Materials Science and Engineering Commons^™

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 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 …

Bayesian Alloy Design With Additive Synthesis, Michael R. Sulwer

Dissertations, Master's Theses and Master's Reports

To reduce carbon emissions and increase power out, steam powerplants need to increase the operating temperatures and pressures of steam turbines to improve efficiency. This necessitates the development of high temperature alloys with superior strength and stability. This research aims to design a class of solid solution High Entropy Alloys (HEAs) to exceed the high temperature performance of commercial alloys like Haynes 230 while maintaining comparable costs for Advanced Ultra Supercritical (A-USC) steam cycles. This project integrates Bayesian optimization and Calculation of Phase Diagrams (CALPHAD) within an Integrated Computational Materials Engineering (ICME) framework to predict and optimize key material properties: …

Iron Ore Tailings Reprocessing By Electrostatic Separation Plus Two Stages Froth Flotation, Vincent Bailey Arohunmolase

Dissertations, Master's Theses and Master's Reports

The reprocessing of tailings is crucial for recovering valuable iron and reducing the environmental impact associated with tailings disposal. This study investigates the practicality of reprocessing tailings to enhance iron oxide content, combining electrostatic separation with a two-stage froth flotation process using oleic acid (direct flotation) and amine (reverse flotation). The primary goal is to efficiently recover valuable iron from tailings, thereby reducing waste and promoting sustainable resource utilization. The process aims to upgrade the iron oxide content to around 93-99% Fe₂O₃, making the recovered material suitable for the production of direct-reduced iron.

Electrostatic separation was …

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 …

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, …

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 …

Surface Chemistry And Adsorption Mechanism Of Orfom® D8 For Cu Depression In Cu-Mo Flotation, Patrick Jeff Mensah

Graduate Theses & Non-Theses

In traditional chalcopyrite-molybdenite (Cu-Mo) flotation separation systems, inorganic depressants such as NaSH and NaCN are used to selectively depress chalcopyrite making it more hydrophilic so molybdenite can be floated and recovered. NaSH and NaCN are highly toxic, have high explosion potential, strong odor, and readily oxidize in air resulting in a high consumption rates. To control oxidation, nitrogen gas, and Nokes reagent are both necessary, making the process even more expensive. In addressing these challenges, attention is fast shifting to disodium carboxymethyl trithiocarbonate (Orfom® D8), a novel organic depressant designed to replace conventional inorganic depressants because it does not easily …

Multiphysics Modeling And Experimental Validation Of High-Strength Steel In Laser Powder Bed Fusion Process, M. Rangapuram, S. Babalola, J. W. Newkirk, L. N. Bartlett, F. W. Liou, K. Chandrashekhara, Stephen R. Cluff

Materials Science and Engineering Faculty Research & Creative Works

Laser powder bed fusion (LPBF) is a subset of the additive manufacturing process in which a laser beam selectively joins the metal powder into a desired part in a sequential layer process. Owing to its complex nature of rapid heating and cooling of the melt pool, there is a need to understand the melt pool behavior and its effects on the final manufactured part. a densely packed powder bed is highly desirable for fabricating a superior part using the LPBF process. in this work, discrete element model was used to generate powder beds with realistic powder properties and various factors …

A General Model For The Ductility Of Intermetallics Applied To Fe-Co Alloys, Wesley Everhart, Joseph Newkirk

Materials Science and Engineering Faculty Research & Creative Works

The mechanical properties, specifically ductility, of high performing soft magnets such as Fe-Co alloys are a limiting factor to their broader use in a number of systems. The understanding of the mechanical robustness in these materials is currently insufficient to be able to support the growing interest in applications such as magnetic shielding or electric motors. Fe-Co alloys provide the highest commercially available magnetic saturation and high magnetic permeability but have very poor ductility. The addition of vanadium to these alloys has allowed for significant commercialization and some ductility improvements, but the fundamental reasons for the observed improvements are not …

Atmosphere Effects In Laser Powder Bed Fusion: A Review, Ben Brown, Cody Lough, Davis Wilson, Joseph Newkirk, Frank Liou

Materials Science and Engineering Faculty Research & Creative Works

The use of components fabricated by laser powder bed fusion (LPBF) requires the development of processing parameters that can produce high-quality material. Manipulating the most commonly identified critical build parameters (e.g., laser power, laser scan speed, and layer thickness) on LPBF equipment can generate acceptable parts for established materials and moderately intricate part geometries. The need to fabricate increasingly complex parts from unique materials drives the limited research into LPBF process control using underutilized parameters, such as atmosphere composition and pressure. As presented in this review, manipulating atmosphere composition and pressure in laser beam welding has been shown to expand …

