Materials Science and Engineering Commons^™

Optimizing Metal 3d Printing, Abram Brown, Lauren Novak

Williams Honors College, Honors Research Projects

Partnered with Lauren Novak we are doing our senior design project on optimizing metal 3D printing with the company nVent. A brief scope of the project is that nVent uses a metal 3D printer to create tooling that is used in a hydraulic pressed and used to create iterations of prototypes during the design process. We will be researching how to decrease the amount the time of the 3D print while doing load tests with v­blocks, wiping tools, and a rib tool. The tests will be on the tooling made using different parameters including infill density, infill geometry, wall thickness, …

Extending Trailer, Alex Grove

Williams Honors College, Honors Research Projects

The goal of this research project is to revolutionize the convenience in towable transportation. This innovative design aims to enhance the versatility of pull-behind trailers by incorporating an extendable feature, allowing users to effortlessly adjust the length according to their specific needs. Whether navigating tight spaces or accommodating extra cargo, our trailer adapts to diverse situations, providing unmatched flexibility. In addition to its adjustable length, the trailer is engineered to be compactable, addressing the storage constraints often faced by users with limited space. The collapsible design ensures easy storage without compromising on functionality, making it an ideal solution for individuals …

Ambient Temperature Strength Degradation Of A Ceramic Matrix Composite Due To Solid Particle Erosion, Jonathan Clawson

Williams Honors College, Honors Research Projects

Solid particle erosion (SPE) is an issue for aircraft exposed to hard, fine particles, such as sand or dust, that can be ingested into the engine at a high velocity without reaching their melting point, resulting in material removal. SPE can be attributed to the intake of particulate debris from the runway or from airborne particulates. The cumulative mass loss from SPE damage affects the structural integrity and performance of the engine; however, its effects on ceramic matrix composites (CMCs), that are being employed in the aerospace industry, are not well understood in literature. The limited SPE research studies that …

Materials Testing For Large Format 3d Printing, William Jenkins

Williams Honors College, Honors Research Projects

An ABS Carbon Fiber blend was printed into single walled hexagons at a variety of settings on a Cincinnati BAAM large format 3D printer. These hexagons were then cut down into sheets and had tensile and flexural test samples cut out of them, in order for materials testing to be performed. Tensile strength, tensile strain, young’s modulus, flexural strength, deflection and elastic modulus were all determined. A desktop CNC machine and a planer were purchased for the manufacturing of these samples, and an efficient cutting procedure was designed and optimized. After all data collection concluded, this data was thoroughly analyzed, …

Schaeffler Icvd Coating Machine, Louis Mcgrath

Williams Honors College, Honors Research Projects

Chemical Vapor Deposition (CVD) is mutual technology used to deposit thin film through a gaseous phase by vaporizing the solid materials. This conventional process usually requires high thermal stability of the materials, which is not applicable for most of the polymeric materials. Therefore, a novel process, initiated Chemical Vapor Deposition (iCVD) is developed by introducing the gaseous monument and initiator to form the thin film in-situ. By adjusting the free-radical polymerization in the vapor phase, a variety of thin and uniform polymer films can be achieved. Depending on the chemistry, iCVD has many categories. This report explains the design …

Short Strand Carbon Fiber Reinforced Polylactic Acid Filament For Additive Manufacturing, Dale Chenoweth, Lukas Seggi, Luke Phillips

Williams Honors College, Honors Research Projects

In this design project, the additive manufacturing filament of short strand carbon fiber (SSCF) reinforced polylactic acid (PLA) composite was developed. The micro-size, precision cut SSCFs were mixed with the PLA pellets through a melting homogenization process. Through this process the composite material block is cut and divided into pieces for ease of pelletizing. The material block pieces are then pelletized to be fed through the single screw extruder to develop the SSCF-PLA composite filament. The SSCF-PLA filaments were manufactured with a varying amount of SSCF ranging from 0.5% to 10% of the material block's weight. Development of a 1% …

Robot-Based 3d Printing, Aaron Hoffman

Williams Honors College, Honors Research Projects

Details of a large-format 3D printer created to print experimental materials, test multi-axis print techniques, and quickly print large objects. The printer consists of a 7-axis robotic arm and pellet extruder, which are controlled by a PC. Experimental materials such as recycled polymers or carbon-fiber reinforced materials can be easily tested with the pellet format of the extruder. The printer can perform different printing techniques and can be used to experiment with material properties when using these techniques with different polymers. The print surface is around 5 times larger than the average commercial 3D printer, and the robotic arm provides …

