Engineering Science and Materials Commons^™

Ultrasonic Non-Destructive Evaluation Of Additively Manufactured Polymer-Ceramic Composites, Christian Alexander Ruiz

Open Access Theses & Dissertations

Digital light processing (DLP) is an attractive additive manufacturing technique due to its ability to create ceramic parts with complex geometries. DLP uses ultraviolet light to polymerize a slurry comprised of ceramic powder and photosensitive resin in layers to create solid parts. Printing parameters such as light intensity and exposure time are critical when producing these parts. Improper parameters can lead to over or under-curing, adversely impacting print quality and strength. Samples were printed at varying layer exposure times and then tested using ultrasonics to determine the degree of conversion. Additionally, ultrasonics were used as a non-destructive technique to obtain …

Double Cantilever Beam Mode-I Testing Validation In Large-Scale Additive Manufacturing Carbon Composite, Luis Alfonso Camacho

Open Access Theses & Dissertations

Testing for mechanical properties for additive manufacturing has been based on already existing standards for traditional manufacturing methods. For composites in large scale additive manufacturing there is a research gap in bond strength and fracture toughness for a single layer interface. By using Double cantilever beam Mode I, this thesis manuscript validates testing parameters and protocols to describe the intricacies of ABS matrix 20 wt.% carbon filled composite, specifically on the layer-to-layer interface. Studies suggest that fracture toughness is sensitive to process parameters, like deflection speed and sharpened crack tip at the layer interface of BAAM 3D printed part and …

Fabrication, Microstructure And Mechanical Characterization Of Crvnbtaw High Entropy Alloy Coatings Using Magnetron Sputtering, Jorge Quezada

Open Access Theses & Dissertations

In this project a CrVNbTaW high entropy alloy was evaluated. The samples were made using radio frequency magnetron sputtering and were made under similar conditions. The deposition parameters were explored to find the ideal deposition process. The process included a pressure from 0.1-2mTorr, 600C, 1 hour duration, at 100W power to guns, and constant argon flow. The samples were fabricated under similar parameters using silicon steel and sapphire substrates. The samples were analyzed and characterized using X-ray diffraction, scanning electron microscopy, atomic force microscopy, nanoindentation and corrosion testing. Based on these results we were able to get a better understanding …

The Qualification Of Sealability And Creep Relaxation Of Additively Manufactured Zytel Gaskets For Pem Fuel Cells, Robert Lazarin

Open Access Theses & Dissertations

The purpose of this thesis is to study the feasibility of low-cost additive manufacturing of gaskets for proton exchange membrane fuel cells exposed to extreme temperature conditions ranging from -55°C to 100°C. With the growing popularity and decreasing costs of additive manufacturing technologies, specifically Material Extrusion (ME), research is being conducted to determine the feasibility of ME components. Thermally cycled PEMFCs may exhibit accelerated gasket deterioration, therefore, the mechanical stability of material extruded gaskets following a harsh thermal cycle must be assessed. The feasibility of the material extruded gaskets will be proven by manufacturing optimization and mechanical testing. The target …

Novel Interlaminar Reinforcement To Enhance The Impact Damage Resistance Of Carbon Fiber-Reinforced Polymer Matrix Composites, Daisy Haidee Mariscal

Open Access Theses & Dissertations

Aerospace, aircraft, marine, and automobile applications are increasingly using composite materials for lighter, higher stiffness, and strength properties. Despite these advantages, composite materials have one major disadvantage. The through-thickness properties are extremely weak when subjected to impact damage. When a composite material is subjected to a low-velocity impact, there is hardly any visible damage on the surface compromising the composite material internally without any external notice. Internal damage may be delamination, which is the most common, matrix cracking, and fiber breakage. A composite material is made up of layers of fiber. The interlaminar region is located in between these layers. …

Suitability Of Low-Cost Additive Manufacturing For Polymer Electrolyte Fuel Cells, David Alexander

Open Access Theses & Dissertations

The purpose of this dissertation is to study the feasibility of low-cost additive manufacturing to fabricate polymer electrolyte fuel cell bipolar plate materials. Traditional manufacturing techniques include molding, milling, hollow embossing, hydro-forming, rolling, and electromagnetic forming. These processes are employed when a design has been selected due to higher costs at low volumes. The combination of high initial costs and bipolar plates being the most expensive component of the polymer electrolyte fuel cell creates incentive to mitigate this obstacle. The feasibility of low-cost additive manufactured bipolar plates will be proven by fabrication, post-processing, and characterization of printed test specimen. The …

