Engineering Commons^™

Investigation Of Microstructure And Mechanical Behavior Of Novel Powder-Extruded Al-Ce-Mg Alloys, Mairym Vazquez

Doctoral Dissertations

Pursuing advanced structural materials with enhanced performance, reduced weight, and lower costs is a constant endeavor in the aerospace and automotive industries. Conventional structural alloys, such as cast irons, carbon steels, and titanium alloys, have strength, weight, and cost limitations. Aluminum-based alloys, known for their lightweight and high strength, have gained popularity in these industries. This dissertation focuses on investigating microstructure and mechanical behavior of novel powder-extruded Al-Ce-Mg alloys as potential candidates for high-performance structural materials.

This research explores using powder extrusion, a well-established forging methodology in the steel industry, to produce Al-Ce-Mg alloys with improved properties and aims to …

Fabrication, Thermophysical, And Mechanical Properties Of Cermet And Cercer Fuel Composites For Nuclear Thermal Propulsion, Neal D. Gaffin

Doctoral Dissertations

Nuclear thermal propulsion (NTP) utilizes nuclear fission to double the efficiency of
in-space propulsion systems compared with traditional combustion rocket systems.
NTP systems are limited primarily by the fuel material choice, due to the extreme
conditions they will need to endure, including temperatures up to 3000 K, multiple
thermal cycles with rapid heating and cooling, exposure to hot flowing hydrogen,
large thermal gradients, and high neutron flux. Particle based fuels, namely ceramic-
metallic (cermet) and ceramic-ceramic (cercer) composites are both promising fuel
element material candidates for NTP. Given the high temperature nature, these
materials are difficult to fabricate and very …

Interfacial Bonding Between Thermoset And Thermoplastic Polyurethane Reinforced Textile Grade Carbon Fiber: Structure Property Relationships, Surbhi Subhash Kore

Doctoral Dissertations

The research work focused on examining the interfacial adhesion of unsized, epoxy, and urethane-sized textile grade carbon fiber (TCF) reinforced in different classes of polyurethane (PU) thermoplastic (TPU) and thermoset (TSU) polyurethane (PU) through the structure-property relationship. The Carbon Fiber Technology Facility (CFTF) at Oak Ridge National Laboratory (ORNL) has produced TCF to reduce the cost of commercial-grade carbon fiber. The first part of the research examined the fundamental relationships between (a) soft segment thermoplastic polyurethane (S-TPU), (b) hard segment thermoplastic polyurethane (H-TPU), (c) thermoset polyurethane (TSU) and TCF reinforcement’s molecular behavior at the interface using the surface and thermal …

Structural Stability Of Thermosets During Material Extrusion Additive Manufacturing, Stian K. Romberg

Doctoral Dissertations

Over the past decade, the scale of polymer additive manufacturing has been revolutionized with machines that print massive thermoplastic parts with greater geometric complexity than can be achieved by traditional manufacturing methods. However, the heat required to print thermoplastics consumes energy and induces thermal gradients that can reduce manufacturing flexibility and final mechanical properties. With the ability to be extruded at room temperature and excellent compatibility with fibers and fillers, thermoset resins show promise to decrease the energy consumption, expand the manufacturing flexibility, and broaden the material palette offered by large-scale polymer additive manufacturing. However, structural instability in the uncured …

Innovations In Aligned And Overmolded Long Fiber Thermoplastic Composites, Shailesh P. Alwekar

Doctoral Dissertations

Long fiber thermoplastic (LFT) composite materials are increasingly used in high performance lightweight automotive, sporting, and industrial applications. LFT composites are processed with extrusion-compression molding (ECM) and/or injection molding (IM). Melt extrusion offers unique opportunities to align long fibers in a thermoplastic polymer melt. The properties of LFT materials are highly influenced by processing techniques which leads to different porosity content, fiber length distribution, and fiber orientation distribution. Hence, it is important to understand the various LFT processing techniques and their effect on mechanical, thermal, and microscopic properties.

