Mechanics of Materials Commons^™

Additive Manufacturing Of Metals: Mechanical Properties And Their Implications, Sean Chih

Discovery Day - Daytona Beach

Additive manufacturing of metals is a relatively new and groundbreaking approach to manufacturing high-performance components. However, variability in mechanical properties from the process creates a barrier before this manufacturing technique can be widely applied. Understanding when and where to use this manufacturing is also important to create components with efficiency and without harmful defects. The objective of this research is to evaluate the effects of build orientation, printing parameters, internal defects, thermal history, and residual stresses, post-processing heat treatments, and fatigue behavior on additively manufactured components. Literature-based research is conducted on commonly used metals for additive manufacturing, such as stainless …

Magnetic Field-Induced Transformation In Polycrystalline Ni2mnal Heusler Type Magnetic Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely, Laura N. Bartlett

Materials Science and Engineering Faculty Research & Creative Works

The martensitic and magnetic transformations, as well as the mechanical properties, of Ni₂MnAl alloys in as-cast (AC) and heat-treated (HT) conditions were investigated. Magnetic-field-induced strain was evaluated via magnetostriction, with reversible strains of 0.14% and 0.2% achieved in the martensitic phase at 2 K for the AC and HT alloys, respectively. Transformation temperatures and Curie temperatures were determined under constant applied magnetic field, revealing that γ-phase inclusions in the AC microstructure suppress antiferromagnetic domain response, yielding a lower magnetization (∼8.4 emu g⁻¹) compared to the HT alloy (∼13.4 emu g⁻¹). Both alloys exhibited hysteretic behavior in the martensitic state and …

Lafe0.925ti0.075o3 Perovskite Coated With Ethyl Cellulose: A High-Stability, Low-Hysteresis Platform For Advanced Humidity Sensing, Akhmad Futukhillah Fataba Alaih, Djoko Triyono, Rifqi Almusawi Rafsanjani

Makara Journal of Science

Humidity sensors are pivotal in numerous sectors, such as environmental monitoring, industrial automation, and health-care. This study presents the fabrication and detailed evaluation of an advanced humidity sensor using ethyl cellulose (EC)-coated LaFe_0.925Ti_0.075O₃ (LFTO) perovskite nanoparticles synthesized via the sol-gel method. The LFTO nanopar-ticles exhibited a mesoporous structure with an enhanced surface area, which significantly improved their moisture adsorption capabilities. The innovative application of EC coating addresses critical substrate adhesion issues, enhancing mechanical stability without compromising sensor sensitivity. Comprehensive performance evaluations revealed minimal hysteresis (

Electropulse Annealing: Phase Composition Of Tial6v4, Vaughn Eckhardt, Ethan Croke, Ian Baker, Russ Taylor

Wetterhahn Science Symposium Posters

Titanium alloy TiAl6V4 is the most ubiquitous titanium alloy used for dental care, aerospace manufacturing, and for high performance vehicles. The material typically undergoes a thermal heat  treatment, but electropulse annealing is another process that involves sending current through the material to heat it up at a quicker rate. The rate of post-annealing cooling is high, and around the material's critical point, its two components, alpha and beta phase, change in relative concentration. After testing multiple current densities and temperatures, in general, as the current density that the sample received during electropulse annealing decreased, both the alpha and beta phases …

Creation Of The 2-Way Cross Laminated Timber Subroutine For Computing Dynamic Analysis Parameters, Joseph Freitas

Architectural Engineering

This document will describe the inputs, methodology, and outputs for the CLT 2-way subroutine for cases with and without openings recently added to a proprietary structural analysis software. For the sake of simplicity, most of the discussion will be focused on cases without openings from here on out, as the verification process for a novel method for cases with openings is still in progress. The CLT 2-way module calculates multi-point resistance functions for panels without openings by automating the procedure outlined in an industry-standard structural design manual. The subroutine also finds the appropriate dynamic response factors, kinetic load multipliers, mass, …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Parts, Logan Trimmer

Harrisburg University Other Works

Presentation covering the broad strokes of the project. The goal was to prove the viability of hybrid/additive manufacturing for high stress automotive applications. This project focused on recreating a piston from an old engine to examine if hybrid manufacturing could be used for such applications. On a small scale, hybrid manufacturing was able to be more cost effective if the costs of the equipment and electricity were ignored. The decision to ignore those costs came from the inability to find accurate prices for industrial casting.

