Materials Science and Engineering Commons^™

Recycling Metal Chips Into Usable Materials, Alex Mortensen, Ben Mortensen

Williams Honors College, Honors Research Projects

This report entails the scope, design considerations, and plans for creating a metal chip converter into metal briquettes. The construction is a set of machines with multiple processes to make the conversion happen. The process includes washing fine metal chips, drying them off, compressing them, and melting them down into usable briquettes. This project is intended to make a simple process to recycle metal chips into usable material for reuse. The project's objective is to reduce the costs of storage and recycling waste by offering a solution to recycle it into materials the shop can reuse.

Engineering Order-Disorder Transitions For High-Performance Thermoelectric Fe2val Heusler Alloys, Cory T. Cline

Dartmouth College Ph.D Dissertations

Fe₂VAl shows great promise as an eco-friendly and low-cost replacement to conventional low-temperature (250-500 K) thermoelectric materials. Current thermoelectric materials use toxic and expensive elements like Te and Sb, whereas Fe₂VAl offers a larger power factor at a lower cost and a reduced risk of environmental pollution. The key issue with Fe₂VAl is the alloy’s relatively large thermal conductivity compared to its semiconductor competitors. This thesis aims to investigate a hierarchical approach to reduce lattice thermal conductivity through a preliminary exploration of heavy element substitutions and mechanical deformation, then through probing order-disorder transitions for …

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 …

An Application Of Optimized Bistable Laminates As A Low Velocity, Low Impact Mechanical Deterrent, Graham Lancaster

All Theses

This research considers the problem of using bistable laminates as a mechanical deterrent to the impending impact of a particle. The structure will be controlled through an algorithm that will utilize piezoelectric devices to activate them in unison with the bistable laminate to successfully deter. A novel experimental setup will be constructed to ensure that the bistable laminate stays fixed when acting as a mechanical deterrent. Piezoelectricity is the main driving force of the bistable laminate to morph and this study will use a Macro Fiber Composite (MFC) actuator that contains piezoelectric ceramic rods in a patch to transfer electrical …

Effects Of Surface Noise On Printing Artifacts: An Artistic Approach To Hiding Print Artifacts, Samuel New

All Theses

This research focuses on improving the quality of Fused Filament Fabrication (FFF) 3D printing by using fractal noise to mask certain print artifacts (e.g. layer lines and stair-stepping). The use of textures is quite common in digital sculpting for aesthetic reasons. This study focuses on finding specific textures that minimize visible 3D print artifacts.

Carbon Fibers From Bio-Based Precursors Derived From Renewable Sources, Sagar Kanhere

All Dissertations

Carbon fibers have the highest strength and modulus among all known fibers and are used as reinforcements in high-performance composites [1]. Carbon fibers also have a very low density relative to metals. Therefore, carbon fibers possess ultrahigh specific strength and modulus, which make them desirable for high-performance light-weight composites. A vast majority of commercial carbon fibers are produced from PAN precursors that are expensive, which limits the use of PAN-derived carbon fibers to aerospace applications (e.g., airplanes). However, for costsensitive applications, there is a need for low-cost, moderate performance carbon fibers. Lignin is a low-cost by-product of pulping and biorefining …

Wet Chemical Synthesis And Properties Of Argyrodite Sulfide Solid Electrolytes For Solid State Lithium Batteries., William Arnold

Electronic Theses and Dissertations

The commercialization of the lithium-ion battery (LIB) in 1991 was responsible for the explosion in portable electronic technologies that has been seen over the past 30 years. With the advent of electric vehicles and other high-powered technologies, there is tremendous demand for LIBs with higher energy density and high safety. To achieve this, new electrode materials must be explored. The obvious choice of anode material would be pure metal lithium, which has a theoretical specific capacity of 3860 mAh g^-1 . Unfortunately, metal lithium anodes have not been widely commercialized due to their tendency to react violently with the …

Near-Ir Laser Ablation Of Simulated Radiologically Contaminated Oxides On Carbon Steel Feeder Pipes, Thao Viet Do

