Metallurgy Commons^™

Understanding Roof Systems Of Metal Buildings, Michael W. Seek, Vincent E. Sagan

Engineering Technology Faculty Publications

[Introduction] A metal building is a system with complex behavior that, when properly accounted for, provides an efficient structural solution. To help the engineer properly design for this behavior, the Metal Building Manufacturers (MBMA) has recently released the Roof Framing Design Guide for Metal Building Systems, 2nd Edition (Roof Framing Design Guide).

Investigation Using Single Point Incremental Forming (Spif) To Fabricate Patient-Specific, Titanium Orbital Floor Implants, Elizabeth M. Mamros, Lauren E. Blaha Md, Christian A. Kauffman Md

Faculty Conference Papers and Presentations

The floor of the human orbit is composed of thin bone that is prone to traumatic fracture. This leads to a loss of support for the eye, which can cause vision changes. Therefore, fractures may need surgical reconstruction using a thin, sheet-like implant. Titanium implants are available off-the-shelf in standard sizes, but fitting to each patient’s unique anatomy requires surgeons to cut, file, and bend these plates. This can be time-consuming and imprecise. To both save time and ensure a perfect fit for the patient, a custom plate can be created prior to surgery. This investigation focuses on single-point incremental …

Characterization And Leaching Feasibility Studies Of Copper Flue Dust For The Recovery Of Main And Trace Metals, Fardis Nakhaei, Marek Locmelis, Lana Alagha, Michael S. Moats, Carlos Eyzaguirre, Cory Smith

Geosciences and Geological and Petroleum Engineering Faculty Research & Creative Works

Although copper smelter dust (CSD) is classified as hazardous waste, it also serves as a valuable secondary resource, offering potential for the recovery of critical elements. In this study, CSD samples were collected from the waste heat boiler (WHB) and electrostatic precipitator (ESP) units connected to the flash smelting furnace at a copper smelter. The representative samples were extensively characterized by particle size, and chemical and mineralogical analyses. Following sample characterization, leaching experiments were performed to evaluate the potential extraction of Cu, Fe, As, Zn, Pb, In, Ga, and Ge from the flue dusts. Distilled water, H2SO4, and HCl were …

Exploration And Synthesis Of Tin Intermetallic Single Crystals, Jared L. Shortt

Graduate Theses/Dissertations

This thesis presents the synthesis and characterization of two tin-based intermetallic compounds: Mn₄.₁₂Sn and Ni₆Sn₈Ge₀.₄₇. Single crystals were grown using a high-temperature self-flux method, allowing for the formation of phase-pure samples suitable for structural and physical property analysis. The crystalline phases were identified and refined using powder and single-crystal X-ray diffraction (XRD), while scanning electron microscopy combined with energy-dispersive X-ray spectroscopy (SEM/EDS) was employed to verify stoichiometry and homogeneity. Magnetization measurements performed using a superconducting quantum interference device (SQUID) magnetometer revealed distinct magnetic behavior in the manganese-rich compound, while the nickel-based compound was explored for potential magnetic features arising from …

Selective Surface Activation And Flotation Of Pyrite For The Recovery Of Tellurium From Sulfide Tailings, Mulenga Mutema Chibesa

Masters Theses

Copper sulfide tailings from past and present mining operations are important secondary sources of critical elements such as tellurium (Te), a key component in cadmium–telluride photovoltaic solar cells. Characterization of tailing streams from copper porphyry (CP) ore flotation revealed that Te-bearing minerals are predominantly hosted in pyrite, which is usually depressed and discarded. Enhancing pyrite recovery is therefore a critical first step toward concentrating Te minerals for downstream extraction. However, pyrite flotation is often hindered by hydrophilic surface complexes formed during prior processing. This research investigated selective flotation of Te-bearing pyrite from CP tailings using micro flotation and bench-scale flotation, …

Characterization And Deportment Of Anode Impurities In Copper Electrorefining, Charles Michael Campbell

