Metallurgy Commons^™

Improving Cast Steel Rail Coupler Fatigue Resistance Through Local Wire-Arc Additive Manufacturing, Andrew M. Bunge

Dissertations, Master's Theses and Master's Reports

Every year, thousands of cast-steel railcar couplers suffer from corrosion-initiated fatigue cracking in similar areas of the coupler’s knuckle; between 2015 and 2018 about 90,000 knuckles were replaced, otherwise these couplers would have been at risk for unexpected failures. These types of couplers have been common in industrial use as early as 1932, hence it is desirable for a countermeasure to the fatigue cracking that does not involve significantly altering the geometry or casting process. Wire arc additive manufacturing (WAM) is a developing technology which boasts the ability to produce complex near-net-shape components; however, less attention has been paid to …

High Temperature Strength Reduces Soldering In Aluminum High Pressure Die Casting, Jacob A. Belke

Dissertations, Master's Theses and Master's Reports

Die soldering, an adhesion defect in high pressure die casting (HPDC), is a symptom of localized sticking where a localized portion of the cast material is adhered to the tooling surface causing build up over time. This requires the tooling to be serviced which incurs additional costs to the process that gets passed on to the parts. Historically, soldering has been mitigated using lubricants, coatings, and alloy chemistry modifications but solder persists.

The Tresca friction thermomechanical model suggests soldering occurs when the local interfacial shear stress between the casting and die surface exceeds the local shear strength of the casting. …

Causational Analysis And Rectification Of Issues Concerning Scale Formation On Hot-Rolled Straight Bar Product And Its Effects On Ultrasonic Testing, Riley Mattix

Williams Honors College, Honors Research Projects

At Charter Steel's NDT Processing Plant located in Cleveland, Ohio, a concern has arisen regarding the recently implemented bar straightening and UT (Ultrasonic Testing) equipment. A substantial amount of mill scale, which is typically removed during the straightening process, is persisting on the bar’s surface throughout most of the NDT procedure. This lingering scale has been observed to flake off once inside the UT equipment, introducing unwanted noise and phantom peaks into the UT readings. Additionally, thick mill scale has been identified as a source of background interference in the received data. In contrast, bars that have been subjected to …

Processing Of Niti Sma For High Reflectivity Applications, Nicholas Dean Asbury

UNF Graduate Theses and Dissertations

Nickel Titanium (NiTi) is a shape memory alloy (SMA) that is capable of being deformed and subsequently returned to the original shape through heating. This unique property makes NiTi a prime material for potential applications in the aerospace industry. As manufacturing capabilities advance, the ability to produce and implement advanced materials, such as shape memory alloys like NiTi, becomes more feasible. One such application being studied is deployable mirrors for imaging satellites. Reflector and mirror surfaces for imaging in the visible and infra-red range of the light spectrum require low surface roughness across the largest allowable area for the collection …

การศึกษาผลของอุณหภูมิอบอ่อนและความเร็วในการรีดต่อโครงสร้างจุลภาคและสมบัติเชิงกลของเหล็กกล้ารูปพรรณรีดร้อนเกรด S450j0, เชิญจุติ อรุณถิน

Chulalongkorn University Theses and Dissertations (Chula ETD)

งานวิจัยนี้ศึกษาผลกระทบของอุณหภูมิการอบอ่อนและความเร็วการรีดต่อโครงสร้างจุลภาค สมบัติเชิงกล และคุณภาพผิวของเหล็กกล้าโครงสร้าง S450J0 ชนิดรีดร้อน โดยมุ่งเน้นกระบวนการผลิตเหล็กกล้าเอชบีมขนาด 305x305x223 กก./ม. การทดลองใช้อุณหภูมิการอบอ่อนและความเร็วการรีดที่แตกต่างกันเพื่อตรวจสอบผลกระทบต่อคุณภาพของผลิตภัณฑ์ ผลการทดลองแสดงให้เห็นว่า อุณหภูมิการอบอ่อนมีอิทธิพลอย่างมีนัยสำคัญต่อสมบัติเชิงกล โดยอุณหภูมิที่สูงขึ้นจะเพิ่มค่าความต้านทานแรงดึงที่จุดครากและความต้านแรงดึง แต่ส่งผลให้ค่าความเหนียวและความแกร่งลดลงในบางกรณี ในทางตรงกันข้าม ความเร็วการรีดที่แตกต่างกันมีผลกระทบเล็กน้อยต่อสมบัติทางกล เนื่องจากอุณหภูมิการรีดขั้นสุดท้ายมีความแตกต่างกันเล็กน้อย การวิเคราะห์โครงสร้างจุลภาคพบว่า อุณหภูมิการอบอ่อนที่สูงขึ้นส่งผลให้ขนาดเกรนเล็กลง ในขณะที่อุณหภูมิที่ต่ำกว่าจะทำให้เกิดการเรียงตัวของเกรนเฟร์ไรต์ที่ชัดเจน นอกจากนี้ ข้อบกพร่องบนพื้นผิวของเหล็ก เช่น รูปแบบรอยแตก ยังได้รับอิทธิพลจากทั้งอุณหภูมิการอบอ่อนและความเร็วการรีด การวิเคราะห์ด้วยกล้องจุลทรรศน์อิเล็กตรอนแบบส่องกราด ยืนยันความลึกและลักษณะของรอยแตกบนผิว ซึ่งสอดคล้องกับการสังเกตจากกล้องจุลทรรศน์แบบแสง โดยสรุป การปรับอุณหภูมิการอบอ่อนและความเร็วการรีดให้เหมาะสมมีความสำคัญอย่างยิ่งในการลดข้อบกพร่องบนพื้นผิวและเพิ่มคุณภาพของผลิตภัณฑ์ในกระบวนการรีดร้อนเหล็กกล้าเอชบีม

