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Development Of Superior Energy Absorbing Devices With Adaptive Capabilities Utilizing Hybrid Cutting/Clamping Deformation Modes, John Magliaro

Electronic Theses and Dissertations

The primary objective of this research was to investigate cutting deformation modes, employing higher-bladed cutters (i.e. 6 or more evenly space blades), with an emphasis on superior energy absorbing capabilities in comparison to axial crushing, the current state-of-the-art. A series of test cases involving AA6061 extrusions were identified utilizing analytical models of the steady-state cutting force and mean crushing force and selecting geometries where the ratio of the former force normalized with respect to the latter exceeded unity. Quasi-static testing confirmed that the total energy absorbing capacity could be exceeded while simultaneously reducing the peak force under quasi-static loading for …

Development Of Superior Energy Absorbing Devices With Adaptive Capabilities Utilizing Hybrid Cutting/Clamping Deformation Modes, John Magliaro

Electronic Theses and Dissertations

The primary objective of this research was to investigate cutting deformation modes, employing higher-bladed cutters (i.e. 6 or more evenly space blades), with an emphasis on superior energy absorbing capabilities in comparison to axial crushing, the current state-of-the-art. A series of test cases involving AA6061 extrusions were identified utilizing analytical models of the steady-state cutting force and mean crushing force and selecting geometries where the ratio of the former force normalized with respect to the latter exceeded unity. Quasi-static testing confirmed that the total energy absorbing capacity could be exceeded while simultaneously reducing the peak force under quasi-static loading for …

Correlating Fracture Toughness And Surface Roughness For A Ductile Epoxy Adhered To Aluminum Substrates, Kurt Ryan Smith

Masters Theses

Adhesively bonded joints are used across multiple disciplines as an efficient and cost effective method for reinforcing, repairing, or creating new structures. Sufficient understanding of the bond line characteristics of the adhesive is necessary to properly design a reliable bonded joint and ensure a long service life. It is well understood that surface preparation has a significant impact on these interface characteristics as a given level of surface roughness achieves mechanical interlocking between the resin and metal and is important to prevent premature interfacial failure [1]. The goal of this study is to characterize the fracture toughness values for an …

Effect Of Surface Roughness And External Loading On Embedment In Steel And Aluminum Bolted Joints, Nathan Stang

Electronic Theses and Dissertations

Embedment in bolted joints is defined as the local deformation of surfaces into one another due to uneven contact. Embedment that occurs after the tightening of a bolted joint can cause loss of preload in the joint potentially leading to failure. VDI 2230, a German standard for bolted joint design, is currently the main source for engineers regarding embedment. It related expected embedment to the surface roughness in steel bolted joints. This research expands on the VDI standard by performing tests on a commonly used aluminum alloy and a steel alloy. Both cold rolled 1045 steel and 6061- T6511 aluminum …

Thermomechanical Mechanisms That Cause Adhesion Of Aluminum High Pressure Die Castings To The Die, Alex Monroe

Dissertations, Master's Theses and Master's Reports

In high pressure die casting (HPDC) of aluminum, cast material adhering to die is a significant defect. Adhesion occurs in two primary ways. The casting may stick preventing its removal from the die. Aluminum can also adhere to the die and buildup in local areas on the die surface with additional casting cycles. This second form of adhesion is called soldering. Lubricant is the best technology to control all forms of adhesion, but it comes at the cost of casting porosity, blisters, reduced die life, and increased die casting machine wear. New strategies to prevent adhesion are desired to eliminate …

Molten Aluminum Capillary Hole-Filling, Cheng-Nien Yu

Theses and Dissertations--Mechanical Engineering

The presence of micrometeoroids and space debris in open space raises the question of a mitigation of the damage caused by a possible impact on the man-made structures such as space shuttles, satellites, and the International Space Station. A method achieving metallic sealed hole would be of an interest for development. This dissertation studies a surface tension driven capillary filling/sealing phenomenon in a controlled atmosphere brazing process of aluminum. The filled vs. non-filled results are predictable using minimization of energy, which shows that the outcomes depend heavily on prescribed configurations of the hole. Equilibrium models show excellent agreement with experimental …

