Hometown: Jeddah, Saudia Arabia
Graduation date: Fall 2023
MORE | Fall 2023
A study on Aluminum Voxels Characteristics Deposited by a New Metal 3D Printing Method
Resonant-Assisted Deposition (RAD) is an emerging metal additive manufacturing technology that shapes metal wire to form three-dimensional objects. Fundamentally, the physics of this solid-state technique utilizes mechanical energy in the form of small-frequency oscillatory strains to soften metals for forming and joining of voxels into 3D parts line by line and layer by layer. The unique nature of using this form of mechanical energy enables the RAD technique to be more than 100X more energy efficient in comparison with existing metal 3D printing technologies (300 W power consumption at the machine level). Currently at the Technology Readiness Level (TRL) of four, RAD’s material and process capabilities require significant R&D work to advance the technique along its technology development and adoption path. Therefore, this study aims to investigate the fundamental effects of process parameters on various quality characteristics of deposited voxels of Al-1%Si material, including geometrical, morphological, and mechanical properties. Factorial experiments of 2 levels and 3 factors were conducted in the thesis work to examine the effects of tool paths, oscillatory strain amplitudes, and amounts of compression.
Mentor: Keng Hsu
Featured project | Fall 2023
Mohammed Bawareth is a manufacturing engineering graduate student participating in the MORE program. Working with Keng Hsu, an associate professor of manufacturing engineering, Bawareth is advancing the understanding of how an additive manufacturing technology that uses vibrations at frequencies higher than the human ability to hear can improve the energy efficiency of metal 3D printing. He was highly involved in research during his mechanical engineering undergraduate studies at ASU through the FURI and Summer Research Initiative programs and has used his work through MORE to support his master’s degree thesis.
What made you want to get involved in research?
My passion for innovation and discovery drives me to seek a fulfilling career in the field of research and development. I desire to be part of a team that explores uncharted territories, uncovers new knowledge and creates groundbreaking solutions to complex problems. My goal is to make a meaningful contribution to society by expanding the frontiers of science and technology and pushing the limits of what is possible.
How will your engineering research project impact the world?
Resonant-assisted deposition, or RAD, is an emerging metal additive manufacturing technology that forms and joins metal wire to form 3D objects. Fundamentally, the physics of this solid-state technique utilizes mechanical energy in the form of small-frequency oscillatory strains to soften metals for forming and joining voxels into 3D parts line by line and layer by layer. The unique nature of using this form of mechanical energy enables the RAD technique to be more than 100 times more energy efficient in comparison with existing metal 3D printing technologies (300-watt power consumption at the machine level).
One of my favorite selling points of my project is the potential for manufacturing in outer space, which could be a game changer. Currently, metal production in space is impossible for many reasons. However, this technology solves two significant challenges associated with space manufacturing. First, it consumes 100 times less energy than other metal additive manufacturing techniques. Secondly, it has the ability to deform and diffuse solid-state metal, unlike other metal additive manufacturing techniques that require powder, which is difficult to control in space.
Beyond applications, this technology would lead to a better fundamental understanding of ultrasound’s effect on metal or other materials when the effect is combined with another type of energy source such as mechanical or thermal.
Have there been any surprises in your research?
My current research has brought many surprises my way. However, the biggest surprise has been my mentor, Professor Keng Hsu. He possesses a remarkable talent for communicating fundamental concepts implicitly, effortlessly translating high-level language intended for users into low-level language suitable for machines. He provides technical training with patience, handles difficult problems and people with ease and offers moral support to all members of his team.
What is the best advice you’ve gotten from your faculty mentor?
My mentor keeps emphasizing the importance of cultivating the ability to translate user-oriented high-level language to machine-oriented low-level language to lead a meaningful research and development career.
How do you see this experience helping with your advanced degree and career goals?
This experience supports my master’s degree thesis. In the future, it will lead to a new research and development endeavor; specifically, I am planning to join a doctoral degree program here at ASU with Professor Keng Hsu’s team.
What advice do you have for other students who might be interested in the MORE program or research in general?
You need to find your “why” and start with your needs.