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A. John Hart

Publications and source records attributed to A. John Hart.

33 records · Page 2Linked to original sources

On-lattice voxelated convolutional neural networks for prediction of phase diagrams and diffusion barriers in cubic alloys

Cluster expansion approximates an on-lattice potential with polynomial regression. We show that using a convolutional neural network (CNN) instead leads to more accurate prediction due to the depth of the network. We construct our CNN potential directly on cubic lattice sites, representing voxels in a 3D image, and refer to our method as the voxelated CNN (VCNN). The convolutional layers automatically integrate interaction terms in the regressor; thus, no explicit definition of clusters is required. As a model system, we combine our VCNN potential with Monte Carlo simulations on a Ni$_{1-x}$Al$_x$ ($x$ < 30%) and predict a disordered-to-ordered phase transition with less than 1 meV/atom error. We also predict the energetic landscape of vacancy diffusion. Classification of formation energy with respect to short-range-ordering of Al alloys around a vacancy reveals that the ordering decreases the probability of Ni diffusion. As the width of our input layer does not depend on the atomic composition, VCNNs can be applied to study alloys with arbitrary numbers of elements and empty lattice sites, without additional computational costs.

cond-mat.mtrl-sci↗

Is Machine Learning Able to Detect and Classify Failure in Piezoresistive Bone Cement Based on Electrical Signals?

At an estimated cost of $8 billion annually in the United States, revision surgeries to total joint replacements represent a substantial financial burden to the health care system. Fixation failures, such as implant loosening, wear, and mechanical instability of the poly(methyl methacrylate) (PMMA) cement, which bonds the implant to the bone, are the main causes of long-term implant failure. Early and accurate diagnosis of cement failure is critical for developing novel therapeutic strategies and reducing the high risk of a misjudged revision. Unfortunately, prevailing imaging modalities, notably plain radiographs, struggle to detect the precursors of implant failure and are often interpreted incorrectly. Our prior work has shown that the modification of PMMA bone cement with low concentrations of conductive fillers makes it piezoresistive and therefore self-sensing such that when combined with a conductivity imaging modality, such as electrical impedance tomography (EIT), it is possible to monitor load transfer across the PMMA using cost-effective, physiologically benign, and real-time electrical measurements. Herein, we expand upon these results by integrating machine learning techniques with EIT. We survey different machine learning algorithms and principal component analysis for application to this problem, including neural networks on voltage readings of an EIT phantom for tracking position of a sample, specifying defect location, and classifying defect types. Our results show advantage of neural network with more than 91.9 %, 95.5 %, and 98 % accuracy in interpreting EIT signals for location tracking, specifying defect location, and defect classification respectively. These preliminary results show that the combination of smart materials, EIT, and machine learning may be a powerful tool for diagnosing the origin and evolution of failure in joint replacement.

eess.SP↗

Key principles for workforce upskilling via online learning: a learning analytics study of a professional course in additive manufacturing

Effective adoption of online platforms for teaching, learning, and skill development is essential to both academic institutions and workplaces. Adoption of online learning has been abruptly accelerated by COVID19 pandemic, drawing attention to research on pedagogy and practice for effective online instruction. Online learning requires a multitude of skills and resources spanning from learning management platforms to interactive assessment tools, combined with multimedia content, presenting challenges to instructors and organizations. This study focuses on ways that learning sciences and visual learning analytics can be used to design, and to improve, online workforce training in advanced manufacturing. Scholars and industry experts, educational researchers, and specialists in data analysis and visualization collaborated to study the performance of a cohort of 900 professionals enrolled in an online training course focused on additive manufacturing. The course was offered through MITxPro, MIT Open Learning is a professional learning organization which hosts in a dedicated instance of the edX platform. This study combines learning objective analysis and visual learning analytics to examine the relationships among learning trajectories, engagement, and performance. The results demonstrate how visual learning analytics was used for targeted course modification, and interpretation of learner engagement and performance, such as by more direct mapping of assessments to learning objectives, and to expected and actual time needed to complete each segment of the course. The study also emphasizes broader strategies for course designers and instructors to align course assignments, learning objectives, and assessment measures with learner needs and interests, and argues for a synchronized data infrastructure to facilitate effective just in time learning and continuous improvement of online courses.

cs.HC↗

Interfacial Load Monitoring and Failure Detection in Total Joint Replacements via Piezoresistive Bone Cement and Electrical Impedance Tomography