Optimizing The Physical Properties Of Biochar For Co2 Adsorption Using Resonant Vibrations, Amirhosein Riahi, Richard Ladouceur

Mining Engineering

Among various Carbon Capture and Sequestration (CCS) technologies, significant emphasis has been placed on biochar as an effective post-combustion CO2 capture method. Biochar demonstrates potential as a technically effective method for stabilizing carbon. However, the efficacy of CCS based on adsorption phenomenon depends on factors such as the CO2 uptake of the adsorbent, kinetic rates, and cyclic adsorption. The study shows that Low-Frequency High Amplitude (LFHA) resonant vibratory mixing improves the physical characteristics and adsorption properties of hemp biochar. According to the results of an analysis of variance (ANOVA), increasing both the mass of biochar and the intensity of resonant …

Development Of Robust Steel Alloys For Laser-Directed Energy Deposition Via Analysis Of Mechanical Property Sensitivities †, Jonathan Kelley, Joseph W. Newkirk, Laura N. Bartlett, Sriram Praneeth Isanaka, Todd Sparks, Saeid Alipour, Frank Liou

Materials Science and Engineering Faculty Research & Creative Works

To ensure consistent performance of additively manufactured metal parts, it is advantageous to identify alloys that are robust to process variations. This paper investigates the effect of steel alloy composition on mechanical property robustness in laser-directed energy deposition (L-DED). In situ blending of ultra-high-strength low-alloy steel (UHSLA) and pure iron powders produced 10 compositions containing 10–100 wt.% UHSLA. Samples were deposited using a novel configuration that enabled rapid collection of hardness data. The Vickers hardness sensitivity of each alloy was evaluated with respect to laser power and interlayer delay time. Yield strength (YS) and ultimate tensile strength (UTS) sensitivities of …

Computational Modeling Of High Yttrium Refractory High Entropy Alloy Microstructures, Kaleb C. Ryan, Marissa M. Baker

College of Engineering Summer Undergraduate Research Program

Refractory high entropy alloys (RHEAs) are advanced metals made up of five or more principal elements in roughly equal amounts. The microstructural effects of alloying with yttrium as a principal element for RHEAs are currently not well understood. This project compared RHEA microstructures from literature with simulations using the High Entropy Alloy Predicting Software (HEAPS), which computes 10 screening criteria to predict the microstructure of a RHEA composition. The accuracy of HEAPS predictions was assessed by comparing them with experimentally validated microstructures found in literature. A combination of criteria was found to have a 95.8% accuracy rate, and a new …

Experimental Investigation And Evaluation Of Mechanical Properties And Microstructural Characterization On Chromium Molybdenum Steel Processed Through Laser Based Welding, Rakesh S

Theses and Dissertations

Creep Strength Enhanced Ferritic (CSEF) martensitic modified 9Cr-1Mo (P91) steel is extensively employed in fast breeder nuclear reactors and thermal power plants owing to its superior resistance to thermal fatigue and oxidation corrosion compared with other low-alloy steels. Despite its excellent high-temperature performance, the weldability of this steel remains a critical concern.

Conventional arc welding processes generate excessive heat input and complex thermal cycles, resulting in heterogeneous microstructures, retention of δ-ferrite, and subsequent degradation in service life. In contrast, high energy density beam welding techniques such as laser and electron beam welding offer precise thermal control and minimal heat-affected zones …

Utilization Of Sodium Flame Synthesis For The Formation And Deposition Of Pure Metal Materials For Applications In Additive Manufacturing, Zachariah Wargel

McKelvey School of Engineering Graduate Student Theses & Dissertations

Advanced material classes, such as high temperature alloys, ceramics, and refractory materials have become a key area of focus for expansion in the realm of additive manufacturing. Factors such as high melting points, material homogeneity, and physical properties such as ductility limit the application of popular additive manufacturing methods to these material classes. By utilizing sodium flame synthesis and deposition (SFD) technology, nanoparticle materials can be synthesized via combustion in a laminar co-flow diffusion burner and impacted such that the deposits can be used to manufacture designed components. By using the applicable precursor materials of metal chlorides and elemental sodium …

Effect Of Impurities In Supercritical Co2 Environment On Steel Corrosion Behavior – An Overview, Shilla Rizqi Widianto, Johny Wahyuadi Soedarsono, Rini Riastuti, Badrul Munir