Thermal Transformations And Mechanical Properties Of All-D-Metal Mn2fecu Heusler-Type Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely

Materials Science and Engineering Faculty Research & Creative Works

All-d-metal Heusler alloys are emerging functional materials in which magnetic ordering, lattice distortion, and mechanical behavior are strongly coupled through d–d electronic interactions. This study systematically investigates the structural, thermal, magnetic, and mechanical properties of Mn₂FeCu synthesized within a Heusler-type compositional framework. SEM/EDS revealed a dual-phase FCC-based microstructure consisting of Mn–Fe–rich and Mn–Cu–rich domains, while XRD confirmed FCC symmetry with compositional partitioning rather than full L2₁ ordering. Differential scanning calorimetry identified partial melting of the Cu-rich phase near ~ 900 °C. Dilatometry showed a thermoelastic FCC → FCT transformation at ~ 770–780 °C with a recoverable strain of ~ 0.067%. …

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 …

Made On Mars: Design And Manufacturing Of Structural Polymer-Regolith Composites, Pailey M. Vitale

Williams Honors College, Honors Research Projects

Human exploration of Mars is constrained by harsh environmental conditions and the prohibitive cost of transporting materials from Earth. Long-term sustainability requires the local production of mechanical and structural components using resources available on Mars, thereby minimizing payload mass. This project investigates polymer–regolith composites derived from atmospheric CO₂ and mineral-rich regolith as a pathway toward in-situ manufacturing. These composites, when compatible with additive manufacturing, could replace imported plastics, enable on-demand fabrication, and support closed-loop recycling systems. The objective is to design and evaluate polymer–regolith composites that maintain mechanical integrity and environmental resistance under Martian conditions, including extreme temperature swings, radiation …

Critical Parameters Controlling Oxide Scale Formation And Hydro-Descaling Efficiency During Steelmaking, Tochukwu Princewill Ojiako

Doctoral Dissertations

In modern steelmaking, cast slabs are exposed to high-temperature oxidizing environments during secondary cooling, reheating, and hot rolling, resulting in the formation of multilayer oxide scales on the steel surface. These scales interact with mold-flux residues originating from the casting process (CC). The morphology, chemistry, and adhesion of oxide scale strongly influence its removability during high-pressure hydraulic descaling and ultimately determine the surface quality of hot-rolled products. However, the mechanistic relationship between oxide scale evolution, scale-steel interfacial structure, and hydraulic descaling performance remains poorly understood.

This dissertation investigates oxide scale formation, modification, and removal in low-carbon thin-slab steels produced by …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Components, Logan Trimmer

Harrisburg University Other Works

The goal of this research was to establish the viability of using hybrid manufacturing for automotive applications. By verifying that high-stress components can be created, it can be assumed that any other lower stress part could be made to match the strength requirements. A limiting factor of adoption for hybrid manufacturing is how new the technology is. Studies on time and cost were performed allowing for comparisons with traditional manufacturing technologies (casting, forging, milling) used in automotive applications. This research utilized a Haas Automation UMC750 5-axis CNC mill with a Meltio laser wire direct energy deposition attachment. Fusion 360 was …

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 …

In-Situ Investigations Of Calcium-Magnesium-Aluminosilicates (Cmas) Infiltration Effects On Thermal Barrier Coatings Under Extreme Environments Replicating Jet Engines, Zachary Stein

Doctoral Dissertations and Master's Theses

Calcium-magnesium-aluminosilicate (CMAS) particulates, such as sand or volcanic ash, are ingested by gas turbine jet engines during operation. When operating within high abundance regions, these particulates negatively interact and degrade the high temperature thermal barrier coatings (TBC) protecting underlying superalloy turbine blades vital to engine operation. These CMAS particulates melt within the engine and infiltrate into the ceramic coatings. In electron-beam physical vapor deposited (EB-PVD) TBCs, the CMAS within the intercolumnar gaps stiffens the coatings and causes thermomechanical induced high stress concentrations, risking crack formation. While molten, the CMAS thermochemically alters and destabilizes the coating, also risking coating failure. Premature, …

Characterization Of The Fatigue Threshold Behavior Of Uhmwpe, Bethany B. Smith, Anurag Roy, Robert O. Ritchie, Lisa A. Pruitt

Faculty Journal Articles

Ultra-high-molecular-weight-polyethylene (UHMWPE) has been the material of choice for bearings in total joint replacements (TJRs) for decades as a result of its excellent wear resistance, chemical inertness, energetic toughness, low friction, and biocompatibility. Utilization of this polymer in orthopedic devices requires oxidation, wear, and fatigue resistance. Balancing these important properties by tailoring processing techniques and modulating microstructural features has been an ongoing endeavor in the field. Research into the clinical applications of UHMWPE has primarily focused on the challenges of wear and oxidation while studies into the realm of fatigue have been more limited. Literature gaps exist in fully understanding …

