Materials Science and Engineering Commons^™

Comparative Evaluation Of Gating Systems In Femnal Castings, K. Balasubramanian, Laura Bartlett, M. Xu

Materials Science and Engineering Faculty Research & Creative Works

To understand the efficiency of gating systems, four systems, namely AFS styled pressurized system, AFS styled non-pressurized system, naturally pressurized system with a side riser and a naturally pressurized system with a top riser, were studied. The naturally pressurized systems were provided with overflows which collected the incoming metal swirl while the pressurized and non-pressurized systems had runner wells. Parameters like velocity of metal flow, air entrapment, microporosity and Niyama criterion were considered, and a design was developed with a common pouring basin using solidification software. Two molds were 3D printed using carbonitride sand, and steel of composition Fe-29Mn-8.2Al-0.91C-0.88Si-0.49Mo was …

Microstructure And Properties Of Oxide Dispersion-Strengthened Alloys, Ertugrul Demir, Seung Min Ha, Anish Ranjan, Xingshuo Zhang, Aaron Penders, Mukesh Bachhav, Xiaochun Li, Lin Shao, Alexander Demblon, Haiming Wen, Enrique Lavernia

Materials Science and Engineering Faculty Research & Creative Works

Oxide dispersion-strengthened (ODS) alloys are a critical class of structural materials for extreme environments, owing to their unique combination of high-temperature strength, thermal stability, and radiation tolerance, enabled by a very high density of nanoscale oxide dispersoids. These features make ODS alloys attractive for advanced nuclear systems, aerospace applications, and other harsh-service conditions where conventional alloys rapidly degrade. Despite decades of development, key challenges remain in understanding how nanoscale oxides interact with matrix microstructures, alloy chemistry, and irradiation-induced defects to control macroscopic performance. This review provides a focused, mechanism-based synthesis of the microstructural features that govern the properties of ODS …

Overcoming Resolution Vs. Throughput Trade-Offs In Ceramic Material Extrusion Additive Manufacturing Via Viscoelastic Filament Stretching, Abid H. Rafi, David W. Lipke, Jeremy L. Watts, Gregory E. Hilmas, Ming C. Leu

Materials Science and Engineering Faculty Research & Creative Works

Fabricating large, monolithic ceramic parts using material-extrusion additive manufacturing remains challenging due to difficulty maintaining uniform moisture content during printing, which can lead to drying-induced defects such as warping and cracking, especially as part size and print time increase. Fabricated parts have trade-offs among print resolution, high throughput, and structural fidelity. Our study has shown that increasing the ratio of nozzle traverse speed vs. material extrusion speed increases filament stretching in viscoelastic ceramic paste, helping to overcome the trade-offs between resolution and throughput. Using aqueous ZrB2–SiC (70/30 vol.%) as a representative ultra-high temperature ceramic paste, rheological characterisation revealed viscoelastic yield-stress …

N-Radii Approach For Multi-Scale Characterization Of Graphite Shape In Cast Iron, Simon N. Lekakh, Laura Bartlett

Materials Science and Engineering Faculty Research & Creative Works

Knowledge of multi-scale particle macro-shape and micro-surface topology is critical in many technical disciplines. Specifically, quality assessment of the shape of the graphite phase in cast irons is essential for day-to-day metal casting operations. Common methods for evaluating particle macro-shape have several drawbacks, often resulting in underestimation of sharp corners and surface texture. In this article, a method based on plotting n-radii from the center of mass to the perimeter and computing multi-scale topological characteristics is described and tested. Parametric tests, involving variations in the number of n-radii and image resolution, were performed to optimize the test parameters. The method …

Modeling Of Transformation Temperatures In Cast Martensitic Stainless Steels-Ca6nm: Effects Of Composition, Heating Rate, And Grain Size, Ugochukwu Agbedo, Mario Buchely, Laura Bartlett, Caelan Kennedy

Materials Science and Engineering Faculty Research & Creative Works

Accurate prediction of the critical transformation temperatures Ac1 and Ac3 is one of the essential factors in the heat treatment of CA6NM cast martensitic stainless steel. In this study, the influence of alloy composition, heating rate, and prior austenite grain size on the critical temperatures was quantified using dilatometric measurements and statistical modeling. Six heat treatment conditions produced prior austenite grain sizes ranging from ~75 to 247 µm. Experimental results showed that grain size variations produced only minor changes in Ac1 and Ac3, indicating a weak dependence of transformation temperatures on prior austenite grain size within the investigated range. In …

