Engineering Commons^™

Accelerated Freezing Due To Droplet Pinning On A Nanopillared Surface, Rachel Bohm, Mohammad Rejaul Haque, Chuang Qu, Edward C. Kinzel, Amy Rachel Betz

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The freezing process is significantly influenced by environmental factors and surface morphologies. At atmospheric pressure, a surface below the dew and freezing point temperature for a given relative humidity nucleates water droplets heterogeneously on the surface and then freezes. This paper examines the effect of nanostructured surfaces on the nucleation, growth, and subsequent freezing processes. Microsphere Photolithography (MPL) is used to pattern arrays of silica nanopillars. This technique uses a self-assembled lattice of microspheres to focus UV radiation to an array of photonic jets in photoresist. Silica is deposited using e-beam evaporation and lift-off. The samples were placed on a …

Spin-Controlled Wavefront Shaping With Plasmonic Chiral Geometric Metasurfaces, Yang Chen, Xiaodong Yang, Jie Gao

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Metasurfaces, as a two-dimensional (2D) version of metamaterials, have drawn considerable attention for their revolutionary capability in manipulating the amplitude, phase, and polarization of light. As one of the most important types of metasurfaces, geometric metasurfaces provide a versatile platform for controlling optical phase distributions due to the geometric nature of the generated phase profile. However, it remains a great challenge to design geometric metasurfaces for realizing spin-switchable functionalities because the generated phase profile with the converted spin is reversed once the handedness of the incident beam is switched. Here, we propose and experimentally demonstrate chiral geometric metasurfaces based on …

Synergic Titanium Nitride Coating And Titanium Doping By Atomic Layer Deposition For Stable- And High-Performance Lifepo₄, Yan Gao, Jonghyun Park, Xinhua Liang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Atomic layer deposition (ALD) method has emerged as a promising technique to address the dissolution and poor conductivity of electrode materials of lithium ion batteries. In this work, surface modification of LiFePO₄ (LFP) was carried out by titanium nitride (TiN) ALD, during which a Ti doping into LFP occurred simultaneously. X-ray photoelectron spectroscopy (XPS) and electrochemical tests were performed to prove the Ti doping, and the composition of TiN layer on the surface of LFP particles was interpreted as a combination of TiN and titanium oxynitride (TiO_xN_y). Owing to the synergy of TiN coating and …

Cell For Flow Battery, Jonghyun Park, Mohammed Abdulkhabeer Al-Yasiri

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A reaction cell for a flow battery having flow channels positioned within a recess of a non-porous and non-brittle housing that is also a dielectric. Positioning the flow channels within the recess eliminates the need for end plates, gaskets, and insulators of conventional designs. A current collector and an electrode within the recess have areas approximately equal to the area of the recess such that they fit within the recess and maximize the contact area between them.

Prediction Of Thermal Conductance At Liquid-Gas Interfaces Using Molecular Dynamics Simulations, James Gonzalez, Josue Ortega, Zhi Liang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Using Molecular Dynamics (MD) Simulations and Theoretical Calculations, We Study Heat Transfer Across Liquid-Gas Interfaces within a Planar Heat Pipe. to Determine the Thermal Conductance (Kapitza Conductance), GK, at the Interface, Two Heat Transfer Mechanisms, Namely, Conduction and Evaporation/condensation Are Considered. in the Case of Interfacial Heat Conduction, Gas Molecules, Particularly Non-Condensable Gas Molecules, Exchange Heat with Liquid Surfaces through Gas-Liquid Collisions, and the Theoretical Expression for GK is Derived from the Kinetic Theory of Gases. for Interfacial Heat Transfer by Evaporation or Condensation, the Theoretical Expression for GK is Derived from the Schrage Relationships. to Assess the Accuracies of …

Near-Infrared Chiral Plasmonic Metasurface Absorbers, Leixin Ouyang, Wei Wang, Daniel Rosenmann, David A. Czaplewski, Jie Gao, Xiaodong Yang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Chirality plays an essential role in the fields of biology, medicine and physics. However, natural materials exhibit very weak chiroptical response. In this paper, near-infrared chiral plasmonic metasurface absorbers are demonstrated to selectively absorb either the left-handed or right-handed circularly polarized light for achieving large circular dichroism (CD) across the wavelength range from 1.3 µm to 1.8 µm. It is shown that the maximum chiral absorption can reach to 0.87 and that the maximum CD in absorption is around 0.70. The current chiral metasurface design is able to achieve strong chiroptical response, which also leads to high thermal CD for …

