Mechanical Engineering Commons^™

Mechanical Properties And Microstructure Of Multi-Materials Fabricated Through A Combination Of Lpbf And Ded Additive Manufacturing Techniques, Christopher J. Bettencourt

All Graduate Theses and Dissertations, Fall 2023 to Present

This research explores the use of different metals combined through 3D-printing to enhance the performance of materials, with a focus on making heat exchangers more cost-effective for renewable energy. The goal is to replace a costly high-temperature alloy with a more affordable low-temperature alloy, using metal additive manufacturing for its benefits such as less material waste, faster production, reduced weight, and the ability to print entire assemblies in one go. The study delves into a unique combination of two 3D-printing techniques, Directed Energy Deposition and Laser Powder-Bed Fusion, to create a multi-material composed of stainless steel 316L and a nickel-based …

Synergistic Strategies In Sinter-Based Material Extrusion (Mex) 3d Printing Of Copper: Process Development, Product Design, Predictive Maps And Models., Kameswara Pavan Kumar Ajjarapu

Electronic Theses and Dissertations

3D printing pure copper with high electrical conductivity and exceptional density has long been challenging. While laser-based additive manufacturing technologies suffered due to copper's highly reflective nature towards laser beams, parts printed via binder-assisted technologies failed to reach over 90% IACS (International Annealed Copper Standard), electrical conductivity. Although promising techniques such as binder jetting, filament, and pellet-based 3D printing that can print copper exist, they however still face difficulties in achieving both high sintered densities and electrical conductivity values. This is due to a lack of comprehensive understanding of property evolution from green to sintered states and the strategies that …

Aluminum-Based Material Fabrication By Friction Stir Processing: Microstructural Evolution And Mechanical Properties, Suhong Zhang

Doctoral Dissertations

Friction stir processing (FSP) is an energy efficient solid-state material processing technique for microstructure modification of commercial high-strength Al alloys. Many variant techniques were developed in recent years that enabled light-weight and high-strength structure fabrication. Identifying relationship among process conditions, microstructures, and mechanical properties is of critical importance to facilitate the practical implementation of these new techniques. The research in the dissertation focusses on developing two main techniques of the FSP: a) friction stir back extrusion (FSBE) of 6063 aluminum alloy for tube making and b) FSP of 7075 aluminum alloy from powder feedstock. FSBE fabricated Al 6063 alloy tubes …

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

All Theses

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 …

Printing, Characterization, And Mechanical Testing Of Additively Manufactured Refractory Metal Alloys, Brianna M. Sexton

Browse all Theses and Dissertations

Refractory metal alloys in the tungsten molybdenum rhenium ternary system were additively manufactured using laser power bed fusion. Four ternary alloys with varying concentrations of tungsten, molybdenum, and rhenium were manufactured and manufactured again with an addition of 1 wt% hafnium carbide. Samples were heat treated to heal cracks, reduce porosity, and reduce inhomogeneity. Material microstructure was characterized before and after heat treatment using microscopy, energy dispersive x-ray spectroscopy, and electron backscatter diffraction mapping. Mechanical testing was conducted on both three-point bend specimens and compression specimens, resulting in maximum bending strengths of 677.86 MPa, and maximum compression 0.2% yield strengths …

Investigation Of Different Hatch Strategies On High Entropy Alloy Fabrication By Selective Laser Melting, Joni Chandra Dhar

Theses and Dissertations

This study investigated the synthesis of CuCrFeNiTiAl high entropy alloy (HEA) from pure elements using selective laser melting (SLM). The objectives are to validate the feasibility of the HEA fabrication from elemental powder materials, and to examine the effect of various hatch strategies and energy densities on the microstructures and other materials properties. 3D samples of CuCrFeNiTiAl alloy were fabricated under different energy densities and with different scan vector lengths. The as-built samples were characterized by X-ray diffraction (XRD), and the microstructures were observed using scanning electron microscopy (SEM). The XRD results showed that face centered cubic, and body centered …

Experimental Characterization And Crystal Plasticity Modeling Of Mechanical Properties And Microstructure Evolution Of Additively Manufactured Inconel 718 Superalloy, Saeede Ghorbanpour