Multiphysics Simulation And Experimental Validation Of Phase Transformation And Hardness In Jominy End-Quenched Low-Alloy Steels, J. S. Alabi, E. Heidari, M. F. Buchely, K. Chandrashekhara, S. N. Lekakh, R. J. O'Malley, V. A. Athavale, A. Kumar

Materials Science and Engineering Faculty Research & Creative Works

High-volume industrial continuous hot-rolled steel heat treatment processes involve sophisticated multi-phase modeling. The performance of a given process can be optimized by coupling phase transformation kinetics with the cooling conditions of the process. This study develops a multiphysics model to simulate an intensive quenching process for steel, which is inherently transient and highly dependent on numerous parameters. The simulated object was a Jominy end-quenched specimen geometry using two commercial steels, AISI 4130 and AISI 4140, with the goal of transferring a verified methodology to the heat treatment process for industrial heavy-section products (bars, slabs). The simulation employs thermal, mechanical, and …

Effect Of Complex Alloying Elements On Oxide Scale Formation And Water-Jet Descaling Performance On Continuously Cast Low-Carbon Steels, Tochukwu P. Ojiako, Tsvetkov Dmitry, Mario Buchely, Haiming Wen, Simon N. Lekakh, Ronald J. O'Malley

Materials Science and Engineering Faculty Research & Creative Works

The formation and evolution of oxide scale in contact with mold flux during continuous casting, subsequent reheating, and hydraulic descaling are strongly governed by steel chemistry. To elucidate the effect of complex alloying elements (Si, Mn, and Cr), two industrially produced continuously cast low-carbon steel grades for manufacturing stamped parts (a base and alloyed steel grade) were investigated. The objective was to determine how alloying elements influence oxidation behavior, scale morphology, interfacial adhesion, and water-jet descaling efficiency. Continuously cast slab specimens were subjected to controlled thermal and atmospheric oxidation cycles simulating multistage industrial practice. Three initial surface conditions (industrial as-cast, …

High Temperature Mold Gap Measurement Using Optical Fiber Interferometry, Jie Huang, Ronald O'Malley, Dinesh Reddy Alla, Deva Prasaad Neelakandan, Muhammad Roman

Patents

A temperature insensitive fiber optic Fabry-Perot interferometer based mold gap measurement system that can be employed in foundry and continuous casting facilities for both non-ferrous and ferrous production applications. For steel continuous casting, the sensor is also capable of detecting crystallite formation in the mold flux layer within the mold gap by detecting reflections from both the flux layer and the steel shell to facilitate direct mold lubrication monitoring for continuous casting. These interferometers can also be easily multiplexed to perform interface shape measurements or monitor gap variations at various positions within a complex mold design. The ability to measure …

Fluorescent Security Glass, Rachel Leigh Grodsky, Richard Brow, Melissa Malone Teague

Patents

A tamper-evident glass and methods of using the tamperevident glass are provided herein. The tamper-evident glass comprising at least a first plurality of tamper-evident elements, which may be unique or near unique to each manufacturing of tamper-evident glass. The initial state of tamper-evident glass and positioning of the plurality of tamper-evident elements may be mapped through digital scanning to create a digital file of the current state of the tamper-evident glass. The tamper-evident glass may be scanned again to create a new digital file for comparison and to determine if a tampering event has occurred. The tamper-evident elements may include …

Elevated Temperature Flexure Behavior Of Continuous Carbon Fiber Reinforced Zrb2–Zrsi2 Ultrahigh Temperature Ceramic Matrix Composites, Jacob Stacy, Aaron Ginsparg, Jason Lonergan, Jeremy Watts, Gregory Hilmas

Materials Science and Engineering Faculty Research & Creative Works

Ultrahigh temperature ceramic matrix composites (UHTCMCs) were fabricated from unidirectional prepreg tapes consisting of a matrix of ZrB₂ with 5, 10, and 15 vol.% ZrSi₂ additions and continuous polyacrylonitrile carbon fibers and were densified at 1600°C in a hot press. The relative matrix densities ranged from 88% to 93% with interlayer spacings of ∼72 µm and fiber volume fractions between 30% and 36%. Phenolic resin additions were utilized to react with ZrSi₂ acting as a transient sintering aid to form ZrC and SiC phases. Elastic moduli of the UHTCMCs decreased with increasing temperature during 4-pt flexure testing. …

Quantitative Grain Structure And Texture Analysis Of Hot-Pressed Zrb2 Via 3d Ebsd, Randi Swanson, Michael Chapman, Yue Zhou, Ashley Hilmas, Lisa Rueschhoff, Michael Uchic, William Fahrenholtz, Scott J. Mccormack

