Manufacturing Commons^™

Designing Robust Quasi-2d Perovskites Thin Films For Stable Light-Emitting Applications, Sharmistha Khan, Reshna Shrestha, Mengru Jin, Doyun Kim, Guan Lin Chen, Ruipeng Li, Yijia Gu, Qing Tu, Namyoung Ahn, Wanyi Nie

Materials Science and Engineering Faculty Research & Creative Works

Quasi-2D perovskite made with organic spacers co-crystallized with inorganic cesium lead bromide inorganics is demonstrated for near unity photoluminescence quantum yield at room temperature. However, light emitting diodes made with quasi-2D perovskites rapidly degrade which remains a major bottleneck in this field. In this work, It is shown that the bright emission originates from finely tuned multi-component 2D nano-crystalline phases that are thermodynamically unstable. The bright emission is extremely sensitive to external stimuli and the emission quickly dims away upon heating. After a detailed analysis of their optical and morphological properties, the degradation is attributed to 2D phase redistribution associated …

Controlling Nitrogen Pickup During Induction Melting Of Ultrahigh-Strength Cr-Ni-Mo-V Steels, Kingsley T. Amatanweze, Viraj A. Athavale, Mario F. Buchely, Laura N. Bartlett, Ronald J. O'Malley, Daniel M. Field

Materials Science and Engineering Faculty Research & Creative Works

Nitrogen pickup during air induction melting can result in porosity and a loss of fracture toughness in ultrahigh-strength quenched and tempered steel castings. Nitrogen atoms are easily adsorbed into liquid steel upon exposure to the air, and argon shrouding alone has limited effectiveness. Previous studies have shown that proper charge sequencing and maintaining a high amount of dissolved oxygen in the melt prior to tapping and deoxidation can limit nitrogen pickup in the melt. In the current study, the effect of melt practice and charging procedure on nitrogen pickup was studied as a function of hold time in a series …

Parametric Analysis Of Water Jet Descaling Efficiency Of Reheated Continuously Cast Thin Slab, Tochukwu P. Ojiako, Mario F. Buchely, Simon Lekakh, Ronald J. O'Malley, Richard Osei, Taha Tayebali

Materials Science and Engineering Faculty Research & Creative Works

Efficient oxide scale removal is critical for maintaining surface quality and process efficiency in steel manufacturing. This study optimizes water jet descaling by evaluating the performance of flat and rotary jet nozzles under varying process parameters. Using a combined approach of experimental analysis and computational fluid dynamics, it investigates the influence of pressure (138–275 bar), lead angle (0°, 15°, 25°), working distance (50–100 mm), and spray angle (15°–25°) on descaling efficiency. Findings indicate that flat jet nozzles achieve superior performance at short working distances due to concentrated impact forces, while rotary jet nozzles sustain efficiency over extended distances through dynamic …

Effect Of Gating Design On Filling And Inclusion Control In An Al-Killed Cr-Mo-Ni Steel, Kingsley T. Amatanweze, Koushik Balasubramanian, Soumava Chakraborty, Viraj A. Athavale, Mario F. Buchely, Laura N. Bartlett, Ronald J. O'Malley, Daniel M. Field, Krista R. Limmer, Katherine M. Sebeck

Materials Science and Engineering Faculty Research & Creative Works

The effect of gating system design on the inclusion population and size distribution in an aluminum-killed low-alloy advanced high strength steel casting was studied. A mold with four different gating systems: pressurized and non-pressurized with side risers, naturally pressurized with a side riser, and naturally pressurized with a top riser, was designed using computational fluid dynamics and solidification software. The design allowed inclusion populations in castings produced with each gating system to be compared during the same pouring event. Samples taken from different positions just below the top surface of each casting were analyzed using an SEM/EDS system with automated …

High Voltage Junction Box For Demonstrator Vehicle, Benjamin Lubowicki, Ryan Dorste

Williams Honors College, Honors Research Projects

Schaeffler, our industry sponsor for this project, is designing a battery pack for a demonstration vehicle that requires a high voltage junction box to route power to the vehicle. The project type is a unique design of a mechanical component, mechanism, and process. Our objective for this project is to assemble provided electro-mechanical components into an enclosure following a provided electrical diagram. The expected deliverables are the following: 3D CAD assembly of final product, FEA analysis of designed components, 2D print of final product, fabrication and assembly of designed parts, technical report documenting design process and installation. The skills required …