Electronic Thesis and Dissertation Repository

As nuclear power plants age and retire from service, many countries face significant challenges concerning the safe long-term storage and disposal of large volumes of low and intermediate level radioactive wastes (L&ILW). The volumes of metallic waste are of particular concern, as when metal corrodes it produces hydrogen that could lead to pressure build-up in interim storage and disposal. In Canada, a significant fraction of the metallic wastes for Canada Deuterium Uranium (CANDU) nuclear reactors are out-of-core reactor components, such as carbon steel (CS) feeder pipes. The radioactive contamination is expected to be largely confined to the surface oxide layers …

Direct Calculation Of Configurational Entropy: Pair Correlation Functions And Disorder, Clifton C. Sluss

Doctoral Dissertations

Techniques such as classical molecular dynamics [MD] simulation provide ready access to the thermodynamic data of model material systems. However, the calculation of the Helmholtz and Gibbs free energies remains a difficult task due to the tedious nature of extracting accurate values of the excess entropy from MD simulation data. Thermodynamic integration, a common technique for the calculation of entropy requires numerous simulations across a range of temperatures. Alternative approaches to the direct calculation of entropy based on functionals of pair correlation functions [PCF] have been developed over the years. This work builds upon the functional approach tradition by extending …

Computational Characterization Of Nonwoven Fibrous Materials: Transport And Wetting Properties, Fang Wang

All Dissertations

Nonwoven fibrous materials represent a platform of flexible material substrates. Nonwovens are widely used in the production of napkins, paper, filters, wound covers and face masks. In addition, for many applications, nonwoven materials interact with fluids. For example, in filtration applications, nonwoven materials are used to clean fluids containing solid particles or emulsified droplets. The filtration performance is affected not only by the geometrical arrangement of fibers in non-woven materials but also wettability of fibers. Understanding the transport properties of nonwoven materials and interactions between the dispersed droplets and solid substrate is crucial for the design and optimization of filter …

Quantum-Mechanical Evaluation Of Defects In Uranium-Bearing Materials, Megan Hoover

All Dissertations

Quantum-mechanical calculations using density functional theory with the generalized gradient approximation were employed to investigate the effects dopants have on the uranium dioxide (UO₂) structure. Uraninite is a common U⁴⁺ mineral in the Earth's crust and an important material used to produce energy and medical isotopes. Though the incorporation mechanism remains unclear, divalent cations are known to incorporate into the uranium dioxide system. Three charge-balancing mechanisms were evaluated to achieve a net neutral system, including the substitution of (1) a divalent cation for a tetravalent uranium atom and oxygen atom; (2) two divalent cations for a tetravalent …

Controlled Manipulation Of Droplets On Fibers: Fundamentals And Printing Applications, Yueming Sun

All Dissertations

In this dissertation, the drop interactions with a single fiber is discussed under an application angle for the development on new Drop-on-Demand (DOD) printhead using a fiber-in-a-tube platform[1] to print highly viscous materials[2]. To control the drop formation and manipulation on fiber, one needs to know how the fiber wetting properties and the fiber diameter influence drop formation. And then, one needs to know the effects of fiber movement in the device on drop formation. These two questions constitute the main theme of this dissertation.

Before this study, it was accepted that the liquids could not form axisymmetric droplets if …

Development Of Smart Wearable Sensory Systems On Flexible And Fabric Platforms For Health Monitoring Applications, Simin Masihi

Dissertations

Wearable sensing technology has recently received an increased attention in both research and commercialization phases and has moved from a vision of science fiction to reality with a wide variety of applications. This incredible growth can be attributed to several factors, such as affordability and ergonomics provided by advances in flexible electronics. The other factors that realized wearable sensing technology include a critical need for more accessible health care services experienced during the recent COVID pandemic, integration to the Internet of Things (IoT), and a growing consumer desire for health awareness. This dissertation presents the fulfillment of three main projects …