Materials Science and Engineering Faculty Research & Creative Works

Understanding and controlling the grain structure of ZrB₂ is critical for optimizing its mechanical and thermal performance in high-temperature applications. Fully dense ZrB₂, densified by hot pressing at 2150˚C and 32 MPa, was analyzed in three dimensions using electron backscattered diffraction, electron and optical microscopy, and mechanical polishing serial sectioning. Grain size followed a gamma distribution, with extreme deviations observed only in the largest 0.1% of grains. Large grains exhibited plate-like morphologies, with the shortest-to-longest axis ratio converging to ∼0.4 as grain volume increased. This work revealed a crystallographically controlled growth mechanism orthogonal to [0001] that is …

Simulated Lunar Gravity Testing Of A Magnetic And Electrostatic System For Beneficiating Lunar Regolith, Blake A. Coffman, Gabriel Porter, Lindsay Manteufel, Mitchell Cottrell, Jeffrey D. Smith, David J. Bayless, William Shonberg, Frank D. Han, Fateme Rezaei, Kirby Runyon

Materials Science and Engineering Faculty Research & Creative Works

We present the design and testing of a lunar regolith beneficiation device that utilizes magnetic and electrostatic separation methods to concentrate desired minerals by removing unwanted material, such as the mineral anorthite, from bulk lunar regolith. The beneficiated materials would have value for downstream in-situ resource utilization (ISRU) processes such as metal extraction, oxygen extraction, and metal oxide additive manufacturing processes. The apparatus uses a dual-strength magnet system with N52 and N42 neodymium magnets to separate particles by magnetic susceptibility. The electrostatic separation system, which acts like a sieve, sorts the regolith simulant by particle size using a single-phase 50% …

The Effects Of Mold Flux Contamination On Oxide Scale Formation And Hydro-Descaling Efficiency During Steel Processing, Tochukwu Princewill Ojiako, Richard Osei, Mario Buchely, Haiming Wen, Simon Lekakh, Ronald O'Malley

Materials Science and Engineering Faculty Research & Creative Works

Oxide scale formation during thin-slab continuous casting has a complex structure, which is influenced by mold flux contamination, that modifies interfacial reactions during solidification, subsequent reheating, and descaling. While individual aspects of the oxidation behavior of carbon steel have been previously examined, the synergetic effects of mold flux contamination during continuous casting and subsequent reheating on scale modification and the efficiency of hydraulic descaling remain inadequately studied. This study quantitatively examines the effect of flux composition on oxide scale evolution, adhesion, and hydraulic removal in low-carbon steel under simulated industrial conditions. Slab samples with as-cast, cleaned, and flux-coated surfaces were …

Viscoelastic Behavior Of Magnetically Filled Pdms Elastomers: Influence Of Filler Loading And Particle Type, Madison Procyk

College of Graduate Studies: Theses & Dissertations

Magnetorheological elastomers (MREs) offer a promising pathway for soft, magnetically actuated drug‑delivery systems, yet material‑selection guidelines remain unclear due to limited comparative data across particle chemistries, size scales, and concentrations. This study systematically evaluates how magnetic filler type (carbonyl iron and magnetite) and particle size (micro vs. nano), at two weight percentages – 40 wt% and 50 wt% – in Sylgard 184 PDMS influence the viscoelastic behavior of MREs intended for compliant biomedical actuation. Eight particle formulations were prepared through sieving, controlled mixing, vacuum degassing, and isotropic curing, producing nineteen total specimens (16 with filler particles and 3 without). Dynamic …

Effect Of Elemental Additions On The Microstructure, Macrostructure, And Mechanical Properties Of Gray Iron, August E. Rautmann

College of Graduate Studies: Theses & Dissertations

Gray iron is composed primarily of an iron matrix and flake graphite, with the higher percentage of volume taken up by the iron matrix. The iron matrix is the transformation product of austenite, and this prior austenite structure is understood to affect the final grain structure. Grain structure affects the properties of a metal, with a finer structure recognized as beneficial for most properties. Thus, the refinement of austenite structure has potential in improving the material properties of gray iron. This study aims to advance the limited knowledge about the control of austenite grain size via elemental additions. Building off …

Recent Advances In Bioceramics, Fundamental Properties And Future Perspective In Biomedical Applications ‒ A Review, Ayesha Younas, Muhammad Umar Aslam Khan, Mohd Faizal Binte Abdullah, Lobat Tayebi, Shuanghu Wang, Abdalla Abdal-Hay, Yichi Xu

