Metallurgy Commons^™

A Study Of Reduced Activation Ferritic Martensitic Metal Core Wire For Wire Arc Additive Manufacturing, Alexander L. Reichenbach

College of Graduate Studies: Theses & Dissertations

This study seeks to determine the technical feasibility of fabricating reduced activation ferritic martensitic (RAFM) steel parts, using a wire arc additive manufacturing (WAAM) process. The WAAM process, manufactures a part by depositing layers of metal onto a substrate to build a large scale near net shape part. RAFM alloy steels are next generation steels designed to resist radiation effects in the radiation intense working environments, such as nuclear reactors. To achieve this, process development and testing to design the WAAM production process with the custom RAFM filler wire was carried out. Several welding waveform modes were tested, and it …

Laptop Recycling Case Study: Estimating The Contained Value And Value Recovery Process Feasibility Of End-Of-Life Consumer Electronics, Zebulon Hart

Theses and Dissertations--Mining Engineering

Work has been done to establish, through the development and use of novel assay techniques and analysis metrics, the contained value of a sampling of laptop computers (as an analog for myriad e-waste sources). This work has conceptualized e-waste as an alternative to geologic-origin complex metallic ores and has likewise evaluated the feasibility of value recovery from e-waste sources in a similar manner to an ore. The application of conventional and novel mineral separation techniques to e-waste recycling processes has been evaluated and positive results are demonstrated. Further, this work has demonstrated the ability to identify the presence of base …

Austenitic, Duplex, And Lean Duplex Stainless Steel Critical Pitting Temperature In Simulated Concrete Environment, Bobby Giebel

Williams Honors College, Honors Research Projects

In this work, the critical pitting temperature (CPT) will be observed for a selection of austenitic (316LN and 24100) and duplex (2205), and lean duplex (2304, 2001) stainless steels in simulated concrete pore solution. To study the influence of temperature on the pitting stability of the stainless steels, three temperatures were tested: 25oC, 45oC, and 65oC for cyclic potentiodynamic polarization (CPP) and electrochemical impedance spectroscopy (EIS). Electrochemical properties of the interfaces we studied via EIS analysis. Kinetics were studied via CPP testing. To reveal the critical pitting temperature of the stainless steels, cyclic thermammetry was used. Characterization of the pits …

Induction Brazing, Austin Squire, Scott Compton, Logan Hathaway, Michael Fleming

Williams Honors College, Honors Research Projects

Our team would like to research and explore ways of designing a portable device that uses induction heating/brazing to connect two exhaust pipes together.

Effect Of Thiosulfate On The Passivation Of Zinc-Alloyed Anodes, (Z32120 And Z13000) At 80°C After 288h Immersion In 3.5% Nacl Solution, Thwelt Thinzar Zaw

Chulalongkorn University Theses and Dissertations (Chula ETD)

In this research, the inhibition of passivation on Zn alloys (Z32120 with Al) and Z13000 without Al) in artificial seawater (3.5% NaCl) mixing with different thiosulfate concentrations (100ppm, 150ppm, 200ppm) were investigated electrochemically after 288h immersion at 80°C and compared the results with that of testing without thiosulfate in the environment. According to the Potentiodynamic polarization test results, it is found that the presence of thiosulfate (S2O32-) in the solution hinders the passivation that was formed during the immersion of Zn alloys between 120h and 288h at 80°C in the absence of thiosulfate. Thiosulfate effect promotes Cl- penetration for not …

Augmented Reality Integrated Welder Training For Mechanical Engineering Technology, Aditya Akundi, Hamid Eisazadeh, Mona Torabizadeh

Engineering Technology Faculty Publications

The shortage of welders is well documented and projected to become more severe for various industries such as shipbuilding in coming years. It is mainly because welding training is a critical and often costly endeavor. This study examines the training potential using augmented reality technology as a critical part of welder training for mechanical engineering technology students. This study assessed the performance of two groups of MET students trained with two different methods. One group received training with the traditional method in three sessions. The second group acquired training initially with an augmented reality welding system for three sessions. Then, …

Method For Reducing Warping Stresses In Torsionally Loaded I-Section Members Using Cfrp Plates, Mamadou Konate, Zia Razzaq