The fundamental process-property relationships in LFT composites are investigated in this dissertation. …

Assessing Mechanical Performance Of Dissimilar Steel Systems Made Via Wire-Arc Additive Manufacturing, Obed Daniel Acevedo

Masters Theses

Hot stamping is part of a specific type of metalworking procedure widely used in the automotive industry. This research seeks to help make hot stamp tooling component production more cost-effective by using large-scale additive manufacturing. Additive manufacturing can produce dissimilar steel components that can be more cost-effective and time-efficient and allow for complex geometries to be made. A dissimilar steel system consisting of 410 martensitic stainless steel and AWS ER70S-6 mild steel is proposed to make hot stamps, making them more cost-efficient. However, the material interface's mechanical behavior in 410SS-mild steel additively manufactured material systems is not well understood. This …

Process-Structure-Property Relationships In 3d-Printed Epoxy Composites Produced Via Material Extrusion Additive Manufacturing, Nadim S. Hmeidat

Doctoral Dissertations

Extrusion-based additive manufacturing (AM) technologies, such as direct ink writing (DIW), offer unique opportunities to create composite materials and novel multi-material architectures that are not feasible using other AM technologies. DIW is a novel 3D-printing approach in which viscoelastic inks, with favorable rheological properties, are extruded through fine nozzles and patterned in a filament form at room temperature.

Recent developments in DIW of polymer composites have led to expanding the range of materials used for printing, as well as introducing novel deposition strategies to control filler orientation and create improved functional/structural composite materials. Despite these substantial advancements, the successful and …

Approximation Of The Time Rate Of Consolidation For Hydraulically Placed Fine Coal Refuse Using A Variable Coefficient Of Consolidation Method, Cyrus Jedari, Eric Drumm, Angelica Palomino

Faculty Publications and Other Works -- Civil & Environmental Engineering

Terzaghi’s consolidation theory assumes strain in soil due to applied overburden pressure is small, and permeability and thus the coefficient of consolidation (C_v) remain constant during consolidation. Although valid for soft soil consolidation, the C_v for hydraulically placed slurry materials with low solids content may change significantly during the consolidation process as the material transitions from a slurry to a solid. In this study, a spatial and temporal variable C_v was used to predict the time rate of consolidation of fine coal refuse placed in an impoundment as a slurry. The results suggest the variable …

Mechanics Of The Solid-State Bonding Under Severe Thermomechanical Processes, Xue Wang

Doctoral Dissertations

Friction stir welding (FSW) has found increased applications in automotive and aerospace industries due to its advantages of solid-state bonding, no fusion and melting, and versatility in various working conditions and material combinations. The extent and quality of the solid-state bonding between workpieces in FSW is the ultimate outcome of their industrial applications. However, the relationship among processing parameters, material properties, and bonding extent and fidelity remains largely empirical, primarily because of the lack of the mechanistic understanding of (1) tool-workpiece frictional behavior, and (2) bonding formation and evolution.

In this dissertation, to study the underlying mechanism of tool-workpiece frictional …

Development Of A Novel Casting Alloy Composed Of Aluminum And Cerium With Other Minor Additions, Zachary Cole Sims

Doctoral Dissertations

Eutectic casting alloys of aluminum and cerium are a recent discovery and early research describes an alloy with great potential to meet the growing demand for a lightweight, economical, high specific strength material for use in high-temperature or extremely corrosive environments. The broad application of aluminum alloys across industry sectors is driven by their collection of balanced properties including economical cost, high specific strength, and flexibility of their production pathways. Additionally, their high corrosion resistance makes them a good choice for structural materials. Despite this, the push to use aluminum alloys in ever more extreme environments with higher temperatures, stresses, …

Modeling Of Dislocation Channel Formation And Evolution In Irradiated Metals, Peter James Doyle

Masters Theses

Defect-free dislocation channel formation has been reported to promote plastic instability during tensile testing via localized plastic flow, leading to a distinct loss of ductility and strain hardening in many low-temperature irradiated materials. In order to study the underlying mechanisms governing dislocation channel width and formation, the channel formation process is modeled via a simple stochastic dislocation-jog process dependent upon grain size, defect cluster density, and defect size. Dislocations traverse a field of defect clusters and jog stochastically upon defect interaction, forming channels of low defect-density. Based upon prior molecular dynamics (MD) simulations and in-situ experimental transmission electron microscopy (TEM) …

Microstructure Control And Correlation To Creep Properties In Grade 91 Steel Weldment After Thermo-Mechanical Treatments And An Fe-30cr-3al Alloy Strengthened By Fe2nb Laves Phase, Benjamin Allen Shassere

Doctoral Dissertations

Type IV cracking in weldments of steel pipes after creep deformation is a concern in modern fossil-fueled power plants. Two possible methods for minimizing or eliminating Type IV cracking will be discussed. The first method alters the initial microstructure of typical Grade 91 steel base metal before welding, while the second provides baseline microstructure characteristics and creep performance of a new alloy that is strengthened by the intermetallic Fe2Nb Laves phase. The initial microstructure of the Grade 91 steel can be controlled by Thermo-Mechanical Treatments, which aids in precipitation of fine (5-10 nm) MX particles in austenite before transformation to …

