Engineering Commons^™

Characterization Of Directed Energy Deposition Additively Manufactured Grcop-42 Alloy, Scott Landes

Electronic Theses and Dissertations

GRCop is an alloy family constructed of copper, chromium, and niobium and was developed by NASA for high heat flux applications. The first of its kind, GRCop-84, was specifically designed for the environments seen by channel cooled main combustion chamber liners. To further increase thermal conductivity while maintaining material strength characteristics, the percentage of alloying elements were cut in half and GRCop- 42 was developed. In recent years, NASA has successfully additively manufactured GRCop with comparable material characteristics to wrought GRCop using a Laser Powder Bed Fusion (L-PBF) process. Benefits of this process include fabrication of intricate cooling channels as …

The Influence Of Heat Treatment On Corrosion Behavior Of Martensitic Stainless Steel Uns 42670, Armen Kvryan

Boise State University Theses and Dissertations

Ceaseless demand for lighter, faster, and more efficient aircraft has been one of the greatest driving forces behind bearing steel innovations. Recent studies demonstrate that corrosion is one of the leading causes of bearing failure in both military and commercial aircraft. High-performing bearing steels are available but are not being used in US military applications due to high cost and security issues when steels are produced outside of the continental United States. One approach to address this issue is to engineer steels that are cost-efficient and heat treated for corrosion resistance, long wear life, etc.

This dissertation presents information on …

Development Of A Multi-Probe Kelvin Scanner Device For Industrially-Relevant Characterization Of Surface-Activated Carbon Fiber Reinforced Thermoplastic Composites, Kirby Simon

McKelvey School of Engineering Theses & Dissertations

Carbon fiber reinforced thermoplastic (CFRTP) composites are becoming increasingly attractive materials in manufacturing due to their lightweight nature, mechanical strength, and corrosion resistance. Surface activation of these materials is usually required during processing to increase the bond strength of assemblies (aerospace and automotive industries) or improve adhesion with implants (biomedical industry). Industrially-relevant, nondestructive quality control methods for assessing the activation state of these materials do not currently exist, however. Applying principles discovered through the use of scanning probe microscopy, a multiple-probe Kelvin scanning (MPKS) device has been developed that can assess the uniformity of the activation state of plasma-treated CFRTP …

Corrosion Initiation And Propagation On Carburized Martensitic Stainless Steel Surfaces Studied Via Advanced Scanning Probe Microscopy, Armen Kvryan, Corey M. Efaw, Kari A. Higginbotham, Olivia O. Maryon, Paul H. Davis, Elton Graugnard, Michael F. Hurley

Materials Science and Engineering Faculty Publications and Presentations

Historically, high carbon steels have been used in mechanical applications because their high surface hardness contributes to excellent wear performance. However, in aggressive environments, current bearing steels exhibit insufficient corrosion resistance. Martensitic stainless steels are attractive for bearing applications due to their high corrosion resistance and ability to be surface hardened via carburizing heat treatments. Here three different carburizing heat treatments were applied to UNS S42670: a high-temperature temper (HTT), a low-temperature temper (LTT), and carbo-nitriding (CN). Magnetic force microscopy showed differences in magnetic domains between the matrix and carbides, while scanning Kelvin probe force microscopy (SKPFM) revealed a 90–200 …

Investigating Using Titanium Zirconium Molybdenum For Additively Manufacturing Aerospace Components, Justin Hunter Vanhoose

Open Access Theses & Dissertations

Mankind throughout history has possessed an innate characteristic to explore, migrating to new frontiers.The requirement for this travel is most broadly associated with the need to pursue more resources. Rockets have been used as a means of weapons since the Sung Dynasty in the thirteenth empire and have now been integrated for travel/transport. The sophistication of rocketry and propulsion has reached a level to where it is plausible that mankind will be a multi-planetary species. The space industry has grown significantly with the advancement of the sophistication of these rocket technologies. However, a specific challenge to overcome in the space …

Development Of Low Cost, Environmentally Friendly And High Strength Carbon Foams From Bread And Cake, Laura Mountain-Tuller

Materials Engineering

Carbon foam is a high niche material that consists of a highly porous, three-dimensional cellular network that is characterized by extremely high strength-to-weight ratios and low thermal conductivity. Due to these properties, carbon foams excel in structural and thermal applications, especially in the aerospace industry. Typically, carbon foams are formed through a heating process called pyrolysis of polymer precursors with high carbon content. This process is done at high temperatures in an oxygen free environment. These precursors are expensive to make and use toxic chemicals to produce, therefore, there is a push to find an environmentally friendly and cost-effective method …

Design Of Shape-Conforming Nosecone For Optimal Fluid Flow From Transonic To Supersonic Range, Anna Tombazzi

Williams Honors College, Honors Research Projects

Modern flight vehicles, such as rockets, missiles, and airplanes, experience a force caused by forebody wave drag during the flight. This drag force is induced when the frontal point of each vehicle breaks the pressure wave during flight. Efforts to reduce this wave drag force to improve flight efficiency include modifying the nosecone profile of the flight vehicles to lower the drag force.