Dome Tester, Clark Bates, Nikolas M. Kulin

Williams Honors College, Honors Research Projects

We are reconfiguring and modifying the previously built dome tester to be more user friendly and mechanically applicable. This has a long-term goal of being a usable teaching tool for manufacturing education within the college of engineering and polymer sciences. The dome tester pushes a metal dome into a clamped sheet of metal to test its forming limits and where necking occurs. We have implemented a better method of viewing the sheet sample as it is being deformed, and improved measuring methods for the distance a sample is deformed. By introducing these changes in conjunction with improved documentation of the …

Defining The Proper Operating Time For The Septa Extractor, Abigail Jones

Williams Honors College, Honors Research Projects

Anionic polymerizations are a common type of reaction used to produce synthetic rubber. During these reactions, it is necessary to charge initiators, modifiers, and other substances, through pressurized containers that are sealed with rubber septa. These septa prevent oxygen and moisture from entering the pressurized container, and the reactor, though they need to be cleaned before use to remove other impurities. Currently a glass Soxhlet Extractor is used to remove such impurities, and though effective, it has a limited capacity, so it has to run frequently. This limitation led to the commissioning of the Septa Extractor, which is an automated …

Anti-Freeze Double Network Hydrogels, William Gross

Williams Honors College, Honors Research Projects

Three polyethylene glycol (PEG) based crosslinkers with repeat unit nominal weights of 62.1, 200, and 400 g/mol in agar/PAM double network (DN) hydrogels were used to study the effect of different crosslinkers on thermal and mechanical properties. Using the one-pot synthesis method, hydrogels with the PEG crosslinkers or methylene-bis-acrylamide (MBAA) were made via sol-gel transition for formation of agar network, and photopolymerization of the PAM network using Irgacure 2959 as photo initiator. Tensile and compression tests were performed on as prepared, swollen, and swollen & cooled specimens of each hydrogel. Freezing time and thermal imaging were performed in -20 °C …

Coolant Capability Study, Christina Grassi

Williams Honors College, Honors Research Projects

The scope of my project is a capability study on different coolants used in manufacturing plants. From this study, the coolant qualities and impact on the manufacturing process will be evaluated in that process and will be documented as a changed standard at the Timken company. Since coolants are sometimes the only fluid on the surface of the parts being manufactured, the rust preventative capabilities will also be studied and evaluated through humidity cabinet testing with and without spiking the coolant with chlorides and sulfates. This project will be carried out on my co-op rotation with the Timken company so …

Wetting Transition Of Texturized Surfaces, Jenna Stephens

Williams Honors College, Honors Research Projects

Building on previous research, this project aims to continue the investigation of the wettability of various liquids on a uniform, texturized surface. Different surface energies can impact the wettability of a surface. The surface can be hydrophilic, hydrophobic, or in between. The goal of this project is to research how features of texturized surfaces affect the wetting transition of water, oil, and a mixture of both. Additionally, this project aims to improve the quality of the 3D printed surfaces. The surfaces that will be studied are constructed using UV cured resin 3D printing and are made up of an array …

Intergranular And Pitting Corrosion Mechanisms Of Sensitized Aluminum Alloy Aa5083, Clayton Egleston

Williams Honors College, Honors Research Projects

The motivation and objectives of this project is to examine the mechanisms of intergranular corrosion (IGC) and pitting corrosion of sensitized AA5083. In this regard, different characterization techniques were used, including optical analysis of microstructure, cyclic potentiodynamic polarization with Tafel fitting, electrochemical impedance spectroscopy with electrical equivalent circuit (EEC) fitting, and potentiostatic current transient monitoring. The transition from IGC to pitting corrosion occurs when the grain boundaries become saturated with the β-phase (Mg₂Al₃). It was found that AA5083 becomes more vulnerable to pitting corrosion as the degree of sensitization increases.

Comparing Weathering Effects Of Ultraviolet And Xenon Arc Accelerated Aging On Polyvinyl Chloride, Collin Mcinnes

Williams Honors College, Honors Research Projects

As the ubiquitousness of polymers increases and begins seeing use in outdoor settings, the need to fully understand how these materials degrade is also necessary. This study aims to compare two known accelerated aging methods, namely an ultraviolet light chamber and a xenon arc light chamber, to understand what differences, if any, manifest in the mechanical, chemical, and cosmetic deterioration of polyvinyl chloride (PVC) after long-term exposure. The study utilizes Fourier-transform infrared spectroscopy, dynamic mechanical analysis, thermogravimetric analysis, and colorimetry analysis to determine the extent of degradation and potential discrepancies between the aging methods.

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.

