Engineering Commons^™

Development And Testing Of High Strength Scalable High Entropy Alloys, Hans Jakob Pommerenke

Doctoral Dissertations

"High entropy alloys have shown promise through their ability to be tailored to specific scenarios. From highly corrosive environments to precipitation strengthened alloys to radiation environments high entropy alloys allow tailor made alloys for every solution. New compositions are developed and tested but little work focuses on the processing effect choosing rather than using processing as a steppingstone to achieve properties without investigating the processing effects. This work focuses on single phase face-centered cubic alloys strengthened by processing and precipitation strengthening. In conjunction with the development of these alloys, the ability to scale production will be investigated and characterized to …

In-Depth Characterization Of The Selective Oxidation Products Of Hafnium Carbide, Jonathan Allen Scott

Doctoral Dissertations

"Materials capable of withstanding oxidative environments at temperatures >2000°C are necessary for hypersonic applications. Hafnium carbide (HfC) shows a combination of properties that lends itself toward these applications; however, its oxidation behavior is poorly understood. At 1300°C, HfC was found to oxidize via the following mechanism: 1) Initial oxidation of both C and Hf present in the system, 2) Formation of an interconnected pore network, whose size is related to the volume of gases being generated during the oxidation process, 3) Growth of the oxide scale to become sufficiently protective, 4) Formation of an initially amorphous “HfO₂C” at …

Processing-Microstructure-Properties Relationships In Additively Manufactured Zrb2-Sic Ceramics, Marharyta Lakusta

Doctoral Dissertations

"The study explores the pressure less sintering (PS) and chemical compatibility of ZrB₂-30 vol.%SiC produced by additive manufacturing (AM) with CO₂. The oxidation kinetics and scale microstructures were compared for ZrB₂-SiC made by hot pressing (HP) and by AM coupled with PS. All specimens exhibited parabolic oxidation kinetics. The difference in oxidation behavior becomes evident at temperatures of 1100-1400°C (200-900h). Oxidation rates increased as grain size increased. Similar oxide scale morphologies were observed in both CO₂ and air, with an outer borosilicate layer and an inner porous ZrO₂ layer containing partially oxidized …

The Development Of Hard Materials And Fibrous Monolith Composites For Friction Stir Welding, Paul Michael Brune

Doctoral Dissertations

"This research focuses on the development of hard materials and fibrous monolith composites for the purpose of adding to current friction stir welding tool technology. Well studied hard material systems, such as WC-Co, were incorporated and evaluated as cell materials for fibrous monolith composites with ductile cell boundaries of Co, W, and Mo. The indentation behavior of the WC-Co and WC-Co-cBN composites indicated possible crack deflection at the cell/cell boundary interface. Cylindrical pin friction stir welding tools were developed for each of the three fibrous monolith material systems. Welding was achieved on AA1100 aluminum, 260 brass, and AISI 1018 steel …

Processing & Properties Of Zirconium Carbide Manufactured By Ceramic On-Demand Extrusion, Clare Sabata

Masters Theses

"This research focuses on the development of a zirconium carbide (ZrC) paste for use in material extrusion direct ink write additive manufacturing (AM) followed by the pressure less densification of ZrC and the mechanical and thermal characterization of the resulting ceramics. A highly loaded, aqueous paste was developed using commercial ZrC powder ball milled to ~1 μm. Optimal dispersant, binder, and solids loading were found by rheological characterization. The paste composition consisted of 46-47 vol% ZrC, 43.5 vol% distilled water, 8.1 vol% dispersant, and 1.6 vol% binder. A yield stress of ~8 Pa allowed for shape retention upon removal of …

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 …

Production Of Glass-To-Metal Seals Using Additive Manufacturing Techniques, Aaron Read

Masters Theses

"Glass-to-metal (GtM) seals are hermetic barriers between glass and metal components, often used in the electronic and vacuum industries. Creating the seals traditionally requires heating all the components to the glass melting temperature, where the glass will flow and bond to the metal. Due to the manufacturing constraints of the individual components and sealing conditions there are geometric and material restrictions. Additive manufacturing techniques were used to make GtM seals to reduce these restrictions.