Development And Application Of 3-D Fuel Performance Modeling To Assess Missing Pellet Surface Influence On Pellet Clad Interaction And Clad Failure, Nathan Allen Capps

Doctoral Dissertations

In the late 1970s PCI related failures caused the implementation of startup ramp restrictions. These ramp restrictions where intended to reduce the stresses caused by pellet cladding contact. These ramp restrictions had a significant impact on Westinghouse fueled PWRs, reducing PCI related failure until 2003. Through investigation into these fuel rod failures lead to the conclusion that missing pellet surfaces (MPS) were the root cause of the failures. MPS are local geometric defects in nuclear fuel pellets that result from pellet mishandling or the manufacturing process. The presence of MPS defects can cause stress concentrations in the clad of sufficient …

Modeling And Experimental Investigation On The Influence Of Radiation Defects On Helium Behavior In Bcc Iron, Zuya Huang

Masters Theses

Fe-based alloys are important structural materials for both fission and fusion energy. For fusion applications, the challenges of radiation-induced changes in microstructure, properties and performance is further challenged by the concomitant production of helium from (n, alpha) nuclear reactions and fusion reactions. Due to the lack of a volumetric, high flux 14-MeV neutron source, studying these phenomena require the use of computational materials modeling and novel experimental methods. In this thesis, molecular dynamics (MD) simulations was used to investigate the synergistic interactions of helium with prismatic dislocation loops characteristic of those observed in neutron irradiated iron to determine how the …

Failure Simulations At Multiple Length Scales In High Temperature Structural Alloys, Chao Pu

Doctoral Dissertations

A number of computational methodologies have been developed to investigate the deformation and damage mechanism of various structural materials at different length scale and under extreme loading conditions, and also to provide insights in the development of high-performance materials.

In microscopic material behavior and failure modes, polycrystalline metals of interest include heterogeneous deformation field due to crystalline anisotropy, inter/intra grain or phase and grain boundary interactions. Crystal plasticity model is utilized to simulate microstructure based polycrystalline materials, and micro-deformation information, such as lattice strain evolution, can be captured based on crystal plasticity finite element modeling (CPFEM) in ABAQUS. The comparison …

Development Of An Efficient Data Processing Procedure For The Prediction Of Cleavage Fracture In Reactor Pressure Vessel Steels Using The J-A2 Method, Phoebe E. Fogelman

Chancellor’s Honors Program Projects

No abstract provided.

Energy Selective Neutron Imaging For The Characterization Of Polycrystalline Materials, Robin Woracek

Doctoral Dissertations

This multipart dissertation focuses on the development and evaluation of advanced methods for material testing and characterization using neutron diffraction and imaging techniques. A major focus is on exploiting diffraction contrast in energy selective neutron imaging (often referred to as Bragg edge imaging) for strain and phase mapping of crystalline materials. The dissertation also evaluates the use of neutron diffraction to study the effect of multi-axial loading, in particular the role of applying directly shear strains from the application of torsion. A portable tension-torsion-tomography loading system has been developed for in-situ measurements and integrated at major user facilities around the …

Discontinuous Element Insertion Algorithm, Timothy James Truster

Faculty Publications and Other Works -- Civil & Environmental Engineering

An algorithm is presented for inserting zero-thickness interface elements, termed herein as “couplers”, into continuous finite element meshes in two and three dimensions. Insertion is governed solely by the mesh topology and is specified according to regions or subdomains within the overall analysis domain, a geometrically intuitive means to designate the coupler locations. The algorithm is self-contained and requires only nodal coordinates and element connectivity as input. A wide class of volume elements and interface couplers are treated within the framework. Since the algorithm is topologically-based, interfaces of arbitrary complexity are naturally accommodated. Separate treatment is given to inserting couplers …

Single Fiber Mechanical Properties Using Nano-Tensile Testing And Carbon Fiber Structure-Property Relationship, Matthew Erich Kant

Doctoral Dissertations

Single carbon fibers are studied using a nano-tensile testing system. This system has unprecedented load and displacement resolution, nN and nm respectively, and the ability to perform dynamic testing for storage and loss modulus during quasi-static tensile extension. Furthermore, improved fiber mounting and alignment procedures coupled with the precision of the nano-tensile testing system assist in unprecedented resolution in single fiber mechanical testing for axial modulus and strength. Hence, using these unique capabilities, the moduli and their statistical distribution of many high performance carbon fibers are reported here. From this, a simplified single parameter model describing the strain dependent modulus …