Structural Design And Application Of Polymeric Silicon Elastomers, Jacob Wyant

Williams Honors College, Honors Research Projects

The purpose of this project was to determine how the polymeric structure and mechanical properties of this elastomer are affected by the ratio between the polydimethylsiloxane macromolecular chains and the crosslinkers. These were determined via tensile and compression testing. Then, spiropyran was added to observe how this fluorescence and crosslinking agent affected the elastomer. Also, the elastomer’s fluorescent and icephobic nature were tested. The elastomers with a higher ratio of crosslinker to macromolecular chain could withstand higher tensile and compressive strains but failed at lower stresses than their counterparts with lower concentrations of crosslinkers. The elastomers were also found to …

Beeswax Wraps As An Alternative To Single-Use Plastics, Sarah Skiver

Williams Honors College, Honors Research Projects

The project goal was to compare the food storage efficacy of sustainable beeswax wraps verses the single-use plastic methods of resealable plastic sandwich bags and plastic cling wrap. The goal was also to test the reusability of the beeswax wraps, as it is a key advantage of beeswax wraps that is advertised. The project purpose was to explore sustainable and eco-friendly alternatives to single use plastics, which are harmful to the environment in both their production and their disposal. Food spoilage was compared in beeswax wrap, plastic sandwich bags, and plastic cling wrap, and spoilage was also observed in a …

Adjust-A-Ramp, Taylor Sharrits, Courtney Banks, Emily Beck, Jazmin Buenrostro

Williams Honors College, Honors Research Projects

Adjust-A-Ramp is a portable ramp designed to ensure the safety of consumers and prevention of damage to cars, specifically towards low profile cars. A low-profile vehicle includes any vehicle that has a clearance off the ground of 6.5 inches or less. Advantages of low-profile vehicles include improved handling, better braking, increased fuel efficiency, increased stability, and an overall luxury aesthetic. The reduced tire size increases grip on smooth surfaces with better wheel response, creating a fast, more efficient ride. The simple tire tread patterns and the stiff sidewalls allow for lower rolling resistance which increases fuel economy. The Adjust-A-Ramp can …

Application Of Sla 3d Printing For Polymers, Taylor Wilson

Williams Honors College, Honors Research Projects

Stereolithography is a type of 3D printing that allows liquid photopolymer resin to be cured into layers that make up a 3D object. Creation of such resins for these purposes can require a significant amount of time to test and develop, and commercial resins also require some amount of testing for printer settings before use. This paper reviews how stereolithography works, the materials used, and experimentation done to compare the resin properties to the determined curing times. Using several commercially available resins, varying base exposure and layer exposure times were used to determine the lowest possible curing time that gave …

Analysis And Comparison Of Nir Pigments For "Cool" Coating Applications, Karey Steinmetz

Williams Honors College, Honors Research Projects

The goal of this research is to compare our own formulation of near infrared radiation (NIR) pigment coating to commercialized ones. These near infrared coatings are designed to be used on roofs of buildings to keep the buildings from absorbing the heat from the sun’s radiation. This would keep the building cooler and use less energy and money to cool the building. In this study, Styrofoam was used to build a lab-scale house and were put under heat lamps that mimicked the sun. Temperatures were taken at three different locations to determine the effectiveness of the pigmented coatings. Color and …

Austenitic, Duplex, And Lean Duplex Stainless Steel Critical Pitting Temperature In Simulated Concrete Environment, Bobby Giebel

Williams Honors College, Honors Research Projects

In this work, the critical pitting temperature (CPT) will be observed for a selection of austenitic (316LN and 24100) and duplex (2205), and lean duplex (2304, 2001) stainless steels in simulated concrete pore solution. To study the influence of temperature on the pitting stability of the stainless steels, three temperatures were tested: 25oC, 45oC, and 65oC for cyclic potentiodynamic polarization (CPP) and electrochemical impedance spectroscopy (EIS). Electrochemical properties of the interfaces we studied via EIS analysis. Kinetics were studied via CPP testing. To reveal the critical pitting temperature of the stainless steels, cyclic thermammetry was used. Characterization of the pits …

Amino-Polymer For Co2 Capture By Vacuum Swing Adsorption, Sean Billy

Williams Honors College, Honors Research Projects

The applications of sorbent compounds in conjunction with amines and other additives is an innovative method at combating CO2 pollution. An ideal solution would use an amine sorbent to trap the high levels of absorbed CO2 with a low binding energy (less than 45 kJ/mol) and subsequently release them into a stored vessel at ambient temperature with a vacuum swing adsorption system. Attempts at finding a best mixture will be conducted through the usage of a vacuum swing system, utilizing a bed syringe containing the sorbent mix and a vacuum syringe to pull on and subsequently release the CO2 into …