Hermetic, single pin seals were produced using printed metal shells, by selective laser melting (SLM), and digital light processing (DLP) printed glass preforms. Glass preforms were …

Sub-Critical Crack Growth And Fatigue Behaviour Of Alkali Silicate Glass, Noah Weyrauch

Masters Theses

"Delayed failure in silicate glasses can be linked to subcritical crack growth (SCCG) where surface defects grow over time until catastrophic failure. This phenomenon originates from stress-enhanced chemical interactions between the environment (e.g. water) and the strained silicate bonds at the crack tip. SCCG must be accounted for to predict the long-term survivability of silicate-glass components. This study compares two methods to measure SCCG parameters for a commercial alkali silicate sealing glass and for a series of binary xNa₂O-(1-x)SiO₂ glasses, where 0.15 ≤ x ≤ 0.35. A constant moment double cantilever beam (DCB) technique was used to …

Intragranular Tungsten-Titanium Carbide Composite Ceramics Via Gas-Solid Displacement Reactions, Ryan Daniel Dempsey

Doctoral Dissertations

"Research presented herein details the synthesis and characterization of nanocomposite ceramics featuring novel heterogeneous microstructures of potential interest in a variety of electrical and structural applications. Specifically, W-TiCy composite ceramics featuring tungsten nanoprecipitates located primarily within TiCy grains have been produced via sintering of intragranular nanocomposite powders produced via reaction processing-based techniques. This dissertation details the thermodynamic basis and applied kinetics of a processing scheme for fabricating nanocomposite ceramics whose morphological heterogeneity reflects that originally developed in the powder state. The first study in this series overviews the motivation for applying metallothermic displacement reactions, conducted through gaseous intermediates, to solid …

Phosphate And Borophosphate Glasses For Optical And Biomedical Applications, Parker Tracy Freudenberger

Doctoral Dissertations

"The goal of this work was to connect the network structures of phosphate and borophosphate glasses to the compositional dependence of properties related to biomedical applications. The glasses were characterized by a variety of techniques, including phosphate ion chromatography, Raman spectroscopy, and ¹¹B and ³¹P Magic Angle Spinning Nuclear Magnetic Resonance spectroscopy, which provide qualitative and quantitative information about the phosphate and borate moieties that constitute the network structures. The systematic addition of borate to a phosphate glass initially creates tetrahedral borate sites that replace P-O-P linkages with B-O-P linkages, and the properties of the resulting borophosphate glasses …

Suppressing Aluminum/Silica Exchange Reaction Between High Aluminum Steel And Mold Flux During Continuous Casting Process, Kuanysh Nurbekuly Yermukhanbetov

Masters Theses

"Mold flux plays one of the critical roles in continuous casting of steel. It performs five primary functions: thermal and chemical insulation, lubrication between the steel strand and mold, absorption of inclusions, and promotion of even heat flux. The aluminum/silica exchange reaction occurring between steel and mold flux during the continuous casting process poses significant challenges in the steel industry. This reaction can lead to various defects in the cast product and adversely affect its surface quality, as well as downstream processing.

In this work, effectiveness of two approaches, namely slag dopant additions and electrochemical techniques, in suppressing the exchange …

Development And Testing Of A Hyperbaric Aerodynamic Levitator For Containerless Materials Research, Sydney Elizabeth Boland

Masters Theses

"This research focused on the development and testing of a hyperbaric aerodynamic levitator for container less materials research of specimens at temperatures greater than 2000°C and pressures up to 10.3 MPa (1500 psi). The effect of specimen size, specimen density, pressure, and flow rate on the levitation behavior was studied. Lightweight specimens demonstrated two stable levitation regimes that were speculated to be associated with a change in the turbulent wake structure. The hyperbaric aerodynamic levitator was also used to determine the effect of pressure on the heat transfer by studying the melting behavior of a levitated 3.0 mm diameter alumina …

Understanding Charge Effects On Marked Ball Wear Rates – A Corrosion Study, John Bailey Fletcher

Masters Theses

"To measure the wear rates of grinding balls within a ball mill, marked ball wear tests (MBWTs) have been used extensively. Using the wear rates from a MBWT, operators select the most cost-effective media for their grinding application. One factor that a MBWT does not account for is the possible interaction between different media materials which could affect their corrosion rates. Galvanic coupling between dissimilar metals can cause significant changes in their corrosion rates. While galvanic interactions between minerals and grinding media have been studied, the interaction between dissimilar media has not. Corrosion rates and potentials of modern high carbon …

