Mechanical Engineering Commons^™

Temperature Gradient Effect On Solid-Liqid Interface Properties Of Al-Cu Alloy: A Molecular Dynamics Study, Prashant Kumar Jha

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Aluminum-copper (Al-Cu) alloys are widely used in the aerospace industry due to their favorable strength-to-weight ratio, good fatigue resistance, and corrosion resistance. These properties make Al-Cu alloys an excellent choice for aircraft structural components that require high strength and low weight. Additive manufacturing (AM), also known as 3D printing, has emerged as a promising processing method for Al-Cu alloys in aerospace manufacturing. AM enables the production of lightweight optimized geometries difficult to manufacture through conventional subtractive methods. AM also reduces material waste by only depositing material where needed in the part geometry. The rapid solidification conditions in AM processes motivate …

Cfrp Delamination Density Propagation Analysis By Magnetostriction Theory, Brandon Eugene Williams

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While Carbon Fiber Reinforced Polymers (CFRPs) have exceptional mechanical properties concerning their overall weight, their failure profile in demanding high-stress environments raises reliability concerns in structural applications. Two crucial limiting factors in CFRP reliability are low-strain material degradation and low fracture toughness. Due to CFRP’s low strain degradation characteristics, a wide variety of interlaminar damage can be sustained without any appreciable change to the physical structure itself. This damage suffered by the energy transfer from high- stress levels appears in the form of microporosity, crazes, microcracks, and delamination in the matrix material before any severe laminate damage is observed. This …

Multiscale Modeling And Gaussian Process Regression For Applications In Composite Materials, Joshua Arp

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An ongoing challenge in advanced materials design is the development of accurate multiscale models that consider uncertainty while establishing a link between knowledge or information about constituent materials to overall composite properties. Successful models can accurately predict composite properties, reducing the high financial and labor costs associated with experimental determination and accelerating material innovation. Whereas early pioneers in micromechanics developed simplistic theoretical models to map these relationships, modern advances in computer technology have enabled detailed simulators capable of accurately predicting complex and multiscale phenomena.

This work advances domain knowledge via two means: firstly, through the development of high-fidelity, physics-based finite …

Characterization Of Mechanically Recycled Polylactic Acid (Pla) Filament For 3d-Printing By Evaluating Mechanical, Thermal, And Chemical Properties And Process Performance, Mahsa Shabani Samghabady

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Polylactic acid (PLA) is a biopolymer made from renewable resources such as sugar and corn. PLA filament is a popular material used in Fused Deposition Modeling (FDM) 3D-printing. While this material has many advantages, all the failed parts, support structures, rafts, nozzle tests, and the many prototype iterations during the 3D-printing process contribute to the plastic pollution and release of greenhouse gases. Although PLA is biodegradable, it can take years to degrade in landfills. Instead of throwing away PLA waste and buying new filaments, PLA can be recycled. Amongst the different recycling technologies, mechanical recycling is the most environmentally friendly. …

Life Cycle Energy Assesment Of Advanced Fiber Reinforced Composite Design And Manufacturing Methodologies, Urjit Lad

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Automotive industry at large is focused on vehicle light-weighting since a 6%-8% increase in fuel efficiency can be achieved with a 10% reduction in vehicle weight [1]. With the growing demand for cost-effective and sustainable light weighting of automobile structures, interest has increased in the application of fiber reinforced plastic (FRP) composites for use in the Body-in-White (BiW), which can account for up to 40% of the total vehicle weight. Traditional FRP composite manufacturing processes like vacuum assisted resin transfer molding, autoclave consolidation or use of automated fiber placement have been successfully used for marine and aerospace applications. However, these …

Mesoscale Modeling And Machine Learning Studies Of Grain Boundary Segregation In Metallic Alloys, Malek Alkayyali

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Nearly all structural and functional materials are polycrystalline alloys; they are composed of differently oriented crystalline grains that are joined at internal interfaces termed grain boundaries (GBs). It is well accepted that GB dynamics play a critical role in many phenomena during materials processing or under operating environments. Of particular interest are GB migration and grain growth processes, as they influence many crystal-size dependent properties, such as mechanical strength and electrical conductivity.

In metallic alloys, GBs offer a plethora of preferential atomic sites for alloying elements to occupy. Indeed, recent experimental studies employing in-situ microscopy revealed strong GB solute segregation …

Classification Of Electrical Current Used In Electroplastic Forming, Tyler Grimm

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Electrically assisted manufacturing (EAM) is the direct application of an electric current to a workpiece during manufacturing. This advanced manufacturing process has been shown to produce anomalous effects which extend beyond the current state of modeling of thermal influences. These purported non-thermal effects have collectively been termed electroplastic effects (EPEs).

