribometer
Sponsor(s):   America Makes, NSF GRFP Fellowship

Sample Results:



Select PFTL References:

3.) Dougherty, P., Pudjoprawoto R., Higgs III, C.F. "An Investigation of the Wear Mechanism Leading to Self-Replenishing Transfer Films," Journal of Wear. August, 2011

4.) Pudjoprawoto, R., Dougherty, P., Higgs III, C.F. "A Volumetric Fractional Coverage Model to Predict Frictional Behavior for In Situ Transfer Film Lubrication." Journal of Wear, July, 2013.