Material Synthesis And Machine Learning For Additive Manufacturing, Jaime Eduardo Regis

Open Access Theses & Dissertations

The goal of this research was to address three key challenges in additive manufacturing (AM), the need for feedstock material, minimal end-use fabrication from lack of functionality in commercially available materials, and the need for qualification and property prediction in printed structures. The near ultraviolet-light assisted green reduction of graphene oxide through L-ascorbic acid was studied with to address the issue of low part strength in additively manufactured parts by providing a functional filler that can strengthen the polymer matrix. The synthesis of self-healing epoxy vitrimers was done to adapt high strength materials with recyclable properties for compatibility with AM …

Synthesis And Characterization Of Tin (Sn) Incorporated Ga2o3, Guillermo Nicolas Gutierrez

Open Access Theses & Dissertations

In this work, we report on the synthesis, characterization of tin (Sn) incorporated gallium oxide Ga2O3 compounds, also included in this work is the effect of tin concentration related to the optical and electrochemical properties. The Sn incorporation into Ga2O3 creates a significant reduction in the bandgap and causes a nonlinear optical activity as the concentration varies. Substantial investigation performed to the structure, phase, and morphology of the mixed compounds governed by the stoichiometry equation Ga2−2xSnxO3-ɗ indicates that the Sn incorporation from 0.00 ≤ x ≤ 0.30 has a significant effect on these properties. To synthesize the Ga-Sn-O compounds a …

Phase Transformation And Strain Hardening Mechanisms In Advanced Engineering Steels, Hangyu Dong

Open Access Theses & Dissertations

Strain hardening and associated deformation mechanisms play a determining role in the performance of metallic materials. The objective of the doctoral research was to explore and fundamentally understand the strain hardening mechanisms in the next generation of advanced engineering steels. Two main work hardening mechanisms, notably, twinning-induced plasticity (TWIP) and transformation-induced plasticity (TRIP)) were identified that governed strength and ductility. In the nanograined austenitic steel with high strength-high ductility combination, processed by the novel phase reversion concept, twinning-induced plasticity (TWIP) was the governing deformation mechanism and contributed to good ductility. In striking contrast, transformation-induced plasticity (TRIP) was the deformation mechanism …

Mechanical Properties And Microstructure Evolution Of Thermally Treated Laser Powder Bed Fusion Alsi10mg, Jorge Merino-Gomez

Open Access Theses & Dissertations

The optimization of mechanical properties with thermal postprocessing treatments was investigated in this study across a wide variety of variants. The relationship between heat treatments and the impacts on the mechanical properties and microstructure of printed materials is a crucial part of additive manufacturing. As a result, the current paper provides a comprehensive overview of postprocess heat treatments for Laser Powder Bed Fusion fabricated AlSi10Mg alloy, including stress relief anneals at 190 and 285 degrees Celsius for 2 hours, hot isostatic pressing at 515 degrees Celsius for 3 hours, hot isostatic pressing + T6 treatment for 6 hours, and final …

Post Processing Of Electron Beam Melted Ti-6al-4v And Binder Jetted 17-4 Stainless Steel, Ahmad Omar Abu-Issa

Open Access Theses & Dissertations

An extensive assortment of HIP parameters have been altered on EBM fabricated Ti-6Al-4V and have shown that cooling rates of 103 oC/min from temperatures above and below the beta transus produced acicular alpha-prime martensite characteristic elongations < 10 %. Optimum yield strength (0.9 GPa), UTS (1.0 GPa) and elongation (~14 %) were achieved for slow cooling (at 102 oC/min) from 850 oC HIP which produced a dense, Widmanstatten alpha structure within the retained, as-fabricated columnar grains by alpha-prime decomposition. These results suggest that manipulation of AM process parameters to produce a small-grain, equiaxed microstructure, HIPed below the beta transus and slow cooled, will have a wide range of superior, isotropic mechanical properties corresponding to a Widmanstatten alpha microstructure within the equiaxed grains. Also, Binder Jetting printing parameters for differing PSD's of low-cost water-atomized 17-4 Stainless Steel were optimized in order to produce high dense parts. Densities ranging from 94-97.5% were achieved, and issues of inhomogeneous porosity were addressed using a fumed silica flow additive.

