Materials Science and Engineering Commons^™

Process-Property-Structure Relationships In Advanced Rare Earth Magnet Manufacturing: Towards Enhanced Performance And Developing Application, Kaustubh Vidyadhar Mungale

Doctoral Dissertations

This research aims to study advanced rare earth magnet manufacturing, focusing on the structure-process-property relationships that govern their performance and applications. Rare earth minerals are classified as critical materials because they are essential in manufacturing products across numerous cutting-edge technologies including electric vehicles, renewable energy systems, and high-performance electronics.

Bonded magnets are composites with permanent magnet powder embedded in a polymer matrix. Finely powdered (3-300 microns) rare earth based intermetallics such as neodymium iron boron (NdFeB) and samarium iron nitride (SmFeN) are blended with engineering polymers such as epoxy, polyamides (PA6/PA12) and polyphenylene sulfide (PPS), followed by molding the compound …

Microstructure-Based High Temperature Processing And Failure Analyses Of Engineering Alloys Under Complex Conditions, Dong Han

Doctoral Dissertations

From traditional petrochemical applications to contemporary manufacturing techniques, advanced structural materials are subjected to intricate thermomechanical and environmental conditions. In these engineering domains, high-temperature deformation plays a pivotal role, profoundly influencing the ultimate outcomes of industrial applications. Nevertheless, the underlying mechanisms of this deformation remain elusive, largely due to the absence of a microstructure-based mechanistic understanding of high-temperature processing and failure of materials.

This dissertation endeavors to comprehensively examine these mechanisms through computational methodologies, focusing on three quintessential topics: grain boundary cavitation failures (2 examples: stress relaxation cracking (SRC) and grain size dependence), high-temperature hydrogen attack (HTHA), and additive friction …

Modeling Powder Spreadability In Powder-Based Processes Using The Discrete Element Method, Austin T. Sutton, M. Hossein Sehhat, Ming C. Leu, Joseph W. Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Powder-bed fusion (PBF) processes refer to a subset of Additive Manufacturing (AM) techniques where powder is spread on the build-plate before melting (by a laser or electron beam). While PBF processes are attractive due to their ability for realizing complex structures that are either difficult or impossible to create through conventional means, the parts fabricated with these techniques can exhibit defects such as pores, inclusions, and excessive surface roughness. To minimize these defects, much research has been dedicated towards process maturation by optimizing laser or electron beam parameters. However, these developmental efforts typically do not address the recoating process where …

Characterization Of Chopped Carbon Fiber Reinforced Composites Produced Using Fused Deposition Modeling, Jonathon Tran, Rachel Shubella

Student Research Symposium

Fused deposition modeling (FDM) is an additive manufacturing (AM) process which can create parts with complex geometries in their final shape without need for additional specialized tools or devices. The FDM process builds parts by adding material layer by layer only where it is needed, saving energy, costs, production time for complex parts, and minimizing waste. Fiber reinforcement can significantly enhance the mechanical properties of a polymer material and depends significantly on the fiber length distribution and fiber orientation distribution of the final part. In this research, we investigated the various infill patterns of FDM printed Markforged onyx which is …

Investigating The Role Of Tesserae In Energy Absorption In Shark Cartilage, Molly Dobrow

UNF Graduate Theses and Dissertations

Unlike mammals, shark endoskeletons are composed of cartilage, which is less stiff compared to bone. Despite this structural disadvantage, sharks have risen to become apex predators, with reported maximum posterior bite force estimates approximating 5914 N in bull sharks. Shark jaws are estimated to undergo high cycle loading within the organism’s lifecycle without evidence of failure. Fatigue resistance may relate to mineral distribution within a component of the endoskeletal system – tesserae. Tesserae are thin, roughly hexagonal tiles composed of calcium phosphate hydroxyapatite (HA) crystals and grow by accretion to eventually surround the hyaline cartilage core. Though tesserae dimensions are …