Creep Behavior Of A Ti-Based Multi-Principal Element Alloy, Benjamin Elbrecht

All Theses

Abstract

The understanding of microstructural damage mechanisms is the foundation of better understanding existing materials and future material development. There are significant challenges to measuring these damage mechanisms in-situ as continuous observation of the state of the microstructure is difficult or impossible for many experimental setups. This thesis presents a method for measuring grain boundary sliding (GBS) and local strain concentrations in-situ via a Heaviside function based algorithm. GBS is the shearing of two grains along their shared grain boundary and is a common damage mechanism in creep which presents as a discontinuity that can be measured with a Heaviside …

Damage In Non-Crimp Fabric Carbon Fiber Reinforced Epoxy Composites Under Various Mechanical Loading Conditions, Aaditya Pradeep Suratkar

Electronic Thesis and Dissertation Repository

Composite materials have emerged in the recent years as a frontrunning lightweight replacement for metals for structural applications in lightweight automobiles. However, the key adoption criteria for composites in lightweight vehicles is their crashworthiness, i.e., the amount of energy a structure made with composites would absorb in a crash event. The energy is absorbed in composites through various damage modes such as matrix cracks, delamination, fiber breakage, etc. Therefore, adoption of a certain composite material system requires thorough understanding of the initiation and propagation of damage until failure in that system under various mechanical loading conditions, which is also the …

Effects Of Release Materials And Temperature Ramp Rates On The Surface Finish Of Carbon-Fiber Composite Components, Sudeep Louis, Thucmy Dang, Ethan Schlocker

Materials Engineering

Toray Advanced Composites is interested in improving their carbon fiber reinforced polymers (CFRP) manufacturing process by enhancing their control on the amount of surface roughness for varied customer preference. Surface roughness of CFRP is important in post-production processes including coating, priming, and painting. This project seeks to determine the effects of three release materials and two temperature ramp rates on the surface finish of CFRP. The release materials used were Tooltech, FEP, and Frekote 770-NC. The two initial temperature ramp rates were 1°F/min and 2°F/min. Surface roughness was measured using a profilometer and analyzed using Ra values. Ra is an …

Analysis Of Novel Corrosion Resistant Maraging Steels For Use In Additive Manufacturing, Bradley Michael Samuel, James Knowlton Smith

Materials Engineering

Stainless maraging steel has been proven to be an industry standard material for plastic injection molds. Its high hardness and corrosion resistance extend the lifetime of the tool. This alloy system is also well-suited to additive manufacturing, which can be utilized to form internal cooling channels, further increasing tool life. Using Rapid Alloy Development (RAD) Oerilkon METCO is developing a new composition of stainless maraging tool steel that has high hardness/strength, is corrosion resistant, and has additive-capable melting and solidification properties. This study tests the hardness and corrosion resistance of the new RAD alloys against the current market competitor Corrax …

Investigation Of The Effects Of Cladding Layers On Longitudinal And Transverse Mechanical Properties In Composite Laminates, Rachel Potratz, Tiffany Foo, Joseph Kamlet

Materials Engineering

The addition of cladding layers to composite laminates is used in industry to improve bond adhesion and the ease of manufacturing. However, there is no public data on the effects of cladding layers on the mechanical properties of composite components. To directly observe how cladding layers affect mechanical properties, four laminates with zero, one, two, and three cladding layers of twill fabric were added symmetrically to a biased core. The mechanical testing performed was tensile, short beam strength, and compression testing in the longitudinal and transverse directions. The measured strengths were related to the longitudinal properties of the core, and …

Non-Destructive Material Analysis Of Metals And Composites Via Thermography, Jonathan R. Doubt, James L. Chapman

Materials Engineering

The Naval Surface Warfare Center, Port Hueneme Division, is interested in the development of non-destructive damage assessment of shipboard materials via drones at distance. Long Pulsed Thermography (LPT), a method of non-destructive evaluation, was investigated as a possible method for detecting damage in metals (5005h24 Al alloy and 1008 carbon steel) and composites (aramid fiber honeycomb sandwich structure) at distances from 0.5 m to 3.0 m. LPT was conducted using two 1000 W can lights to heat the samples, and a FLIR E8-XT thermal camera. The images were then analyzed using ImageJ software to determine if damage could be detected …