Doctoral Dissertations

In this thesis, the mechanical behavior of the additively manufactured (AM) IN718 nickel-based superalloy and their correlations with the evolution of microstructure are studied comprehensively. The effects of manufacturing parameters, build orientations, and post processing procedures, i.e. standard heat treatment and hot isostatic pressing (HIP), on various mechanical properties including monotonic compression and tension strength, low cyclic fatigue performance, high cyclic fatigue behaviour, and fatigue crack growth behavior are investigated. Due to the high temperature applications of the IN718 alloy, elevated temperature properties are examined as well. Electron Backscattered Diffraction (EBSD) technique is employed to measure the initial and deformed …

Materials-Processing Relationships For Metal Fused Filament Fabrication Of Ti-6al-4v Alloy., Paramjot Singh

Electronic Theses and Dissertations

Additive manufacturing (AM) is at the mainstream to cater the needs for rapid tooling and small-scale part production. The metal AM of complex geometries is widely accepted and promoted in the industry. While several metal AM technologies exist and are matured to a level where expectation in terms of design and properties are possible to realize. But the metal AM suffers from the heavy expense to acquire equipment, isotropic property challenges, and potential hazards to work with loose reactive metal powder. With this motivation, the dissertation aims to develop the fundamental aspects to print metal parts with bound Ti-6Al-4V powder …

Microstructure And Mechanical Behavior Of Metastable Beta Type Titanium Alloys, Chirag Dhirajlal Rabadia

Theses: Doctorates and Masters

Current biomaterials such as stainless steel, Co-Cr alloys, commercially pure titanium and Ti-6Al- 4V either possess poor mechanical compatibility and/or produce toxic effects in the human body after several years of usage. Consequently, there is an enormous demand for long-lasting biomaterials which provide a better combination of mechanical, corrosion and biological properties. In addition to this, alloys used in high-strength applications possess either high-strength or large plasticity. However, a high-strength alloy should possess a better blend of both strength and plasticity when used in high-strength applications. Metastable β-titanium alloys are the best suited alloys for biomedical and high-strength applications because …

A Study On Ultrasonic Energy Assisted Metal Processing : Its Correeltion With Microstructure And Properties, And Its Application To Additive Manufacturing., Anagh Deshpande

Electronic Theses and Dissertations

Additive manufacturing or 3d printing is the process of constructing a 3-dimensional object layer-by-layer. This additive approach to manufacturing has enabled fabrication of complex components directly from a computer model (or a CAD model). The process has now matured from its earlier version of being a rapid prototyping tool to a technology that can fabricate service-ready components. Development of low-cost polymer additive manufacturing printers enabled by open source Fused Deposition Modeling (FDM) printers and printers of other technologies like SLA and binder jetting has made polymer additive manufacturing accessible and affordable. But the metal additive manufacturing technologies are still expensive …

Off Axis Compressive Response Of Ice-Templated Ceramics, Rahul Kumar Jujjavarapu

Mechanical & Aerospace Engineering Theses & Dissertations

The off-axis compressive behavior of ice-templated ceramic was analyzed using experimental results and micro-mechanical model simulation. Ice-templated ceramics is a versatile processing technique used to manufacture anisotropic ceramic foam by exploiting the anisotropic growth characteristics and lamellar morphology. The ice-templating process results in processing-structure-property relationships determined by the microstructure. The processed alumina samples which were later manufactured by water jet machine from the freeze casting were tested under quasi-static off-axis loading conditions and were used to determine the mechanical properties of the material. Digital image correlation (DIC) was used to measure the strain response of ice-templated ceramic under off-axis loading. …

Process-Property-Microstructure Relationships In Laser-Powder Bed Fusion Of 420 Stainless Steel., Subrata Deb Nath

Electronic Theses and Dissertations

Laser-powder bed fusion (L-PBF) is an additive manufacturing technique for fabricating metal components with complex design and customized features. However, only a limited number of materials have been widely studied using L-PBF. AISI 420 stainless steel, an alloy with a useful combination of high strength, hardness, and corrosion resistance, is an example of one such material where few L-PBF investigations have emerged to date. In this dissertation, L-PBF experiments were conducted using 420 stainless steel powders to understand the effects of chemical composition, particle size distribution and processing parameters on ensuing physical, mechanical and corrosion properties and microstructure in comparison …

Material-Process-Property Relationships Of 17-4 Stainless Steel Fabricated By Laser-Powder Bed Fusion Followed By Hot Isostatic Pressing., Harish Irrinki