Effect Of Boron In Cast Iron, Suyash Durendra Pawaskar

Masters Theses

"Boron, mostly considered a residual element, has started to cause issues in the cast iron foundries by causing a decrease in the strength of pearlitic gray and ductile iron castings. Because of the increase in the use of boron-added steel scrap from automotive steel and a lack of agreement on the critical levels of boron in cast iron, foundries are facing difficulties in controlling the microstructure of gray iron castings when boron is present. The current investigation was designed to analyze the effects of boron in cast irons and predict a mechanism to understand its effects with a vision of …

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 …

Mechanical Properties Of Boride Based Ceramics, Alec Murchie

Doctoral Dissertations

“This research focuses on the elevated mechanical properties of diboride based materials at room and elevated temperatures. These materials include a ZrB₂ ceramic, a ZrB₂-WC-SiC ceramic, and a (Hf,Mo,Nb,Ta,W,Zr)B₂ high entropy boride (HEB). The room temperature flexural strength for the ZrB₂ ceramic was 447 MPa and the fracture toughness was 2.3 MPa·m^1/2. The strength decreased to 196 MPa at 1800°C, and then increased to 360 MPa at 2300°C. The fracture toughness increased to 3.1 MPa·m^1/2 at 2200°C. The strength up to 1800°C was likely controlled by a combination of effects: surface damage …

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 …

Investigation Of The Thermodynamics Of Iron Phosphate Melts And Stability Of Iron Phosphate Glasses: Effects Of Composition And Iron Redox Ratio, Melodie Linda Schmitt

Doctoral Dissertations

“Iron phosphate glasses with Fe/P = 0.33 - 0.67, O/P = 3.0 - 3.5 and Fe²⁺/ΣFe = 0.16- 0.52 were prepared by altering batch compositions and melt conditions. Thermal analyses indicate polyphosphate glasses with intermediate chain lengths are most stable against devitrification. Heterogeneous crystallization occurs on the glass surface and is dependent on iron valence state, particle size, heating rate, temperature and oxygen availability in the atmosphere. Oxidation of ferrous iron on the glass surface occurs at temperatures as low as Tg, and thus crystallization behavior and stability can be altered via post-melt heat treatments. A novel preparation …

Bulk Nanostructured Steels For Nuclear Reactor And Extreme Environment Applications, Maalavan Arivu

Doctoral Dissertations

"Candidate accident tolerant FeCrAl fuel (ATF) claddings for light water reactors (LWRs) need to be thinner than current Zircaloys owing to higher neutronic penalty, demanding an improvement in strength. Therefore, equal channel angular pressing (ECAP), and high-pressure torsion (HPT) were used to produce bulk ultra-fine grained and nanocrystalline Kanthal-D [KD; Fe-21Cr-5Al-0.026C (wt.%) alloy] which resulted in an improvement in strength of up to 3 times their nominal strength from grain boundary strengthening, and dislocation strengthening. Dynamic recovery was promoted due to ECAP at 520 oC rendering it with a large area fraction of less mobile low angle grain boundaries (LAGBs) …

Production Of Non-Oriented Electrical Steel Thin Strip Simulating Conditions Of The Direct Twin-Roll Casting Process, Yizhou Du

Doctoral Dissertations

"In this study, a method to cast non-oriented (NGO) electrical steel with conditions of an industrial twin roll thin strip casting (TRSC) process was investigated. A novel vacuum assisted fast cooling (VA) sampling method was developed to produce 2 mm thick strip simulating conditions of an industrial TRSC process. The effects of solidification cooling rate, hot rolling deformation, and annealing time on inclusion distribution, magnetic properties, grain growth, and texture evolution of 3.4 wt.% Si NGO electrical steel with different carbon and sulfur (C&S) levels were analyzed. Samples were thermo-mechanically treated which simulated an industrial TRSC process. After a long …

Joining Of Ultra-High Temperature Ceramics To The Same And Refractory Metals Via Fusion Welding, Jecee Jarman

Doctoral Dissertations

"This research focuses on the joining of ultra-high temperature ceramics to either themselves or refractory metals/alloys via fusion welding and the mechanical strength of produced joints. The ceramics studied consisted of compositions within a diboride-carbide-carbide ternary system while metals studied consisted of molybdenum and a molybdenum alloy. SiC-ZrB2-ZrC ceramics on a binary join between pure SiC and the ternary eutectic composition were found to be weldable when SiC content was below ~57.5 vol%. Compositions above 57.5 vol% SiC were unweldable based on pitting and off-gassing behavior. Welded strength of ceramics was ~180-300 MPa in the SiC-ZrB2-ZrC ternary eutectic composition, ~180-220 …