Evaluating The Effects Of Granulated Rubber And Glass Fibers In Polymer Concrete As A Structural Material For Wafer Grinding Machines, Kevin Gabriel Kuehn, Philip Randall Streeter

Materials Engineering

Polymer concrete is a composite material used to replace cast iron and steel in wafer grinding machines for vibration damping. During the grinding and lapping processes of manufacturing silicon wafers, excessive vibrations may cause subsurface damage which requires additional polishing and reduces yield. Nine compositions containing various levels of granulated rubber and glass fibers were manufactured. CRM WRF-10 granulated rubber was examined at 0%, 5%, and 10% and Corning Cem-Fil glass fibers were added at 0%, 0.5%, and 1% by weight. Smooth-On EpoxAcast 690 epoxy resin was held constant at 16% for each composition. Crushed granite aggregate from Martin Marietta, …

On The Effects Of Additive Manufacturing Process Parameters On The Performance Of Hastelloy-X: A Neutron Diffraction Experiment And Crystal Plasticity Finite Element Model, Ahmed Aburakhia

Electronic Thesis and Dissertation Repository

Additive manufacturing (AM) is increasingly becoming one of the favourable manufacturing techniques in various industries, such as transportation and energy. The reason for the extensive use of AM lies in the ability to use a wide range of process parameters for manufacturing engineering parts with complex geometries that cannot be effectively manufactured using traditional methods such as casting or forging. Understanding the role of process parameters is crucial for developing predictive models, as well as for manufacturing engineering components with the desired properties.

This research aims to characterize the influence of AM process parameters on the deformation mechanisms of Hastelloy-X, …

A Modular Synthesis Of Processable And Thermally Stable Semi-Fluorinated Aryl Ether Polymers Via Step-Growth Polymerization Of Fluoroalkenes, Ketki Eknath Shelar

Theses and Dissertations

Tailored fluoropolymers remain the leading choice for a wide variety of advanced high-performance applications, including electronic/optical and energy conversion, owing to their unique blend of complementary high-performance properties. Amorphous semi-fluorinated polymers exhibit improved solubility and melt processability when compared to traditional perfluoropolymers. A leading class of semi-fluorinated aryl ether polymers includes perfluorocyclobutyl (PFCB), perfluorocycloalkenyl (PFCA), and fluoroarylene vinylene ether (FAVE) polymers. Monomers containing aromatic trifluorovinyl ethers (TFVE) are used to synthesize PFCB polymers via radical-mediated [2+2] cyclodimerization. On the other hand, FAVE and PFCA polymers are polymerized via base-mediated nucleophilic addition/elimination of bisphenols with TFVE monomers and decafluorocyclohexene respectively. The …

Challenges And Signal Processing Of High Strain Rate Mechanical Testing, Barae Lamdini

Theses and Dissertations

Dynamic testing provides valuable insight into the behavior of materials undergoing fast deformation. During Split-Hopkinson Pressure Bar testing, stress waves are measured using strain gauges as voltage variations that are usually very small. Therefore, an amplifier is required to amplify the data and analyze it. One of the few available amplifiers designed for this purpose is provided by Vishay Micro-Measurements which limits the user’s options when it comes to research or industry. Among the challenges of implementing the Hopkinson technology in the industry are the size and cost of the amplifier. In this work, we propose a novel design of …

Characterization Of Hydrogen Embrittlement Sensitivity In High Hardness Steels, David Ahlen Salley

Theses and Dissertations

High hardness steels can be affected by delayed brittle cracking often attributed to hydrogen embrittlement. Improved resistance to hydrogen embrittlement would be beneficial to many industries including military, automotive, and high-rise construction. While other prevention methods include coating, trapping, and barriers, design efforts in this study were focused on improving intrinsic properties to be more resistant to hydrogen embrittlement. Four alloys targeting 477 – 534 HB were designed and produced in-house and compared against a commercial grade 500 HB alloy. Charpy V-notch (CVN) impact toughness and tensile specimens were made according to ASTM E23 and ASTM E8 to characterize mechanical …