Journal of Materials Exploration and Findings

Carbon capture, utilization, and storage (CCUS) technology is one of the available technologies to reduce presence of greenhouse gasses. Implementation of CCUS technology strongly relates with the CO₂ transportation from the capturing facility to the storage in the geological reservoir. The most economical method for large-scale and long-distance CO₂ transportation is using pipeline in supercritical phase. Moreover, presence of impurities such as water, O₂, SO₂, H₂S, NO₂ may cause detrimental effect towards carbon steel pipeline. This paper intends to provide an initial information for supercritical CO₂ pipeline material selection, which …

Hollow Connecting Rod Thin Wall Austempered Ductile Iron (Twadi) For Manufacturing Light Weight Components, Ricardina Freitas Da Silva, Bambang Suharno, Rianti Dewi Sulamet-Ariobimo

Journal of Materials Exploration and Findings

Efforts made by the automotive industry to reduce energy consumption have encouraged researchers to carry out various studies. One way is to make components lighter by casting thin wall austempered ductile iron (TWADI). Reducing the weight of components such as connecting rods (conrod) will result in lower energy consumption, but provided that these components still meet standards in terms of mechanical properties and microstructure or even exceed them. In this research, design optimization was applied to conrod by making the area I-beam zero mm (hollow), with hope that it can replace conrod Vespa PX-150. While the manufacturing process is divided …

Analysis Risk Based Inspection Api 581 On Lpg Spherical Tank At Pt. Xyz, Sigit Trahmawan, Eddy Sumarno Siradj, Jaka Fajar Fatriansyah

Journal of Materials Exploration and Findings

Liquified petroleum gas (LPG) spherical tanks are pressure vessel equipment for storing fuel gas products. The high pressure along with the fuel gas inside as flammable and combustible substance means that this equipment might result major accident hazard such as explosion, fires and environmental pollution. This study is aimed calculated and mitigate risk on 500 metric ton capacity LPG spherical tank using Risk-based inspection (RBI) analysis method that makes risk as its foundation. This RBI method uses quantitative analysis referring to API 581 to determine the risk of LPG Spherical Tank by determining the probability of failure (PoF) and the …

Settingsorder Article Reprints Open Accessarticle A Model To Account For The Effects Of Load Ratio And Hydrogen Pressure On The Fatigue Crack Growth Behavior Of Pressure Vessel Steels, Ashok Saxena, Kip O. Findley

Mechanical Engineering Faculty Publications and Presentations

A phenomenological model for estimating the effects of load ratio R and hydrogen pressure P_H2 on the hydrogen-assisted fatigue crack growth rate (HA-FCGR) behavior in the transient and steady-state regimes of pressure vessel steels is described. The "transient regime" is identified with crack growth within a severely embrittled zone of intense plasticity at the crack tip. The "steady-state" behavior is associated with the crack growing into a region of comparatively lower hydrogen concentration located further away from the crack tip. The model treats the effects of R and P_H2 as being functionally separable. In the transient …

Computational Alchemy: Pioneering Spintronic, Thermoelectric, And Optoelectronic Materials Design Through First-Principles Calculations And Machine Learning, Eesha Sanjay Andharia

Graduate Theses and Dissertations

Intelligent materials discovery and design plays a pivotal role in advancement of spintronics, optoelectronics and thermoelectric devices and technology. In this study, we investigate three types of materials using first principles calculations. First, the structural, electronic, and magnetic properties of CrTiCoZ (Z = Al, Si) equiatomic quaternary Heusler alloys were investigated. CrTiCoAl compound was found to exhibit a half metallic ferromagnetic structure and Curie temperature above room temperature, which makes it an ideal candidate for magnetic tunnel junction, the basic building block of Spintronic devices. Second, we use Green’s function to obtain the finite temperature phonons by including quartic anharmonicity …

Modeling Study Of Si3N4 Waveguides On A Sapphire Platform For Photonic Integration Applications, Diandian Zhang, Shui-Qing Yu, Gregory J. Salamo, Richard A. Soref, Wei Du

Electrical Engineering and Computer Science Faculty Publications and Presentations

Sapphire has various applications in photonics due to its broadband transparency, high-contrast index, and chemical and physical stability. Photonics integration on the sapphire platform has been proposed, along with potentially high-performance lasers made of group III–V materials. In parallel with developing active devices for photonics integration applications, in this work, silicon nitride optical waveguides on a sapphire substrate were analyzed using the commercial software Comsol Multiphysics in a spectral window of 800~2400 nm, covering the operating wavelengths of III–V lasers, which could be monolithically or hybridly integrated on the same substrate. A high confinement factor of ~90% near the single-mode …