Doctoral Dissertations

The objective of this research was to study the deportment of the group 15 elements, arsenic, antimony and bismuth during copper electrorefining. Samples were collected from six industrial copper anodes with different compositions. Specimens were physically characterized and electro refined to understand the differences in the behavior of selected impurities. Inclusions in the cast metal structures were characterized using automated scanning electron microscopy and energy dispersive spectroscopy to measure and correlate their size, shape and composition. Arsenic and lead were found to have a positive correlation between concentration and size of inclusions. Using wavelength dispersive spectroscopy, multiphase inclusions were examined, …

Metathesis Or Isomerization: Counteranion Directed Reactivity Of Grubbs I, Paul D. Miller, Joe B. Calkins, Craig A. Bayse, Trandon A. Bender

Chemistry & Biochemistry Faculty Publications

Catalytic isomerization of alkenes has garnered interest for many years, but there are remaining challenges when it comes to thermodynamic selectivity and uncontrolled isomerization. Nonbiased substrates, be it sterically or thermodynamically, remain challenging for many catalysts, with a few examples available in the more modern literature. Herein, we present the controlled isomerization of linear alkenes with a cocatalytic mixture of commercially available catalyst and reagents: Grubbs I, tris(pentafluorophenyl)borane, and triethylsilane. DFT calculations indicate that an observed alkylidyne hydride intermediate is in rapid equilibrium with an alkylidene that binds the alkene substrate. This combination results in a pi-acidic metal and a …

Amphiphilic Tripodal Metalloligands: Synthesis, Coordination Chemistry And Preliminary Catalysis, Austin W. Medley, Paul D. Miller, Craig A. Bayse, Robert D. Pike, Trandon A. Bender

Chemistry & Biochemistry Faculty Publications

Triscatecholate binding has been widely studied in the context of biological systems, supramolecular chemistry, and weak aggregate interactions. However, the utilization of the triscatecholate binding motif for the preparation of metalloligands remains unexplored. Herein, we report the synthesis, structural characterization, and functional studies of a triscatecholate ligand with an appended pyridyl residue as a candidate for such applications. Our findings reveal that the selective formation of cis-triscatecholate-based metalloligands is influenced by electronic effects on the catecholate anions, enabling the targeted synthesis of Al(III), Ga(III), and In(III) triscatecholate metalloligands capable of binding Zn(II) and Ru(II) at the appended pyridyl moiety for …

Atomistic Calculations Characterizing Thermodynamic And Mechanical Properties Of High Entropy Alloys, Sarah O'Brien

Theses and Dissertations--Chemical and Materials Engineering

High entropy alloys (HEAs) are an exciting new class of materials. HEAs combine multiple elements in concentrations ranging from 5% to 35%. The large variation in concentrations increases the alloy’s entropy, stabilizing it. The stabilization is due to both an increased configurational entropy and increases the vibrational entropy when the alloy is at higher temperatures. This was seen for both MoNbTaW and FeNiMoW by combining the atomistic techniques: density functional theory (DFT) and density functional perturbation theory (DFPT). For MoNbTaW, the composition plays a large role in stabilizing the alloy over the configuration of elements. For the three-phase alloy, FeNiMoW, …

Fabrication And Characterization Of Cast Copper Heatsinks For Computer Chip Cooling, John James Recktenwald

Graduate Theses, Dissertations, and Problem Reports (ETD)

Humanity has worked copper for millennia, from primitive tools in prehistory to the wires and cooling solutions facilitating the modern digital age. While high performance fin style heatsinks are commonplace, more complex heatsink geometries in high performance applications are rare due to manufacturing challenges. In this study a casting process was developed to fabricate copper pin fin heatsinks. To assess the performance of heatsinks fabricated using the process three pin fin heatsinks were fabricated, one machined from a commercially manufactured billet, one machined from a cast block, and one cast directly to final shape. Each of the three heatsinks were …

