Metal 3D Printing of Low-NOX Fuel Injectors with Integrated Temperature Sensors (Final Technical Report)
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This technical report presents the exploration of design and prototyping of an Oxy-fuel injector with integrated temperature sensing capabilities using Additive Manufacturing (AM) technology. The AM process has proven itself as a viable method to fabricate complex shapes for custom-designed metallic components rapidly. The lack of assembly requirements and the virtually unlimited geometrical complexity renders the AM process particularly attractive for fabricating complex energy system components. The unique layer-by-layer fabrication technique allows the embedding of sensors within complex components early in the design process. Sensors can be embedded (without post-production component modifications) in AM-fabricated components through two distinct processes: Stop and Go or Post-Integration. The Stop and Go fabrication process allows sensor placement within a cavity during fabrication; where the process is allowed to continue upon sensor placement. Post-integration process supports selective build of customized compartments for sensors within the part. The Stop and Go process requires an extremely accurate re-alignment of the powder-bed during the restart process. Additionally, metallization and shorting of sensors due to a considerably high temperature of the AM process creates significant fabrication challenges and limit the types of sensors that can be embedded. The Post-Integration of sensors is a practical alternative for components that can be effectively designed and fabricated with pre-built complex sensor compartments without the need for post-production component modifications. The proposed effort aimed at exploring the fabrication of an oxy-fuel injector designed for high-pressure Oxy-Combustion applications (Combustor for Directly Heated Supercritical Power Cycle) with integrated temperature measurement capabilities using the AM technique. Since the current design methodology of injectors is based on conventional fabrication techniques (e.g., multi-step machining and welding processes), a new paradigm of design methodology needs to be developed for their adaptation in the AM fabrication process. One of the most challenging issues addressed in powder bed fusion is the removal of powder from internal channels/cavities as the powder to be removed has been lightly sintered during the fabrication process. In this research, a major task has been assigned to developing and evaluating powder removal techniques that will ultimately be used when removing sintered powder from cavities/channels used for sensor placement. Achieving thorough powder removal will permit the incorporation of intricate cavities, integrated fasteners, or other novel features to incorporate sensors into parts directly post-fabrication – allowing for the novel, AM-based design practices to be developed and employ for sensor integration. The designed injector was initially tested at atmospheric conditions to review its successful operation. The tests were carried out for different firing inputs; with a minimum of 55 kW and a maximum of 275 kW. Later tests were carried out for pressurized conditions between 82 kW to 275 kW firing input. A pressure of 16.35bar was observed in the combustion chamber pressure during the pressurized test of 275 kW firing input; test duration was 15 seconds. Integrated thermocouples within the injector provided temperature data for test operations. The data revealed during the atmospheric condition the injector temperature is almost unaffected by the combustion. However, during the pressurized condition, the injector temperature rapidly up to 205°C within 15 seconds; at a 275 kW firing input.Keywords:
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In the last few years new fabrication methods, called rapid prototyping (RP) techniques, have been developed for the fabrication of hydroxyapatite scaffolds for bone substitutes or tissue engineering applications. With this generative fabrication technology an individual tailoring of the scaffold characteristics can be realised. In this work two RP techniques, a direct (dispense-plotting) and an indirect one (negative mould technique), are described by means of fabricating hydroxyapatite (HA) scaffolds for bone substitutes or bone tissue engineering. The produced scaffolds were characterised, mainly regarding their pore and strut characteristics. By these data the performance of the two fabrication techniques was compared. Dispense-plotting turned out to be the faster technique while the negative mould method was better suited for the fabrication of exact pore and strut geometries.
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The porous structure of anodes in SOFCs is the key factor to improve its performance and the manufacturing method to control its design needs to be established. Additive manufacturing, so-called 3D printing technology can be a prospective method for the fabrication of electrodes of SOFCs. In this experiment, stereolithography, which is a form of 3D printing technology using UV-light with approximately 365nm wavelength and photo-curable resin, is applied. The UV-light that goes through pinholes enables the production of multiple cylindrical objects at once. As a result, the objects and the empty spaces between them make the porous structure. Moreover, by changing the size and the number of holes and distance between them, the fabrication of an anode with the desired microstructure can be expected.
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Stereolithography is a novel fabrication process based on and developed by layer manufacturing,and the fabrication time of the prototyping parts is one of the key issues during manufacturing.The time mainly comprises of two parts,one is the scanning time to cure liquid resin,and the other is the auxiliary time to assure normal fabrication process whose decrease helps to the shortening fabrication time.The choice of the fabrication direction is another main influence factor,and suitable direction can cut down the time greatly.The scanning parameters affects the fabrication efficiency and large hatch space is going to shorten the reciprocating distance during the scanning,attaining the aim to reduce the prototyping time.
