Researchers at Kennesaw State University have found that adjusting 3D printing build settings can make printed components nearly three times stronger. The study, led by Assistant Chair Aaron Adams and mechatronics engineering student Eric Miller, focuses on how internal structural features affect performance in critical applications such as nuclear energy.
The research aims to address limitations in current nuclear fuel usage. “Right now, the fuel is in the form of a pellet about the size of a penny, and the pellets are stacked together like a roll of coins,” said Adams, an associate professor of mechanical engineering technology. “These fuel pellets are then placed inside a fuel rod. When the nuclear reaction begins, they heat up, expand, and come into contact with the rod wall. Because they have no room to expand, they must be removed before the fuel is completely depleted, limiting how much of the fuel can be used.”
The team is exploring how 3D printing can create internal channels and lattice structures that allow materials room to expand. Adams stated the goal is to “achieve a 15 percent increase in fuel utilization using complex geometries.” Miller’s work involves designing models, preparing simulations, and using Finite Element Analysis to test various combinations of lattice angles and densities.
The project, supported by KSU’s Summer Undergraduate Research Program and Sophomore Scholars Program, has presented computational challenges. “If you sum up our biggest challenge in one word, it’s resources, specifically our ability to run highly computational simulation models,” Adams said. Miller will present the team’s findings at an upcoming American Society of Mechanical Engineers conference.
Miller noted the research has expanded his understanding beyond his typical coursework. “Getting into strength of materials and FEA has been a great learning experience,” he said. “Even when something appears to be a failure, it’s still a success because it tells us what direction not to take.”
Source: kennesaw.edu