Investigations On The Fatigue Strength Of Threads Produced By Different Fabrication Techniques, Philippe Du Maire, Jürgen Hoffmeister, Andreas Öchsner, Michael Johlitz

15th International Conference on Shot Peening

The increasing importance of sustainability in engineering demands the development of long-lasting, high-performance components that reduce material and energy consumption over time. This study investigates how different thread manufacturing processes, i.e., cutting, rolling, and deep rolling, affect the fatigue strength of bolts made from 42CrMo4+QT steel. Cylindrical specimens with M12 threads were subjected to cyclic tensile loading with constant mean stress. Fatigue strength was evaluated using the staircase method, and supporting analyses included X-ray diffraction for residual stress, and full width half maximum examination and Vickers microhardness measurements. Results show that thread rolling significantly improves fatigue strength, achieving 113.8 MPa …

Effects Of Laser Peening On Fatigue Properties Of Welded Aluminum Thin Plates, Kiyotaka Masaki, Yoshio Mizuta, Satoshi Tamaki, Yuji Sano

15th International Conference on Shot Peening

To improve the fatigue properties of welded aluminum alloy thin plates used in transportation machinery, handheld laser peening (HH-LP) was applied to 2 mm-thick A5083-O specimens prepared by bead-on TIG welding. Conventional laser peening often causes warping in thin plates, but the HH-LP treatment using low-energy laser pulses avoids this problem. The HH-LP treatment introduced compressive residual stresses of over 200 MPa on the heat-affected zone (HAZ) of the welded specimens. Fatigue tests under plane bending conditions revealed that the HH-LP treatment significantly improved the fatigue strength of the welded specimens, achieving a level comparable to that of the base …

Tensile Creep Of A Hybrid Polymer-Matrix/Ceramic-Matrix Composite At Elevated Temperature, Waleed S. Alshehri

Theses and Dissertations

Advanced aerospace systems require structural materials that can perform reliably in high-temperature environments for long durations. The performance of standard polymer matrix composites (PMCs) in these conditions is often limited by their susceptibility to time-dependent deformation, such as creep. The objective of this research is to characterize the high-temperature creep behavior of a novel unitized material system comprising a polymer matrix composite (PMC) and a ceramic matrix composite (CMC) co-cured together. The PMC part consists of the polyimide matrix reinforced with laminated carbon fibers woven in an eight harness satin weave (8HSW). The CMC part consists of a zirconia-based ceramic …

Shape Memory Behavior In Medium To High Entropy Shape Memory Alloys: Design, Prediction, And Experimental Analysis, Hatim Raji

Theses and Dissertations

This dissertation provides a data-driven system integrating synthetic data generation and machine learning (ML) techniques to create multicomponent SMA compositions with specific transformation temperatures (TTs). Models were trained to represent the nonlinear dependencies influencing martensitic transformation behavior by using elemental, thermodynamic, and process-related aspects. The capacity of the ML models on medium entropy NiTiHfPd and high entropy NiTiHfZrCu systems accuracy was confirmed by experimental validation showing TTs closely matched with model outputs.

Advancing Multi-Physics Modeling For Microwave Heating: Application In Micro-Reactor Design And Optimization, Raghav Adhikari

All Theses

Microreactors are a type of small-scale chemical reactors for achieving reduced volume, improved product selectivity and higher reaction rate. It allows precise temperature control, which is crucial for sensitive chemical processes. Microreactors can be employed as key components of conducting small-scale reactions with improved reactor configuration and process efficiency. It is important to identify a localized and precise heating mechanism to trigger and control the corresponding chemical reactions.

In fact, microwave heating has gathered significant attention in recent years due to its ability to deliver efficient, rapid, and localized heating, which can accelerate reaction rates and enhances the reaction selectivity. …

Mno2 Nanoscale Interface Modification, Alexander C. Skoppe

Doctoral Dissertations and Master's Theses

Interface modification of carbon fibers has been shown to improve the mechanical performance of composites. In addition, interface modification of carbon fiber composites can impart multifunctionality into the resulting composite. This work will explore ZnO and MnO2 as interface modifications for use on carbon fibers. When exposed to high temperatures, carbon fibers undergo fiber degradation, leading to the need for low-temperature hydrothermal processes. This work will develop and characterize a nanoscale ZnO and MnO2 interface modification for use on carbon fibers. These nanomodifications will be developed with low-temperature processes, minimizing the fiber degradation that the fibers undergo. Fourier transform infrared …

