Materials Science and Engineering Commons^™

Effect Of Boron In Cast Iron, Suyash Durendra Pawaskar

Masters Theses

"Boron, mostly considered a residual element, has started to cause issues in the cast iron foundries by causing a decrease in the strength of pearlitic gray and ductile iron castings. Because of the increase in the use of boron-added steel scrap from automotive steel and a lack of agreement on the critical levels of boron in cast iron, foundries are facing difficulties in controlling the microstructure of gray iron castings when boron is present. The current investigation was designed to analyze the effects of boron in cast irons and predict a mechanism to understand its effects with a vision of …

Understanding Charge Effects On Marked Ball Wear Rates – A Corrosion Study, John Bailey Fletcher

Masters Theses

"To measure the wear rates of grinding balls within a ball mill, marked ball wear tests (MBWTs) have been used extensively. Using the wear rates from a MBWT, operators select the most cost-effective media for their grinding application. One factor that a MBWT does not account for is the possible interaction between different media materials which could affect their corrosion rates. Galvanic coupling between dissimilar metals can cause significant changes in their corrosion rates. While galvanic interactions between minerals and grinding media have been studied, the interaction between dissimilar media has not. Corrosion rates and potentials of modern high carbon …

Bulk Nanostructured Steels For Nuclear Reactor And Extreme Environment Applications, Maalavan Arivu

Doctoral Dissertations

"Candidate accident tolerant FeCrAl fuel (ATF) claddings for light water reactors (LWRs) need to be thinner than current Zircaloys owing to higher neutronic penalty, demanding an improvement in strength. Therefore, equal channel angular pressing (ECAP), and high-pressure torsion (HPT) were used to produce bulk ultra-fine grained and nanocrystalline Kanthal-D [KD; Fe-21Cr-5Al-0.026C (wt.%) alloy] which resulted in an improvement in strength of up to 3 times their nominal strength from grain boundary strengthening, and dislocation strengthening. Dynamic recovery was promoted due to ECAP at 520 oC rendering it with a large area fraction of less mobile low angle grain boundaries (LAGBs) …

Joining Of Ultra-High Temperature Ceramics To The Same And Refractory Metals Via Fusion Welding, Jecee Jarman

Doctoral Dissertations

"This research focuses on the joining of ultra-high temperature ceramics to either themselves or refractory metals/alloys via fusion welding and the mechanical strength of produced joints. The ceramics studied consisted of compositions within a diboride-carbide-carbide ternary system while metals studied consisted of molybdenum and a molybdenum alloy. SiC-ZrB2-ZrC ceramics on a binary join between pure SiC and the ternary eutectic composition were found to be weldable when SiC content was below ~57.5 vol%. Compositions above 57.5 vol% SiC were unweldable based on pitting and off-gassing behavior. Welded strength of ceramics was ~180-300 MPa in the SiC-ZrB2-ZrC ternary eutectic composition, ~180-220 …

Zinc Plating From Alkaline Non-Cyanide Bath, Abdul J. Mohammed

Masters Theses

“Alkaline non-cyanide zinc plating baths are preferred when trying to avoid the toxicity of cyanide baths or corrosivity of acid baths. Without additives, alkaline zincate baths produce powdery non-adherent deposits which have no use in commercial plating. Additives must be added at optimum concentrations to produce adherent, bright and uniform zinc deposits. In this study electrochemical tests were used to determine effects of additives on cathodic polarization, throwing power and morphology of deposits. Current density distribution in a unique bath of 37.5 g L^-1 Zn and 210 g L^-1 NaOH was modelled using COMSOL and validated two plating …

Controlling Microalloy Interactions On Precipitation, Hot Ductility, And Microstructure -- Mechanical Property Relationships, Madhuri Varadarajan

Masters Theses

“One of the main problems faced in the continuous casting of micro-alloy steels is the formation of transverse cracks. Transverse cracks are surface, or near-surface cracks formed perpendicular to the casting direction. The research focuses on using laboratory hot tensile tests methods to determine the low ductility ranges in high strength steel grades with different micro-alloy additions of titanium, niobium, and vanadium. The hot ductility of commercially produced as-cast slab and beam blank samples was evaluated using two experimental methods: tensile testing utilizing a servo-hydraulic load frame with a resistance furnace and thermomechanical testing using rapid Joule heating. The tests …

Processing To Enable Direct-Write Additive Manufacturing Of Ceramics And Ceramic Composites, Austin Martin

Doctoral Dissertations

"This research focuses on the processing of novel feedstocks for and during direct-write additive manufacturing (AM), specifically the direct ink writing (DIW) and Ceramic On-Demand Extrusion (CODE) manufacturing processes, in order to produce ceramic and ceramic-based composite components. Strongly dispersed, concentrated (φ = 0.42), nanoparticle (d₅₀ ~0.3 µm), zirconia (ZrO₂) pastes were used to print densely filled, large continuous volume (≳ 1 cm³) ceramic components. An elastic shear modulus (G’) of 56,000 Pa and yield stresses between 6 and 10 Pa allowed for printed components of 34.5 mm in height over 115 layers without slumping …

Novel Ferromagnetic Materials With Improved Mechanical Performance, Wesley Alexander Everhart

Doctoral Dissertations

"The ductility of intermetallics has long been a hindrance to their broad adaptation despite a significant range of properties such as magnetic, half-metallic, and shape memory behavior. The lack of a general theory for the ductility of intermetallics along with the lack of prior art that experimentally measured mechanical properties drives the need for significant investment in many of these novel magnetic materials in order to even understand, let alone correct, poor ductility.