Microwave-Assisted Reduction Of Critical Metal Oxides From E-Waste Mixture, Kurundu Shavinka Jayasekera

Graduate Theses, Dissertations, and Problem Reports (ETD)

The efficient recovery of critical metals such as tantalum (Ta), manganese (Mn), gallium (Ga), and indium (In) from electronic waste (e-waste) is essential for resource sustainability and environmental protection. This research uses microwave-assisted treatment to investigate the carbothermal reduction of these four specific metals from their oxides in a simulated e-waste mixture, with carbon black serving as both a microwave coupling and reduction agent. Microwave processing is used specifically because it offers a rapid and energy-efficient alternative to conventional thermal methods, with the benefits of intrinsic heating and selective heating of materials. The first experiments centered on understanding the effects …

Advanced Air Preheater Sealing Systems For Enhanced Efficiency And Reliability In Thermal Power Plants, Pavan Kumar Ravulaparthy

Theses and Dissertations

Global electricity generation still relies heavily on thermal power plants, which consume vast amounts of fuel and emit significant amounts of carbon dioxide. A major but often overlooked source of inefficiency in these plants lies within the rotary regenerative air preheater (RAPH), a critical heat-exchange component where air leakage can exceed 20% in aging units. This leakage increases fuel consumption, parasitic fan power, and CO₂ emissions, while degrading boiler reliability.

This research introduces advanced adaptive sealing systems designed to mitigate these losses by dynamically compensating for rotor eccentricity, thermal distortion, and wear under harsh operating conditions. Brush seals, composed of …

Evaluating The Effectiveness Of Stay-In-Place Forms To Improve The Tosional Stability Of Box Beam Bridges During Erection, Karl E. Barth, Michael W. Seek, Gregory K. Michaelson, Dimitra Pyrialakou, Brook T. Woldegabriel

Engineering Technology Faculty Publications

Cold-formed tub girders provide an effective steel solution for short-span bridges. The girders are often delivered with an open top with stay-in-place forms installed on site. Walkways may be installed to the side of the girder that can induce significant torsion rotations in the open cross section. Full scale tests on girder specimens have shown that installing one or two panels of stay in place forms at the ends of the girder can significantly reduce the torsion rotation of the girder by providing warping resistance. Cantilever tests on the stay in place forms are performed to investigate the influence of …

Characterization Of The Solid-State Bonding For Simulated Charge And Seam Welds In The Porthole Die Extrusion Process, Randall L. Bowers

Theses and Dissertations--Chemical and Materials Engineering

The isothermal (ISO-T) compression configuration is ideal for utilizing as a material input of flow stress at temperature and strain rate in models of the porthole die extrusion process due to the isothermal nature of the test. Micro-tensile testing was conducted to validate the solid-state welding integrity of the ISO-T samples at various temperatures and strain rates. Results of the mechanical testing were correlated with fractography and microstructural evaluations of the welds to confirm bonding behavior. Both clean interface conditions and oxidation and lubrication layers were evaluated to simulate the difference of seam and charge welds in the process. Results …

Combinatorial Thin Film Approach To Accelerate Materials Discovery: Development Of Nanoporous And Bulk Multi-Principal Element Alloys, Tibra Das Gupta

Theses and Dissertations--Chemical and Materials Engineering

Multi-principal element alloys (MPEAs) have garnered significant attention in materials science due to their potential for exhibiting a combination of desirable properties stemming from their unique configurational entropy. While early research focused on equiatomic compositions, recent studies have indicated that non-equiatomic MPEAs may offer superior mechanical performance. However, the identification of optimal non-equiatomic compositions remains challenging due to the vast compositional space and the reliance on time-consuming and computationally expensive methods. This dissertation presents a combinatorial thin film approach as a rapid and efficient strategy for discovering two types of materials: nanoporous and bulk MPEAs.