Oxidation Of Silicon Carbide And Graphite For High Temperature Gas-Cooled Reactor Applications, Adam Thomas Bratten

Doctoral Dissertations

"This research focuses on the oxidation behavior of silicon carbide and matrix grade graphite, specifically as it pertains to accident scenarios in Gen IV thermal spectrum high temperature gas cooled nuclear reactors. It is imperative to understand the oxidation behavior of such materials to predict their response to off-normal environments and certify their accident tolerance to implement Gen IV reactors. The onset of oxidation temperature of matrix graphite was found to have a strong dependence on the microstructure, and therefore processing parameters, of the materials. The A3-3 type grade contained regions of partially graphitized carbon that were more disordered and …

Effects Of Vacancies And Electron Temperature On The Electron Phonon Coupling In Cubic Silicon Carbide And Their Connection To The Inelastic Thermal Spike, Salah Al-Smairat

Doctoral Dissertations

“The electron-phonon interaction is an important interaction in many solids as it influences transport phenomena and related quantities such as the electrical and thermal conductivities, especially in nuclear and space applications. The importance of the electron-phonon interaction in primary damage production in 3C-SiC is the subject of this research.

The electron-phonon coupling factor was calculated using a hybrid Density Functional Perturbation Theory - Classical Electron Gas model. The coupling factor was calculated as a function of electron temperature in pristine and defective 3C-SiC, and relaxed defective cells. The electron-phonon coupling is found to depend strongly on the electronic temperature and …

Molten Steel Interactions With Tundish Linings And Refractory Glazes, Tyler Michael Richards

Doctoral Dissertations

"In the final stages of casting, molten steel is in contact with two main types of refractories: the working lining of the tundish used to serve as an intermediate vessel between the ladle and copper mold, and the various glazed carbon-bearing refractories used to control the flow of steel from the ladle to the tundish and from the tundish to the mold. If steel interacts with these refractories in such a way as to result in the formation of inclusions, it may be too late to remove them, leading to degradation of the steel’s mechanical properties. Understanding these interactions and …

Development And Application Of Ensemble Machine Learning Algorithms To Enable A Priori, High-Fidelity, And Prompt Predictions And Optimizations Of Complex Materials And Systems, Taihao Han

Doctoral Dissertations

"Complex materials consisting of multiple chemical components/phases have been widely used in different engineering applications that have strict criteria. To optimize the mixture design of complex materials, researchers invest enormous resources in cumbersome experiments. However, due to substantial variations in precursors and processing techniques, it has been challenging to develop theoretical frameworks (i.e., empirical models) that could produce reliable predictions of properties of complex materials. In recent years, scientists have harnessed the power of machine learning (ML) and “Big” data to uncover the underlying mixture design-property correlations and produce high-fidelity predictions of properties of complex materials. The ML models autonomously …

Processing To Enable Direct-Write Additive Manufacturing Of Ceramics And Ceramic Composites, Austin Martin

Doctoral Dissertations

"This research focuses on the processing of novel feedstocks for and during direct-write additive manufacturing (AM), specifically the direct ink writing (DIW) and Ceramic On-Demand Extrusion (CODE) manufacturing processes, in order to produce ceramic and ceramic-based composite components. Strongly dispersed, concentrated (φ = 0.42), nanoparticle (d₅₀ ~0.3 µm), zirconia (ZrO₂) pastes were used to print densely filled, large continuous volume (≳ 1 cm³) ceramic components. An elastic shear modulus (G’) of 56,000 Pa and yield stresses between 6 and 10 Pa allowed for printed components of 34.5 mm in height over 115 layers without slumping …

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 …

Novel Ferromagnetic Materials With Improved Mechanical Performance, Wesley Alexander Everhart

Doctoral Dissertations

"The ductility of intermetallics has long been a hindrance to their broad adaptation despite a significant range of properties such as magnetic, half-metallic, and shape memory behavior. The lack of a general theory for the ductility of intermetallics along with the lack of prior art that experimentally measured mechanical properties drives the need for significant investment in many of these novel magnetic materials in order to even understand, let alone correct, poor ductility.

This dissertation includes work that explored the effect of vanadium content and quenching rate on the microstructure and ductility of Fe-Co alloys. Results indicated that a martensitic …

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 …

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 …