Engineering Commons^™

Bulk Nanostructured Steels For Nuclear Reactor And Extreme Environment Applications, Maalavan Arivu

Doctoral Dissertations

"Candidate accident tolerant FeCrAl fuel (ATF) claddings for light water reactors (LWRs) need to be thinner than current Zircaloys owing to higher neutronic penalty, demanding an improvement in strength. Therefore, equal channel angular pressing (ECAP), and high-pressure torsion (HPT) were used to produce bulk ultra-fine grained and nanocrystalline Kanthal-D [KD; Fe-21Cr-5Al-0.026C (wt.%) alloy] which resulted in an improvement in strength of up to 3 times their nominal strength from grain boundary strengthening, and dislocation strengthening. Dynamic recovery was promoted due to ECAP at 520 oC rendering it with a large area fraction of less mobile low angle grain boundaries (LAGBs) …

Joining Of Ultra-High Temperature Ceramics To The Same And Refractory Metals Via Fusion Welding, Jecee Jarman

Doctoral Dissertations

"This research focuses on the joining of ultra-high temperature ceramics to either themselves or refractory metals/alloys via fusion welding and the mechanical strength of produced joints. The ceramics studied consisted of compositions within a diboride-carbide-carbide ternary system while metals studied consisted of molybdenum and a molybdenum alloy. SiC-ZrB2-ZrC ceramics on a binary join between pure SiC and the ternary eutectic composition were found to be weldable when SiC content was below ~57.5 vol%. Compositions above 57.5 vol% SiC were unweldable based on pitting and off-gassing behavior. Welded strength of ceramics was ~180-300 MPa in the SiC-ZrB2-ZrC ternary eutectic composition, ~180-220 …

Processing To Enable Direct-Write Additive Manufacturing Of Ceramics And Ceramic Composites, Austin Martin

Doctoral Dissertations

"This research focuses on the processing of novel feedstocks for and during direct-write additive manufacturing (AM), specifically the direct ink writing (DIW) and Ceramic On-Demand Extrusion (CODE) manufacturing processes, in order to produce ceramic and ceramic-based composite components. Strongly dispersed, concentrated (φ = 0.42), nanoparticle (d₅₀ ~0.3 µm), zirconia (ZrO₂) pastes were used to print densely filled, large continuous volume (≳ 1 cm³) ceramic components. An elastic shear modulus (G’) of 56,000 Pa and yield stresses between 6 and 10 Pa allowed for printed components of 34.5 mm in height over 115 layers without slumping …

Novel Ferromagnetic Materials With Improved Mechanical Performance, Wesley Alexander Everhart

Doctoral Dissertations

"The ductility of intermetallics has long been a hindrance to their broad adaptation despite a significant range of properties such as magnetic, half-metallic, and shape memory behavior. The lack of a general theory for the ductility of intermetallics along with the lack of prior art that experimentally measured mechanical properties drives the need for significant investment in many of these novel magnetic materials in order to even understand, let alone correct, poor ductility.

This dissertation includes work that explored the effect of vanadium content and quenching rate on the microstructure and ductility of Fe-Co alloys. Results indicated that a martensitic …

Mechanical Properties Of Boride Based Ceramics, Alec Murchie

Doctoral Dissertations

“This research focuses on the elevated mechanical properties of diboride based materials at room and elevated temperatures. These materials include a ZrB₂ ceramic, a ZrB₂-WC-SiC ceramic, and a (Hf,Mo,Nb,Ta,W,Zr)B₂ high entropy boride (HEB). The room temperature flexural strength for the ZrB₂ ceramic was 447 MPa and the fracture toughness was 2.3 MPa·m^1/2. The strength decreased to 196 MPa at 1800°C, and then increased to 360 MPa at 2300°C. The fracture toughness increased to 3.1 MPa·m^1/2 at 2200°C. The strength up to 1800°C was likely controlled by a combination of effects: surface damage …

Scale Formation, Properties And De-Scaling In Steelmaking, Richard Osei

Doctoral Dissertations

During continuous castings, reheating, and hot rolling, slab surfaces are exposed to atmospheres containing oxidizing gases which results in scale formation. Inefficient removal of the formed scale during reheating affects product surface quality. The effect of steel composition and operating parameters on scale formation and scale removal efficiencies were investigated. Experimental investigations were carried out using a thermogravimetric (TGA) apparatus designed to replicate the combustion gas atmosphere and temperature in actual industrial slab reheat furnaces. Report on oxidation kinetics, scale structure and properties, and descaling were conducted on laboratory cast and industrial samples. Different characterization techniques were used to analyze …

Investigation Of The Thermodynamics Of Iron Phosphate Melts And Stability Of Iron Phosphate Glasses: Effects Of Composition And Iron Redox Ratio, Melodie Linda Schmitt

Doctoral Dissertations

“Iron phosphate glasses with Fe/P = 0.33 - 0.67, O/P = 3.0 - 3.5 and Fe²⁺/ΣFe = 0.16- 0.52 were prepared by altering batch compositions and melt conditions. Thermal analyses indicate polyphosphate glasses with intermediate chain lengths are most stable against devitrification. Heterogeneous crystallization occurs on the glass surface and is dependent on iron valence state, particle size, heating rate, temperature and oxygen availability in the atmosphere. Oxidation of ferrous iron on the glass surface occurs at temperatures as low as Tg, and thus crystallization behavior and stability can be altered via post-melt heat treatments. A novel preparation …

Peritectic Behavior Detection And Prediction In Fe-C-Si-Mn-Al System, Damilola Balogun

Doctoral Dissertations

"The non-uniformity of shell growth in the continuous casting of peritectic steels constitutes a major barrier to the commercial production of many steel grades such as Advanced high strength steels (AHSS), transformation induced plasticity (TRIP) steels, abrasion-resistant steels, advanced armor plate steels, and many newly proposed steel grades that contain high levels of silicon, manganese, and aluminum.