This project revolved around creating a design to make the transformation of nosecone shapes from a ¾ Parabolic profile to a ½ Power Series profile possible, mid-flight. Using a novel nosecone assembly, shape memory alloys (SMAs) and …

Development Of Low Cost Braze Alloys For Aerospace Applications, Alyssa M. Elliott, Sandy Babich, Blake Whitmee

Materials Engineering

Non-precious metal braze alloys can help lower the cost of brazing, which is a commonly-used joining process in the aerospace industry. A-286, a stainless steel superalloy, and Inconel© 718, a nickel-based superalloy, are both commonly used alloys at Aerojet Rocketdyne. Both alloys were brazed into butt joints using nickel-based braze alloys: AMS 4776, 4777, and 4778. The brazed samples were machined into a modified version of the ASTM E8 subsize specimen samples and tensile tested to compare the strength and calculated elongation of the brazed samples to the base metals’ properties. All of the brazed samples fractured at the joint, …

An Investigation Of The Use Of Cerium And Polyhedral Oligomeric Silsesquioxanes For The Protection Of Polymeric Epoxy Compounds In The Low Earth Orbit Environment, Jessica Miriam Piness

Dissertations

Low Earth orbit presents many hazards for composites including atomic oxygen, UV radiation, thermal cycling, micrometeoroids, and high energy protons. Atomic oxygen and vacuum ultraviolet radiation are of concern for space-bound polymeric materials as they degrade the polymers used as matrices for carbon fiber composites, which are used in satellites and space vehicles due to their high strength to weight ratios. Epoxy-amine thermosets comprise a common class of matrix due to processability and good thermal attributes. Polyhedral oligomeric silsesquioxanes (POSS) have shown the ability to reduce erosion in polyimides, polyurethanes, and other polymers when exposed to atomic oxygen. The POSS …

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 …

Analysis Of Shear Strength Variance Of Ph 15-7 Mo Blind Rivet Stems For Aerospace Applications, Miles Macarthur, Kent C. Majewski

Materials Engineering

This project attempts to reduce manufacturing costs incurred to Cherry Aerospace by variance in material properties. To track and predict the shear strength of PH 15-7 Mo stainless steel rivet stems throughout the heat treatment process, samples were taken from several steps in the manufacturing process and experimental heat treatments were performed across a range of temperatures. The supplied rivet stems were heat treated for four hours at temperatures from 520°C to 560°C, in increments of 10°C. Double shear testing in accordance with ASTM 1312-13A revealed that there is no apparent correlation between the strength of the supplied wire and …

Electrochemical Characterization Of Precious Metal Braze Alloys Using Potentiodynamic Polarization, Maxwell Glen Martin, Mason Gregory Morgan, Matthew David Vance

Materials Engineering

This study aimed to characterize the electrochemical behavior of six precious metal braze alloys by performing potentiodynamic polarization tests (ParStat 2273) based on ASTM Specifications G5 and G59. To determine the extent to which the alloys will contribute to galvanic corrosion in a marine environment (3.5 wt% NaCl), corrosion analysis software was used to produce fitted Tafel lines to determine the open circuit potential, V_oc, for each alloy. The V_oc values for the alloys were found to be -66.58 mV for Gold ABA, 13.01 mV for Nicoro^®, -39.00 mV for Nioro^®, 23.4 mV …

Relationship Between Bagging Methods And Pre-Weld Holding Times On Porosity Formation In 2219 Aluminum Ac-Tig Welds, Mariah Grace Head, Tyson Daniel Mobley

Materials Engineering

The purpose of this study was to determine relationships between bagging methods and pre-weld holding times on the formation of porosity when AC-TIG welding 2219 aluminum. Considering the strict guidelines and specifications required within the aerospace industry, maintaining quality welds is of paramount importance to control part integrity for aerospace applications. This project focused on two parameters involved in the preparation of aluminum parts for welding: bagging method and pre-weld holding time. Welding geometry was simplified to bead-on plate instead of the standard joint welds. Radiographic analysis of the samples showed that all levels of both parameters produced “passing welds.” …

Thermal Infrared Reflective Metal Oxide Sol-Gel Coatings For Carbon Fiber Reinforced Composite Structures, Brandon Demar Richard

USF Tampa Graduate Theses and Dissertations

Recent trends in composite research include the development of structural materials with multiple functionalities. In new studies, novel materials are being designed, developed, modified, and implemented into composite designs. Typically, an increase in functionality requires additional material phases within one system. The presence of excessive phases can result in deterioration of individual or overall properties. True multi-functional materials must maintain all properties at or above the minimum operating limit. In this project, samples of antimony and cobalt-doped tin oxide (ATO(Co2O3)) sol-gel solutions are used to coat carbon fibers and are heat treated at a temperature range of 200 - 500 …