Characterization And Modeling Of H- Primary Stripper Foils For The Spallation Neutron Source, Leo Vernon Saturday Iii

Doctoral Dissertations

The Spallation Neutron Source (SNS) is currently preparing for a Proton Power Upgrade project that will increase the operating power of the beamline. Due to this increase in power, a major concern is whether the current stripper foils will be able to withstand the higher power beam. Here, we analyze the current nanocrystalline diamond as well as microcrystalline diamond stripper foils in order to assess their ability to withstand the higher power beamline. In this work we assess the samples’ room temperature thermal conductivity, as well as other material constants, develop a method for in situ analysis of stripper foil …

Optimizing Aqueous Processing Of Nickel-Rich Cathode Material In Ultra-Thick Lithium-Ion Batteries, Alexander J. Kukay

Doctoral Dissertations

Lithium-ion batteries (LIBs) have been an instrumental technology since their commercialization in the 1990s. Although much progress has been made in terms of cost and efficiency of production, several challenges remain. Notably, as LIB technology continues to be applied to the transportation sector for electrified mobility in the form of electric vehicles, the question of production ethics and environmental sustainability becomes paramount. The aim of this dissertation is to address some of these concerns in the form of cathode processing techniques. This dissertation focuses on optimization of aqueous processing applied to cathode active materials. First, a study demonstrating the feasibility …

Additive Manufacturing Of Variable Contrast Computed Tomography Anatomical Phantoms Using A Single Feedstock In Fused Filament Fabrication, Cory J. Darling

University of New Orleans Theses and Dissertations

Anatomical phantoms used in biomedical education and training benefit greatly from Fused filament fabrication’s (FFF) ability to rapidly produce complex and unique models. Current materials and methods used in FFF have limited ability to accurately produce phantoms that can mimic the radiological properties of multiple biological tissues. This research demonstrates that the CT contrast of FFF produced models can be modified by varying the concentration of bismuth oxide in acrylonitrile butadiene styrene (ABS) filaments and a tunable CT contrast that mimics the CT contrast ranging from fatty tissue to cortical bone using a single composite filament without introducing artificial image …

Enhancing Stability Of High-Nickel Cathodes For Lithium-Ion Batteries Through Additive Manufacturing Of Cathode Structure, Matthew Sullivan

Mechanical Engineering Undergraduate Honors Theses

Lithium-ion batteries (LIBs) are currently the best method to store electrical energy for use in portable electronics and electronic vehicles. New cathode materials for LIBs are consistently studied and researched, but few are as promising and attainable as nickel-rich transition metal oxides such as LiNi1-x-yMnxCoyO2 (NMC). NMC materials exist with many different mass ratios, but higher nickel content materials provide higher energy density. With this increase in capacity comes a sacrifice with cyclability, as high-nickel NMC variants are prone to structure collapse, transition metal dissolution, and cracks due to volume change. In this report, mechanical modification of the electrode by …

Sustainable Composites From Agricultural And Petroleum Waste, Menisha S. Karunarathna

All Dissertations

Green gas emission has been a pervasive and persistent subject of debate for a prolonged period. The soaring number of industries and vehicle fuel emissions presage a concomitant rise in global CO₂ emissions. Global cement production is responsible for 8% of the total CO₂ release, yet, the production continues due to the surging demand. Hence, there is an ongoing quest to find alternatives for cement and building materials produced with zero to lower CO₂ emissions. The work presented in this dissertation focuses on finding recyclable, zero CO₂ gas-producing high sulfur biocomposites materials, which can compete with …

Zero-Power Ac Current Sensor, Omar Aragonez

Mechanical Engineering ETDs

In this study, a magnetic piezoelectric cantilever powered AC current and frequency sensor is proposed. This paper covers the configuration of the experimental setup, finite element modeling of the magnetic coupling, and the optimal spatial location of the magnetic proof mass in relation to the wire for smart grid applications. Solid and stranded copper wires of various gauges were used and carried current up to 30A. The magnets act as a proof mass to lower the frequency while also coupling to the magnetic field generated by the current carrying wire. The frequency of the AC current produces a sinusoidal force …