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Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications / STEVEN MILWARD

Swansea University Author: STEVEN MILWARD

DOI (Published version): 10.23889/SUthesis.59454

Abstract

The design of components for the optical industry requires a consideration into the thermal expansion co-efficient of the materials used. Often the body material of an optical system exceeds the thermal expansion of the lens material. This can lead to lens decentre and misalignment. This thesis will...

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Published: Swansea 2020
Institution: Swansea University
Degree level: Doctoral
Degree name: Ph.D
Supervisor: Lavery, Nick
URI: https://cronfa.swan.ac.uk/Record/cronfa59454
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first_indexed 2022-02-25T12:16:25Z
last_indexed 2022-03-05T04:26:08Z
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spelling 2022-03-04T11:57:03.7268543 v2 59454 2022-02-25 Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications 07d90b01f43793a2a3ebb11ba538a4eb STEVEN MILWARD STEVEN MILWARD true false 2022-02-25 The design of components for the optical industry requires a consideration into the thermal expansion co-efficient of the materials used. Often the body material of an optical system exceeds the thermal expansion of the lens material. This can lead to lens decentre and misalignment. This thesis will investigate the use of additive manufacturing to tailor the thermal expansion co-efficient of the parts produced so that they match the thermal expansion co-efficient of the lens material. Several state-of-the-art additive manufacturing methods are investigated to achieve this. These include metal laser powder bed fusion, polymer fused deposition modelling, and continuous fibre re-enforced polymer fused deposition modelling. A method used to tailor the co-efficient of thermal expansion focuses on the design of the components, while another method focuses on the adjustment of the materials used. The design of an optical system features two metals with different thermal expansion co-efficients which work together to produce a different overall thermal expansion co-efficient similar to the lens material. Another method investigates the use of the low expansion invar alloy, and the controlled expansion aluminium - silicon alloy. Adjusting the elemental constituents by mixing the alloy powders with elemental powders has shown to successfully change the overall constituents of the printed alloy, opening up the avenue for tailoring thermal expansion in-situ with the build process. A promising method of controlling thermal expansion with polymers is shown by introducing inclusions into the polymer filament feedstock material. The introduction of carbon and glass fibres as well as metal and organic particles shows a remarkable ability to adjust the co-efficient of thermal expansion over a wide range. Using a fibre polymer printer, a composite can be printed with a layer of carbon, glass, or Kevlar fibre laid in a predetermined orientation. This method provides the widest range of thermal expansion control. E-Thesis Swansea LPBF, SLM, L-PBF, CTE, Additive, FDM, composites, thermal expansion, lattice, AlSi, Invar, polymer, AM, in-situ 5 10 2020 2020-10-05 10.23889/SUthesis.59454 COLLEGE NANME COLLEGE CODE Swansea University Lavery, Nick Doctoral Ph.D NRN national research network for Wales This work was partially supported by the Welsh Government and Higher Education Funding Council for Wales through the Sêr Cymru National Research Network in Advanced Engineering and Materials and by the Materials Advanced Characterization Centre (MACH1) at Swansea University. 2022-03-04T11:57:03.7268543 2022-02-25T12:13:24.9934367 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised STEVEN MILWARD 1 59454__22455__e558b89b376c45b59c1876ab41790168.pdf Milward_Steven_PhD_Thesis_Final.pdf 2022-02-25T13:00:34.6627493 Output 24473486 application/pdf E-Thesis – open access true Copyright: The Author, Steven Milward, 2020. true eng
title Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications
spellingShingle Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications
STEVEN MILWARD
title_short Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications
title_full Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications
title_fullStr Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications
title_full_unstemmed Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications
title_sort Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications
author_id_str_mv 07d90b01f43793a2a3ebb11ba538a4eb
author_id_fullname_str_mv 07d90b01f43793a2a3ebb11ba538a4eb_***_STEVEN MILWARD
author STEVEN MILWARD
author2 STEVEN MILWARD
format E-Thesis
publishDate 2020
institution Swansea University
doi_str_mv 10.23889/SUthesis.59454
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
document_store_str 1
active_str 0
description The design of components for the optical industry requires a consideration into the thermal expansion co-efficient of the materials used. Often the body material of an optical system exceeds the thermal expansion of the lens material. This can lead to lens decentre and misalignment. This thesis will investigate the use of additive manufacturing to tailor the thermal expansion co-efficient of the parts produced so that they match the thermal expansion co-efficient of the lens material. Several state-of-the-art additive manufacturing methods are investigated to achieve this. These include metal laser powder bed fusion, polymer fused deposition modelling, and continuous fibre re-enforced polymer fused deposition modelling. A method used to tailor the co-efficient of thermal expansion focuses on the design of the components, while another method focuses on the adjustment of the materials used. The design of an optical system features two metals with different thermal expansion co-efficients which work together to produce a different overall thermal expansion co-efficient similar to the lens material. Another method investigates the use of the low expansion invar alloy, and the controlled expansion aluminium - silicon alloy. Adjusting the elemental constituents by mixing the alloy powders with elemental powders has shown to successfully change the overall constituents of the printed alloy, opening up the avenue for tailoring thermal expansion in-situ with the build process. A promising method of controlling thermal expansion with polymers is shown by introducing inclusions into the polymer filament feedstock material. The introduction of carbon and glass fibres as well as metal and organic particles shows a remarkable ability to adjust the co-efficient of thermal expansion over a wide range. Using a fibre polymer printer, a composite can be printed with a layer of carbon, glass, or Kevlar fibre laid in a predetermined orientation. This method provides the widest range of thermal expansion control.
published_date 2020-10-05T04:16:46Z
_version_ 1763754122237968384
score 11.012678

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