Comparative Study Of Experimental And Fea Strain Data For Cnt-Coated Fiberglass Sensors, Extensometers, And Metal Foil Strain Gauges, Omar Dwidar

Master's Theses

Material testing is essential across industries such as aerospace, automotive, and construction, playing a critical role in verifying material selection, diagnosing failures, and understanding the development of flaws in structures. These insights are key to designing successful, reliable systems. Conventional metal foil strain gauges are low cost and reliable but provide limited sensitivity with a typical gauge factor around 2. Extensometers provide highly sensitive strain measurements with the disadvantage of a bulky form factor. With advanced materials such as carbon nanotubes, it is possible to manufacture a sensor with the sensitivity closer to that of an extensometer with the small …

Mechanistic Insights Into Polymer-Assisted Graphene Exfoliation: The Roles Of Velocity, Adhesion, Cohesion, Temperature, Peeling Mode, And Edge Defect Via Coarse-Grained Molecular Dynamics, Linjiale Dai

All Theses

Graphene exfoliation is a critical step in the fabrication of high-quality graphene

layers. However, the underlying fracture mechanisms remain poorly understood. In this

work, I employed coarse-grained (CG) molecular dynamics (MD) simulations to

investigate how factors such as interfacial binding energy, substrate cohesion, temperature,

peeling mode, and edge defects influence the outcome of the exfoliation process. To model

polymer-assisted mechanical exfoliation, I used a finite-size system in which multilayer

graphene (MLG) is sandwiched between two thin polymer films. Leveraging the

spatiotemporal efficiency of the CG model, I performed fifty simulation iterations per

parameter set and analyzed the results from a …

Innovative Design Methodology For Durable Open-Graded Friction Course Asphalt Mixtures, Anas Abualia

LSU Doctoral Dissertations

Open-graded friction course (OGFC) is a thin asphalt mixture surface layer with a high percentage of coarse aggregates and high interconnected air voids, which provides improved skid resistance, visibility, and decreased pavement-tire noise. However, construction personnel at DOTD reported that conventional OGFC mixtures have short service life (raveling distress). Further, their structural contribution to the pavement structure is commonly neglected and designed only for functionality purposes.

The objective of this study was to develop a rational mix design methodology to improve the durability of OGFC asphalt mixtures. Specific objectives are to: (1) conduct a rheological and chemical characterization of polymer-, …

Improvement Of Microcracking And Mechanical Properties Of Tungsten Fabricated Via Laser Powder Bed Fusion Through Alloying With Reactive Secondary Constituents, William S. Mockel

Theses and Dissertations

Tungsten (W), a Group VI transition metal, possesses a number of advantageous properties, most notably its impressive mechanical performance at extreme temperatures. While tungsten's nature render traditional manufacturing methods difficult, additive manufacturing through laser powder bed fusion (LPBF) presents a promising avenue for fabricating tungsten components. However, the material’s high ductile-to-brittle transition temperature combined with the embrittling effect of impurities mean that the residual stresses imparted by LPBF result in microcracking in tungsten, degrading its usefulness. This study sought to improve the characteristics of LPBF-W through the removal of embrittling oxygen content via alloying with low concentrations of reactive elements, …

Integrating Off-Spec Scms Into Plc Blends, George A. Qubty

Civil Engineering Theses - Archive

Off-spec supplementary cementitious materials (SCMs) remain underutilized due to variability in reactivity and non-conformance with existing standards. This study evaluates the hydration behavior and fresh-state and mechanical performance of these materials in Portland limestone cement (PLC) systems. One Class F fly ash (FA), one bottom ash (BA), and two calcined clays (HACC and LACC) were evaluated as 20 % replacements to PLC. Hydration behavior was characterized using isothermal calorimetry and thermogravimetric analysis (TGA), while fresh-state and mechanical performance were assessed through flow table, Vicat setting time, load–crack mouth opening displacement (CMOD) flexural testing, and compressive strength testing. HACC increased compressive …

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 …

Effects Of Soil Properties On Cp Performance, Cecilia Segretario

Williams Honors College, Honors Research Projects

This research aims to evaluate the affect of various soil properties on the effectiveness of cathodic protection (CP) in preventing underground pipeline corrosion. Metal coupons of common pipeline materials with applied CP will be mounted in several separate controlled soil environments to manipulate real world underground corrosion scenarios. Each soil environment will have different physical properties by mixing the soil with a prepared chemical solution. The physical properties to be evaluated include pH, resistivity, and moisture content. At the end of a corrosion duration, weight loss method will be used to evaluate the corrosion rate over that period. Additionally, the …