Keywords

Metal Additive Manufacturing, Atomic Diffusion Additive Manufacturing, Binder Jetting Printing, Powder Bed Fusion, Qualification approach, Neutron Diffraction, Gas turbine, high temperature material characterization

Abstract

This study aims to introduce a new qualification approach designed to enhance the overall integrity of complex cooling structures in gas turbine blades produced through 3D printing, with a focus on achieving maximum density. The primary objective is to present a comprehensive qualification and validation methodology tailored for components manufactured via binder jetting printing and non-selective laser melting (SLM) powder-based atomic diffusion additive manufacturing. This innovative qualification approach undergoes validation through stages encompassing design, printing, comprehension of thermal debinding and sintering processes, post-processing, optimization, and characterization, all aimed at achieving complex cooling structures with optimal density using stainless steel material and In718 as a case study. Subsequently, the material properties obtained are compared with those of IN718 produced via laser-based manufacturing. Thorough characterization is conducted before and after sintering to assess the impact of sintering on density enhancement. Experimental optimization employing the Taguchi matrix with an L9 orthogonal array involves the selection of three key parameters: sintering time, sintering temperature, and heat treatment. The procedural framework established in this research applies to high-temperature applications wherein components are fabricated using atomic diffusion additive manufacturing or binder jetting printing techniques. Testing and inspection procedures involve neutron scattering, radiography, and CT scanning methods, with a specific emphasis on neutron scattering measurements conducted under externally heated and internally cooled conditions to evaluate residual strains within the gas turbine environment. Understanding the interplay between residual stresses originating from manufacturing processes and thermal stresses provides valuable insights into the impact of additive manufacturing on component performance in thermal environments, thus contributing to the advancement of the proposed study.

Completion Date

2024

Semester

Summer

Committee Chair

Kapat, Jayanta

Degree

Doctor of Philosophy (Ph.D.)

College

College of Engineering and Computer Science

Department

Mechanical and Aerospace Engineering

Degree Program

Ph.D. Mechanical Engineering

Format

application/pdf

Identifier

DP0028554

URL

https://purls.library.ucf.edu/go/DP0028554

Language

English

Release Date

8-15-2025

Length of Campus-only Access

1 year

Access Status

Doctoral Dissertation (Campus-only Access)

Campus Location

Orlando (Main) Campus

Accessibility Status

Meets minimum standards for ETDs/HUTs

Download

Restricted to the UCF community until 8-15-2025; it will then be open access.

Share

COinS