Additive Manufacturing Of Novel Lightweight Insulation Refractory With Hierarchical Pore Structures By Direct Ink Writing, Saisai Li, Jiaxuan Xin, Ruoyu Chen, Haiming Wen

Materials Science and Engineering Faculty Research & Creative Works

A direct ink writing process using fly ash foaming slurries was employed for the additive manufacturing of lightweight mullite insulation refractory with hierarchical pore structures. The viscosity, thixotropy, and shear thinning behavior of the inks were analyzed to investigate the effect of the inorganic binder and dispersant of the foaming inks. A slurry exhibiting excellent rheological characteristics was identified, consisting of 45 wt% fly ash floating beads, 55 wt% water, 3.0 wt% additional dispersant, and 6.0 wt% additional binder. Furthermore, through the optimization of printing parameters such as printing pressure and printing speed, notable enhancements were achieved in the pore …

Production Of Glass-To-Metal Seals Using Additive Manufacturing Techniques, Aaron Read

Masters Theses

"Glass-to-metal (GtM) seals are hermetic barriers between glass and metal components, often used in the electronic and vacuum industries. Creating the seals traditionally requires heating all the components to the glass melting temperature, where the glass will flow and bond to the metal. Due to the manufacturing constraints of the individual components and sealing conditions there are geometric and material restrictions. Additive manufacturing techniques were used to make GtM seals to reduce these restrictions.

Hermetic, single pin seals were produced using printed metal shells, by selective laser melting (SLM), and digital light processing (DLP) printed glass preforms. Glass preforms were …

Advancements And Challenges In Additively Manufactured Functionally Graded Materials: A Comprehensive Review, Suhas Alkunte, Ismail Fidan, Vivekanand Naikwadi, Shamil Gudavasov, Mohammad Alshaikh Ali, Mushfig Mahmudov, Seymur Hasanov, Muralimohan Cheepu

Engineering Technology Faculty Publications

This paper thoroughly examines the advancements and challenges in the field of additively manufactured Functionally Graded Materials (FGMs). It delves into conceptual approaches for FGM design, various manufacturing techniques, and the materials employed in their fabrication using additive manufacturing (AM) technologies. This paper explores the applications of FGMs in diverse fields, including structural engineering, automotive, biomedical engineering, soft robotics, electronics, 4D printing, and metamaterials. Critical issues and challenges associated with FGMs are meticulously analyzed, addressing concerns related to production and performance. Moreover, this paper forecasts future trends in FGM development, highlighting potential impacts on diverse industries. The concluding section summarizes …

Characterization Of Interlayer Laser Shock Peening During Fused Filament Fabrication Of Polylactic Acid (Pla), Fabien Denise

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

The field of additive manufacturing (AM) has gained a significant amount of popularity due to the increasing need for more sustainable manufacturing techniques and the adaptive development of complex product geometries. The problem is that AM parts routinely exhibit flaws or weaknesses that affect functionality or performance. Over the years, surface treatments have been developed to compensate certain flaws or weaknesses in manufactured products. Combining surface treatments with the modularity of additive manufacturing could lead to more adaptable and creative improvements of product functions in the future. The current work evaluates the feasibility of pursuing a new research axis in …

Advancing Additive Manufacturing For Biomedical Applications: Antimicrobial And X-Ray Absorptive Composite Filaments For Fused Filament Fabrication, John M. Arnold Jr

University of New Orleans Theses and Dissertations

The objective of this research was to investigate the use of nano- and microparticle amendments for the creation of Poly-lactic Acid composite materials for use in biomedical applications using the Fused Filament Fabrication process of Additive Manufacturing. Composites were created with the goal of imparting the useful properties of antimicrobial activity and x-ray absorption to the material. In addition to testing the efficacy of the particle amendments in achieving the desired properties, the thermal and mechanical properties of the composite materials were tested to ensure that the composites would be compatible with the Fused Filament Fabrication process and would produce …

Investigation Of Deformation Behavior Of Additively Manufactured Aisi 316l Stainless Steel With In Situ Micro-Compression Testing, Fei Teng, Ching-Heng Shiau, Cheng Sun, Robert C. O'Brien, Michael D. Mcmurtrey