Electronic Theses and Dissertations

17-4 PH stainless steel is commonly used in medical, tooling, automotive, chemical and aerospace industries due to its excellent strength and corrosion properties. Additive manufacturing processes such as laser-powder bed fusion (L-PBF) have gained attention and importance due to the potential to produce complex-shaped three-dimensional parts for various industries. In order to manufacture three-dimensional components from 17-4 PH stainless steel powder using L-PBF, it is critical for design and manufacturing engineers to have an awareness of various material options and corresponding processing and post-processing conditions to obtain useful mechanical properties from the process. The goal of this dissertation is to …

Investigation Of Microstructure And Mechanical Properties By Direct Metal Deposition, Jingwei Zhang

Doctoral Dissertations

"Microstructure and properties of Direct Metal Deposition (DMD) parts are very crucial to meeting industrial requirements of parts quality. Prediction, and control of microstructure and mechanical properties have attracted much attention during conventional metal manufacturing process under different conditions. However, there is few investigations focused on microstructure simulation and mechanical properties control under different process parameters during DMD process. This dissertation is intended to develop a multiscale model to investigate Ti6Al4V grain structure development and explore Ti6Al4V based functionally graded material (FGM) deposit properties during DMD process. The first research topic is to investigate and develop a cellular automaton-finite element …

Microstructural Evaluation Of Hydrogen Embrittlement And Successive Recovery In Advanced High Strength Steel, Quentin Scott Allen

Theses and Dissertations

Advanced high strength steels (AHSS) have high susceptibility to hydrogen embrittlement, and are often exposed to hydrogen environments in processing. In order to study the embrittlement and recovery of steel, tensile tests were conducted on two different types of AHSS over time after hydrogen charging. Concentration measurements and hydrogen microprinting were carried out at the same time steps to visualize the hydrogen behavior during recovery. The diffusible hydrogen concentration was found to decay exponentially, and equations were found for the two types of steel. Hydrogen concentration decay rates were calculated to be -0.355 /hr in TBF steel, and -0.225 /hr …

Processing, Microstructure, And Mechanical Properties Of Zirconium Diboride-Molybdenum Disilicide Ceramics And Dual Composite Architectures, Ryan Joseph Grohsmeyer

Doctoral Dissertations

"This research had two objectives: characterization of processing-microstructure-mechanical property relationships of conventional ZrB₂-MoSi₂ ceramics at room temperature (RT) and 1500⁰C in air, and fabrication of ZrB₂-MoSi₂ dual composite architectures (DCAs) for use near 1500⁰C. Elastic moduli, fracture toughness, and flexure strength were measured at RT and 1500⁰C for 15 ZrB₂-MoSi₂ ceramics hot pressed using fine, medium, or coarse ZrB₂ starting powder with 5-70 vol.% MoSi₂, referred to as FX, MX, and CX respectively where X is the nominal MoSi₂ content. MoSi₂ decomposed during sintering, resulting in …

Shape Memory Behavior Of Dense And Porous Niti Alloys Fabricated By Selective Laser Melting, Soheil Saedi

Theses and Dissertations--Mechanical Engineering

Selective Laser Melting (SLM) of Additive Manufacturing is an attractive fabrication method that employs CAD data to selectively melt the metal powder layer by layer via a laser beam and produce a 3D part. This method not only opens a new window in overcoming traditional NiTi fabrication problems but also for producing porous or complex shaped structures. The combination of SLM fabrication advantages with the unique properties of NiTi alloys, such as shape memory effect, superelasticity, high ductility, work output, corrosion, biocompatibility, etc. makes SLM NiTi alloys extremely promising for numerous applications.

The SLM process parameters such as laser power, …

Microstructure, Wetting Angle And Corrosion Of Aluminum-Silicon Alloys, Shvetashva Suri

Theses and Dissertations

In this study the effect of composition, surface roughness and water droplet size on contact angle and corrosion properties of cast Aluminum-Silicon alloys containing Si from 5% to 50% have been examined. The water contact angle was measured on a given sample using a goniometer. In addition, the effect of surface roughness and droplet size on contact angle has been measured for alloys at a fixed composition. The microstructures can be found in this report with sizes of primary and eutectic Silicon as well as inter-particle spacing between Silicon. Contact angle measurements are accompanied with a photographic validation of the …

Secondary Electron Emission From Plasma Processed Accelerating Cavity Grade Niobium, Miloš Bašović

Mechanical & Aerospace Engineering Theses & Dissertations

Advances in the particle accelerator technology have enabled numerous fundamental discoveries in 20th century physics. Extensive interdisciplinary research has always supported further development of accelerator technology in efforts of reaching each new energy frontier.