Theoretical Modeling And Experimental Investigation Of Phase Selection During Rapid Solidification Of Alloys, Azeez Aremu Akinbo

Masters Theses

"A novel model, rooted in time-dependent nucleation theory, has been created to explore how rapid solidification affects the extended solubility in metal alloys. This model was used to forecast solubility concerning undercooling in multiple binary aluminum (Al) alloys, and its predictions for both eutectic and peritectic systems closely match experimental data. It was demonstrated that this developed model surpasses the T0 line method, which does not consider the kinetic aspects of nucleation. Furthermore, the model can be extended to ternary and multicomponent phases by assuming that the scarcest element or the slowest diffusing component restricts nucleation. Al-Cu and Al-Cr, vital …

ผลกระทบของการอบอ่อนซ้ำระหว่างอุณหภูมิวิกฤตต่อโครงสร้างจุลภาค และคุณสมบัติทางกลของเหล็กกล้าดูอัลเฟส, วิชยุตม์ ชูเมือง

Chulalongkorn University Theses and Dissertations (Chula ETD)

ในการศึกษานี้ ได้มีการประยุกต์การอบอ่อนซ้ำระหว่างอุณหภูมิวิกฤตเพื่อปรับเปลี่ยนสมบัติทางกลของเหล็กกล้าดูอัลเฟสที่มีส่วนผสม 0.107%C-2.39%Mn-0.453%Si ผลการอบอ่อนซ้ำระหว่างอุณหภูมิวิกฤต (IC2) ถูกตรวจสอบโดยการสังเกตโครงสร้างจุลภาค การทดสอบแรงดึงและการทดสอบความแข็งแบบวิกเกอร์ แล้วจึงเปรียบเทียบผลกับชิ้นงานที่อบอ่อนระหว่างอุณหภูมิวิกฤตครั้งเดียว (IC1) โดยพบว่าการเพิ่มอุณหภูมิการอบอ่อนระหว่างอุณหภูมิวิกฤตส่งผลให้ความเค้นคราก ความต้านทานแรงดึง และความแข็งเพิ่มขึ้นในขณะที่ความเหนียวลดลงเนื่องจากการเพิ่มขึ้นของปริมาณมาร์เทนไซต์เป็นหลัก หลังจาก IC2 ส่งผลให้ชิ้นงานมีขนาดเกรนเฟร์ไรต์และปริมาณมาร์เทนไซต์ลดลงเล็กน้อย และจากผลการทดสอบแรงดึงพบว่า IC2 สามารถเพิ่มความเหนียวโดยไม่ส่งผลให้ความแข็งแรงลดลงอย่างมีนัยสำคัญ จากผลลัพธ์ที่ได้บ่งบอกว่าสามารถใช้วิธีการอบอ่อนซ้ำระหว่างอุณหภูมิวิกฤต เพื่อปรับปรุงคุณสมบัติทางกลของเหล็กกล้าดูอัลเฟสได้ โดยไม่เพิ่มความซับซ้อนให้กับกระบวนการผลิตมากเกินไป

A Review On Biochar As An Adsorbent For Pb(Ii) Removal From Water, Pushpita Kumkum, Sandeep Kumar