Synthesis And Characterization Of Functiona Materials For 3d Printed Composites, Elizabeth Irene Reza

Open Access Theses & Dissertations

The following body of work encompasses the synThesis, upscaling, additive manufacturing, and characterization of microspheres as functional fillers incorporated into polymer syntactic foams. Synthesizing microspheres permits control over morphology, dispersion of particles, and size while the use of direct write manufacturing allowed for the controllability of filler orientation. Two different syntactic foams were developed from similar methodologies: (1) a silicone syntactic foam (2) epoxy syntactic foam. The silicone epoxy foam showed an increasing in damping and elastic modulus. The epoxy syntactic foams showed an enhanced thermal and electrical properties.

Additive Manufacturing Of Engineered Material Systems For Energy Applications, Luis Angel Chavez

Open Access Theses & Dissertations

Despite increasing efforts to use renewable electricity generation techniques in the last couple of decades, the world is still heavily reliant on traditional power generation techniques. This creates the need to make such systems cheaper and less pollutant through improvements to their efficiency. Increasing the efficiency and reliability of energy conversion systems, specially those based on combustion processes has been of interest for many years. However, material limitations have brought these systems to a stagnant condition.

A novel approach to help increase the efficiency of such systems is to closely monitor their operating conditions and therefore be able to increase …

Effect Of Flow Velocity And Geometry On The Signal From A Piezoelectric Flow Rate Sensor, Jad Gerges Aboud

Open Access Theses & Dissertations

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Cmas/Volcanic Ash Infiltration Performance Of Yttria Rich-Zirconia Thermal Barrier Coatings Produced By Electron Beam Physical Vapor Deposition, Juan Jose Gomez Chavez

Open Access Theses & Dissertations

For many years the use of thermal barrier coatings (TBC) in gas turbine engines has allowed a significant increase in engine operating temperatures which are above the Ni-based super alloys' melting point. The base material for TBCs is the state of the art 7 wt % yttria stabilized zirconia (YSZ) which provides the thermal protection. Current industry demands for increased engine efficiency has pushed TBCs to the limits where significant technological constrains have been identified. One of the main ones represents the high temperature corrosion of the TBC material due to the ingestion of silicate based airborne particles commonly referred …

Tailoring The Mechanical And Optical Properties Of Silicon-Niobium-Nitride Composite Coatings, Cristian Orozco

Open Access Theses & Dissertations

Nitride nanocomposite thin films have generated significant attention as a result of their robust mechanical properties, excellent triobology, and good chemical (corrosion) stability. Due to their excellent hardness and high wear resistance NbN coatings have found use in a wide variety of applications such as the coating of cutting tools and to strengthen the surface mechanical properties of superconducting cavities. The mechanical properties of NbN can be further improved through mixing with Si3N4, leading to the formation of a nanocomposite structure. NbN-Si3N4 nanocomposite coatings have been actively studied due to their high hardness, high elastic modulus, and high resistance to …

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 …

Direct Write 3d Printing Of Functional Ceramics, Jorge Angel Diaz

Open Access Theses & Dissertations

Humidity sensors are used in many industries and are important for ensuring quality and safety. Ceramic sensors are preferred because of their quick response time, ability to withstand high temperatures and excellent Chemical and mechanical stability. The manufacturing world has been moving toward additive manufacturing which is a form of synthesizing 3D tangible layer by layer in witch minimal waste is produced. Additive manufacturing also is known as 3D printing has opened new possibilities to design engineers by giving them design freedom and access to the layers of a part to allow embedded sensors. There is a category of ceramics …

Titanium Incorporated Gallium Oxide (Ga-Ti-O): Structure Property Relationship And Performance Evaluation For Extreme Environment Applications, Sandeep Manandhar

Open Access Theses & Dissertations

The existing power generation systems, which utilize fossil fuels, are in dire need of efficient, reliable chemical sensors that can operate safely at higher temperatures. These sensors control the combustion environment and the emissions during combustion. Several sensing materials such as SnO2, ZnO, TiO2, WO3, and Ga2O3 exhibit high sensitivity to certain type of chemical molecules and in a certain range of temperatures. Among these candidate materials, β-Ga2O3 is stable at very high temperatures and has shown functionality for oxygen sensing at higher temperatures (>700°C). However, the response time and sensitivity must be significantly improved in order to derive …