Multifidelity Modeling Of Ultrasonic Testing Simulations With Cokriging, Leifur Leifsson, Xiaosong Du, Slawomir Koziel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Multifidelity methods are introduced to the nondestructive evaluation (NDE) of measurement systems. In particular, Cokriging interpolation metamodels of physics-based ultrasonic testing (UT) simulation responses are utilized to accelerate the uncertainty propagation in model-assisted NDE. The proposed approach is applied to a benchmark test case of UT simulations and compared with the current state-of-the-art techniques. The results show that Cokriging captures the physics of the problem well and is able to reduce the computational burden by over one order of magnitude compared to the state of the art. To the best of the author's knowledge, this the first time multifidelity methods …

Fast Uncertainty Propagation Of Ultrasonic Testing Simulations For Mapod And Sensitivity Analysis, Xiaosong Du, Leifur Leifsson, Praveen Gurrala, Jiming Song, Slawomir Koziel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Model-assisted probability of detection (MAPOD) and sensitivity analysis (SA) are widelyused for measuring the reliability of nondestructive testing (NDT) systems., such as ultrasonictesting (UT), and understanding the effects of uncertainty parameters. In this work, a stochastic expansion-based metamodel is used in lieu of the physics-based NDT simulation model for efficient uncertainty propagation while keeping satisfactory accuracy. The proposed stochasticmetamodeling approach is demonstrated for MAPOD and SA on a benchmark case for UT simulations on a fused quartz block with a spherically-void defect. The proposed approach is compared with direct Monte Carlo sampling (MCS), and MCS with Kriging metamodels. The results …

Revealing Particle-Scale Powder Spreading Dynamics In Powder-Bed-Based Additive Manufacturing Process By High-Speed X-Ray Imaging, Luis I. Escano, Niranjan D. Parab, Lianghua Xiong, Qilin Guo, Cang Zhao, Kamel Fezzaa, Wes Everhart, Tao Sun, Lianyi Chen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Powder spreading is a key step in the powder-bed-based additive manufacturing process, which determines the quality of the powder bed and, consequently, affects the quality of the manufactured part. However, powder spreading behavior under additive manufacturing condition is still not clear, largely because of the lack of particle-scale experimental study. Here, we studied particle-scale powder dynamics during the powder spreading process by using in-situ high-speed high-energy x-ray imaging. Evolution of the repose angle, slope surface speed, slope surface roughness, and the dynamics of powder clusters at the powder front were revealed and quantified. Interactions of the individual metal powders, with …

Effects Of Nearwall Modeling In The Improved-Delayed-Detached-Eddy-Simulation (Iddes) Methodology, Rohit Saini, Nader Karimi, Lian Duan, Amsini Sadiki, Amirfarhang Mehdizadeh

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The present study aims to assess the effects of two different underlying RANS models on overall behavior of the IDDES methodology when applied to different flow configurations ranging from fully attached (plane channel flow) to separated flows (periodic hill flow). This includes investigating prediction accuracy of first and second order statistics, response to grid refinement, grey area dynamics and triggering mechanism. Further, several criteria have been investigated to assess reliability and quality of the methodology when operating in scale resolving mode. It turns out that irrespective of the near wall modeling strategy, the IDDES methodology does not satisfy all criteria …

Locomotion Of A Cylindrical Rolling Robot With A Shape Changing Outer Surface, Michael G. Puopolo, Jamey D. Jacob, Emilio Gabino

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A cylindrical rolling robot is developed that generates roll torque by changing the shape of its flexible, elliptical outer surface whenever one of four elliptical axes rotates past an inclination called trigger angle. The robot is equipped with a sensing/control system by which it measures angular position and angular velocity, and computes error with respect to a desired step angular velocity profile. When shape change is triggered, the newly assumed shape of the outer surface is determined according to the computed error. A series of trial rolls is conducted using various trigger angles, and energy consumed by the actuation motor …

Deformation Of A Ferrofluid Droplet In Simple Shear Flows Under Uniform Magnetic Fields, Md Rifat Hassan, Jie Zhang, Cheng Wang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

We numerically investigate the deformation and orientation of a ferrofluid droplet in a simple shear flow under a uniform magnetic field. The numerical simulation is based on the finite element method and couples the magnetic and flow fields. A level set method is used to model the dynamic motion of the droplet interface. Systematic numerical simulations are used to assess the effects of the direction and the strength of the magnetic field. Focusing on low Reynolds number flows (Re ≲ 0.02), the numerical results indicate that at a small capillary number (Ca ≈ 0.02), the magnetic field dominates over the …

