Doctoral Dissertations
Abstract
"This work investigates Laser Foil Printing (LFP), a novel metal additive manufacturing (AM) process that fabricates parts layer-by-layer using metal foils. To enhance LFP productivity, the process steps were optimized, and an 88.1% reduction in processing duration was achieved. A unique aspect of this study was the introduction of laser polishing as an edge polishing technique within the LFP process. This innovative approach, employing an overlapping spiral pattern, leverages selective laser remelting and erosion to effectively suppress elevated edges. To stabilize the molten melt pool, a discrete spot scanning strategy was implemented. The fabricated parts were subjected to detailed analysis, including melt pool dimension evaluation using scanning electron microscopy (SEM) and residual stress assessment using X-ray diffraction (XRD). Compared to line-raster scanning, discrete spot scanning resulted in a 18.6% reduction in residual stresses. Grain size analysis, conducted using electron backscatter diffraction (EBSD), revealed a correlation with the observed reduction in residual stresses. Additionally, temperature sensors were successfully embedded into metal parts using the discrete scanning strategy. To gain further insights into the melt pool dynamics and thermal behavior, numerical simulations and infrared (IR) thermography were conducted for both continuous line and discrete spot scanning strategies. The simulation model accurately predicted melt pool dimensions, achieving an accuracy range of 81.1% to 96.8%. IR measurements revealed that continuous line scanning produced larger melt pools with varying cooling rates along the path, while discrete spot scanning offered a more uniform surface thermal gradient and consistent cooling rates"-- Abstract, p. iv
Advisor(s)
Leu, M. C. (Ming-Chuan)
Park, Jonghyun
Committee Member(s)
Liou, Frank W.
Newkirk, Joseph William
Chandrashekhara, K.
Department(s)
Mechanical and Aerospace Engineering
Degree Name
Ph. D. in Mechanical Engineering
Publisher
Missouri University of Science and Technology
Publication Date
Spring 2025
Pagination
xvii, 170 pages
Note about bibliography
Includes_bibliographical_references_(pages 40, 78, 106, 156 and 165-168)
Rights
©2024 Tunay Turk , All Rights Reserved
Document Type
Dissertation - Open Access
File Type
text
Language
English
Thesis Number
T 12476
Recommended Citation
Turk, Tunay, "Sensor Embedding And Thermal Monitoring Strategies For Laser-Foil-Printing Additive Manufacturing" (2025). Doctoral Dissertations. 3364.
https://scholarsmine.mst.edu/doctoral_dissertations/3364