Tungsten Doping Induced Superior Mechanical Properties Of Hafnium Oxide For Energy Applications, Ann Marie Uribe

Open Access Theses & Dissertations

Hafnium oxide, or hafnia, is a high temperature refractory material with good electrical, chemical, optical, and thermodynamic properties. The effects of dopants have been widely studied, especially after the discovery of ferroelectricity induced in hafnia thin films. While attractive and used in the opto-electronic, memory devices, and semiconductor industries, there is a lack in the literature on enhancing the mechanical properties of hafnium oxide, specifically through doping it with tungsten, another material of interest particularly for future high temperature device applications. Thus, this work aimed to grow hafnia thin films doped with varying amounts of tungsten. The samples were grown …

Comprehensive Finite Element Modeling Of Ti-6al-4v Cellular Solids Fabricated By Electron Beam Melting, Edel Arrieta

Open Access Theses & Dissertations

Additive manufacturing permits the fabrication of cellular metals which are materials that can be highly customizable and possess multiple and extraordinary properties such as damage tolerance, metamorphic and auxetic behaviors, and high specific stiffness. This makes them the subject of interest for innovative applications. With interest in these materials for energy absorption applications, this work presents the development of nonlinear finite element models in commercial software platforms (MSC Patran/Nastran) that permit the analysis of the deformation mechanisms of these materials under compressive loads. In the development of these models, a detailed multiscale study on the different factors affecting the response …

Structural And Mechanical Characterization Of Nanocrystalline Tungsten And Tungsten-Based Alloy Thin Films For Extreme Environment Applications, Gustavo Martinez

Open Access Theses & Dissertations

Extreme environments associated with nuclear applications often results in degradation of the physical, mechanical and thermo-mechanical properties of the materials. Tungsten (W) exhibits unique physical and mechanical properties, which makes tungsten a good candidate for nuclear applications; however, intrinsic W exhibits low fracture toughness at all temperatures in addition to a high ductile to brittle transition. In the present work, nanocrystalline W, W-Y and W-Mo alloys were nanoengineered for nuclear applications. Nanocrystalline tungsten coatings with a thickness of ~1 µm were deposited onto Silicon (100) and Sapphire (C-plane) using RF and DC sputtering techniques under various growth conditions. Yttrium content …

Organic-Inorganic Graphite And Transition Metal Dichalcogenide Based Composites For 3d Printing, Jorge Alfredo Catalan Gonzalez

Open Access Theses & Dissertations

This project was multipronged to help fuse together topics of additive manufacturing and two-dimensional (2D) layered materials, and studying the mechanical and electrical properties of the composites produced. The composites are made from the thermoplastic polymer acting as a matrix and the graphite and 2D transition metal dichalcogenides (TMDs) serving as the filler or reinforcement. Different concentrations of TMD's were added to the matrix to study the effect of composition on the mechanical and electrical properties. To shed insights into the mechanical properties, test coupons were produced as "dog bone" structures for tensile testing using the ASTM D638 type 5 …

Mechanically Activated Magnesiothermic Combustion Synthesis Of Zirconium And Hafnium Diborides, Sergio Cordova

Open Access Theses & Dissertations

Magnetohydrodynamic (MHD) generation of electric power has the potential to increase the thermal efficiency of fossil-fuel burning power plants. Electrode materials in MHD generators must possess a high melting point, high electrical and thermal conductivities, chemical stability, and resistance to thermal shock, oxidation, and plasma sparks/arcs. Ultra-high temperature ceramics based on diborides of zirconium and hafnium (ZrB2 and HfB2) are promising materials for this application. Self-propagating high-temperature synThesis (SHS) is an attractive method for their large-scale fabrication, but SHS of ZrB2 and HfB2 from elemental Zr, Hf, and B is not economically viable because of the high cost of the …

Test Methods For The Fracture And Fatigue Crack Growth Behavior Of Hot Mix Asphalts, Eduardo Garcia