Accelerating cavities, which are used to transfer energy to accelerated charged particles, have been one of the main focuses of research and development in the particle accelerator field. Over the last fifty years, in the race to break energy barriers, there has been constant improvement of the maximum stable accelerating field achieved in accelerating cavities. Every increase in the maximum attainable accelerating fields allowed for higher …

Cryogenic Processing Of Al 7050-T7451 Alloy For Improved Surface Integrity, Bo Huang

Theses and Dissertations--Mechanical Engineering

Al 7050-T7451 alloy with good combinations of strength, stress corrosion cracking resistance and toughness, is used broadly in the aerospace/aviation industry for fatigue-critical airframe structural components. However, it is also considered as a highly anisotropic alloy as the crack growth behavior along the short transverse direction is very different from the one in the long transverse direction, due to the inhomogeneous microstructure with the elongated grains distributed in the work material used in the sheet/plate applications. Further processes on these materials are needed to improve its mechanical and material properties and broaden its applications.

The material with ultra-fine or nano …

An Adapted Approach To Process Mapping Across Alloy Systems And Additive Manufacturing Processes, Luke Charles Sheridan

Browse all Theses and Dissertations

The continually growing market for metal components fabricated using additive manufacturing (AM) processes has called for a greater understanding of the effects of process variables on the melt pool geometry and microstructure in manufactured components for various alloy systems. Process Mapping is a general approach that traces the influence of process parameters to thermal behavior and feature development during AM processing. Previous work has focused mainly on Ti-6Al-4V (Ti64), but this work uses novel mathematical derivations and adapted process mapping methodologies to construct new geometric, thermal, and microstructural process maps for Ti64 and two nickel superalloy material systems. This work …

Elucidating The Role Of Microstructure, Texture, And Microtexture On The Dwell Fatigue Response Of Ti-6al-4v, Alec Mitchell Blankenship

Browse all Theses and Dissertations

Ambient temperature dwell sensitivity is known to be deleterious to the fatigue response of near-alpha titanium alloys. Dwell fatigue refers to the presence of a sustained hold at peak stress as opposed to the continuous variation of normal cyclic fatigue loading. This reduction in failure life-times from dwell loading is attributed to early crack nucleation and faster crack propagation. The degradation is the result of plastic anisotropy on the microstructural scale along with tendency of titanium alloys to creep at low temperatures at stresses well below the 0.2% offset yield strength. Despite being the most widely used titanium alloy, Ti-6Al-4V …

Edge Fracture Prediction Of Dual Phase Steels With Consideration Of Microstructures, Ming Wen

Wayne State University Dissertations

In recent years, Advanced High Strength Steels (AHSS) have been used for the lightweight structural design and manufacturing in automotive industry. This class of sheet metals are prone to edge fracture during stamping production, and the fracture often occurs at much lower strain than that predicted based on the forming limit curves. The uncertainty in predicting edge fracture represents a great challenge in the application of AHSS. This dissertation is focused on the better understanding of edge fracture phenomenon through experimental observation and computer modeling with the consideration of microstructure effect.

In this dissertation, Hole Expansion (HE) test was used …

Bridging The Nano- And Macro-Worlds: Thermal Property Measurement Using Thermal Microscopy And Photothermal Radiometry – Application To Particle-Irradiation Damage Profile In Zirconium Carbide, Colby Bruce Jensen

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

Multiscaled experimental investigations of heat transfer from nanoscales to macroscales are requisite to progress in energy technologies. In nuclear applications, material properties can undergo significant alteration due to destructive interaction with irradiating particles at microstructural levels that affect bulk properties. This study expands the current knowledge base regarding thermal transport in ion-irradiated materials through the use of a multiscaled experimental approach using four complementary thermal wave methods. For the first time, the in-depth thermal conductivity profile of an ion-irradiated sample is measured directly.

