Session: 15-01-02: General Topics on Risk, Safety, and Reliability II

Paper Number: 163782

Additive Manufacturing Reliability Based on Microscope Analysis 

Additive manufacturing (AM) has revolutionized the production of aerodynamic components, enabling the rapid prototyping of complex geometries. However, the reliability and consistency of these components under varied operational conditions remain areas of active research. This study asks the research question: How do varying production parameters on a 3D printer affect the reliability of additively manufactured aerospace components? Three objectives were defined to answer this question: first, to identify the optimal set of printing temperatures; second, to determine the optimal settings for the printer that are independent of temperature (i.e. thickness and velocity); and third, to integrate the results using global optimization to determine the ideal set of parameters for 3D printing. Nozzle temperature and bed temperature were varied independently of each other to determine the optimal set of printing temperatures. The results were examined using microscopic analysis, by comparing the changed parameters vs control parameters.  Nozzle speed and layer height were also varied independently of each other to determine the optimal 3D printer settings. 

A series of wing models were fabricated using AM, with systematic variations being applied to the different temperature parameters, layer height, and nozzle speed. When varying the parameters, a statistical approach was taken. For a given range of values for any parameter, values were tested at the mean and two standard deviations on either side of the mean. The model was printed using polyethylene terephthalate glycol, which was selected as the AM material due to its ease of printing and impact resistance. Then, the external surfaces of the models were analyzed with a microscope to examine the reliability of the external surface of each print, capturing any differences and trends that resulted from varying the parameters used to print them. For each model, a range of different pictures was taken with a microscope at varying magnification. Next, the wing models were cut and analyzed internally using microscopic analysis to determine the characteristics of the internal structures. This ensured that any variation within the models was captured. Finally, the results were combined using global optimization to establish the ideal set of AM printing parameters. This work bridged the gap between the reliability of AM and its applications in aerodynamics, which offers guidance for the design of 3D-printed aerospace components mainly by ensuring that the material properties of AM components are consistent with the expected qualities. This allows for rapid prototyping of aerodynamic components and confidence in the quality and consistency of the components. 

Presenting Author: Nazir Gandur Texas Tech University

Presenting Author Biography: I am an Assistant Professor at Embry-Riddle Aeronautical University in the Department of Aerospace Engineering (No. 1 in Best Aerospace Engineering undergraduate programs without a PhD option in the US for 2024). I hold a PhD in mechanical engineering from Texas Tech University, and a master’s degree from the same university. My bachelor's degree in Mechanical Engineering was performed in Brazil at Instituto Militar de Engenharia. I had the opportunity to study abroad at United States Military Academy, West Point, and TU Dortmund in Germany. I am passionate about teaching and sharing knowledge in a way that affects my students life.

Authors:

Jasmine Dumo Aranda Embry-Riddle Aeronautical University
Lucas Henry Knoth Embry-Riddle Aeronautical University
Alexis Rohrke Embry-Riddle Aeronautical University
Nazir Laureano Gandur Embry-Riddle Aeronautical University
Desirae Elaine Grumbine Embry-Riddle Aeronautical University