Open Access Theses & Dissertations

The service life and mechanical properties of bituminous mixtures are greatly affected by distress problems such as fracture, thermal cracking, and fatigue cracking of the asphalt layers. The fracture and fatigue crack growth (FCG) behavior of bituminous mixtures are difficult to quantify due to material-, test-, and equipment-related uncertainties. The goal of this study is to introduce a systematic fracture and fatigue crack growth testing approach for hot mix asphalts (HMAs). The objective is to experimentally evaluate the fracture resistance and fracture toughness behavior of a dense-graded HMA material at different temperatures and varying thicknesses. The effect of thickness on …

Mechanically Activated Combustion Synthesis Of Molybdenum Borosilicides For Ultrahigh-Temperature Structural Applications, Alan Alberto Esparza Hernandez

Open Access Theses & Dissertations

The desire to improve the efficiency of power generation gas-turbines has led to a relentless quest for new, ultrahigh-temperature structural materials to replace the current nickel-based superalloys. These materials have reached the maximum allowable operating temperature determined by the melting temperature of these alloys, which is about 1150 °C. These materials could be replaced by molybdenum silicides and borosilicides based on Mo5SiB 2 (T2) phase due to their high melting point and mechanical properties. A major challenge, however, is to simultaneously achieve high oxidation resistance and acceptable mechanical properties at elevated temperatures. One novel approach to improve these properties is …

Damage Tolerance And Assessment Of Unidirectional Carbon Fiber Composites, Mark David Flores

Open Access Theses & Dissertations

Composites are beginning to be used in a variety of different applications throughout industry. However, certification and damage tolerance is a growing concern in many aerospace and marine applications. Although compression-after-impact have been studied thoroughly, determining a damage tolerance methodology that accurately characterizes the failure of composites has not been established. An experimental investigation was performed to study the effect of stacking sequence, low-velocity impact response, and residual strength due to compression and fatigue. Digital Image Correlation (DIC) captured the strains and deformation of the plate due to compression. Computational investigations integrated non-destructive techniques (C-Scan, X-Ray) to determine the extent …

Structural, Dielectric, And Ferroelectric Characterization Of Lead-Free Calcium-Cerium Co-Doped Batio3 Ceramics, Juan Alberto Duran

Open Access Theses & Dissertations

Structure, morphology, and regulation of the dielectric properties via close-composition intervals is demonstrated for variable-cerium, constant-calcium co-doped barium titanate (Ba0.80Ca0.20CeyTi1-yO3; y=0.0-0.25; referred to BCCT). The effect of variable Ce-content on the structure and dielectric properties of BCCT is investigated. X-ray diffraction spectra confirms the studied samples are mainly in BT tetragonal phase with a small secondary phase detected as CaTiO3 in BCCT for y = 0.20 and 0.25. However, the lattice parameter reduction was evident with increasing Ce-content. Composition-driven dielectric constant leap (4,000-5,500) was observed from intrinsic BCT to BCCT for (y = 0.0-0.04). The temperature dependent dielectric constant showed …

Yttria Rich Tbcs As Candidates For Cmas Resistant Top Coats, Juan Jose Gomez

Open Access Theses & Dissertations

State of the art thermal barrier coatings (TBC) commonly made of 7-8 wt. % yttria stabilized zirconia (7YSZ) are used in modern gas turbines to generate a thermal protection to the underlying super alloy components. TBCs allow higher operating temperatures for hot gas path components, thus, generating higher engine efficiency. The infiltration of molten glassy mineral deposits composed of CaO-MgO-Al2O3-SiO2 (CMAS) represents one of the major threats in reducing performance and service life in aero and land based gas turbine engines. The CMAS deposits are ingested into the engine carried commonly in sand, runways debris, fly ash and volcanic ash. …

Simulation Of Infiltrating Rate Driven By Surface Tension-Viscosity Of Liquid Elements From The Titanium Group Into A Packed Bed, Arturo Medina

Open Access Theses & Dissertations

The simulation of infusion of molten reactive metals (e.g., yttrium) into a porous, carbide packed bed to create carbide and boride composites was studied at ultrahigh temperatures (>1700°C). The infusion was investigated through a computational fluid dynamic (CFD) system of capillary pores and compared to a predicted analytical calculation formulated by Selmak and Rhines. Simulations of two-phase flow penetration of yttrium into a packed bed of B4C were investigated and compared with titanium, zirconium, hafnium, and samarium liquids. The non-reactive, liquid metal infusion was primarily driven by the surface tension and viscosity. The liquid metal depth and rate of …