Materials Science and Engineering Faculty Publications and Presentations

Additive manufacturing techniques are being used more and more to perform the precise fabrication of engineering components with complex geometries. The heterogeneity of additively manufactured microstructures deteriorates the mechanical integrity of products. In this paper, we printed AISI 316L stainless steel using the additive manufacturing technique of laser metal deposition. Both single-phase and dual-phase substructures were formed in the grain interiors. Electron backscatter diffraction and energy-dispersive X-ray spectroscopy indicate that Si, Mo, S, Cr were enriched, while Fe was depleted along the substructure boundaries. In situ micro-compression testing was performed at room temperature along the [001] orientation. The dual-phase substructures …

Investigating The Effect Of Bead Geometry On Fiber Orientation And Thermomechanical Properties For Large-Format Extrusion-Based Additive Manufacturing, Joanna F. Keaton

Electronic Theses and Dissertations

In large-format extrusion-based additive manufacturing of polymer composites, the relationship between material properties and processing parameters requires further investigation. This thesis focuses on the relationship between fiber orientation and thermomechanical properties for short fiber-filled thermoplastic polymer systems manufactured by extrusion-based additive manufacturing. Fiber orientation is particularly important in determining the thermomechanical properties of the composite material as properties in the direction of deposition are expected to be higher for highly aligned fibers than randomly aligned fibers. Fiber orientation distribution, which is related to processing parameters and deposition conditions, can be efficiently represented by the orientation tensor. The orientation tensor can …

Mechanical Characterization Of Automated Fiber Placement And Additive Manufacturing Hybrid Composites, Lucan Haviland

Electronic Theses and Dissertations

This thesis presents the optimization of processing parameters based on the mechanical properties of Continuous Fiber-Reinforced Thermoplastic (CFRTP) Unidirectional (UD) consolidated tapes. The UD tapes were consolidated using an AFP head and a thermoforming press for comparison. The adhesive strength of hybrid parts consisting of CFRTP UD tape bonded to a 3D-printed substrate with the same matrix system were investigated. Large Area Additive Manufacturing (LAAM) was utilized for the 3D-printed parts. Different types of thermoplastic composite materials were explored, including Glass Fiber reinforced Polyethylene Terephthalate Glycol (GF/PETG), Carbon Fiber reinforced Polyethylene Terephthalate Glycol (CF/PETG), Carbon Fiber reinforced Polycarbonate (CF/PC), and …

Fatigue And Fracture Of Electron Beam Melting Ti-6al-4v, William A. Grell

Electronic Theses and Dissertations

For applications in the aerospace field, selection of materials for a given design requires an understanding of critical properties, like fatigue and fracture, in addition to static mechanical and physical properties. With the ongoing advancements in metallic additive manufacturing techniques and the interest in applying the process to aerospace applications, there is a clear need to fully characterize properties. Arguably, the most attractive alloy for applications in aerospace is the Ti-6Al-4V alloy. The current dissertation examines the mechanical properties of the alloy, made by the Electron Beam Melting (EBM) Powder Bed Fusion (PBF) method. As illustrated in this work, the …

Point Heat Source Correlation To Microstructural Evolution In Advanced Manufacturing, Mark Anderson

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Although there are different ways that advanced manufacturing can be performed, the use of single-point heat sources has become the standard to control a final product’s properties. It is imperative to understand how the heat source used in the different advanced manufacturing processes affect the microstructure of interest. The intimate relationship between the heat source and microstructure allows for controlling and tailoring a part’s properties. Utilizing different microstructural analysis, the cross-correlation of various point heat sources to developed microstructure was conducted in this dissertation.

