Session: 17-01-01: Research Posters

Paper Number: 150553

150553 - On-Demand Rapid Fabrication of Components Using Forward Operating Base Aluminum Waste 

Abstract

Danyang Zheng, Yutao Wang, Brajendra Mishra and Jianyu Liang,

The U.S. military generates significant amounts of aluminum waste at forward operating bases (FOBs), presenting both environmental challenges and potential resource opportunities. According to studies by the U.S. Army Research Laboratory and the Natick Soldier Research Development and Engineering Center, aluminum comprises the second largest category of metal waste at FOBs[1, 2]. This research aims to develop an agile, mobile manufacturing process to reclaim and recycle this aluminum waste on-site, enhancing operational sustainability and reducing logistical burdens.

The study's primary objective is to develop a mobile casting system to meet the specific requirements of aluminum recycling in field conditions. This involves developing a 3D printing-enabled rapid-casting manufacturing process and designing a mobile foundry system to house this process. The research seeks to validate the system's effectiveness in real-world recycling scenarios, potentially transforming battlefield waste into valuable products. This remanufacturing process encompasses three main stages: preparation, casting, and post-treatment. In the preparation stage, waste aluminum is characterized and prepared for reprocessing. The casting stage utilizes stereolithography (SLA) 3D printing to create investment casting patterns, followed by mold making and casting using recycled aluminum. The post-treatment stage involves part removal, cleaning, and quality assessment.

To enable field deployment, the project develops a mobile foundry design that fits within standard shipping containers. This mobile system comprises three specialized containers: one for investment preparation, another for casting and heat treatment, and a third for product characterization. This design aims to maximize efficiency and portability while maintaining process integrity.

In addition, this research addresses the challenges of thin-wall formation in aluminum alloy casting. Through in-depth investigation, the study identifies critical variables affecting casting quality and develops strategies to improve thin-wall formation in recycled aluminum parts. This includes optimizing parameters such as mold design, metal flow, and cooling rates.

Preliminary results demonstrate the feasibility of producing quality aluminum parts from recycled FOB waste. The research has made significant progress in optimizing casting parameters for thin-wall formation in aluminum alloys. Additionally, the implementation of simulation tools has provided valuable insights into predicting and improving casting quality for intricate geometries. The research contributes to advancing both materials science and military engineering by developing a novel, field-deployable recycling and manufacturing process. It addresses critical sustainability issues in military operations while potentially reducing supply chain vulnerabilities. The mobile foundry system provides on-site, rapid manufacturing capabilities.

 

Reference:

[1] J. A. Margolin et al., "Test Standards for Contingency Base Waste-to-Energy Technologies," Army Research Lab ADELPHI, 2015.

[2] S. D. Cosper et al., "Contingency Base Camp Solid Waste Generation," Engineer Research and Development Center Champaign IL Construction, 2013.

 

Presenting Author: Danyang Zheng Worcester Polytechnic Institute

Presenting Author Biography: Danyang Zheng is a Ph.D. candidate in Materials Science and Engineering at Worcester Polytechnic Institute, expected to graduate in August 2024. His research focuses on the rapid fabrication of components using aluminum waste in forward operating bases. Danyang holds a Master's degree in Materials Science and Engineering from Boston University and a Bachelor's degree in the same field from Jilin University, China. His diverse research experience includes work on neutron diffraction, thin film preparation, and corrosion protection. Danyang has presented his research at the Materials Research Society (MRS) fall meeting and regularly participates in the Materials Recovery Technology for Defense Supply Resiliency biannual meetings. With expertise in various materials characterization techniques and computational tools, Danyang is passionate about advancing materials science for practical applications.

Authors:

Danyang Zheng Worcester Polytechnic Institute
Yutao Wang Worcester Polytechnic Institute
Brajendra Mishra Worcester Polytechnic Institute
Jianyu Liang Worcester Polytechnic Institute