Civil & Environmental Engineering Faculty Publications

Heavy metal contamination in drinking water is a growing concern due to its severe health effects on humans. Among the many metals, lead (Pb), which is a toxic and harmful element, has the most widespread global distribution. Pb pollution is a major problem of water pollution in developing countries and nations. The most common sources of lead in drinking water are lead pipes, faucets, and plumbing fixtures. Adsorption is the most efficient method for metal removal, and activated carbon has been used widely in many applications as an effective adsorbent, but its high production costs have created the necessity for …

Parametric Optimization Of Friction Stir Welding Of Aa6061-T6 Samples Using The Copper Donor Stir-Assisted Material Method, Aiman H. Al-Allaq, Joseph Maniscalco, Srinivasa Naik Bhukya, Zhenhua Wu, Abdelmageed Elmustafa

Mechanical & Aerospace Engineering Faculty Publications

This study presents an optimization of the process parameters for the effect of copper (Cu) donor material percentage on the friction stir welding (FSW) of AA6061-T6 alloy. Extensive factorial experiments were conducted to determine the significance of the rotational speed (ω), the transverse speed (v), the interface coefficient of friction (μ), and the Cu donor material percentage in the plunge, left, right, and downstream zones. Design Expert 13 software was used to identify the number of simulation experiments to be conducted using the Abaqus simulation software. From Design Expert 13, which is a thorough multi-objective optimization analysis software, we were …

Real-Time Spectroscopic Ellipsometry For Flux Calibrations In Multi-Source Co-Evaporation Of Thin Films: Application To Rate Variations In Cuinse₂ Deposition, Dhurba R. Sapkota, Balaji Ramanujam, Puja Pradhan, Mohammed A. Razooqi Alaani, Ambalanath Shan, Michael J. Heben, Sylvain Marsillac, Nikolas J. Podraza, Robert W. Collins

Electrical & Computer Engineering Faculty Publications

Flux calibrations in multi-source thermal co-evaporation of thin films have been developed based on real-time spectroscopic ellipsometry (RTSE) measurements. This methodology has been applied to fabricate CuInSe₂ (CIS) thin film photovoltaic (PV) absorbers, as an illustrative example, and their properties as functions of deposition rate have been studied. In this example, multiple Cu layers are deposited step-wise onto the same Si wafer substrate at different Cu evaporation source temperatures (TCu). Multiple In₂Se₃ layers are deposited similarly at different In source temperatures (TIn). Using RTSE, the Cu and In₂Se₃ deposition rates are determined as …

Isolation And Characterization Of Caffeine-Degrading Bacteria From Coffee Plantation Areas In Malaysia, Elvina Clarie Dullah, Mohd Fazli Farida Asras

Makara Journal of Technology

Decaffeination by microbial degradation is currently the most optimal and low-cost approach, involving only microbial cells and/or their enzymes. The bacterium was characterized using a series of biochemical tests. Positive results were obtained from carbohydrate fermentation, citrate utilization, and catalase tests, while negative results were obtained from Voges-Proskauer (VP) and indole tests. Three different caffeine concentrations of 0.25%, 0.4%, and 2% were tested and measured through Gas Chromatography-Mass Spectrophotometry (GC-MS) analysis. The highest caffeine reduction (89.25%) was found when 0.25% caffeine was used in the media. Only a small amount of caffeine was reduced to 0.4% and 2%, with 34.78% …

Optimization Of The Building Envelope And Roof Shading To Reduce The Energy Consumption Of College Low-Rise Buildings In Indonesia, Nasruddin Nasruddin, Azimil Gani Alam, Mohammad Imroz Sohel

Makara Journal of Technology

Energy consumption in buildings is a crucial concern globally, prompting researchers to explore innovative solutions to mitigate its impact. This study investigates the optimization of building envelopes and roof shading systems of existing buildings in Indonesia to realize notable energy savings. Multiple scenarios were explored, with modifications to building envelopes and roof shading, highlighting the overall thermal transfer value as a key parameter. Using EnergyPlus simulations, the efficacy of natural ventilation in corridors and roof shading modifications was assessed in reducing energy consumption. The findings revealed that renovating existing buildings by optimization of the building envelope and roof shading by …

Mechanical Characterization Of Functionally Graded M300 Maraging Steel Cellular Structures, Bradley Jay Sampson

Theses and Dissertations

Traditional methods for increasing the energy absorption of a structure involve using a stronger material or increasing the volume of the structure, resulting in a higher cost or additional weight. Additive manufacturing (AM) can be used to maximize the energy absorption of materials with the ability to create complex geometries such as cellular structures. Previous work has shown that the energy absorption of additively manufactured parts can be improved through functionally graded cellular structures; however, this strategy has not been applied to ultra-high strength steel materials. This work characterizes the effect of multiple functional-grading strategies (e.g. uniform, rod-graded, size-graded) on …

