Thin wall fabrication and heat treatment response in additive manufacturing

Thin wall features in additively manufactured components often respond differently to post-processing heat treatments for stress relief compared to bulk material. These differences can lead to unexpected distortion, residual stress retention, or property variation, creating challenges for both design and qualification.

This project focuses on understanding how and why thin walls behave differently from bulk sections during stress-relief heat treatments. The work will examine differences in thermal history, geometry, and material response that arise during fabrication and subsequent heat treatment. Emphasis will be placed on identifying the factors that drive these differences rather than assuming bulk material behavior applies to thin features.

These challenges are particularly relevant for aerospace and nuclear applications, where thin wall structures are common and heat treatment response is tightly coupled to performance and certification requirements. The project will offer opportunities to collaborate with partners working in these application spaces.

Based on this understanding, the project will explore design strategies that can mitigate adverse responses in thin wall structures. The goal is to connect fabrication behavior and heat treatment response to practical design guidance for thin wall features in additively manufactured parts.

The project is intended as an exploratory and understanding-driven study, suitable for an advanced undergraduate student interested in additive manufacturing, heat treatment, and design-for-manufacturing considerations.