Shape-Based Separation Of Micro-/Nanoparticles In Liquid Phases, Behrouz Behdani, Saman Monjezi, Mason J. Carey, Curtis G. Weldon, Jie Zhang, Cheng Wang, Joontaek Park

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The production of particles with shape-specific properties is reliant upon the separation of micro-/nanoparticles of particular shapes from particle mixtures of similar volumes. However, compared to a large number of size-based particle separation methods, shape-based separation methods have not been adequately explored. We review various up-to-date approaches to shape-based separation of rigid micro-/nanoparticles in liquid phases including size exclusion chromatography, field flow fractionation, deterministic lateral displacement, inertial focusing, electrophoresis, magnetophoresis, self-assembly precipitation, and centrifugation. We discuss separation mechanisms by classifying them as either changes in surface interactions or extensions of size-based separation. The latter includes geometric restrictions and shape-dependent transport …

Ultrafast X-Ray Imaging Of Laser-Metal Additive Manufacturing Processes, Niranjan D. Parab, Cang Zhao, Ross Cunningham, Luis I. Escano, Kamel Fezzaa, Wes Everhart, Anthony D. Rollett, Lianyi Chen, Tao Sun

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The high-speed synchrotron X-ray imaging technique was synchronized with a custom-built laser-melting setup to capture the dynamics of laser powder-bed fusion processes in situ. Various significant phenomena, including vapor-depression and melt-pool dynamics and powder-spatter ejection, were captured with high spatial and temporal resolution. Imaging frame rates of up to 10 MHz were used to capture the rapid changes in these highly dynamic phenomena. At the same time, relatively slow frame rates were employed to capture large-scale changes during the process. This experimental platform will be vital in the further understanding of laser additive manufacturing processes and will be particularly …

Experimental Characterization Of A Direct Metal Deposited Cobalt-Based Alloy On Tool Steel For Component Repair, Xinchang Zhang, Tan Pan, Wei Li, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Die casting dies made of tool steel is subject to impact, abrasion and cyclic thermomechanical loading that delivers damage such as wear, corrosion, and cracking. To repair such defects, materials enveloping the damage need to be machined and refilled. In this study, V-shape defects with varied sidewall inclination angles were prepared on H13 tool steel substrates and refilled with cobalt-based alloy using direct metal deposition (DMD) for superior hardness and wear resistance. The microstructure of rebuild samples was characterized using an optical microscope (OM) and scanning electron microscope (SEM). Elemental distribution from the substrate to deposits was analyzed using energy …

Additive Manufacturing Of Metal Bandpass Filters For Future Radar Receivers, Bradley Grothaus, Dane Huck, Austin T. Sutton, Ming-Chuan Leu, Ben Brown

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective laser melting (SLM) is a powder-bed fusion (PBF) process that bonds successive layers of powder with a laser to create components directly from computer-aided design (CAD) files. The additive nature of the SLM process in addition to the use of fine powders facilitates the construction of complex geometries, which has captured the attention of those involved in the design of bandpass filters for radar applications. However, a significant drawback of SLM is its difficulty in fabricating parts with overhangs necessitating the use of support structures, which, if not removed, can greatly impact the performance of bandpass filters. Therefore, in …

Use Of Swir Imaging To Monitor Layer-To-Layer Part Quality During Slm Of 304l Stainless Steel, Cody S. Lough, Xin Wang, Christopher C. Smith, Olaseni Adeniji, Robert G. Landers, Douglas A. Bristow, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper evaluates using in-situ SWIR imaging to monitor part quality and identify potential defect locations introduced during Selective Laser Melting (SLM) of 304L stainless steel. The microstructure (porosity, grain size, and phase field) and engineering properties (density, modulus, and yield strength) depend on the thermal history during SLM manufacturing. Tensile test specimens have been built with a Renishaw AM250 using varied processing conditions to generate different thermal histories. SWIR imaging data is processed layer-to-layer to extract features in the thermal history for each process condition. The features in the thermal history are correlated with resulting part engineering properties, microstructure, …

Mechanical Properties Of Zr-Based Bulk Metallic Glass Parts Fabricated By Laser-Foil-Printing Additive Manufacturing, Yingqi Li, Ming-Chuan Leu, Hai-Lung Tsai