Cost-Effective Brake Rotor Resurfacing Tool, Raider Morgan, Benjamin Vaughan

Williams Honors College, Honors Research Projects

Brake rotors can develop uneven spots over time, causing vibration and poor braking performance. Commercial brake lathes are effective but often too expensive or complicated for at-home mechanics. This project aimed to create a low-cost tool, around $200–$300, to resurface four rotors in under two hours. We explored two main designs: a pad file system and a motorized endmill powered by a handheld drill. Calculations ultimately showed that the pad file was not viable, so the final prototype produced was the endmill-based design. Our testing showed we were limited by poor stiffness in the endmill and unforeseen loading. Although the …

Zips Baja Chassis Manufacturing Design, Alex Love, David Scruppi

Williams Honors College, Honors Research Projects

The Society of Automotive (SAE) annually organizes collegiate design team competitions for university organizations nationwide. Baja SAE tasks teams comprised entirely of students with developing, iterating, manufacturing, testing, and competing with an offroad race buggy in accordance with all SAE regulations. Teams are responsible for producing a tech compliant vehicle for each competition season, travelling across the United States to put their designs to the test. In the 2022-2023 competition season, SAE introduced ruleset clarifications on the chassis manufacturing process, essentially mandating the production of all vehicle frames to be manufactured entirely in house with no external assistance. A chassis …

Akronauts Turbopump Research Project, Gerald Drabeck Iii, Michael Mccalla, Joshua Skelton

Williams Honors College, Honors Research Projects

The idea of this project is to design a turbo pump template capable of fitting into future Akronauts rocket designs. This allows the rockets to travel higher due to the reduced net weight. Many methods were used to verify the rigidity and feasibility of the design, such as Finite Element Analysis and fluid dynamics simulations.

Kb Bioenergy Mobile Dewatering System Research, Wyatt Balser, Nathan Szymczak

Williams Honors College, Honors Research Projects

This report outlines the design and development of a mobile skid-mounted dewatering system intended for high-solids sludge processing at wastewater treatment facilities. The goal was to create a self-contained, transportable unit capable of reliably separating water from sludge using a screw press, while integrating upstream processes such as polymer conditioning, sludge maceration, and pumping. The final design prioritizes serviceability, structural integrity, and operational simplicity, featuring a consolidated equipment layout, engineered piping diagrams, and vendor-specified components.

Throughout the project, multiple design alternatives were evaluated using a weighted decision matrix, leading to the selection of a skid platform over a trailer configuration …

Design And Development Of A Rapid Tensile Quench Rig, Tyler Jewell, Justin Naylor

Williams Honors College, Honors Research Projects

This report outlines the design process and implantation of a tensile quenching rig that incorporated forced convection and a frequency generator. When any metal is quenched, a vapor barrier forms around it. When this happens, it limits the heat flux that may occur until the barrier turns into just nucleate boiling. The vapor barrier acts as an insulator and causes the heat flux to fluctuate, causing uneven hardening which would limit the use of some materials. To combat this effect, we are trying to use forced convection, and something new, which is adding high frequency waves into the quenching process. …

3d Printing Of A Solid-State Battery, Maurizio A. Brozzi

Honors Undergraduate Theses

Solid-state battery research has gained significant attention in recent years, as it provides a unique solution for several common issues in conventional Li-ion batteries. Additionally, as additive manufacturing technologies continue to advance, they have the potential to fabricate solid-state batteries with new materials. The objective of this study is to explore the feasibility of 3D printing of a solid-state battery. By creating an initial PEO-PSF hybrid polymer matrix dissolved in DMSO and adding a lithium salt, the base electrolyte ink was formed. With the addition of conductive additives and active material, electrode inks were also produced. Super P was used …

Effect Of Manufacturing Process On Mechanical Properties Of Polyetheretherketone (Peek) Cranial Implants Produced By Single-Point Incremental Forming (Spif), Elizabeth M. Mamros, Ihab Ragai, Brian Young

Faculty Conference Papers and Presentations

Polyetheretherketone (PEEK) is one of the most commonly used materials for cranioplasty due to its biocompatibility, relatively high strength, and light weight. Cranial implants manufactured from PEEK sheets using the same manufacturing process, e.g., single point incremental forming (SPIF), will have differing part properties based on the selected polymer forming process. Three fabrication methods for PEEK sheets were investigated: extrusion, modified hot pressing, and injection molding. Material characterization specimens were extracted for tensile, impact, and differential scanning calorimetry (DSC) experiments. The PEEK sheets were also subjected to formability tests at room temperature using SPIF. Slight differences in ultimate tensile strength …