Laser powder bed fusion allows for unique print-to-part protocols, but the dynamics of the process makes …

Correlating Large-Format Additive Manufacturing Processing Parameters To Fiber Length And The Mechanical Performance Of Reinforced Polymer Composites, Andrew Phillip Rhodes

Masters Theses

The Big Area Additive Manufacturing (BAAM) system at Oak Ridge National Laboratory has been used to produce carbon fiber reinforced structures for several years, including vehicles, building constituents, composite tooling, etc. While the development of a large-format polymer additive manufacturing (AM) system has moved quickly, the impact of the BAAM’s extruder on the length of carbon fiber feedstock has not been systematically studied. Numerous studies in processing fiber reinforced thermoplastics in plasticizing and injection molding systems have shown that fibers are subjected to significant shear as they are processed, which can cause a drastic reduction in fiber length which negatively …

Fast-, Light-Cured Scintillating Plastic For 3d-Printing Applications, Brian G. Frandsen, Michael Febbraro, Thomas Ruland, Theodore W. Stephens, Paul A. Hausladen, Juan J. Manfredi, James E. Bevins

Faculty Publications

Additive manufacturing techniques enable a wide range of possibilities for novel radiation detectors spanning simple to highly complex geometries, multi-material composites, and metamaterials that are either impossible or cost prohibitive to produce using conventional methods. The present work identifies a set of promising formulations of photocurable scintillator resins capable of neutron-gamma pulse shape discrimination (PSD) to support the additive manufacturing of fast neutron detectors. The development of these resins utilizes a step-by-step, trial-and-error approach to identify different monomer and cross-linker combinations that meet the requirements for 3D printing followed by a 2-level factorial parameter study to optimize the radiation detection …

Influence Of Dilute Silicon Carbide Nanoparticle Additions To The Microstructure And Mechanical Properties Of Laser Powder Bed Fusion Molybdenum, Nathan E. Ellsworth

Theses and Dissertations

Consolidation of pure molybdenum through laser powder bed fusion and other additive manufacturing techniques is complicated by a high melting temperature, thermal conductivity, and ductile-to-brittle transition temperatures. Nano-sized silicon carbide particles (0.1 wt%) were homogeneously mixed with molybdenum powder and the printing characteristics, chemical composition, microstructure, and mechanical properties were compared to pure molybdenum for scan speeds of 100, 200, 400, and 800 mm/s. The addition of silicon carbide improved the consolidation and mechanical properties and the oxygen content was reduced. Two mechanisms of oxygen reduction were identified as responsible for the improvements: oxidation of free carbon and the creation …

Development Of Novel Turbomachinery Manufacturing Methods, Timothy P. Winkler

Theses and Dissertations

Compact turbine engines are of increasing interest as a means of propulsion for small, lightweight, low cost, unmanned aerial systems. This study looks to leverage advancements in novel manufacturing technology to produce turbomachinery components while simultaneously reducing costs and manufacturing time. To determine the feasibility of drop-in replacements for stock components this study focused on several research areas. This included materials research on both polymer-reinforced and ceramic materials, specimen tensile testing to determine temperature-dependent material properties, finite element analysis of multiple candidate materials, design and fabrication of a spin test rig, and physical spin testing of manufactured components to predict …

Material Property Dependence Of Nanoparticle Silicon Carbide Alloying In Additively Manufactured Molybdenum, Andrew P. Mason

Theses and Dissertations

The structural performance of additively manufactured Mo printed by LPBF can be significantly improved by nanoparticle alloying. Previous AFIT studies of SiC nanoparticle addition conducted by Ellsworth (2022) et al. demonstrated increased powder consolidation, leading to reduced porosity, increased microhardness, and a shift in atomic defect concentrations. The addition of defected SiC particles is proposed to reduce in situ oxidation by acting as a sacrificial oxidizing agent and contributing to the formation of Mo disilicide secondary phases. This study investigated the relationship between laser powder bed fusion Mo microscale and nanoscale properties with varying SiC particle size while maintaining a …

Laser Powder Bed Fusion Of Molybdenum And Mo-0.1sic Studied By Positron Annihilation Lifetime Spectroscopy And Electron Backscatter Diffraction Method, Nathan E. Ellsworth, Joshua R. Machacek, Ryan A. Kemnitz, Cayla C. Eckley, Brianna M. Sexton, Joel S. Gearhart, Larry W. Burggraf