Microstructure, Quasi-Static, And High-Strain Rate Dynamic Characterization Of Metakaolin And Fly Ash Based Geopolymers For Structural Applications, Damian Lee Stoddard

Electronic Theses and Dissertations

Geopolymers are a class of rapid setting cementing systems that have been used as mortar or additives in concrete mixes to improve properties. Several types of geopolymer systems such as metakaolin and fly ash based geopolymers are widely used, and are available in different mixture proportions [1, 2]. Metakaolin (Al2Si2O7), a dehydroxylated form of Kaolinite (Al2Si2O5(OH)4) clay readily available from many sources, provides several benefits whenadded to a concrete mix design or used as a mortar system, including durability, freeze/thaw, acid resistance, and high temperature resistance [3]. Class F fly ash-based mortar geopolymers provide added fire retardation, reduces crack formation, …

Synthesis, Microstructure And Performance Evaluation Of Gadolinium Incorporated Cobalt Ferrite Ceramics, Md Taibur Rahman

Open Access Theses & Dissertations

Spinel structured ferrites exhibit remarkable properties and phenomena, which are attractive for application in sensors and actuators, magneto-electronics, and electrochemical energy storage devices. Among spinel ferrites, cobalt ferrite CoFe₂O₄ (CFO) has attracted remarkable attention and widely studied because of their electro-magnetic properties, chemical stability and mechanical hardness. The properties and phenomena of CFO ceramics are dependent on microstructure and chemistry, which in turn depend on the synThesis processes and conditions employed for fabrication. Generally exact chemical composition, processing temperature, reactive or processing atmosphere (if any) and the ions that substitute Fe³⁺/Fe²⁺ ions dictate the …

An Investigation Into The Mechanisms Of Formation Of The Hard Zone In Fsw X65, Jacob D. Allred

Theses and Dissertations

Friction stir welding (FSW) of HSLA steel commonly produces a hard zone (HZ) on the advancing side (AS) of the weld. Despite its detrimental effects on weld toughness, the mechanisms of its formation have not been thoroughly investigated and are not well understood. This paper investigates the various mechanisms in FSW believed to affect the weld HZ, namely: strain, strain-rate, peak temperature and cooling rate. Gleeble tests indicate that strain and strain rate have negligible effects on weld HZ with cooling rate and peak temperature as dominant effects. Jominy tests resulted in cooling rate having 270% greater influence than peak …

The Effect Of Cooling Rate Of Friction Stir Welded High Strength Low Alloy Steel, Scott Anthony Rose

Theses and Dissertations

The friction stir welding of steel has produced a hard zone in several different alloys. Despite its detrimental effects on weld toughness, the reasons behind neither its formation nor a method of reducing its size or effects have been explored. Recent advances in process control allow for direct heat input control, which combined with the use of backing plates of different thermal conductivity allows for an expansion of the process window. These control methods also affect the HAZ cooling rate by providing greater range (a 60% increase compared to a fixed backing plate) and control (five welds within 16 °C/s). …

A Hybrid Bishop-Hill Model For Microstructure Sensitive Design, Ribeka Takahashi

Theses and Dissertations

A method is presented for adapting the classical Bishop-Hill model to the requirements of elastic/yield-limited design in metals of arbitrary crystallographic texture. The proposed Hybrid Bishop-Hill (HBH) model, which will be applied to ductile FCC metals, retains the `stress corners' of the polyhedral Bishop-Hill yield surface. However, it replaces the `maximum work criterion' with a criterion that minimizes the Euclidean distance between the applicable local corner stress state and the macroscopic stress state. This compromise leads to a model that is much more accessible to yield-limited design problems. Demonstration of performance for the HBH model is presented for an extensive …

Study On The Fracture Toughness Of Friction Stir Welded Api X80, Allan M. Tribe

Theses and Dissertations

High strength low alloy (HSLA) steels have been developed to simultaneously have high yield strength and high fracture toughness. However, in practical applications steel must be welded. Traditional arc welding has proven detrimental to the fracture toughness of HSLA steels. Friction stir welding has recently shown mixed results in welding HSLA steels. The range of welding parameters used in these recent studies however has been very limited. With only a few welding parameters tested, the effect of spindle speed, travel speed, and heat input on the fracture toughness of friction stir welded HSLA steel remains unknown. To understand how the …