Sep, 2026
ORNL Report
Publications
Showing 143 results for Author: Ahmed A. Hassen
Aug, 2026
Conference Paper
Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency
Thermoforming of short-fiber reinforced thermoplastic sheets offers a viable pathway for producing lightweight composite components; however, inherent anisotropy in fiber reinforced sheets can limit structural performance under multidirectional loading. In this work, short carbon fiber, glass fiber, and hybrid fiber–reinforced PETG sheets were evaluated as candidate feedst…
Aug, 2026
Conference Paper
Influence of Surface Treatment on the Interfacial and Mechanical Performance of Metal-Insert Overmolded Composites
Structural composites with metal inserts are gaining increasing interest enabling light weight design for energy efficiency, provide insulation, corrosion protection without compromising mechanical integrity. Such over molded metal-polymer composites show strong potential in many automotive and aerospace component parts, e.g. car bumper, chassis, door, brackets, fasteners,…
Jul, 2026
Conference Paper
A User-Friendly GUI Tool for Automated Microstructural Analysis of Fiber-Reinforced Composites and Porous Structures
Understanding and quantifying microstructural features such as fiber orientation and porosity is critical for predicting the mechanical behavior and performance of fiber-reinforced polymer composites. Traditional manual analysis is time-consuming, subjective, and unsuitable for high-throughput datasets. We present a graphical user interface (GUI) application that automates…
Jul, 2026
Conference Paper
Demonstration of high-rate manufacturing of π-joint using additive manufacturing
Bonded composite Ï€-joints are critical to support wing geometries in aerospace/aircraft structures. Its lightweight and robust load-bearing capabilities/design guarantee high structural integrity and reliability. Current manufacturing techniques of Ï€-joints are complex and laborious, and do not always offer high-quality joining. This study presents a high-rate manufacturin…
Jun, 2026
Conference Paper
Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency
Thermoforming of short-fiber reinforced thermoplastic sheets offers a viable pathway for producing lightweight composite components; however, inherent anisotropy in fiber-reinforced sheets can limit structural performance under multidirectional loading. In this work, short carbon fiber, glass fiber, and hybrid fiber–reinforced PETG sheets were evaluated as candidate feedst…
May, 2026
Conference Paper
HYBRID COMPOSITES VIA CO-EXTRUSION ADDITIVE MANUFACTURING-COMPRESSION MOLDING FOR PERFORMANCE OPTIMIZATION
The growing demand for hybrid polymer composites with multifunctional properties has led to the development of various hybridization techniques, such as multi-material compounding and controlled laminate stacking sequence. In this study, a novel hybrid manufacturing approach was used by integrating a multiplexing extrusion system (MExS) based on additive manufacturing with…
May, 2026
Journal
Engineering mechanical and thermomechanical performance in additive manufacturing–Compression molded composites through multiplexed extrusion
Traditional extrusion-based additive manufacturing is limited to single material systems, restricting the multifunctional properties of composites. To overcome this limitation, multiplexed additive manufacturing–compression molding (AM-CM) was employed to fabricate multi-material thermoplastic composites with spatially tailored architectures. Neat acrylonitrile butadiene s…
Mar, 2026
Conference Paper
Graded Infill Structure of Wind Turbine Blade Accounting for Internal Stress in Big Area Additive Manufacturing
In additively manufactured (AM) components, infill structure significantly affects the mechanical performance of the final printed part. However, mechanical stress induced by operation loads has been so far neglected for infill patterning. Most slicers currently available in the market provide infill patterns that are uniform in shape and size regardless of the operational…
Mar, 2026
Conference Paper
Large-scale additive manufacturing with reactive polymers
The focus on large-scale polymer Additive Manufacturing (AM) has previously been on thermoplastic materials. However, Magnum Venus Products (MVP) along with researchers at Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) are introducing a unique AM system capable of depositing reactive polymers in a large format. The system’s footprint is 4…
Mar, 2026
Conference Paper
Thermal Analysis of Large Area Additive Manufacturing Resistance Heating Composites for Out of Oven/Autoclave Applications
Additive Manufacturing (AM) of carbon fiber (CF) reinforced composite has received growing attention because of the design flexibility, superior mechanical properties, improved thermal properties, and weight reduction. Autoclave tooling was proven to be a successful application for large scale AM technology. The capital cost, and cost associated with heating, and cycle tim…