Faculty Publications

Positron annihilation lifetime spectroscopy (PALS) has been used for the first time to investigate the microstructure of additively manufactured molybdenum. Despite the wide applicability of positron annihilation spectroscopy techniques to the defect analysis of metals, they have only been used sparingly to monitor the microstructural evolution of additively manufactured metals. Molybdenum and molybdenum with a dilute addition (0.1 wt%) of nano-sized silicon carbide, prepared via laser powder bed fusion (LPBF) at four different scan speeds: 100, 200, 400, and 800 mm/s, were studied by PALS and compared with electron backscatter diffraction analysis. The aim of this study was to clarify …

Additive Manufacturing Of (Mgconicuzn)O High-Entropy Oxide Using A 3d Extrusion Technique And Oxide Precursors, Ruoyu Chen, Saisai Li, Qingfeng Yan, Haiming Wen

Materials Science and Engineering Faculty Research & Creative Works

This report presents an additive manufacturing approach, for the first time, to producing high-entropy oxides (HEOs) using a 3D extrusion-based technique with oxide precursors. The precursors were prepared by a wet chemical method from sulfates. Additives were utilized to optimize the rheological properties of the printing inks with these precursors, and the properties of the printed HEOs were improved by increasing the solid content of the inks. When ink with a solid content of 78 wt% was used for printing, the resulting HEO exhibited a relative density of 92% and a high dielectric constant after undergoing pressure less sintering at …

Performance Evaluation Of Composite Sandwich Structures With Additively Manufactured Aluminum Honeycomb Cores With Increased Bonding Surface Area, M. Rangapuram, S. K. Dasari, Joseph William Newkirk, K. Chandrashekhara, H. Misak, P. R. Toivonen, D. Klenosky, T. Unruh, J. Sam

Materials Science and Engineering Faculty Research & Creative Works

Modern aerostructures, including wings and fuselages, increasingly feature sandwich structures due to their high-energy absorption, low weight, and high flexural stiffness. The face sheet of these sandwich structures are typically thin composite laminates with interior honeycombs made of Nomex or aluminum. Standard cores are structurally efficient, but their design cannot be varied throughout the structure. With additive manufacturing (AM) technology, these core geometries can be altered to meet the design requirements that are not met in standard honeycomb cores. This study used a modified aluminum honeycomb core, with increased surface area on the top and bottom, as the core material …

Multimaterial, Core-Shell Direct Ink Writing Of Flexible Strain Sensors For Pneumatically-Actuated Soft Robotic Hinge Joints, John Michael Burke

Graduate Theses, Dissertations, and Problem Reports

Direct ink writing (DIW) provides for an expansive material library and the ability to print multiple materials with tailored functionalities in a controllable and single-step process. Particularly beneficial is the net shape printing under ambient conditions of a wide range of materials normally incompatible with one another. Coaxial DIW is a 3D printing technique that allows for two dissimilar inks to be extruded simultaneously in a co-flow manner. In this work, custom-designed coaxial nozzles were 3D-printed using a stereolithography printer. Composite inks comprised of thermoplastic polyurethane and silver were developed and studied. The coaxial nozzles were then used to co-extrude …

Enhanced Performance Of 3d Electroactive Polymer Transducers Via Hierarchical Structures, Frederick B. Holness

Electronic Thesis and Dissertation Repository

Conjugated polymers (CPs) are a class of polymers that exhibit a change in size or shape in response to electrical stimuli. The unique combination of electrical and mechanical properties facilitates the fabrication of novel devices in a broad range of applications including: sensors, actuators, and lab-on-a-chip systems. The alternating single and double bonds along the polymer chain of CPs enables their electroactive properties but is also responsible for processability associated with CPs that has limited fabrication methods. Recently a photosensitive CP composite enabling additive manufacturing (AM) of 3D CP structures was developed. However, the introduction of a copolymer for mechanical …