Aseptic loosening, or loss of implant fixation, is a common complication following total joint replacement. Revision surgeries cost the healthcare system over $8 billion annually in the US. Despite the prevalence of aseptic loosening, timely and accurate detection remains a challenge because traditional imaging modalities such as plain radiographs struggle to reliably detect the early stages of implant loosening. Motivated by this challenge, we present a novel approach for in vivo monitoring and failure detection of cemented joint replacements. Poly(methyl methacrylate) (PMMA) bone cement is modified with low volume fractions of chopped carbon fiber (CF) to impart piezoresistive-based self-sensing. Electrical impedance tomography (EIT) is then used to detect and monitor load-induced deformation and fracture of CF/PMMA in a phantom tank. We therefore show that EIT indeed is able to adeptly detect loading force on a prosthetic surrogate, distinguish between increasing load magnitudes, detect failure of implant fixation, and even distinguish between cement cracking and cement de-bonding. Because EIT is a low-cost, physiologically benign, and potentially real-time imaging modality, the feasibility study herein presented has potential to transform the standard of care for post-operative monitoring of implant conditions. Beyond clinical relevance, this technique could positively impact orthopedic researchers by providing, via in vivo monitoring, insight into the factors that initiate aseptic loosening.

eess.SP↗

Improved Rheometry of Yield Stress Fluids Using Bespoke Fractal 3D Printed Vanes

To enable robust rheological measurements of the properties of yield stress fluids, we introduce a class of modified vane fixtures with fractal-like cross-sectional structures. A greater number of outer contact edges leads to increased kinematic homogeneity at the point of yielding and beyond. The vanes are 3D printed using a desktop stereolithography machine, making them inexpensive (disposable), chemically-compatible with a wide range of solvents, and readily adaptable as a base for further design innovations. To complete the tooling set, we introduce a textured 3D printed cup, which attaches to a standard rheometer base. We discuss general design criteria for 3D printed rheometer vanes, including consideration of sample volume displaced by the vanes, stress homogeneity, and secondary flows that constrain the parameter space of potential designs. We also develop a conversion from machine torque to material shear stress for vanes with an arbitrary number of arms. We compare a family of vane designs by measuring the viscosity of Newtonian calibration oils with error <5% relative to reference measurements made with a cone-and-plate geometry. We measure the flow curve of a simple Carbopol yield stress fluid, and show that a 24-arm 3D printed fractal vane agrees within 1% of reference measurements made with a roughened cone-and-plate geometry. Last, we demonstrate use of the 24-arm fractal vane to probe the thixo-elasto-visco-plastic (TEVP) response of a Carbopol-based hair gel, a jammed emulsion (mayonnaise), and a strongly alkaline carbon black-based battery slurry.

cond-mat.soft↗

Plasticity and damage mechanisms in Ti-6Al-4V printed with selective laser melting

The ability to create complex geometries with tailored material properties has brought interest in using additive manufacturing (AM) techniques in various industrial applications. However, the complex relationship between AM process parameters, microstructure, and resultant properties of metals needs to be fully understood for the widespread use of metal AM. In this study, selective laser melting is used to print Ti-6Al-4V. In-situ tensile tests with concurrent detailed microstructural analysis using electron backscatter diffraction, electron channeling contrast imaging, and digital image correlation are performed to understand the damage mechanism and its relation to the microstructure. Our results show that the as-printed part develops a hierarchical microstructures, consisting of primary, secondary, and tertiary α^' martensite. This hierarchical structure is formed as a result of cyclic heat treatment during the course of selective laser melting. Upon deformation, strain localization within primary α^' martensite results in microscopic ductile micro-void formation and coalescence, as well as macroscopic brittle fracture. In addition to localization inside primary α^', surface steps at the boundaries of these high aspect ratio grains are formed which reveal the contribution of interfacial plasticity to the overall deformation of the material.

physics.app-ph↗

Shear Melting and Recovery of Crosslinkable Cellulose Nanocrystal-Polymer Gels

Cellulose nanocrystals (CNC) are naturally-derived nanostructures of growing importance for the production of composites having attractive mechanical properties, and offer improved sustainability over purely petroleum-based alternatives. Fabrication of CNC composites typically involves extrusion of CNC suspensions and gels in a variety of solvents, in the presence of additives such as polymers and curing agents. However, most studies so far have focused on aqueous CNC gels, yet the behavior of CNC-polymer gels in organic solvents is important to their wider processability. Here, we study the rheological behavior of composite polymer-CNC gels in dimethylformamide, which include additives for both UV and thermal crosslinking. Using rheometry coupled with in-situ infrared spectroscopy, we show that under external shear, CNC-polymer gels display progressive and irreversible failure of the hydrogen bond network that is responsible for their pronounced elastic properties. In the absence of cross-linking additives, the polymer-CNC gels show negligible recovery upon cessation of flow, while the presence of additives allows the gels to recover via van der Waals interactions. By exploring a broad range of shear history and CNC concentrations, we construct master curves for the temporal evolution of the viscoelastic properties of the polymer-CNC gels, illustrating universality of the observed dynamics with respect to gel composition and flow conditions. We therefore find that polymer-CNC composite gels display a number of the distinctive features of colloidal glasses and, strikingly, that their response to the flow conditions encountered during processing can be tuned by chemical additives. These findings have implications for processing of dense CNC-polymer composites in solvent casting, 3D printing, and other manufacturing techniques.