Study Of Wire Arc Additive Manufacturing With Aluminum Alloy 2219, Sritam Kumar Dash

Theses and Dissertations

This thesis discusses WAAM (wire arc additive manufacturing) technology using TIG (Tungsten Inert Gas) welding method with aluminum 2219 as the substrate and aluminum 2319 as the filler material. The most important characteristic of this method of manufacturing is very little wastage of material as it does not follow the conventional method of manufacturing where material is removed from a bigger block to finally achieve the desired shape. This method uses a layer by layer approach to build the part. Generally, in additive manufacturing, the production time may vary depending on the type of method used. The material deposition rate …

Improving The Delivered Specific Impulse Of Composite Rocket Propellant Through Alteration Of Chemical Composition: Methodology And Parameters For Characterization Of Propellant And Validation Of Simulation Software Common To The Amateur Rocketry Community, Isaac O'Brien, Austin Ryan

Williams Honors College, Honors Research Projects

In this study, two solid composite rocket propellants were designed utilizing ProPEP, a rocket propellant formulation software common in the amateur and hobby rocketry communities. The two propellants were designed to optimize specific impulse relative to a literature propellant designed by 1020 Research Labs. The literature propellant was also tested in order to validate the design of experiment as well as the mixing and testing procedures. All three propellants, which includes the literature propellant RCS-P, and the two novel propellants AKR-P1 and AKR-P2 were characterized with static tests. The results of the static tests provide data on propellant performance and …

Laser Ablation Of Aluminum, Erika Nosal, Zachary Rahe, Arthur Pamboukis

Williams Honors College, Honors Research Projects

The laser ablation of metal carries relevance in a variety of engineering industries. This includes, but is not limited to, processes such as micromachining, or implementation on aircraft weaponry. The latter application is the reasoning for why aluminum is the specific metal in consideration, as it is commonly used for the construction of aircraft components.

The scope of this project was to optimize the energy dispersed through laser ablation on aluminum by mathematical modeling. The transient conduction process in the aluminum was modeled using a 2-dimensional cylindrical coordinate system in both MATLAB and ANSYS/Fluent. These models were adopted to simulate …

All-Terrain Storage Surfboard Carts, Ben M. Kennedy, Danny Riedeman, Roberto Gonzalez

Mechanical Engineering

All Terrain Storage consists of three mechanical engineering students: Roberto Gonzalez, Ben Kennedy, and Danny Riedeman. The goal of All Terrain Storage is to design and create two portable storage devices for the non-profit organization AmpSurf. AmpSurf helps veterans, people with disabilities, and anyone else who could be helped through adaptive surfing and other outdoor activities. Their current method of storing and transporting equipment for events is carrying it from the trailer in the parking lot through the sand onto the beach. This document will provide: a more thorough introduction to AmpSurf and the project, the objectives, background information, the …

In Silico Analysis Of Advanced Processing Methods For Light-Weight Alloys Powders, Marjan Nezafati

Theses and Dissertations

Light-weight Al and Mg-based metal-matrix nanocomposites (MMNCs) are lauded as one of the most promising structural materials for vehicle, military, and construction applications. These MMNCs are often synthesized using the powder metallurgy (PM) process under liquid nitrogen cryogenic environments to control the grain sizes. It is believed that proper incorporation of the nitrogen species into the bulk lattice during processing could strongly enhance the mechanical properties of MMNCs by forming N-rich dispersoids. In this work, using the density-functional theory (DFT), the adsorption, absorption and diffusion behavior of nitrogen molecule/atoms have been studied and related to t Al and Mg MMNC …

Friction Bit Joining Of Similar Alloy Sheets Of High-Strength Aluminum Alloy 7085, Matthew R. Okazaki

Theses and Dissertations

Friction Bit Joining (FBJ) is a new technology used primarily in joining dissimilar metals. Its primary use has been focused in the automotive industry to provide an alternative joining process to welding. As automotive manufacturing has continually pushed toward using dissimilar materials, new joining processes have been needed to replace traditional welding practices that do not perform well when materials are not weld compatible. FBJ meets these needs perfectly as it provides strength as well as the ability to join materials of almost any kind.The purpose of this research was to explore different applications of the FBJ process. Traditionally FBJ …

