Vibration-induced void reduction in high particle load propellant suspensions

Abstract

Hybrid manufacturing, namely the integration of fusion deposition manufacturing and liquid deposition manufacturing, has the potential to combine geometric freedom with superior mechanical performance and manufacturing speed. A persistent challenge in this hybrid process is the occurrence of voids within the highly viscous, particle loaded fluid structures, which significantly reduces structural integrity, causes particle concentrations, and can impede the function of the final product. This work evaluated the effects of induced vibration on void reduction during procedural stratification in additively manufactured forms. The study employed a two factor experimental design, precise measurement methods, and statistical analysis to quantify the relationship between vibration parameters and void reduction. The linear speed and distance traveled of the build apparatus, resulting in induced vibration, were the parameters under consideration. The results can be used to identify an optimal configuration for minimizing voids, thereby improving the quality and reliability of hybrid manufactured propellant grains.