Boeing

AM Machine Gas Flow Characterization & Improvements - Phase 3

Gas flow in metal AM printers is a key process variable. Recirculation and non-uniformity of the gas flow in a printer can be a source of material defects. This student team worked to generate PIV analysis of the baseline gas flow in an EOSM290 printer, and to design devices to improve upon the EOSM290 gas flow test developed by the 2022 & 2023 capstone teams. This student team worked to use CFD to develop easily attachable devices for the EOSM290 AM printer to reduce recirculation and improve gas flow uniformity and generate PIV analysis of the improvements. This student team also worked to analyze materials printed with the improvements and/or different gas flow settings to demonstrate the impact on material properties from gas flow. The student team worked to collect new, targeted Particle Image Velocimetry (PIV) gas flow measurement data to correlate it with existing material performance data (either from UW or provided by Boeing). This student team also worked to build and validate the improvement devices with PIV testing in a mock-up EOSM290 printer developed by prior capstone teams, then worked to build and test materials on the actual UW EOSM290 with these improvement devices to determine if they had an effect on material performance or defect rates.