Novelis Teaching Table, Phillip Laplante, Robert Hemker, Taylor Mcgriff, Juan Restrepo, Shelly Abraham

KSU Journey Honors College Capstones and Theses

Novelis is a company that specializes in metal casting, recycling, and rolling. They primarily focus on aluminum rolling for cans and car bodies but are an industry leader in numerous related areas. As the rolling process is not taught in most general engineering courses, Novelis periodically teaches new engineers and technicians about the specifics of this relatively mathematically complex process. Most of the current teaching methods are through PowerPoint presentations and group exercises, with minimal hands-on involvement. One of the most useful tools for teaching the rolling process is an actual jeweler’s rolling mill, which Novelis currently possesses, but is …

Toward A Production Ready Fbj Process For Joining Dissimilar Combinations Of Gadp 1180 Steel And Aa 7085-T76, Kevin Alexander Shirley

Theses and Dissertations

Friction Bit Joining (FBJ) is a new technology that can be used to join dissimilar materials together. This ability makes it a good candidate for creating light weight structures for the automotive industry by combining lightweight materials such as aluminum to stronger materials like advanced high-strength steels. The automotive industry and many other industries have great interest in reducing structure weight to increase fuel efficiency. The purpose of this research is to make FBJ of GADP 1180 to AA 7085-T76 a production ready process by (1) better understanding the effects of process parameters, bit design and tool design on joint …

In-Situ Particle Sizing Of Agglomerates In Aluminized Solid Composite Propellants Using Digital Inline Holography (Dih), Michael S. Powell

Open Access Theses

Aluminized ammonium perchlorate composite propellants (APCP) form large molten agglomerated particles that can result in poor combustion performance and increased two-phase flow losses. Quantifying agglomerate size distributions is important for assessing these losses for different types of aluminum fuels that can help improve rocket performance. It is highly desirable to measure particle sizes in-situ using non-intrusive optical methods, rather than conventional particle collection, which can have large uncertainties. Regular high-speed microscopic imaging suffers from a limited depth of field. Digital inline holography (DIH) is an alternative approach that results in 3D information through numerical reconstruction. In this paper, DIH approach …

Met 314 Torque Measurement, Jose Bejar

All Undergraduate Projects

As part of the Mechanical Engineering Technology program, students are required to take a Thermodynamics class. In this class one of the labs they do consists of an air motor running a water pump. The professor teaching that class wanted a device that would fit within the lab rig which would calculate the torque produced by the motor. Therefore this project consists of building a device that will allow the case (body) of the air motor to fully rotate opposite to the rotation of the shaft in order to measure the torque the motor produces at certain revolutions per minute. …

Combustion Of Novel Thermite Mixtures For Iodine Generation, Sergio Emanuel Guerrero

Open Access Theses & Dissertations

Halogen-containing reactive materials could be used for mitigating the spread of hazardous, active biological microorganisms aerosolized as a result of explosion. The present work exhibits experimental results on the combustion of mechanically alloyed aluminum-iodine (Al-I2) powder mixed with Fe2O3, CuO, MoO3, Bi2O3, and I2O5. Wet mixing was used to prepare the samples, which were then compacted into pellets and ignited with a CO2 laser. A chamber was designed and built to accommodate for combustion and collection of products, and the available laser ignition setup was modified to enable combustion experiments with rapidly burning gas-generating mixtures. High-speed video recording was used …

Hybrid Manufacturing Processes For Fusion Welding And Friction Stir Welding Of Aerospace Grade Aluminum Alloys, Megan Alexandra Gegesky

Masters Theses

"Friction stir welding and processing can provide for joints in aerospace grade aluminum alloys that have preferable material properties as compared to fusion welding techniques. Aerospace grade aluminum alloys such as AA2024-T3 and AA7075-T6 are considered non-weldable by traditional fusion welding techniques. Improved mechanical properties over previously used techniques are usually preferable for aerospace applications. Therefore, by combining traditional fusion welding and friction stir processing techniques, it could be plausible to create more difficult geometries in manufactured parts instead of using traditional techniques. While this combination of fusion welding and friction stir processing is not a new technology, its introduction …