Structural Analysis Of The Tablerock Thrust Sheet, Grandfather Mountain Window, Northwestern North Carolina: Emplacement Kinematics Of A Large Horse In A Major Thrust System, Ann Elizabeth Walker

Masters Theses

The Tablerock thrust sheet is exposed along the southwestern margin of Grandfather Mountain window in northwestern North Carolina, where it separates basement and cover rocks inside the window from basement thrust sheets of the overriding Blue Ridge-Piedmont megathrust sheet. It is a complex of footwall-derived horses of rifted-margin metasedimentary rocks, including Neoproterozoic to Early Cambrian Chilhowee Group quartzite and phyllite, and Shady Dolomite. Penetrative deformation throughout the Tablerock thrust sheet is defined by an extensively transposed foliation, and strong colinearity between well developed transport lineations and SE/NW-trending tight, isoclinal, and sheath folds. Centimeter- to meter-scale sheath folds are common throughout …

An Automated Finite Element Analysis Framework For The Probabilistic Evaluation Of Composite Lamina Properties, Jonathan Phillips Weigand

Masters Theses

This thesis outlines the development of computational modeling tools used to predict the elastic properties of composite lamina from representative volume elements (RVE) using numerical methods. The homogenization approach involves the use of Gauss’s Theorem to simply the average volumetric strain integral into a surface integral containing which is defined by surface displacements and their direction. Simulations of RVEs under specific loading conditions (longitudinal tension or shear and transverse tension or shear) are then performed in the software package ABAQUS to obtain the surface displacements. It was found that obtaining quality meshes and applying periodic boundary conditions for each RVE …

Dynamic Mutual Capacitive Sensor For Human Interactions., Jonathan William Huber

Doctoral Dissertations

This dissertation introduces the novel concept of removing the ground conductive plate by utilizing body capacitance as the ground in the capacitive sensor, whereby circuit pressure sensing can occur with only one plate and one dielectric. Additionally, body capacitance sensing was limited to a binary touch-no-touch output, whereas the method presented here can sense various applied pressures. The resulting circuit acts as an antenna that receives local capacitance signals from a human interaction.

The advantage of this design is that it allows for both proximity sensing and pressure sensing (once the body part is touching the dielectric material). This setup …

Modeling And Development Of A Mems Device For Pyroelectric Energy Scavenging, Salwa Mostafa

Doctoral Dissertations

As the world faces an energy crisis with depleting fossil fuel reserves, alternate energy sources are being researched ever more seriously. In addition to renewable energy sources, energy recycling and energy scavenging technologies are also gaining importance. Technologies are being developed to scavenge energy from ambient sources such as vibration, radio frequency and low grade waste heat, etc. Waste heat is the most common form of wasted energy and is the greatest potential source of energy scavenging.

Pyroelectricity is the property of some materials to change the surface charge distribution with the change in temperature. These materials produce current as …

Effect Of Moisture Absorption On The Sinter Quality Of Central Solenoid (Cs) Coil Pack, Zeshaan Sher Mohammed

Masters Theses

Fusion energy has been said to be the solution to all the world’s energy problems. The International Thermonuclear Experimental Reactor (ITER) is the flagship project to demonstrate the feasibility of fusion energy. The Central Solenoid (CS), an important component of the reactor, is needed to induce plasma current, initiate, ramp-up, ramp-down, and sustain plasma in a very controlled manner. In order to achieve this, the CS coil packs must be manufactured under controlled conditions. The CS conductor is an advanced cable-in-conduit Nb3Sn superconductor. The CS cable will be made in long continuous sections but with thousands of meter of cable …

Methods For Characterizing Mechanical Properties Of Wood Cell Walls Via Nanoindentation, Yujie Meng

Masters Theses

Nanoindentation is a method of contacting a material whose mechanical properties are unknown with another material whose properties are known. Nanoindentation has the advantage of being able to probe a material’s microstructure while being sensitive enough to detect variations in mechanical properties. However, nanoindentation has some limitations as a testing technique due to the specific formation and structure of some biomaterials. The main objective of this research is to identify any factors that influence the nanoindentation measurement of wood cell walls (a typical biomaterial).

The function of the embedding media in describing the properties of wood cells is poorly understood. …