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Michael Maravola's Thesis.pdf (3.62 MB)

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Low Coefficient of Thermal Expansion Composite Tooling Manufactured via Additive Manufacturing Technologies

Maravola, Michael
http://rave.ohiolink.edu/etdc/view?acc_num=ysu154704993501967

Abstract Details

2018, Master of Science in Engineering, Youngstown State University, Department of Civil/Environmental and Chemical Engineering.
The incorporation of additive manufacturing (AM) enables the ability to fabricate composite tooling molds rapidly and in a cost effective manner. This work has demonstrated the practice of an additive technology for manufacturing composite processing tools. In particular, this work has addressed tooling that is functional in the range of autoclave temperatures around 180°C. This has led to the use of Invar and ceramic materials for use in composite molding tools because of their relatively low coefficient of thermal expansion (CTE) performance, which is in range to that commonly displayed by carbon fiber reinforced composites during their solidifying curing process. In this project, three main approaches have been considered. The first innovative approach was based on printing a mold based on silica sand and infiltrating it with a polymer to yield a robust ceramic composite tooling. The second approach investigated the use of binder jetting to 3D print sand molds to cast molten Invar to produce the composite tooling. Indeed, 3D sand printing offers the ability to cast complex geometries without the geometric limitations associated with conventional pattern making. An additional technology using a Hybrid Direct Energy Deposition (DED) System for cladding Invar upon a steel molding structure has also been considered for producing potential composite tooling. Indeed, this unique approach could represent a promising technology for producing low cost composite tooling since only a small layer of Invar would be cladded to a non-expensive substrate. The results have shown that the aforementioned processes have successfully resulted in low CTE composite tooling molds. This work presents innovative AM processes by initially investigating additive manufacturing processes for composite tooling.
Pedro Cortes, PhD (Advisor)
Brett Conner, PhD (Committee Member)
Jason Walker, PhD (Committee Member)
115 p.
Materials Science
Additive manufacturing; 3D printing; Composite tooling; Low coefficient of thermal expansion

Recommended Citations

Citations

  • Maravola, M. (2018). Low Coefficient of Thermal Expansion Composite Tooling Manufactured via Additive Manufacturing Technologies [Master's thesis, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu154704993501967

    APA Style (7th edition)

  • Maravola, Michael. Low Coefficient of Thermal Expansion Composite Tooling Manufactured via Additive Manufacturing Technologies. 2018. Youngstown State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu154704993501967.

    MLA Style (8th edition)

  • Maravola, Michael. "Low Coefficient of Thermal Expansion Composite Tooling Manufactured via Additive Manufacturing Technologies." Master's thesis, Youngstown State University, 2018. http://rave.ohiolink.edu/etdc/view?acc_num=ysu154704993501967

    Chicago Manual of Style (17th edition)

ysu154704993501967
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This open access ETD is published by Youngstown State University and OhioLINK.