While there is a distinct difference in results between steady-state (ideal DC) testing and pulsed current testing, the very definition of these two EAM methods has not been well established. A "long" pulse may be considered DC current; a "short" pulse may produce electroplastic effects; and even "steady-state" current shapes …

Machine Learning-Based Data And Model Driven Bayesian Uncertanity Quantification Of Inverse Problems For Suspended Non-Structural System, Zhiyuan Qin

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Inverse problems involve extracting the internal structure of a physical system from noisy measurement data. In many fields, the Bayesian inference is used to address the ill-conditioned nature of the inverse problem by incorporating prior information through an initial distribution. In the nonparametric Bayesian framework, surrogate models such as Gaussian Processes or Deep Neural Networks are used as flexible and effective probabilistic modeling tools to overcome the high-dimensional curse and reduce computational costs. In practical systems and computer models, uncertainties can be addressed through parameter calibration, sensitivity analysis, and uncertainty quantification, leading to improved reliability and robustness of decision and …

Effects Of Polymer Side-Group Size On Interfacial Mechanics Of Graphene-Polymer Nanocomposites, Grace Brokaw

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Graphene-reinforced polymer nanocomposites possess excellent mechanical, thermal, and electrical properties, which make them promising candidates for various applications. Favorable interfacial interactions and mechanics between graphene sheets and polymer matrices are often essential to achieve superior mechanical properties. Nevertheless, it remains largely elusive how molecular features of polymer systems, particularly the side-group size of polymer chains, affect the interfacial mechanics between graphene sheets and polymer matrices, primarily due to challenges in well controlling these features in experiments. On the other hand, exploring their roles in the mechanical properties of graphene-polymer nanocomposites is very expensive to study with all-atomistic molecular dynamics (MD) …

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

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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 …

Design And Development Of A Multi-Material, Cost-Competitive, Lightweight Mid-Size Sports Utility Vehicle’S Body-In-White, Amit M. Deshpande, Rushabh Rajesh Sadiwala, Nathan Brown, Sai Aditya Pradeep, Leon M. Headings, Ningxiner Zhao, Brad Losey, Ryan Hahnlen, Marcelo J. Dapino, Gang Li, Srikanth Pilla

Publications

Vehicle light-weighting has allowed automotive original equipment manufacturers (OEMs) to improve fuel efficiency, incorporate value-adding features without a weight penalty, and extract better performance. The typical body-in-white (BiW) accounts for up to 40% of the total vehicle mass, making it the focus of light-weighting efforts through a) conceptual redesign b) design optimization using state-of-the-art computer-aided engineering (CAE) tools, and c) use of advanced high strength steels (AHSS), aluminum, magnesium, and/or fiber-reinforced plastic (FRP) composites. However, most of these light-weighting efforts have been focused on luxury/sports vehicles, with a relatively high price range and an average production of 100,000 units/year or …

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

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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 …

A Study On Effect Of Manufacturing Parameters On Morphology Of A356 Aluminum Foam, Nikhil Nanabhau Mahajan

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Metal foams have shown an excellent promise for usage as multifunctional material concerning research & development in the last 20 years. They provide remarkable mechanical as well as physical properties being lightweight. Open-cell metal foams have already been used in sound and noise absorption. Open-cell metal foams are outstanding for use in heat exchangers, filters, and many more applications, while closed-cell foams show excellent characteristics in impact energy absorptions. Closed-cell metal foams have higher energy absorption than their solid parent metal as they convert most of the impact energy into deformation energy. Metal foams have been used as prominent safeguard …

Investigating The Effects Of Sic Abrasive Particles On Friction Element Welding, Gaurav Awate

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The growing demands on reducing the harmful emissions from automobiles have forced automakers to reduce the weight of the vehicle. The increasing demands on improving the fuel economy also has challenged automotive manufacturers to make the vehicle as lightweight as possible. However, the challenge is also to ensure that the vehicle meets safety standards. For the vehicle to meet these standards, it needs to be of adequate strength as well. Automotive manufacturers have adopted a strategy of using multi-material construction to achieve the target. But with multi-material construction comes the requirement of advanced joining techniques that are capable of joining …

Thermoforming Process Effects On Structural Performance Of Carbon Fiber Reinforced Thermoplastic Composite Parts Through A Manufacturing To Response Pathway, Madhura Limaye, Sai Aditya Pradeep, Anmol Kothari, Sushil Savla, Akshat Agha, Srikanth Pilla, Gang Li

Publications

Thermoforming process of thermoplastic-based continuous CFRP's offer a major advantage in reducing cycle times for large-scale productions, but it can also have a significant impact on the structural performance of the parts by inducing undesirable effects. This necessitates the development of an optimal manufacturing process that minimizes the introduction of undesirable factors in the structure and thereby achieves the targeted mechanical performance. This can be done by first establishing a relationship between the manufacturing process and mechanical performance and successively optimizing it to achieve the desired targets. The current study focuses on the former part, where a manufacturing-to-response (MTR) pathway …

Mechanical Interfacial Locking And Multiscale Modeling Of Reinforced Thermoplastic Composites For Structural Applications, Anmol Kothari

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The ever-growing pressure of reducing the adverse impact of transportation systems on environment has pushed industries towards fuel-efficient and sustainable solutions. While several approaches have been used to improve fuel efficiency, the light-weighting of structural components has proven broadly effective. In this regard, reinforced thermoplastic composites (RTPC), owing to their high recyclability, higher impact strength and fast cycle times, have become competitive candidates at an industrial scale. However, to implement RTPC toward large scale structural applications several challenges pertaining to material design and manufacturing effects need to be addressed. To this end, a computational study is carried out to address …

Advanced Bulk Processing Of Lightweight Materials For Utilization In The Transportation Sector, Justin Milner

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The overall objective of this research is to develop the microstructure of metallic lightweight materials via multiple advanced processing techniques with potentials for industrial utilization on a large scale to meet the demands of the aerospace and automotive sectors. This work focused on (i) refining the grain structure to increase the strength, (ii) controlling the texture to increase formability and (iii) directly reducing processing/production cost of lightweight material components. Advanced processing is conducted on a bulk scale by several severe plastic deformation techniques including: accumulative roll bonding, isolated shear rolling and friction stir processing to achieve the multiple targets of …