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 …

Ease Of Product Disassembly Through A Systematic Structured Time-Based Design For Disassembly Methodology, Emeka S. Igwe

College of Graduate Studies: Theses & Dissertations

This research introduces a systematic time-based design for disassembly (DfD) framework aimed at optimizing product disassembly by addressing important features like liaisons between components in product, component accessibility and the overall modularity of the product. This study specifically covers electromechanical and mechatronic systems in both household and industrial setup, identifying their disassembly challenges and high value pointers for improvement. The methodology involves using a design for disassembly framework called LeanDfD in carrying out a holistic disassembly process and evaluating quantitative metrics like disassembly time and complexity and suggesting further redesign strategies to minimize disassembly time and cost. Adopting this systematic …

Development Of A Design Tool For Tow-Steered Composite Structures With Machine Learning-Assisted Modeling, Bangde Liu

Industrial, Manufacturing, and Systems Engineering Dissertations - Archive

Fiber-reinforced composites (FRCs) are widely used in aerospace, automotive, and other engineering applications due to their lightweight characteristics and superior mechanical properties. Traditional FRCs employ a fixed fiber orientation in each layer, and while different layup sequences can tailor performance, the mechanical properties remain spatially uniform. Tow-steered composites, which enable fibers to follow curvilinear paths, offer the potential for spatially varying stiffness and strength, improving structural performance.

This dissertation addresses key challenges in modeling and designing tow-steered composite structures, including the lack of commercial design tools, the high computational cost of design optimization, and the need to efficiently evaluate manufacturing …

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 …

Affordable And Sustainable: Innovating Filament Extrusion For Recycled Materials, Turab S. Rizvi

Undergraduate Research Posters

The chemical stability, toxicity and non-biodegradability of the polymers pose a significant environmental threat. Addressing end-of-life treatment sustainability is crucial for mitigating these issues. The customized Lyman filament extruder in the Advanced Magnetic Materials Processing Laboratory represents an innovative approach to advancing sustainability in renewable energy production and CO₂ mitigation. Redesigning the thermal system and screw operation will tackle key challenges, including precise temperature control, consistent material flow to handle diverse recycled materials. Integrating an advanced thermal regulation system will reduce the energy consumption by maintaining optimal thermal conditions, thereby lowering the CO₂ footprint of the recycling process. The optimized …

Framework For Development Environment Selection In Digital Twin Applications, Carlos Dodero Fernandez

Graduate Theses, Dissertations, and Problem Reports (ETD)

Digital Twin (DT) technology, a cornerstone of Industry 4.0, facilitates real-time synchronization between virtual models and physical manufacturing systems, enhancing operational efficiency and decision-making. However, its widespread adoption is hindered by the absence of standardized methods for selecting Development Environments (DEs) for DTs, compounded by challenges in cost, interoperability, and connectivity with Industrial Internet of Things (IIoT) protocols. This thesis proposes a Systematic Selection Framework to address this gap, offering a structured methodology to evaluate DEs based-on visualization quality, scalability, interoperability, and cost-effectiveness for manufacturing applications. The framework categorizes and compares sixteen DEs into Game Engines, Robotics Engines, and Simulation …

Laser Based Metal 3d Printer, Inura Goonawardena

All Graduate Theses, Dissertations, and Other Capstone Projects

The technology and applications of additive manufacturing (AM) have advanced significantly in recent years. Research from hobbyist to industrial scale has evolved and has seen advancements in materials that can be utilized for industrial manufacturing. The Institute for Machine Tools and Industrial Management at the Technical University of Munich (TUM) developed the reAM250, an open-source research platform for Powder Bed Fusion with a Laser (LPBF). It was made available to facilitate study into component-level innovation, control techniques, and process monitoring without the budgetary and intellectual property constraints of commercial machines. This paper delves into the concept and production of the …

Pulsed Arc Additive Manufacturing Of A Functionally Graded Er2209 Duplex Stainless Steel And Hsla-100 Structure: Morphology, Characterization, And Mechanical Performance, Stevens G. Hill Jr

College of Graduate Studies: Theses & Dissertations

Wire arc additive manufacturing is a process well suited to the efficient production of large structures. Duplex stainless steel exhibits high corrosion resistance and good strength which can be highly beneficial for industrial use. However, its use is limited due to its cost and complexity in controlling microstructure to achieve desired properties. In many cases, it can be highly beneficial to manufacture a component which uses specialty steel grades such as duplex stainless steel only where necessary, and utilizes more affordable, commonly available steels for reinforcement or bulk structural support. A functionally graded material satisfies these requirements by providing a …