Enhanced performance of magnetic floating devices enabled through metal additive manufacturing

Examensarbete för masterexamen

Please use this identifier to cite or link to this item: https://hdl.handle.net/20.500.12380/300770
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Bibliographical item details
Type: Examensarbete för masterexamen
Title: Enhanced performance of magnetic floating devices enabled through metal additive manufacturing
Authors: Mehta, Bharat
Abstract: This master’s thesis work is focused on establishing the functionalities that can be achieved by utilising additive manufacturing in products currently manufactured using traditional techniques. Additive manufacturing is seen to be a game changer in the current manufacturing scenario. With the fact that complex parts can be made easily and higher design freedom is available, it is possible to push design and material limits further by employing concepts such as lattice structures and topology optimised structures in order to obtain higher strength to weight ratios. Hence, a primary study into the designability of a magnetic floating device was done. It was followed by a secondary study into the mass-manufacturability aspect which is mostly affected by printing parameters. For this master’s thesis work, a family of products which work as floating devices, currently being manufactured at ABB, have been selected to investigate and develop a mass-manufacturable design which can provide much higher specific buckling strength than the current manufacturing methods. It was critical to keep the products similar or better in all performance characteristics (such as corrosion resistance, temperature performance, surface roughness, etc.). The investigation was not limited to using additive manufacturing but rather to suggest optimised techniques to design and manufacture the product family. The material used to study in this thesis was 316L stainless steel, since ABB typically uses the same material for manufacturing the product and it was readily available for additive manufacturing. As a result, several stiffened structures were shown for this product, which were simulated to show significant improvement in performance and manufacturability, improving the specific buckling strength by about three times the current part. From the experiments conducted, a relation between the failure mode of thin shell under uniaxial compression was developed and tailored properties of lattice structures were also studied. Furthermore, an extended study into the effect of laser power, layer thickness, laser speed and scan strategy was also conducted to understand the mass manufacturability of thin cylindrical shells.
Keywords: Additive manufacturing;Laser powder bed fusion;thin wall shells;lattice structures;LPBF process parameters;3D printing;316L stainless steel
Issue Date: 2020
Publisher: Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap
URI: https://hdl.handle.net/20.500.12380/300770
Collection:Examensarbeten för masterexamen // Master Theses (IMS)

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