Reducing Material Discontinuities in Additively Manufactured Potassium Nitrate and Sucrose Propellant Grains

Hybrid manufacturing, namely the integration of additive manufacturing and casting, 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 cast structures, which significantly reduces structural integrity and can impede the function of some cast final products. This work seeks to evaluate the effects of induced vibration on void formation during procedural stratification casting in additively manufactured forms. The study will employ a two factor experimental design, precise measurement methods, and statistical analysis to quantify the relationship between vibration parameters and void formation. The linear speed and distance traveled of the build apparatus, resulting in induced vibration, will be the parameters under consideration. The results are expected to provide evidence-based recommendations for minimizing voids, thereby improving the quality and reliability of hybrid manufactured castings.