metal 3d printing of low-nox fuel injectors with …...•begin the re-design and fabrication of a...
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Metal 3D Printing of Low-NOx Fuel Injectors with Integrated
Temperature SensorsTorres, J., 1,3 Mireles, J., 1,3 Chowdhury, A., 1,2 Wicker, R.,1,3 Choudhuri, A.,1,2
1 Department of Mechanical Engineering, The University of Texas at El Paso2 Center for Space Exploration and Technology Research, The University of Texas at El Paso
3 W.M. Keck Center for 3D Innovation, The University of Texas at El Paso
Process Characterization:
Objective:• To utilize additive manufacturing for the fabrication of
seamless low-NOx fuel injectors with integrated
temperature measurement capabilities.
Electron Beam Melting:
Results
Future WorkMethodology & Materials
Introduction
Powder removal methodologies:
Powder removal demonstration:
The authors acknowledge the financial support for this work by
the DOE - National Energy Technology Laboratory. Award
Number:DE-FE0026330.
Acknowledgements
Student Involvement
• Evaluate other powder removal methods including process
parameter variations.
• Begin the re-design and fabrication of a Low-NOx fuel injector
given design constraints.
Takeaways:
Process characterization:
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
Task 1: Development of design methodologies for EBM
Fabrication of test parts for technology evaluation
Evaluation of test parts
Re-design for AM of Low-NOx fuel injector
Alternative designs for sensor integration
Task 2: Development of powder removal techniques
Powder removal for internal channels
Powder removal for internal cavities
Process parameter modifications for optimal powder sintering
Task 3: Testing of EBM-fabricated fuel injectors
Functionality assessment of EBM-fabricated fuel injector
Year 1 Year 2 Year 3
Letter Feature Factor Tested
A Square base
Dimensional accuracy
B Lateral ridges (+)
C Lateral ridges (-)
D Descending cylinders (-)
E Descending cylinders (+)
F Staircase (-)
G Staircase (+)
H Cylinders (-)
I Cylinders (+)
J Ramps Surface roughness
K Rectangular prisms Linear displacement error
L Tensile bar Ultimate tensile strength
EBM part fabrication:
Test parts fabricated
from different
machine models
a) A2X, b) A3, c) S12
a) b)
c)
Test parts fabricated for powder removal
demonstration, each containing different
sized output channels (1mm - 6mm)
Measurement setup
Process characterization:
• Features smaller than 2.5 mm become deformed and the
fabricated part measured larger than the intended geometry.
• Features larger than 2.5 mm are very close to the intended
geometry.
• Walls tend to be thicker than the intended geometry, which may
be due to surface roughness due to powder size.
Powder removal:
• Powder removal did not progress after 10 minutes of removing
powder using the machine’s powder removal station.
• Ultrasonic powder removal method is currently under further
evaluation.
13
13.5
14
14.5
15
15.5
16
16.5
17
17.5
18
1 mm hole 2 mm hole 4 mm hole 6 mm hole
Wei
ght
(gra
ms)
19mm Cylinder
Weight Initial Weight (+2 min) Weight (+2 min) Weight (+2 min) Weight (+2 min)
126
127
128
129
130
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134
135
1 mm hole 2mm hole 4 mm hole 6 mm hole
Wei
ght
(gra
ms)
35mm Cylinder
Weight Initial Weight (+2 min) Weight (+2 min) Weight (+2 min) Weight (+2 min) Weight (+2 min)
38
39
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41
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44
45
46
47
1 mm hole 2 mm hole 4 mm hole 6 mm hole
Wei
ght
(gra
ms)
25mm Cylinder
Weight Initial Weight (+2 min) Weight (+2 min) Weight (+2 min) Weight (+2 min) Weight (+2 min)
0
5
10
15
20
Arcam A2 Arcam A2x Arcam S12
Dim
ensi
on
al d
evia
tio
n (
mm
)
Dimensional Deviation vs. Machine Model
0
0.5
1
1.5
2
2.5
3
3.5
4
D1* D2 D3 D4 D5 D6 D7
Dia
met
er (
mm
)
Cylindrical Boss Diameter
Original Arcam A2 Arcam A2x Arcam S12
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
E1 E2 E3 E4 E5 E6 E7**
Dia
met
er (
mm
)
Cylinder Hole Diameter
Original Arcam A2 Arcam A2x Arcam S120
5
10
15
20
25
30
35
Arcam A2 Arcam A2x Arcam S12
Surf
ace
Ro
ugh
nes
s (R
a)
Surface Roughness (45° ramp)
0
5
10
15
20
25
30
Arcam A2 Arcam A2x Arcam S12
Surf
ace
Ro
ugh
nes
s (R
a)
Surface Roughness (10° ramp)
289
289.5
290
290.5
291
291.5
292
292.5
293
293.5
294
294.5
1 mm hole 2 mm hole 4 mm hole 6 mm hole
Wei
ght
(gra
ms)
45mm Cylinder
Weight Initial Weight (+2 min) Weight (+2 min) Weight (+2 min) Weight (+2 min)