Civil & Environmental Engineering Faculty Publications

This paper presents a method for reducing warping normal stresses in torsionally loaded I-section members by utilizing carbon fiber-reinforced polymer (CFRP) plates. The CFRP plates are bonded to the outer surfaces of the flanges with a view to reducing warping normal stresses. The maximum warping normal stress in the flanges of a steel I-shaped member without the CFRP plates is compared to those obtained with the CFRP plates having various thicknesses. It has been found that the use of CFRP plates bonded to both flanges of the I-section result in a substantial reduction of the warping stresses. For the study …

Derivation, Exploration And Evaluation Of Non-Equiatomic High Entropy Alloys, Artashes Ter-Isahakyan

Theses and Dissertations--Chemical and Materials Engineering

High-entropy alloys (HEAs) are a class of multicomponent alloys based on an innovative alloying strategy that employs multi-principle elements in relatively high concentrations. Commonly defined as alloys that contain at least five principal elements, each with a concentration between 5 and 35 at %. The term entropy refers to the excess configurational entropy associated with HEAs, which is thought to facilitate the formation of solid solutions. The design strategy results in vast compositional space for exploration and innovative potential triggering a renaissance in physical metallurgy. These alloys may have favorable properties compared to conventional dilute solid solutions, but their preeminent …

Precision Machining Of Polymer Matrix Composites, Victor Martinez Polanco

All Graduate Theses, Dissertations, and Other Capstone Projects

This experiment was started to figure how the precision machining of polymer matrix composites differ from metals such as aluminum and steel. Polymer matrix composites are highly used in powered vehicles for their strength and light weight properties, but they are typically not machined to their final product how metals are. Polymer matrix composites are typically manufactured near their final shape, with some trimming involved to complete its shape. This research machined carbon fiber manufactured through a wet layup and through resin infusion, as well as aluminum and steel to compare their machineability and their surface finish. These materials were …

ผลของความหนาแน่นพลังงานในการขึ้นรูปต่อโครงสร้างจุลภาคและสมบัติทางกลของโลหะแก้วTi-Zr-Cu ที่ถูกขึ้นรูปด้วยวิธีการเพิ่มเนื้อวัสดุ, ภัทรพงษ์ วรรณประไพ

Chulalongkorn University Theses and Dissertations (Chula ETD)

โลหะผสม Ti58.5Zr31.5Cu10 เนื้อพื้นไทเทเนียมที่ถูกเสริมแรงด้วยเฟส β ถูกขึ้นรูปด้วยวิธีการขึ้นรูปแบบเพิ่มเนื้อวัสดุ (additive manufacturing) ด้วยการใช้ผงโลหะที่ถูกผสมโดยใช้ผงโลหะบริสุทธิ์ของทั้งสามธาตุ งานวิจัยนี้ทำการศึกษาเกี่ยวกับผลของความหนาแน่นพลังงานที่ใช้ในการขึ้นรูปต่อการผสมกันของโลหะและความไม่สม่ำเสมอของโครงสร้างจุลภาครวมไปถึงเฟสที่เกิดขึ้น ซึ่งถูกตรวจสอบด้วยเทคนิค X-ray diffraction (XRD) Scanning electron microscope (SEM) และ Electron probe micro analyzer (EPMA) โดยผลลัพธ์แสดงให้เห็นว่าความหนาแน่นพลังงานสูงขึ้นนำไปสู่การตกผลึกมากขึ้น ในขณะที่ความหนาแน่นพลังงานต่ำกว่ามีแนวโน้มที่จะส่งผลให้เกิดโลหะผสมที่มีเนื้อพื้นอสัณฐาน (BMGC) และ เฟสยูเทคติค โดยโครงสร้างจุลภาคของโลหะผสมที่มีเนื้อพื้นอสัณฐาน ประกอบด้วยเฟส β ที่มีลักษณะเดนไดรท์และโครงสร้างอสัณฐานในบริเวณช่องว่างระหว่างเดนไดรท์ (interdendritic region) ธาตุ Ti เกิดการรวมตัวจำนวนมากบริเวณเฟสเนื้อพื้น β ในขณะที่ธาตุ Cu และ Zr รวมตัวกันจำนวนมากบริเวณเฟสอสัณฐานและเฟสยูเทคติค จากการตรวจสอบเพิ่มเติมเกี่ยวกับการกระจายตัวทางเคมีภายในแอ่งน้ำโลหะ พบว่าเมื่อความหนาแน่นพลังงานต่ำจะมีความไม่สม่ำเสมอของธาตุผสม เนื่องจากการขาดการไหลของของเหลวภายในแอ่งน้ำโลหะ ที่เป็นตัวกระตุ้นการผสมกันของธาตุ การจำลองการไหลของของไหลด้วยความร้อนตามหลักการพลศาสตร์ของไหลเชิงคำนวณ (CFD) ได้ถูกดำเนินการเพื่อจำลองปรากฎการณ์ที่เกิดขึ้นเพื่อตรวจสอบการผสมทางเคมีของธาตุผสม เมื่อความหนาแน่นของพลังงานในการขึ้นรูปสูงขึ้น ความเร็วของการไหลที่ถูกเหนี่ยวนำจะทำหน้าที่กวนสารเคมี ทำให้การผสมกันของธาตุมีประสิทธิภาพมากขึ้น ในขณะที่เมื่อความหนาแน่นพลังงานต่ำลง การผสมของธาตุค่อนข้างจำกัดเนื่องจากการไหลเวียนของของไหลน้อยลง ส่งผลให้องค์ประกอบทางเคมีไม่สม่ำเสมอในบางบริเวณ อัตราการเย็นตัวที่สูงขึ้นยังพบได้ในแบบจำลองในสภาพที่มีความหนาแน่นของพลังงานต่ำกว่า ความแปรผันขององค์ประกอบทางเคมีที่ไม่สม่ำเสมอในบางบริเวณนี้ โดยเฉพาะอย่างยิ่งในบริเวณที่มีการรวมตัวของธาตุ Cu และ Zr สูง นำไปสู่การเกิดความไม่สม่ำเสมอของโครงสร้างจุลภาคของ BMGC และเฟสยูเทคติก งานวิจัยนี้แสดงให้เห็นถึงความเข้าใจเกี่ยวกับพฤติกรรมของของไหลภายในแอ่งน้ำโลหะของผงโลหะที่ถูกผสมโดยใช้ผงโลหะบริสุทธิ์ที่ถูกขึ้นรูปด้วยวิธีการขึ้นรูปแบบเพิ่มเนื้อวัสดุ ซึ่งอาจนำไปสู่การปรับปรุงและพัฒนาโครงสร้างจุลภาคให้มีประสิทธิภาพมากขึ้นสำหรับการผลิตโลหะผสมเนื้อพื้นไทเทเนียมที่ถูกเสริมแรงด้วยเฟสต่างๆ