cond-mat.soft↗

Critical Influences of Particle Size and Adhesion on the Powder Layer Uniformity in Metal Additive Manufacturing

The quality of powder layers, specifically their packing density and surface uniformity, is a critical factor influencing the quality of components produced by powder bed metal additive manufacturing (AM) processes, including selective laser melting, electron beam melting and binder jetting. The present work employs a computational model to study the critical influence of powder cohesiveness on the powder recoating process in AM. The model is based on the discrete element method (DEM) with particle-to-particle and particle-to-wall interactions involving frictional contact, rolling resistance and cohesive forces. Quantitative metrics, namely the spatial mean values and standard deviations of the packing fraction and surface profile field, are defined in order to evaluate powder layer quality. Based on these metrics, the size-dependent behavior of exemplary plasma-atomized Ti-6Al-4V powders during the recoating process is studied. It is found that decreased particle size / increased cohesiveness leads to considerably decreased powder layer quality in terms of low, strongly varying packing fractions and highly non-uniform surface profiles. For relatively fine-grained powders (mean particle diameter $17 μm$), it is shown that cohesive forces dominate gravity forces by two orders of magnitude leading to low quality powder layers not suitable for subsequent laser melting without additional layer / surface finishing steps. Besides particle-to-particle adhesion, this contribution quantifies the influence of mechanical bulk powder material parameters, nominal layer thickness, blade velocity as well as particle-to-wall adhesion. Finally, the implications of the resulting powder layer characteristics on the subsequent melting process are discussed and practical recommendations are given for the choice of powder recoating process parameters.

cs.CE↗

Modeling and Characterization of Cohesion in Fine Metal Powders with a Focus on Additive Manufacturing Process Simulations

The cohesive interactions between fine metal powder particles crucially influence their flow behavior, which is in turn important to many powder-based manufacturing processes including emerging methods for powder-based metal additive manufacturing (AM). The present work proposes a novel modeling and characterization approach for micron-scale metal powders, with a special focus on characteristics of importance to powder-bed AM. The model is based on the discrete element method (DEM), and the considered particle-to-particle and particle-to-wall interactions involve frictional contact, rolling resistance and cohesive forces. Special emphasis lies on the modeling of cohesion. The proposed adhesion force law is defined by the pull-off force resulting from the surface energy of powder particles in combination with a van-der-Waals force curve regularization. The model is applied to predict the angle of repose (AOR) of exemplary spherical Ti-6Al-4V powders, and the surface energy value underlying the adhesion force law is calibrated by fitting the corresponding angle of repose values from numerical and experimental funnel tests. To the best of the authors' knowledge, this is the first work providing an experimental estimate for the effective surface energy of the considered class of metal powders. By this approach, an effective surface energy of $0.1mJ/m^2$ is found for the investigated Ti-6Al-4V powder. This value is considerably lower than typical experimental values for flat metal contact surfaces in the range of $30-50 mJ/m^2$, indicating the crucial influence of factors such as surface roughness and chemical surface contamination on fine metal powders. More importantly, the present study demonstrates that a neglect of the related cohesive forces leads to a drastical underestimation of the AOR and, consequently, to an insufficient representation of the bulk powder behavior.

cs.CE↗

Crack formation in wet colloidal pillars

We investigate the initiation of cracks in vertically freestanding water-saturated colloidal pillars constructed using a direct-write technique. Paradoxically, the cracks form during drying at the free end, far from the substrate, where the particle network is unconstrained in contracting its volume as it bears compression by a uniform capillary pressure acting at its outer surface. This is explained by a dominant balance of wetting energy terms, from which follows a simple relationship between the particle size and pillar dimensions that captures the presence or absence of cracks. This relationship provides a practical guideline for fabricating crack-free colloidal structures.

cond-mat.soft↗

Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation

Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes.

