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Towards Defect-Free Printing of High-Strength Aluminium Alloys

Rooijen, T.L. van (2024) Towards Defect-Free Printing of High-Strength Aluminium Alloys.

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Abstract:The Friction Screw Extrusion Additive Manufacturing (FSEAM) approach is developed as a solid-state additive manufacturing alternative to overcome problems of aluminium and magnesium alloys in fusion-based additive manufacturing. The current system is prone to unsteady, varying material flow rates at certain process conditions affecting the product’s geometrical stability. Furthermore, a research gap exists on the role of the tool gap and the tool rotation rate on the system’s parameters, which is crucial for further optimization of FSEAM. An extensive systematic experimental study was performed in this thesis with a modified Friction Screw Extrusion (FSE) setup based on the principles of FSEAM. The experiments were performed with various tool rotation rates, tool gaps and extrusion speeds. The FSE experiments were conducted successfully. Detailed analysis of the video recordings successfully retrieved material extrusion speed data. A small region in the process window showed speed variations compliant with FSEAM observations. Correlation analysis revealed clear linear correlation between variations in extrusion speed and normal force in that region of the process window. The developed correlation method was found to be a clear indicator in predicting the occurrence of extrudate speed variation. Severity coefficients were proposed, which could possibly be used for improved process control.
Item Type:Essay (Master)
Faculty:ET: Engineering Technology
Subject:52 mechanical engineering
Programme:Mechanical Engineering MSc (60439)
Link to this item:https://purl.utwente.nl/essays/98195
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