Electrical & Computer Engineering Faculty Publications

Bioceramics are important biomaterials in biomedical engineering because of their biocompatibility, bioactivity, osteoconductivity, and structural resemblance to actual bone tissue. In recent years, materials science and nanotechnology have enabled the use of bioceramics in bone regeneration, dental restoration, tissue engineering, drug delivery systems, and implantable medical devices. This comprehensive review covers advances in bioceramics, including calcium phosphates, hydroxyapatite (HAp), tricalcium phosphate, bioactive glasses, zirconia, alumina, and multifunctional ceramic nanocomposites. Priority is given to techniques such as additive manufacturing, 3D printing, sol-gel processing, electrospinning, and nanostructuring to improve mechanical strength, porosity, bioactivity, and cell interactions. Recent advances include ion doping, surface …

Application Of A Hyaluronic Acid-Based Lotions Containing Hydroxyapatite Nano-Particles Approach For Treatment Of Initial Dental Caries, Zahra Gharavi, Zahra Namazi, Fatemehsadat Pishbin, Helia Givian, Maryam Torshabi, Farhood Najafi, Parisa Amdjadi

Electrical & Computer Engineering Faculty Publications

This study evaluated the remineralization potential of a ceramic–polyelectrolyte system, based on a novel combination of hydroxyapatite nanoparticles (HAp NPs) and a hyaluronic acid (HY) matrix, for dental enamel, a tissue that remains challenging to repair in clinical dentistry. Nano-Hydroxyapatite (nanoHAp) powder was synthesized and characterized using X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), field-emission scanning electron microscopy (FE-SEM), dynamic light scattering (DLS), and zeta potential analysis to confirm their crystalline structure, functional groups, morphology, particle size distribution, and colloidal stability. HY-based suspensions (remineralizing lotions) containing 5, 10, and 12 wt% of the synthesized nanoHAp particles were formulated via a …

Effect Of Graphene Oxide On The Upconversion Photoluminescence Behavior Of Er/Yb Co-Doped Pvdf-Go Composite Nanofibers, Saptasree Bose, Jack Ryan Summers, Bhupendra B. Srivastava, Karen Lozano, Victoria Padilla-Gainza

Mechanical Engineering Faculty Publications

Upconversion photoluminescence (UCPL) materials, particularly rare-earth (RE) doped nanoparticles, have garnered significant attention due to their ability to convert near-infrared (NIR) excitation into visible emission, offering benefits such as high photostability, long lifetimes, low autofluorescence, and deep tissue penetration. Among various platforms, polymer-based one-dimensional (1D) nanofibers with in-situ lanthanide doping remain relatively unexplored, despite their superior mechanical flexibility, processability, and potential for improved luminescence performance. In this study, we report the fabrication and UCPL quenching behavior of Er3+/Yb3+ co-doped polyvinylidene difluoride (PVDF) nanofibers incorporated with graphene oxide (GO), synthesized for the first time using the scalable Forcespinning® technique. PVDF, a …

High Temperature Creep Deformation Mechanism Of Fe28.2ni18.8mn32.9al14.1cr6 High Entropy Alloy And Its Modified Alloys, Edwin S. Jiang, I. Baker

Dartmouth College Ph.D Dissertations

Fe28.2Ni18.8Mn32.9Al14.1Cr6 eutectic high entropy alloy exhibits a good combination of room-temperature and high temperature properties, including tensile strength, ductility, and corrosion resistance, making it a promising candidate for structural applications in extreme environments. However, the creep deformation behavior of this alloy— and high-entropy alloys (HEAs) in general—remains insufficiently understood. This dissertation systematically investigates the high-temperature creep deformation mechanisms of Fe28.2Ni18.8Mn32.9Al14.1Cr6 and its derivatives.

Creep mechanisms and associated microstructural changes were examined across a wide range of strain rates using strain-rate jump and constant-stress tests. Two dominant regimes were identified: dislocation glide/solute-drag at low strain rates, and dislocation climb at high …

Engineering Disorder, Defects, And Electrical Transport For High-Performance Thermoelectric Fe2val Heusler Alloys, James Russell Taylor Iv

Dartmouth College Ph.D Dissertations

Fe₂VAl is a promising low-temperature thermoelectric material for waste-heat energy conversion because it is easily processed and comprised of earth-abundant, non-toxic, and low-cost elements. However, viability for applications faces two major challenges: high thermal conductivity and low p-type Seebeck coefficients. This primarily experimental work aims to address these issues through extrinsic and self-doping, point-defect and disorder generation through thermal and electrical processing, disordered and metastable phase composition quantification, and comparison of transport measurements to modeled electronic features.

An accessible phase quantification method was developed for bulk Fe₂VAl using laboratory X-ray diffraction equipment to compare thermoelectric properties …