This dissertation includes work that explored the effect of vanadium content and quenching rate on the microstructure and ductility of Fe-Co alloys. Results indicated that a martensitic …

Experimental Optimization Of Simulated Ring Rolling Operation For Heavy Rail Industry, Jacob M. Summers

Masters Theses

“Industrially cast AISI 1070 steel wheel pre-forms from Amsted Rail Co. were experimentally hot rolled to simulate the conditions for industrial wheel rolling. Ring rolling of near net shape castings can improve location specific properties by decreasing segregation, closing porosity, and reducing grain size without the use of multiple forging operations in a traditional forging line. As-cast wheel sections were subjected to thermomechanical processing routes using a 2-high rolling mill in a temperature range of 830°C to 1200°C. The goal being to simulate the ring rolling process and optimize benefits of mechanical properties of the as-rolled steel. Charpy V- and …

Mechanical Properties Of Boride Based Ceramics, Alec Murchie

Doctoral Dissertations

“This research focuses on the elevated mechanical properties of diboride based materials at room and elevated temperatures. These materials include a ZrB₂ ceramic, a ZrB₂-WC-SiC ceramic, and a (Hf,Mo,Nb,Ta,W,Zr)B₂ high entropy boride (HEB). The room temperature flexural strength for the ZrB₂ ceramic was 447 MPa and the fracture toughness was 2.3 MPa·m^1/2. The strength decreased to 196 MPa at 1800°C, and then increased to 360 MPa at 2300°C. The fracture toughness increased to 3.1 MPa·m^1/2 at 2200°C. The strength up to 1800°C was likely controlled by a combination of effects: surface damage …

Scale Formation, Properties And De-Scaling In Steelmaking, Richard Osei

Doctoral Dissertations

During continuous castings, reheating, and hot rolling, slab surfaces are exposed to atmospheres containing oxidizing gases which results in scale formation. Inefficient removal of the formed scale during reheating affects product surface quality. The effect of steel composition and operating parameters on scale formation and scale removal efficiencies were investigated. Experimental investigations were carried out using a thermogravimetric (TGA) apparatus designed to replicate the combustion gas atmosphere and temperature in actual industrial slab reheat furnaces. Report on oxidation kinetics, scale structure and properties, and descaling were conducted on laboratory cast and industrial samples. Different characterization techniques were used to analyze …

Investigation Of The Thermodynamics Of Iron Phosphate Melts And Stability Of Iron Phosphate Glasses: Effects Of Composition And Iron Redox Ratio, Melodie Linda Schmitt

Doctoral Dissertations

“Iron phosphate glasses with Fe/P = 0.33 - 0.67, O/P = 3.0 - 3.5 and Fe²⁺/ΣFe = 0.16- 0.52 were prepared by altering batch compositions and melt conditions. Thermal analyses indicate polyphosphate glasses with intermediate chain lengths are most stable against devitrification. Heterogeneous crystallization occurs on the glass surface and is dependent on iron valence state, particle size, heating rate, temperature and oxygen availability in the atmosphere. Oxidation of ferrous iron on the glass surface occurs at temperatures as low as Tg, and thus crystallization behavior and stability can be altered via post-melt heat treatments. A novel preparation …

Peritectic Behavior Detection And Prediction In Fe-C-Si-Mn-Al System, Damilola Balogun

Doctoral Dissertations

"The non-uniformity of shell growth in the continuous casting of peritectic steels constitutes a major barrier to the commercial production of many steel grades such as Advanced high strength steels (AHSS), transformation induced plasticity (TRIP) steels, abrasion-resistant steels, advanced armor plate steels, and many newly proposed steel grades that contain high levels of silicon, manganese, and aluminum.

The shell growth non-uniformity experienced in the continuous casting of peritectic steels results in the formation of defects in the as-cast slab and therefore increases the operating risk from cast aborts and breakouts. The ability to predict and avoid peritectic behavior at the …

Development And Application Of Ensemble Machine Learning Algorithms To Enable A Priori, High-Fidelity, And Prompt Predictions And Optimizations Of Complex Materials And Systems, Taihao Han

Doctoral Dissertations

"Complex materials consisting of multiple chemical components/phases have been widely used in different engineering applications that have strict criteria. To optimize the mixture design of complex materials, researchers invest enormous resources in cumbersome experiments. However, due to substantial variations in precursors and processing techniques, it has been challenging to develop theoretical frameworks (i.e., empirical models) that could produce reliable predictions of properties of complex materials. In recent years, scientists have harnessed the power of machine learning (ML) and “Big” data to uncover the underlying mixture design-property correlations and produce high-fidelity predictions of properties of complex materials. The ML models autonomously …

The Effect Of Mass Transport On Deposit Quality In Copper Electrowinning, Joseph Bauer

Doctoral Dissertations

"Roughness and nodulation of copper electrodeposits depend strongly on mass transfer conditions of copper ions to the electrode surface. Mass transfer properties in electrowinning electrolytes were first characterized. The effective diffusivity of cupric ion was measured with a rotating disk electrode in CuSO₄-H₂SO₄ electrolytes at temperatures relevant to electrowinning, with and without additives. Adding 20 mg L^-1 of chloride ion increased the measured diffusion coefficient, but commercial smoothing additives had little effect. An empirical formula to predict cupric diffusivity was generated for later use in mass transport modeling.