The first study explores the …

Microstructural Characterization Of Complex Metal Alloy Systems With A Focus On Electron Microscopy, Alexandra Allamon

Theses and Dissertations--Chemical and Materials Engineering

Multi-principal element alloys (MPEAs)/high-entropy alloys (HEAs) are a class of materials that provide novel and superior combinations of properties, with promise for use in challenging application areas that many of the current established materials cannot fit. With a higher number of constituent elements, many of the newly created alloys are compositionally complex in nature, known to contain combinations of relatively soft FCC phases, hard BCC phases, and, in some cases, even harder intermetallic phases. Microstructural study of these new materials is essential to understanding the enhanced properties they may possess, but their complexity can make this study much more challenging …

Preparation Of Mocvd-Grown Photocathodes Containing A Strained Gaas/Gaasp Superlattice, G. Blume, A. Masters, J. Grames, M. Stutzman, M. Grau, S. Marsillac

Physics Faculty Publications

In this work, we investigate heat cleaning options for high-polarization GaAs/GaAsP strained-superlattice (SSL) photocathodes with a distributed Bragg reflector (DBR) that were grown using metalorganic chemical vapor deposition (MOCVD). This was done using a microMott polarimeter at Jefferson Lab to optimize both quantum efficiency and polarization. The fabrication process for MOCVD-grown photocathodes does not allow for the inclusion of an arsenic cap, contrary to what is done when fabricating photocathodes using molecular-beam epitaxy (MBE). Without proper preparation, the performance of MOCVD-grown photocathodes can be limited due to surface contamination. Here, we varied both duration and temperature of the heat cleaning …

Effect Of Alloying Additions On Austenite Refinement In Nickel-Alloyed Ductile Cast Irons, Adnan Adib Aahamed

College of Graduate Studies: Theses & Dissertations

The benefits associated with the application of ductile irons are significantly attributed to the control of microstructures, with refinement of austenitic matrix during solidification playing a significant role. Nickel alloyed ductile irons are attractive due to their potential for high ductility and suitability for potential high-temperature applications with stable austenitic microstructure. Refinement of austenite grain structure is thus important to enhance the mechanical properties of the alloyed ductile iron. This research investigates the impact of in-mold additions of different alloying elements on the austenite morphology and grain refinement of nickel-alloyed ductile iron along with the associated mechanical properties. A hypoeutectic …

A Novel Technique For Improved Measurement Of Graphite And Inclusions In Ductile Iron Contaminated By Boron, Chase Schroeder, Colleen Lehrer, Simon Lekakh, Laura Bartlett

Materials Science and Engineering Faculty Research & Creative Works

The highly heterogeneous microstructure of ductile iron in casting includes graphite particles, non-metallic inclusions, microporosity, and other features, such as carbides distributed in the ferrite–pearlite matrix. Determination and comprehensive quantification of microstructural features are practically important however challenging. An advanced methodology based on an automated SEM/EDX analysis was developed and compared to the standard optical imaging method. In addition to backscattered electron contrast, sensitive to atomic number, a novel methodology added EDX data to identify and classify the multiple structural features at micron resolution thresholding. To quantify the shape of individual phases, the eight chord raster algorithms was used and …

Understanding Heterogeneous Nucleation In Iron Alloys From First Principles: A Review And Discussion, Semen Naumovich Lekakh

Materials Science and Engineering Faculty Research & Creative Works

Heterogeneous nucleation during solidification plays a key role in structure formation of different types of iron-based alloys, including steels and cast irons. A review summarizes the novel theoretical methods which were used to understand the nature of heterogeneous nucleation in iron-based alloys. An ab initio simulation of atomic adsorption was used to predict the activity of heterogeneous nuclei, and the thermodynamic methods were applied to design conditions for desired precipitate formation in the iron melts. A high-resolution TEM study of individual nucleus and statistics of nuclei family, obtained from an automated SEM/EDX analysis, illustrates a possibility to design processes of …