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The application of bulk metallic glasses (BMGs) has been traditionally limited to parts with small dimensions and simple geometries, due to the requirement of fast cooling during the conventional process of casting. This research exemplifies a promising additive manufacturing method, i.e., laser-foil-printing (LFP), to fabricate high-quality BMG parts with large dimensions and complex geometries. In this study, Zr_52.5Ti₅Al₁₀Ni_14.6Cu_17.9 BMG parts were fabricated by LFP technology in which MG foils are laser welded layer-by- layer upon a substrate. The mechanical properties of the fabricated BMG parts were measured using micro-indentation, tensile test …

Recyclability Of 304l Stainless Steel In The Selective Laser Melting Process, Austin T. Sutton, Caitlin S. Kriewall, Ming-Chuan Leu, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

During part fabrication by selective laser melting (SLM), a powder-bed fusion process in Additive Manufacturing (AM), a large amount of energy is input from the laser into the melt pool, causing generation of spatter and condensate, both of which have the potential to settle in the surrounding powder-bed compromising its reusability. In this study, 304L stainless steel powder is subjected to five reuses in the SLM process to assess its recyclability through characterization of both powder and mechanical properties. Powder was characterized morphologically by particle size distribution measurements, oxygen content with inert gas fusion analysis, and phase identification by X-ray …

Additive Manufacturing Of Metal Functionally Graded Materials: A Review, Yitao Chen, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Functionally graded materials (FGMs) have attracted a lot of research interest due to their gradual variation in material properties that result from the non-homogeneous composition or structure. Metal FGMs have been widely researched in recent years, and additive manufacturing has become one of the most important approaches to fabricate metal FGMs. The aim of this paper is to review the research progress in metal FGMs by additive manufacturing. It will first introduce the unique properties and the advantages of FGMs. Then, typical recent findings in research and development of two major types of metal additive manufacturing methods, namely laser metal …

Effects Of Identical Parts On A Common Build Plate On The Modal Analysis Of Slm Created Metal, Tristan Cullom, Troy Hartwig, Ben Brown, Kevin Johnson, Jason Blough, Andrew Barnard, Robert G. Landers, Douglas A. Bristow, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The frequency response of parts created with Additive Manufacturing (AM) is a function of not only process parameters, powder quality, but also the geometry of the part. Modal analysis has the potential to evaluate parts by measuring the frequency response which are a function of the material response as well as the geometry. A Frequency Response Function (FRF) serves as a fingerprint of the part which can be validated against the FRF of a destructively tested part. A practical scenario encountered in Selective Laser Melting (SLM) involves multiple parts on a common build plate. Coupling between parts influences the FRF …

Effect Of Environmental Variables On Ti-64 Am Simulation Results, Aaron Flood, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In metal AM the environment is critical and therefore care should be taken to ensure that the simulation matches reality. This paper will investigate the effect that various environmental factors have on the results of the simulation. This will help to determine their importance in the simulation setup. The material properties which relate to this are the convective coefficient and the emissivity. These material properties will be investigated to determine their effect on the outcome of the simulation. In addition to these properties, the size of the substrate will be investigated to determine if any results are altered. Lastly, the …

Incorporation Of Automated Ball Indentation Methodology For Studying Powder Bed Fabricated 304l Stainless Steel, Sreekar Karnati, Jack L. Hoerchler, Aaron Flood, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Automated Ball Indentation (ABI) is a viable method for estimating the ductility, yield stress, and ultimate stress, among other metrics, in different metallic materials. Currently, ABI data analysis utilizes Holloman’s Power Law to model the plastic region of the true stress-true strain curve. While this formulation is accurate for some materials, its relevance for additively manufactured austenitic stainless steels, such as 304L, needed investigation. The deviation of the material’s plastic behavior from the Power Law was investigated. In order to better model this behavior, both the Voce and Ludwigson formulation were investigated. These formulations were tested for both wrought and …

Characterization Of Impact Toughness Of 304l Stainless Steel Fabricated Through Laser Powder Bed Fusion Process, Sreekar Karnati, Atoosa Khiabhani, Aaron Flood, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In this research, the impact toughness of powder bed based additively manufactured 304L stainless steel was investigated. Charpy specimens were built in vertical, horizontal and inclined (45⁰) orientations to investigate the variation in toughness with build direction. These specimens were tested in as-built and machined conditions. A significant difference in toughness was observed with varying build directions. The lowest toughness values were recorded when the notch was oriented in line with the interlayer boundary. The highest toughness was recorded when the notch was perpendicular to the interlayer boundary. A significant scatter in toughness values was also observed. The variation and …