Surface Modification Of Aluminum Alloys By Plasma Electrolytic Oxidation, Vahid Dehnavi

Electronic Thesis and Dissertation Repository

Plasma Electrolytic Oxidation (PEO) is a surface treatment for the production of ceramic oxide coatings with great properties, such as high wear and corrosion resistance, on metal substrates, particularly aluminum and magnesium alloys. Formation of PEO coatings involves complex processes and mechanisms that are difficult to study. Currently, the PEO process is in a transition phase from research to commercial application, with a primary focus on the corrosion and wear protection of light alloys, and has recently generated interest as a promising surface treatment for biomedical applications.

To justify the industrial application of PEO, a more systematic and in-depth study …

Fabrication And Enhancement Of Aluminum-Based Microchannel Devices, Paul Joseph Hymel

LSU Master's Theses

Microscale molding replication and transient liquid phase (TLP) bonding were used to fabricate Al-based microchannel heat exchangers (MHEs) and micro gas chromatograph (mGC) columns. Metal-based microchannel heat exchangers often experience corrosion as a result of their operating conditions. To address this problem, an internal anodization method was developed in Al microtubes by pulsing the flow of electrolyte through a microtube when the current dropped below a set value. The anodic aluminum oxide (AAO) films were characterized by scanning electron microscopy (SEM), focused ion beam (FIB) cross sections, and X-ray energy dispersive spectroscopy (EDS) to determine their growth rate and morphology. …

Experimental Study On The Fabrication Of Advanced Materials For Energy Applications Using High Energy Mechanical Milling, Ashvin Kumar Narayana Swamy

Open Access Theses & Dissertations

The reaction of aluminum (Al) powder with water has the potential for on demand hydrogen generation. Conventional Al powders, however, react with water slowly due to a highly protective oxide layer on the particle surface. Current methods for Al activation involve harmful and expensive materials. The nano-scale Al powders also remain very expensive and have problems such as a large amount of oxide on the surface. The use of aluminum in an energy generation cycle is also hindered by the fact that, although Al is the most abundant metal in the Earth's crust, its recovery from ore consumes a lot …

Investigation Of Aluminum Equation Of State Generation, Aaron Ward

Master's Theses (2009 -)

There are many forms and methods to construct equations of state, EOSs. These methods are usually tailored for the particular problem of interest. Here, the EOSs of interest are those used in modeling shock responses. These EOSs cover a wide range of physical characteristics such as detonation and explosions, armor and anti-armor materials, and space structures protection. Aluminum will be the primary focus of this work. Aluminum was chosen because it has been studied in great length in the shock regime and is a common component in shock experiments and space type vehicles.

The Composition And Distribution Of Coal-Ash Deposits Under Reducing And Oxidizing Conditions From A Suite Of Eight Coals, David R. Brunner

Theses and Dissertations

Eighteen elements, including: carbon, oxygen, sodium, magnesium, aluminum, silicon, phosphorus, sulfur, chlorine, potassium, calcium, titanium, chromium, manganese, iron, nickel, strontium, and barium were measured using a scanning electron microscope with energy dispersive spectroscopy from deposits. The deposits were collected by burning eight different coals in a 160 kWth, staged, down-fired, swirl-stabilized combustor. Both up-stream and down-stream deposits from an oxidizing region (equivalence ratio 0.86) and reducing region (equivalence ratio 1.15) were collected. Within the deposits, the particle size and morphology were studied. The average particle cross-sectional area from the up-stream deposits ranged from 10 - 75 µm2 and had a …

Combustion Of Lunar Regolith Mixed With Energetic Additives: Thermodynamic Calculations And Experimental Studies, Francisco Alvarez

Open Access Theses & Dissertations

The future of space exploration will require longer missions in order to better understand the conditions of near-Earth celestial objects, like the Moon or Mars. Future space missions will require the development of goods, such as propulsion fuel and structural materials, produced using the extraterrestrial resources available. The area that develops these technologies is called In-Situ Resource Utilization (ISRU). ISRU allows reducing the payload, and as a consequence reduces the energy consumption and cost of space travel. The production of structural materials on the Moon can be accomplished using Self-Propagating High-Temperature Synthesis (SHS). This work describes the combination of ISRU …

