Session: 04-20-01: Design of Engineered Materials and Components for Additive Manufacturing

Paper Number: 144485

144485 - Vibrational Analysis of Additively Manufactured 3d Printed Metal Beams With Multiple Void Defects 

Additive manufacturing (AM) has expanded across a broad range of industries, including aerospace, automotive, as well as oil and gas/energy industries due to its ability to produce specialized components not otherwise possible with traditional methods. In the oil and gas industry, AM provides transformative benefits, including the ability to design unique parts with complex geometries that enhance efficiency and resilience, such as advanced turbines or valves. This technology allows the industry to move past relying on traditional Original Equipment Manufacturers (OEMs), and facilitates the customization of parts to optimize the geometries, enhance operational demands, and acquire parts that are no longer available, reducing lead times and associated costs. However, internal defects compromise the part's structural integrity and mechanical performance, leading to potential equipment failure and operational disruptions. These internal defects introduce significant risks to safe and efficient operations in such an industry, highlighting the importance of advanced quality assurance and internal defects detection methods. Metal 3D printing technology has proven transformative for its ability to achieve both tuneable material properties and design complexity. With its surge in popularity, new challenges have arisen for quality assurance, particularly in detecting and characterizing internal defects. This study expands on our previous work to analyze the vibrational response of 3D printed metal beams containing multiple defects instead of a single defect. 

This study applies analytical and Finite Element Methods (FEM) to analyze the vibrational response of 3D printed metal beams to locate multiple internal defects modeled as voids. Moreover, the impact of these defects on the structural integrity is characterized. Integral to this approach, is the use of the Relative Frequency Shift (RFS) method that examines the natural frequency changes on a 3D printed metal beam with multiple internal voids. This method identifies the impact of these voids on the composition, structure, and mechanical properties of the beam. In addition to RFS methodologies, this paper utilizes ANSYS, an engineering simulation software, to validate the findings. With ANSYS modeling capabilities, real-world conditions can be applied, and simulate the effects of defect detection and characterization of the multiple voids. ANSYS offers capabilities for RFS to detect changes in natural frequencies of 3D printed metal parts. With a combination of FEM and analytical methods, this work provides a comprehensive and efficient approach to detecting internal voids, improving quality assurance, and ensuring structural integrity. The methods demonstrated in this work optimize the design and manufacturing process, ensuring the reliability and performance of the 3D printed metal parts for various industries.

Presenting Author: Samaher Shaheen California State University, Chico

Presenting Author Biography: Samaher Shaheen is an undergraduate mechanical engineering student at California State University, Chico. She is working towards her Bachelors of Science in Mechanical Engineering. Her research interests include vibrational analysis methodologies, additive manufacturing, and 3D metal printing. She has previously presented research at Material Research Society Spring 2024 Conference. Her current work focuses on detecting and locating defects within 3D printing metal parts.

Authors:

Samaher Shaheen California State University, Chico
Sam Lloyd-Harry California State University, Chico
Dennis O'connor California State University, Chico