Development Of Iii-V And Iv Epitaxy On Sapphire Technology, Emmanuel Wangila

Graduate Theses and Dissertations

This research presents comprehensive insights into the epitaxial growth of germanium (Ge) on c-plane sapphire substrates using molecular beam epitaxy (MBE). The direct growth of Ge on sapphire typically yields three-dimensional (3D) Ge islands with diverse growth directions, multiple primary domains, and twinned crystals. However, incorporating a thin AlAs nucleation layer proves instrumental in enhancing surface and material quality. With a 10 nm AlAs layer, the achieved surface exhibits improved characteristics, including a smoother surface, single epitaxial orientation, sharper rocking curve, and a single domain. This study surpasses previous works by achieving a single primary domain and reducing twinning. Furthermore, …

Modeling Powder Spreadability In Powder-Based Processes Using The Discrete Element Method, Austin T. Sutton, M. Hossein Sehhat, Ming C. Leu, Joseph W. Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Powder-bed fusion (PBF) processes refer to a subset of Additive Manufacturing (AM) techniques where powder is spread on the build-plate before melting (by a laser or electron beam). While PBF processes are attractive due to their ability for realizing complex structures that are either difficult or impossible to create through conventional means, the parts fabricated with these techniques can exhibit defects such as pores, inclusions, and excessive surface roughness. To minimize these defects, much research has been dedicated towards process maturation by optimizing laser or electron beam parameters. However, these developmental efforts typically do not address the recoating process where …

Pulsing-Induced Healing Of A Surface Crack Of A Nickel-Based Alloy, Liwei Wang, Mingming Quan, Zhen Tan, Ming Liu, Dianlong Wang, Xiao Yang, Ying Liu, Yaning Mao, Zhimin Liang, Fuqian Yang

Chemical and Materials Engineering Faculty Publications

In this work, we demonstrate the feasibility of applying electric pulses to heal surface cracks on nickel-based alloy GH4169 under compressive load. There exists an incubation time for the onset of the healing of a crack, which is associated with local temperature at the crack tip. The crack size decreases with increasing the pulsing time at a constant healing rate prior to complete healing of the crack. Increasing compressive load accelerates the healing process. The electric pulsing leads to the formation of an influential zone surrounding the crack with the finest grain sizes in the healed crack and the coarsest …

Extreme Value Statistics Analysis Of Process Defects In Additive Manufacturing Materials, Ayorinde E. Olatunde, Kristen Hernandez, Austin Ngo, Arafath Nihar, Thomas G. Ciardi, Rachel Yamamoto, Pawan K. Tripathi, Roger H. French, John J. Lewandowski, Anirban Mondal

Faculty Scholarship

Fatigue and fracture studies focused on process defects that occur in Additive Manufacturing (AM) materials have shown that defect populations possess features which are better measured with extreme value statistics (EVS). In AM alloys, defect occurrences increase with material volume. This situation facilitates the need to model process defects in the path of fatigue crack growth with suitable statistical tools, such as EVS, which is more cost-effective when compared to destructive experiments. The application of EVS on defect space features helps determine the difference in defects present on fracture surfaces. As the fatigue quality of any material depends on its …

Photodegradation Of Microplastics Through Nanomaterials: Insights Into Photocatalysts Modification And Detailed Mechanisms, Yiting Xiao, Yang Tian, Wenbo Xu, Jun Zhu

Biological and Agricultural Engineering Faculty Publications and Presentations

Microplastics (MPs) pose a profound environmental challenge, impacting ecosystems and human health through mechanisms such as bioaccumulation and ecosystem contamination. While traditional water treatment methods can partially remove microplastics, their limitations highlight the need for innovative green approaches like photodegradation to ensure more effective and sustainable removal. This review explores the potential of nanomaterial-enhanced photocatalysts in addressing this issue. Utilizing their unique properties like large surface area and tunable bandgap, nanomaterials significantly improve degradation efficiency. Different strategies for photocatalyst modification to improve photocatalytic performance are thoroughly summarized, with a particular emphasis on element doping and heterojunction construction. Furthermore, this review …

Metallurgical Impact Of Switching From Hammer Units To Hydraulic Presses For Forging, Cole Hawker, Jacob Reed

Materials Engineering

Carlton Forge Works (CFW) is evaluating the retirement of its hammer units in favor of hydraulic presses to address safety concerns in forging aerospace components. This paper investigates the metallurgical implications of this transition, emphasizing the importance of superior microstructures and meeting industry standards and customer requirements. The alloys in question are Titanium-6Al-4V (Ti64) and Inconel 718 (INCO 718), which comprise a majority of CFW’s production. Ti64's high specific strength and thermal stability make it ideal for aerospace applications, while INCO 718 is recognized for superior high-temperature creep performance. Defects like freckles and white spots in INCO 718 are analyzed …