Boundary layer thickness information for commercial …

Effects Of Vacancies And Electron Temperature On The Electron Phonon Coupling In Cubic Silicon Carbide And Their Connection To The Inelastic Thermal Spike, Salah Al-Smairat

Doctoral Dissertations

“The electron-phonon interaction is an important interaction in many solids as it influences transport phenomena and related quantities such as the electrical and thermal conductivities, especially in nuclear and space applications. The importance of the electron-phonon interaction in primary damage production in 3C-SiC is the subject of this research.

The electron-phonon coupling factor was calculated using a hybrid Density Functional Perturbation Theory - Classical Electron Gas model. The coupling factor was calculated as a function of electron temperature in pristine and defective 3C-SiC, and relaxed defective cells. The electron-phonon coupling is found to depend strongly on the electronic temperature and …

Corrosion Protection Mechanisms Of Trivalent Chromium Based Passivations On Γ-Znni Coated Al6061-T6 Alloy, Kevin Foster

Doctoral Dissertations

“The role of cobalt in trivalent chromium passivations (TCPs) to improve corrosion resistance of γ-ZnNi coated steel and aluminum is based on its effect on hexavalent chromium content in the passive layer. Investigations of both a cobalt-containing and cobalt-free TCP on SAE 1008 steel indicated that both passivations protect well for up to 1000 hours in neutral salt spray exposure (SSE). A repetition on Al 6061-T6 alloy indicated that TCP performed much better than cobalt-free TCP implicating the underlying substrate. Optical and electron micrographs indicated physical changes such as crack thickness, crack density, passivation porosity, and passivation thickness existed between …

Production Of Non-Oriented Electrical Steel Thin Strip Simulating Conditions Of The Direct Twin-Roll Casting Process, Yizhou Du

Doctoral Dissertations

"In this study, a method to cast non-oriented (NGO) electrical steel with conditions of an industrial twin roll thin strip casting (TRSC) process was investigated. A novel vacuum assisted fast cooling (VA) sampling method was developed to produce 2 mm thick strip simulating conditions of an industrial TRSC process. The effects of solidification cooling rate, hot rolling deformation, and annealing time on inclusion distribution, magnetic properties, grain growth, and texture evolution of 3.4 wt.% Si NGO electrical steel with different carbon and sulfur (C&S) levels were analyzed. Samples were thermo-mechanically treated which simulated an industrial TRSC process. After a long …

Oxidation Of Silicon Carbide And Graphite For High Temperature Gas-Cooled Reactor Applications, Adam Thomas Bratten

Doctoral Dissertations

"This research focuses on the oxidation behavior of silicon carbide and matrix grade graphite, specifically as it pertains to accident scenarios in Gen IV thermal spectrum high temperature gas cooled nuclear reactors. It is imperative to understand the oxidation behavior of such materials to predict their response to off-normal environments and certify their accident tolerance to implement Gen IV reactors. The onset of oxidation temperature of matrix graphite was found to have a strong dependence on the microstructure, and therefore processing parameters, of the materials. The A3-3 type grade contained regions of partially graphitized carbon that were more disordered and …

Molten Steel Interactions With Tundish Linings And Refractory Glazes, Tyler Michael Richards

Doctoral Dissertations

"In the final stages of casting, molten steel is in contact with two main types of refractories: the working lining of the tundish used to serve as an intermediate vessel between the ladle and copper mold, and the various glazed carbon-bearing refractories used to control the flow of steel from the ladle to the tundish and from the tundish to the mold. If steel interacts with these refractories in such a way as to result in the formation of inclusions, it may be too late to remove them, leading to degradation of the steel’s mechanical properties. Understanding these interactions and …

Characterization Of Cermet Fuel For Nuclear Thermal Propulsion (Ntp), James Floyd Mudd

Masters Theses

“A manned flight to Mars is met with many technical challenges, not the least of which is the development of propulsion technology capable of moving a transit vehicle from Earth orbit to Mars orbit. NASA is investigating Nuclear Thermal Propulsion (NTP) as a way of reducing flight time and providing the option for a mid-mission abort. NTP, which uses a high temperature nuclear reactor to heat a propellant, requires advanced fuel materials capable of withstanding temperatures well in excess of 2000 K. Among the fuel options are ceramic metal (cermet) composites composed of refractory metals and Ultra-High Temperature Ceramics (UHTCs). …