Effects Of Titanium And Cerium Addition On Grain Size And Mechanical Properties Of Ductile Iron Castings, Shelton F. Fowler Iv

College of Graduate Studies: Theses & Dissertations

According to the Hall-Petch equation, the refinement of grains in metals increases the yield strength of the material. Austenite grain size influences the fineness of microstructural constituents in the ferrous alloys. It is well studied that cerium and titanium refine the austenite in steels and some gray irons, but no studies have been done to systematically explore the effects of cerium and titanium additions on austenite in ductile iron. This study sought to determine the effects of selected levels of these elements on the grain size within ductile iron. A hypoeutectic iron was chosen for testing as the proeutectic phase …

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 …

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 …

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 …

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 …

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 …

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 …

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 …

Functionally Magnetic Gradient Copper-Nickel Material Fabricated Via Directed Energy Deposition, Vy Tran Phuong Nguyen

Graduate Theses, Dissertations, and Problem Reports (ETD)

Functionally gradient materials (FGMs) of CuSn10 and Inconel 718 were fabricated via a hybrid directed energy deposition (DED) system. The objective of the present thesis is to determine the feasibility of manufacturing CuSn10 and Inconel 718 FGMs via DED and investigate the physical and mechanical properties and the microstructures of the resulting FGMs. The physical tests comprised of conductivity and Seebeck coefficient measurements. The microstructure analysis and mechanical testing include microscopic imaging, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and hardness test. In addition, compressive strength test was performed to analyze the interface bonding behaviors.

Development Of Oxide Dispersion Strengthening (Ods) Alloys Powder For Additive Manufacturing, Changyu Ma

Graduate Theses, Dissertations, and Problem Reports (ETD)

Additive manufacturing (AM) fabricated oxide dispersion strengthened (ODS) alloys are given high expectations for critical structural components such as the first stage turbine blade for their excellent creep strength and oxidation resistance compared to superalloys. However, the powder feedstock processing is still an open question since current state-of-the-art processes are not capable of achieving ultrafine strengthening elements such as Y₂O₃ in powder which leads to agglomeration issues in as-consolidated alloys. In this research, the oxidation behavior and stability of ultrafine oxide in AM-printed alloys using mechanically alloyed powders were evaluated at 1100 ^oC. In addition, a …