Fatigue Life Analysis Of T-38 Aileron Lever Using A Continuum Damage Approach, James D. Gyllenskog

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

In a recent investigation conducted by the United States Air Force, the mechanical failure of the aileron lever, manufactured from 2014-T6 aluminum, caused the fatal mishap of a T-38 trainer aircraft. In general the locations of cracks are unknown and must be determined by simulation. In this study we propose to use a continuum damage modeling approach to determine the degradation and damage in a material as the number of cycles of loading increases. This approach successfully predicts the location of crack initiation, propagation path, and propagation rate. A stress-based model in conjunction with the successive initiation technique is utilized. …

Stress Intensity Factor Dependence Of Hg-Al Liquid Metal Embrittlement, Scott Keller

Electronic Theses and Dissertations

When high strength aluminum alloys are subjected to liquid metals, physical and chemical reactions ensue resulting in what is known as liquid metal embrittlement (LME). A subset of environmentally-assisted cracking, LME is exhibited when a liquid metal, e.g. Hg or Ga, comes into intimate contact with a solid metal having significant susceptibility. As mechanical loads are applied, the interaction between the two metals results in a reduction in the flow properties of the solid metal. Several theories have been proposed to identify the underlying microstructural failure mechanism; however, none have been widely accepted, as failures can typically incorporate features common …

Mesoscale Behavior Of An Aluminum-Manganese Dioxide-Epoxy Mixture Under Shock Loading: From Milli To Nano-Sized Aluminum Particles, Andrew Fraser

Master's Theses (2009 -)

The main focus of this thesis is to explore the dynamic shock compaction of multiple component mixtures, specifically Al-MnO₂-Epoxy. This will be facilitated by initially simulating the bulk dynamic response in a mesoscale configuration and then comparing these results to experimental data. The mesoscale simulations were performed in the shock code CTH. The first section will discuss the matching of experimental data to computational results. With the goal of determining the bulk shock Hugoniot, a one-dimensional flyer plate configuration was created while using a grain-geometry imported from an scanning electron microscope (SEM) micrograph of the mixture. Both the …

An Investigation Of Wear-Resistant Coatings On An A390 Die-Cast Aluminum Substrate, D. Adam Mower

Theses and Dissertations

In this investigation, four coatings were tested for their ability to increase the wear life of A390 aluminum primary clutch sheaves used in continuously variable transmission (CVT). The coatings tested were: hard chrome, electroless nickel metal, hard coat anodizing and composite ceramic coating. The primary clutch sheave material is a die-cast A390 aluminum. A wear test stand was developed to duplicate wear found on CVTs currently in use. The wear was evaluated using four methods. First, the change in shift characteristics of the CVT while running on the wear test stand, second a change in performance using an ATV and …

A Torque Based Power Input Model For Friction Stir Welding, Jefferson W. Pew

Theses and Dissertations

For decades models have been developed for predicting the size of the weld nugget and heat affected zones in fusion welded structures. The basis for these models is the welding heat input, which is fairly well understood for most arc welding processes. However, this traditional approach is not as straightforward for Friction Stir Welding (FSW). To date, there is no definitive relationship to quantify the heat input for FSW. An important step to establish a heat input model is to identify how FSW process parameters affect weld power. This study details the relationship between FSW process parameters and torque for …

Effect Of Polymorphic Phase Transformations Within An Alumina Layer On The Ignition Of Aluminum Particles, Mikhaylo Aleksiyovych Trunov

Dissertations

Experimental measurements of aluminum ignition temperature and models used to describe aluminum ignition are reviewed. It is shown that the current models cannot describe ignition of aluminum powders of different sizes and ignited under various experimental conditions. The properties of and phase changes occurring in the alumina scale existing on the surface of aluminum particles at different temperatures are systematically studied. The mechanism of aluminum oxidation is quantified and a new simplified ignition model is developed.

Thermogravimetry was used to study the oxidation of aluminum powders of various particle sizes and surface morphologies in oxygen at temperatures up to 1500°C. …