Electrochemical Chloride Removal, Marcus Yudt

Williams Honors College, Honors Research Projects

Electrochemical chloride removal (ECR) was tested to see its effectiveness in preventing corrosion on rebar samples within 3.5 wt% sodium chloride concrete. In order to do this, three scenarios were evaluated using electrochemical techniques such as cyclic potentiodynamic polarization and electrochemical impedance spectrsoscopy as well as visual inspections. The three scenarios that were evaluated were one with no chlorides present within the concrete, one that was a worst-case scenario where extreme pitting and corrosion were initiated, and one that had chlorides present and received the ECR treatment. Cyclic polarization curves showed that the ECR and reference without chlorides had similar …

Additive Manufacturing Waste Management System - Plastic Extrusion Process, Gabriel Bennett, Lindsay Liebrecht, David Lyogky, Wilson Woods

Williams Honors College, Honors Research Projects

3D printing is a fast-growing market with its main source of waste being PLA and ABS plastics. In 2019, the global additive manufacturing market grew to over $10.4 billion, crossing the pivotal double-digit billion threshold for the first time in its nearly 40-year history. (SmarTech Analysis, 2020 Additive Manufacturing Market Outlook and Summary of Opportunities Report). The waste is generated from failed prints and rejected support structures which are common occurrences for personal use. Plastic recycling has become one of the leading discussions of environmental protection and waste management. The 3D market currently does not offer an effective and affordable …

Induction Brazing, Austin Squire, Scott Compton, Logan Hathaway, Michael Fleming

Williams Honors College, Honors Research Projects

Our team would like to research and explore ways of designing a portable device that uses induction heating/brazing to connect two exhaust pipes together.

Cathodic Protection, Michaela Schaber

Williams Honors College, Honors Research Projects

This Honors Research Project explores cathodic protection of reinforcing steel in concrete. It uses NACE SP0408-201 Cathodic Protection of Reinforcing Steel in Buried or Submerged Concrete Structures as the guidelines for experiments and supporting literature. An economic analysis will be included to fulfill Design requirements. Different voltage and other applications will be explored to determine the lowest obtainable cost-efficient corrosion rate. The method of cathodic protection focused on for this project is impressed current cathodic protection.

Recycled Printer Filament, Charlotte Hyland, Troy D. Molinar

Williams Honors College, Honors Research Projects

The purpose of this research is to examine the effects of recycling PLA filament for 3D printing on its material properties. After examining these effects, PLA and carbon fiber additives were mixed with recycled PLA pellets in different ratios to attempt to regain material properties lost in the recycling process. To complete these findings, an experiment was design and executed.

The research found that tensile strength during multiple iterations of recycling remained mostly unaffected, however, the strain degraded exponentially. In the PLA additive study, high ratios of PLA additive were able to increase the strength and strain properties of the …

Electrochemical Impedance Spectroscopy Analysis Of Corrosion Of Reinforcing Steel In Fly Ash Mortar By Means Of Transmission Line Modeling, Padraig Stack

Williams Honors College, Honors Research Projects

Electrochemical impedance spectroscopy (EIS) is an important non-destructive tool that allows for a deeper understanding of the electrochemical processes and mechanisms occurring in an electrochemical cell. Equivalent electrical circuits (EECs) are used to model the impedance data into electrical components, such as resistors and capacitors, on a circuit. Current potentiostat offers software packages that can analyze the frequency response, but the software only supports “simple” EEC that can be written as fixed electrical components in some combination of series and parallel. Park and Macdonald propose a transmission line model (TLM) that does not use lumped-element models, instead, the values of …

Atmospheric Corrosion Of Galvanically Coupled Aluminum Alloys And Carbon Steel, Mitchell Felde

Williams Honors College, Honors Research Projects

Aluminum alloys are a steadily growing material being commonly used in lieu of typical steels. Additional alloying, heat treatment, and other property enhancing processes are expanding the use of these alloys. However, with this expansion, galvanic corrosion is becoming more of an issue in the design stage due to the combination of these alloys with steels. The automotive industry is one industry where the use of aluminum alloys is becoming common practice. Aluminum alloys provide a lightweight aspect over the conventional carbon steel that was used previously. As a result of this transition towards more lightweight materials, galvanic coupling is …

Design And Analysis Of One-Piece 10” Carbon Fiber Wheels For Zips Racing Zr20 Formula Sae Racecar, Patrick Kruse, Henry J. Wathen, Jordan J. Hyde, Nicholas D. Dobben, Jordan D. Blake

Williams Honors College, Honors Research Projects

Reducing the weight of a vehicle in racing can substantially improve the vehicle dynamics and general performance capabilities. More specifically, the reduction of the unsprung corner weight can provide noticeable performance gains in handling and responsiveness, leading to a quicker, more agile car due to a lower yawing moment of inertia. Unsprung weight reduction also improves the car’s ability to maintain contact between the tires and the road surface for a more consistent grip. In this project we identified the loads that act on the wheel rims according to the data collected from the sensors in the car’s suspension, and …