A Study On Early Age Properties Of Concrete For Precast And 3d Printing, Debalina Ghosh

Doctoral Dissertations

Concrete is the second-most consumed material, leading the global Portland cement production of 4.1 billion tons in 2020 and 5-8% of global Carbon dioxide (CO₂) emission annually. As with any other material and practice, the construction industry is also ever-changing to meet market demand, evolving technology, and resource limitation. In the case of concrete construction, one of the main concerns is the lack of automation. In the last few decades, some new construction methods have risen to address this concern. Some of these economic and successful practices are precast construction, self-compacting concrete (SCC), and 3D printing of concrete(3DPC). …

Optimized 3d-Printing Of Carbon Fiber-Reinforced Polyether-Ether-Ketone (Cfr-Peek) For Use In Overmolded Lattice Composite, Ryan C. Ogle

Masters Theses

Current orthopedic implants are overwhelmingly composed from metallic materials. These implants show superior mechanical properties, but this can additionally result in stress shielding due to a modulus mismatch between the bone tissue and implanted device. Polymeric implants reduce this stress shielding effect but have much lower mechanical properties, limiting their use. Polylactic acid (PLA) is a widely used biodegradable thermoplastic polymer, however, its use has been limited by the polymer’s mechanical properties and rapid loss of strength during degradation in vivo. Polyether-ether-ketone (PEEK) is another common biocompatible polymer , with chemical and mechanical properties which make it a popular alternative …

Characterization Of Materials Properties In Additively Manufactured Aisi-420 Martensitic Steel Deposited By Laser Engineered Net Shaping, Md Mehadi Hassan

Nanoscience and Microsystems ETDs

Metal additive manufacturing (AM) is a disruptive technology enabling the fabrication of complex and near-net-shaped parts by adding material layer-wise. It offers reduced lead production time. AM processes are finding applications in many industrial sectors such as aerospace, automotive, biomedical, and mold tooling. Despite the tremendous advantages of AM, some challenges still prevent this technology's adoption in high-standard applications. Anisotropy and inhomogeneity in the mechanical properties of the as-built parts and the existence of pores and lack-of-fusion defects are considered the main issues in directed energy deposition (L-DED) parts. Laser-engineered net shaping LENS® offers excellent possibilities to fabricate metal tools …

Additive Manufacturing Of Complexly Shaped Sic With High Density Via Extrusion-Based Technique – Effects Of Slurry Thixotropic Behavior And 3d Printing Parameters, Ruoyu Chen, Adam Bratten, Joshua Rittenhouse, Tian Huang, Wenbao Jia, Ming-Chuan Leu, Haiming Wen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive manufacturing of dense SiC parts was achieved via an extrusion-based process followed by electrical-field assisted pressure-less sintering. The aim of this research was to study the effect of the rheological behavior of SiC slurry on the printing process and quality, as well as the influence of 3D printing parameters on the dimensions of the extruded filament, which are directly related to the printing precision and quality. Different solid contents and dispersant- Darvan 821A concentrations were studied to optimize the viscosity, thixotropy and sedimentation rate of the slurry. The optimal slurry was composed of 77.5 wt% SiC, Y2O3 and Al2O3 …

Thermal Post-Processing Of 3d Printed Polypropylene Parts For Vacuum Systems, Pierce Mayville, Aliaksei L. Petsiuk, Joshua M. Pearce

Michigan Tech Publications

Access to vacuum systems is limited because of economic costs. A rapidly growing approach to reduce the costs of scientific equipment is to combine open-source hardware methods with digital distributed manufacturing with 3D printers. Although high-end 3D printers can manufacture vacuum components, again, the cost of access to tooling is economically prohibitive. Low-cost material extrusion 3D printing with plastic overcomes the cost issue, but two problems arise when attempting to use plastic in or as part of vacuum systems: the outgassing of polymers and their sealing. To overcome these challenges, this study explores the potential of using post-processing heat treatments …