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3D printing is called as desktop fabrication. It is a process of prototyping where by a structure is synthesized from a 3d model. The 3d model is stored in as a STL format and after that forwarded to a 3D printer. It can use a wide range of materials such as ABS,PLA, and composites as well.3D printing is a rapidly developing and cost optimized form of rapid prototyping.The 3D printer prints the CAD design layer by layer forming a real object. 3D printing process is derived from inkjet desktop printers in which multiple deposit jets and the printing material, layer by layer derived from the CAD 3D data. 3D printing significantly challenges mass production processes in the future. This type of printing is predicted to influence industries, like automotive, medical, education, equipment, consumer products industries and various businesses.
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Fused Deposition Modeling (FDM), better known as 3D printing, has revolutionized modern manufacturing processes and the ever-increasing use of 3D printers is popular not least because of the wide range of materials available for printing. When applying the FDM process to the development of prototypes, it is possible to go from an idea to a first iteration of the product within a few hours, and from an initial concept to a final product within a few days depending on the complexity of the desired structure. We applied FDM-related open-source 3D software and a 3D printer to produce parts for devices being applied in wood anatomy and dendroecology. In this paper, we present the basic requirements for prototyping by showing detailed examples of new devices developed and produced using a 3D printer and related modeling software.
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3D printing is called as desktop fabrication. It is a process of prototyping where by a structure is synthesized from a 3d model. The 3d model is stored in as a STL format and after that forwarded to a 3D printer. It can use a wide range of materials such as ABS, PLA, and composites as well.3D printing is a rapidly developing and cost optimized form of rapid prototyping. The 3D printer prints the CAD design layer by layer forming a real object. 3D printing process is derived from inkjet desktop printers in which multiple deposit jets and the printing material, layer by layer derived from the CAD 3D data. 3D printing significantly challenges mass production processes in the future. This type of printing is predicted to influence industries, like automotive, medical, education, equipment, consumer products industries and various businesses
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Abstract: In R&D there is need of rapid prototyping to validate new concepts. 3D printing is widely used now a days For rapid prototyping of new concepts. As there are numerous 3D printing technologies are available now in market so it is always difficult to select correct 3D printing technology to replicate plastic material as per requirement in prototyping. Engineers in industry initially struggle or spend time to select best suited 3D printing technology for rapid prototyping of their concept or part. In this study we will be reviewing different available 3D printing technologies and its capabilities in terms of adding properties in printed parts. We will be selecting most common plastic which are being used in industry. For selected materials best suited 3D printing technologies will be compared on the basis of required material properties Keywords: 3D printing, Plastics, RPT, Comparison, Product
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Abstract: 3D printing is called as desktop fabrication. It is a process of prototyping where by a structure is synthesized from a 3d model. The 3d model is stored in as a STL format and then forwarded to a 3D printer. It can use a good range of materials like ABS, PLA, and composites also .3D printing may be a rapidly developing and price optimized sort of rapid prototyping. The 3D printer prints the CAD design layer by layer forming a true object. 3D printing springs from inkjet desktop printers during which multiple deposit jets and therefore the printing material, layer by layer derived from the CAD 3D data. 3D printing significantly challenges production processes within the future. This type of printing is predicted to influence industries, like automotive, medical, education, equipment, consumer products industries and various businesses. Keywords: 3d printing, Rapid Prototyping, ABS, PLA
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Purpose The purpose of this paper is to investigate the process of rapid prototyping eddy current sensors using 3D printing technology. Making full use of the advantages of 3D printing, the authors study on a new method for fabrication of an eddy current sensor. Design/methodology/approach In this paper, the authors establish a 3D model using SolidWorks. And the eddy current sensor is printed by the fused deposition modeling method. Findings Measurement results show that the 3D printing eddy current sensor has a wider linear measurement range and better linearity than the traditional manufacturing sensor. Compared to traditional eddy current sensor fabrication method, this 3D printed sensor can be fabricated at a lower cost, and the fabrication process is more convenient and faster. Practical implications This demonstrated 3D printing process can be applied to the 3D printing of sensors of more sophisticated structures that are difficult to fabricate using conventional techniques. Originality/value In this work, the process of rapid prototyping eddy current sensors using 3D printing is presented. Sensors fabricated with the 3D printing possess lots of merits than traditional manufactures. 3D printed sensors can be customized according to the configuration of the overall system, thus reducing the demand of sensor's rigid mounting interfaces. The 3D printing also reduce design costs as well as shortens the development cycle. This allows for quick translation of a design from concept to a useful device.
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3D printing is called as desktop fabrication. It is a process of prototyping where by a structure is synthesized from a 3d model. The 3d model is stored in as a STL format and after that forwarded to a 3D printer. It can use a wide range of materials such as ABS, PLA, and composites as well.3D printing is a rapidly developing and cost optimized form of rapid prototyping. The 3D printer prints the CAD design layer by layer forming a real object. 3D printing process is derived from inkjet desktop printers in which multiple deposit jets and the printing material, layer by layer derived from the CAD 3D data. 3D printing significantly challenges mass production processes in the future. This type of printing is predicted to influence industries, like automotive, medical, education, equipment, consumer products industries and various businesses
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