In-Situ Optical Emission Spectroscopy During Slm Of 304l Stainless Steel, Cody S. Lough, Luis I. Escano, Minglei Qu, Christopher C. Smith, Robert G. Landers, Douglas A. Bristow, Lianyi Chen, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper demonstrates the potential of in-situ Optical Emission Spectroscopy (OES) to monitor the Selective Laser Melting (SLM) process. A spectrometer is split into the beam path of a home-built SLM system to collect visible light emitted from the melt pool and plume. The inline configuration allows signal collection regardless of the laser scan location. The spectral data can be used to calculate the temperature of the vapor plume and correlated with the melt-pool size. The effects of varying the atmosphere and pressure on the OES signal are also explored. These results demonstrate that OES can provide useful feedback to …

Development Of Pre-Repair Machining Strategies For Laser-Aided Metallic Component Remanufacturing, Xinchang Zhang, Wenyuan Cui, Leon Hill, Wei Li, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Remanufacturing worn metallic components can prolong the service life of parts that need frequent replacement but are extremely costly to manufacture, such as aircraft titanium components, casting dies. Additive manufacturing (AM) technology enables the repair of such valuable components by depositing filler materials at the worn area layer by layer to regenerate the missing geometry. In general, damaged parts would be inspected and pre-machined prior to material deposition to remove oil, residue, oxidized layers or defects located in inaccessible regions. Therefore, the motivation of this paper is to introduce pre-repair machining strategies for removing contaminated materials from damaged components and …

General Rules For Pre-Process Planning In Powder Bed Fusion System -- A Review, Tan Pan, Sreekar Karnati, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Powder bed fusion (PBF) is one of the current additive manufacturing techniques that can fabricate almost fully dense functional metal components. Through a layer by layer fabrication methodology, complex geometries to meet the requirements of aerospace, automotive, biomedicine industries, etc. can be produced. The success of a build largely depends on having a flawless pre-process planning, including build orientation selection, support structure optimization, process parameter chosen, etc., which closely relates to the quality of the final products. Geometric inaccuracy and poor surface quality can occur due to a bad build plan. This review presents the crucial general planning rules for …

Frequency Response Inspection Of Additively Manufactured Parts For Defect Identification, Kevin Johnson, Jason Blough, Andrew Barnard, Troy Hartwig, Ben Brown, David Soine, Tristan Collum, Edward C. Kinzel, Douglas A. Bristow, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The goal of this paper is to evaluate internal defects in AM parts using dynamic measurements. The natural frequencies of AM parts can be identified by measuring the response of the part(s) to a dynamic input. Different excitation methods such as a modal impact hammer or shakers can be used to excite the parts. Various methods exist to measure the parts' responses and find the natural frequencies. This paper will investigate the use of Doppler lasers, accelerometers and Digital Image Correlation (DIC). The parts evaluated in this work include sets of parts that are still attached to the AM build …

Effects Of Thermal Camera Resolution On Feature Extraction In Selective Laser Melting, Xin Wang, Cody S. Lough, Douglas A. Bristow, Edward C. Kinzel, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective Laser Melting (SLM) is a common additive manufacturing process which uses a laser energy source to fuse metal powder layer by layer. Engineering properties and microstructure are related to the part’s thermal history. It is important to measure the thermal history in-situ to qualify parts and provide the sensing which is necessary for process control. A common measurement tool for this purpose is a thermal camera that records the thermal emission of the part’s surface.

This study investigates the effects of spatial sampling resolution of thermal cameras when monitoring the temperature in SLM processes. High-fidelity simulation of an SLM …

Thermal And Mechanical Response Of Inner Cone Sample Of Zrb₂-Sic Ceramic Under Arc-Jet Conditions, Jun Wei, Lokeswarappa R. Dharani, K. Chandrashekhara

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Under arc-jet test conditions, ZrB₂-SiC ceramic will undergo high temperature oxidation and develop an external glassy layer (SiO₂), zirconia sub-layer (ZrO₂) and SiC-depleted diboride layer (ZrB₂). This study relates to finite element modeling of the effects of oxidation on heat transfer and mechanical behavior of ZrB₂-SiC ceramic under arc-jet test conditions. A steady-state heat transfer FE method was employed to conduct the heat transfer analysis to obtain the temperature distribution in the inner body of the cone. The surface thermal conditions available in the literature were used in the heat …