physics.app-ph↗

Twist Coupled Kirigami Cellular Metamaterials and Mechanisms

Manipulation of thin sheets by folding and cutting offers opportunity to engineer structures with novel mechanical properties, and to prescribe complex force-displacement relationships via material elasticity in combination with the trajectory imposed by the fold topology. We study the mechanics of cellular Kirigami that rotates upon compression, which we call Flexigami; the addition of diagonal cuts to an equivalent closed cell permits its reversible collapse without incurring significant tensile strains in its panels. Using finite-element modeling and experiment we show how the mechanics of flexigami is governed by the coupled rigidity of the panels and hinges and we design flexigami to achieve reversible force response ranging from smooth mono-stability to sharp bi-stability. We then demonstrate the use of flexigami to construct laminates with multi-stable behavior, a rotary-linear boom actuator, and self-deploying cells with activated hinges. Advanced digital fabrication methods can enable the practical use of flexigami and other metamaterials that share its underlying principles, for applications such as morphing structures, soft robotics and medical devices.

physics.app-ph↗

Fast Desktop-Scale Extrusion Additive Manufacturing

Significant improvements to the production rate of additive manufacturing (AM) technologies are essential to their cost-effectiveness and competitiveness with traditional processing routes. Moreover, much faster AM processes, in combination with the geometric versatility of AM, will enable entirely new workflows for product design and customization. We present the design and validation of a desktop-scale extrusion AM system that achieves far greater build rate than benchmarked commercial systems. This system, which we call FastFFF, is motivated by our recent analysis of the rate-limiting mechanisms to conventional fused filament fabrication (FFF) technology. The FastFFF system mutually overcomes these limits, using a nut-feed extruder, laser-heated polymer liquefier, and servo-driven parallel gantry system to achieve high extrusion force, rapid filament heating, and fast gantry motion, respectively. The extrusion and heating mechanisms are contained in a compact printhead that receives a threaded filament and augments conduction heat transfer with a fiber-coupled diode laser. The prototype system achieves a volumetric build rate of 127 cm3/hr, which is 7-fold greater than commercial desktop FFF systems, at comparable resolution; the maximum extrusion rate of the printhead is ~14-fold greater (282 cm3/hr). The performance limits of the printhead and motion systems are characterized, and the tradeoffs between build rate and resolution are assessed and discussed. The combination of high-speed motion and high deposition rate achieved by the FastFFF technology also poses challenges and opportunities for toolpath optimization and real-time deposition control. High-speed desktop printing raises the possibility of new use cases and business models for AM, where handheld parts are built in minutes rather than hours.

physics.app-ph↗

A Framework for Teaching the Fundamentals of Additive Manufacturing and Enabling Rapid Innovation

The importance of additive manufacturing (AM) to the future of product design and manufacturing systems demands educational programs tailored to embrace its fundamental principles and its innovative potential. Moreover, the breadth and depth of AM spans several traditional disciplines, presenting a challenge to instructors yet giving the opportunity to integrate knowledge via creative and challenging projects. This paper presents our approach to teaching AM at the graduate and advanced undergraduate level, in the form of a 15-week course developed and taught at the Massachusetts Institute of Technology. The lectures begin with in-depth technical analysis of the major AM processes. In lab sessions, students operate and characterize desktop AM machines, and work in teams to design and fabricate a bridge having maximum strength per unit weight while conforming to geometric constraints. To conclude the semester, teams created prototype machines for printing molten glass, soft serve ice cream, biodegradable material, and carbon fiber composites, as well as for large area parallel extrusion and for in situ optical scanning during printing. We conclude that AM education, while arguably rooted in mechanical engineering, is truly multidisciplinary, and that education programs must embrace this context.

physics.ed-ph↗

Fabrication and electrical integration of robust carbon nanotube micropillars by self-directed elastocapillary densification

Vertically-aligned carbon nanotube (CNT) "forest" microstructures fabricated by chemical vapor deposition (CVD) using patterned catalyst films typically have a low CNT density per unit area. As a result, CNT forests have poor bulk properties and are too fragile for integration with microfabrication processing. We introduce a new self-directed capillary densification method where a liquid is controllably condensed onto and evaporated from CNT forests. Compared to prior approaches, where the substrate with CNTs is immersed in a liquid, our condensation approach gives significantly more uniform structures and enables precise control of the CNT packing density and pillar cross-sectional shape. We present a set of design rules and parametric studies of CNT micropillar densification by this method, and show that self-directed capillary densification enhances the Young's modulus and electrical conductivity of CNT micropillars by more than three orders of magnitude. Owing to the outstanding properties of CNTs, this scalable process will be useful for the integration of CNTs as functional material in microfabricated devices for mechanical, electrical, thermal, and biomedical applications.

cond-mat.mtrl-sci↗