The shell growth non-uniformity experienced in the continuous casting of peritectic steels results in the formation of defects in the as-cast slab and therefore increases the operating risk from cast aborts and breakouts. The ability to predict and avoid peritectic behavior at the …

Development And Application Of Ensemble Machine Learning Algorithms To Enable A Priori, High-Fidelity, And Prompt Predictions And Optimizations Of Complex Materials And Systems, Taihao Han

Doctoral Dissertations

"Complex materials consisting of multiple chemical components/phases have been widely used in different engineering applications that have strict criteria. To optimize the mixture design of complex materials, researchers invest enormous resources in cumbersome experiments. However, due to substantial variations in precursors and processing techniques, it has been challenging to develop theoretical frameworks (i.e., empirical models) that could produce reliable predictions of properties of complex materials. In recent years, scientists have harnessed the power of machine learning (ML) and “Big” data to uncover the underlying mixture design-property correlations and produce high-fidelity predictions of properties of complex materials. The ML models autonomously …

The Effect Of Mass Transport On Deposit Quality In Copper Electrowinning, Joseph Bauer

Doctoral Dissertations

"Roughness and nodulation of copper electrodeposits depend strongly on mass transfer conditions of copper ions to the electrode surface. Mass transfer properties in electrowinning electrolytes were first characterized. The effective diffusivity of cupric ion was measured with a rotating disk electrode in CuSO₄-H₂SO₄ electrolytes at temperatures relevant to electrowinning, with and without additives. Adding 20 mg L^-1 of chloride ion increased the measured diffusion coefficient, but commercial smoothing additives had little effect. An empirical formula to predict cupric diffusivity was generated for later use in mass transport modeling.

Boundary layer thickness information for commercial …

Effects Of Vacancies And Electron Temperature On The Electron Phonon Coupling In Cubic Silicon Carbide And Their Connection To The Inelastic Thermal Spike, Salah Al-Smairat

Doctoral Dissertations

“The electron-phonon interaction is an important interaction in many solids as it influences transport phenomena and related quantities such as the electrical and thermal conductivities, especially in nuclear and space applications. The importance of the electron-phonon interaction in primary damage production in 3C-SiC is the subject of this research.

The electron-phonon coupling factor was calculated using a hybrid Density Functional Perturbation Theory - Classical Electron Gas model. The coupling factor was calculated as a function of electron temperature in pristine and defective 3C-SiC, and relaxed defective cells. The electron-phonon coupling is found to depend strongly on the electronic temperature and …

Corrosion Protection Mechanisms Of Trivalent Chromium Based Passivations On Γ-Znni Coated Al6061-T6 Alloy, Kevin Foster

Doctoral Dissertations

“The role of cobalt in trivalent chromium passivations (TCPs) to improve corrosion resistance of γ-ZnNi coated steel and aluminum is based on its effect on hexavalent chromium content in the passive layer. Investigations of both a cobalt-containing and cobalt-free TCP on SAE 1008 steel indicated that both passivations protect well for up to 1000 hours in neutral salt spray exposure (SSE). A repetition on Al 6061-T6 alloy indicated that TCP performed much better than cobalt-free TCP implicating the underlying substrate. Optical and electron micrographs indicated physical changes such as crack thickness, crack density, passivation porosity, and passivation thickness existed between …

Production Of Non-Oriented Electrical Steel Thin Strip Simulating Conditions Of The Direct Twin-Roll Casting Process, Yizhou Du

Doctoral Dissertations

"In this study, a method to cast non-oriented (NGO) electrical steel with conditions of an industrial twin roll thin strip casting (TRSC) process was investigated. A novel vacuum assisted fast cooling (VA) sampling method was developed to produce 2 mm thick strip simulating conditions of an industrial TRSC process. The effects of solidification cooling rate, hot rolling deformation, and annealing time on inclusion distribution, magnetic properties, grain growth, and texture evolution of 3.4 wt.% Si NGO electrical steel with different carbon and sulfur (C&S) levels were analyzed. Samples were thermo-mechanically treated which simulated an industrial TRSC process. After a long …

Oxidation Of Silicon Carbide And Graphite For High Temperature Gas-Cooled Reactor Applications, Adam Thomas Bratten

Doctoral Dissertations

"This research focuses on the oxidation behavior of silicon carbide and matrix grade graphite, specifically as it pertains to accident scenarios in Gen IV thermal spectrum high temperature gas cooled nuclear reactors. It is imperative to understand the oxidation behavior of such materials to predict their response to off-normal environments and certify their accident tolerance to implement Gen IV reactors. The onset of oxidation temperature of matrix graphite was found to have a strong dependence on the microstructure, and therefore processing parameters, of the materials. The A3-3 type grade contained regions of partially graphitized carbon that were more disordered and …

Molten Steel Interactions With Tundish Linings And Refractory Glazes, Tyler Michael Richards

Doctoral Dissertations

"In the final stages of casting, molten steel is in contact with two main types of refractories: the working lining of the tundish used to serve as an intermediate vessel between the ladle and copper mold, and the various glazed carbon-bearing refractories used to control the flow of steel from the ladle to the tundish and from the tundish to the mold. If steel interacts with these refractories in such a way as to result in the formation of inclusions, it may be too late to remove them, leading to degradation of the steel’s mechanical properties. Understanding these interactions and …