Cobalt Chromium In Biomedical Applications And The Development Of A Pspp Map, Nouralhouda Jamal

BCoE Publications

During the world wars, Cobalt-Chromium (Co-Cr) alloys gained prominence for their use in aircraft engine components, where they exhibited high temperature strength and durability. They are used in a wide range of industries due to their unique set of qualities, particularly strength, corrosion resistance, and biocompatibility. They have emerged as versatile materials with a broad spectrum of applications, from aerospace and automotive components to biomedical implants.

This paper presents a thorough analysis of its composition, processing techniques, microstructure, mechanical properties, and performance characteristics. The primary goal of this project is to develop a PSPP (Process, structure, properties, and performance) map …

The Shape Modulation Of Laser-Induced Nanowelded Microstructures Using Two Colors, Ariel Rogers, Isabelle Niyonshuti, Jun Ou, Diksha Shrestha, Deborah Okyere, Jingyi Chen, Yong Wang

Physics Faculty Publications and Presentations

The light-based nanowelding of metallic nanoparticles is of particular interest because it provides convenient and controlled means for the conversion of nanoparticles into microstructures and the fabrication of nanodevices. In this study, we investigated the wavelength dependence of laser-induced nanowelded shapes of silver nanoparticles (AgNPs). We observed that the nanowelded microstructures illuminated with only a 405 nm laser were more branched than those formed via illumination using both the 405 nm and 532 nm lasers. We quantified this observation by two compactness descriptors and examined the dependence of the power of the 532 nm laser. More importantly, to understand the …

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

All Theses

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 …

Implementation Of Experimental Static Recrystallization Of High Strength Steel Into Computational Simulation Of Multi-Pass Slab Hot Rolling, S. K. Dasari, S. Ganguly, A. Abutunis, K. Chandrashekhara, M. F. Buchely, S. N. Lekakh, R. J. O'Malley, T. Natarajan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Microstructural changes and softening due to static recrystallization have a critical influence on thermo-mechanical behavior of high strength steels during industrial multi-pass hot rolling. Numerical simulation using finite element analysis (FEA) can be used to accurately predict the softening behavior during the hot rolling process. Therefore, the implementation of an experimentally defined static recrystallization model into FEA is necessary to get realistic simulation prediction. in this study, the extent of softening during static recrystallization in Si and Mn alloyed high strength steel was measured using double hit tests. a Gleeble™ thermo-mechanical simulator was used to perform the double hit tests …

An Investigation Into The Challenges Of Contemporary Additive Manufacturing: Insights Into The Metallurgical Response Of Materials And Relevant Solution, Huan Ding

LSU Doctoral Dissertations

Additive Manufacturing (AM) has gained attention in recent years due to its unique capabilities in the fabrication of complex parts. As with any new research, there is still a lack of sufficient understanding in the field of additive manufacturing, and further investigation is needed to solve existing problems. Ultimately, the aim is to enable the widespread use of AM components across various industries.

Chapter One provides a brief introduction to the background and current bottlenecks of additive manufacturing technology. Chapter two focuses on the development of high-strength 7075 aluminum alloy (Al7075) for Fused Deposition Modeling and Sintering (FDMS) technology. Al7075 …

Corrosion Case Study On Pipeline, Kangze Ren

Corrosion Research

The Kashagan pipeline leaks were likely caused by sulfur stress corrosion cracking, a combined corrosion mechanism developed by the presence of high pressure, the high level of hydrogen sulfide(the main "ingredient" of sour gas), and poor metallurgical choice. Improper welding and poor metallurgical examination were blamed for causing the leaking issue. The purpose of the current review is to raise the alarm about the inappropriate corrosion management of Kashagan oil production and its societal and environmental consequences.

Machine Learning Prediction Of Hea Properties, Nicholas J. Beaver, Nathaniel Melisso, Travis Murphy

College of Engineering Summer Undergraduate Research Program

High-entropy alloys (HEA) are a very new development in the field of metallurgical materials. They are made up of multiple principle atoms unlike traditional alloys, which contributes to their high configurational entropy. The microstructure and properties of HEAs are are not well predicted with the models developed for more common engineering alloys, and there is not enough data available on HEAs to fully represent the complex behavior of these alloys. To that end, we explore how the use of machine learning models can be used to model the complex, high dimensional behavior in the HEA composition space. Based on our …