Materials Science and Engineering Commons^™

Removal Of Non-Metallic Inclusions From Molten Steel By Ceramic Foam Filtration, Soumava Chakraborty

Doctoral Dissertations

”Ceramic filters are routinely used in steel foundries to remove non-metallic inclusions from steel melt. Removal efficiency for both solid and liquid inclusions by magnesia-stabilized zirconia foam filters (10ppi) were evaluated and distribution of the captured inclusions through the filter thickness was also investigated. A mold design was developed using a commercial computational fluid dynamics software package to produce two castings that fill simultaneously, one with a filter and the other without a filter, from a single ladle pour, while also matching the fill rates and avoid turbulence and reoxidation during pouring. An industrial-scale experiment was also performed to investigate …

Studying The Effects Of Various Process Parameters On Early Age Hydration Of Single- And Multi-Phase Cementitious Systems, Rachel Cook

Doctoral Dissertations

”The hydration of multi-phase ordinary Portland cement (OPC) and its pure phase derivatives, such as tricalcium silicate (C₃S) and belite (ß-C₂S), are studied in the context varying process parameters -- for instance, variable water content, water activity, superplasticizer structure and dose, and mineral additive type and particle size. These parameters are studied by means of physical experiments and numerical/computational techniques, such as: thermodynamic estimations; numerical kinetic-based modelling; and artificial intelligence techniques like machine learning (ML) models. In the past decade, numerical kinetic modeling has greatly improved in terms of fitting experimental, isothermal calorimetry to kinetic-based modelling …

Transition Metal Chalcogenide Hybrid Systems As Catalysts For Energy Conversion And Biosensing, Siddesh Umapathi

Doctoral Dissertations

"Generation of hydrogen and oxygen through catalyst-aided water splitting which has immense applications in metal air batteries, PEM fuel cells and solar to fuel energy production, has been one of the critical topics in recent times. The state of art oxygen evolution reaction (OER), oxygen reduction reaction (ORR), hydrogen evolution reaction (HER) catalysts are mostly comprised of precious metals. The current challenge lies in replacing these precious metal-based catalysts with non-precious earth-abundant materials without compromising catalytic efficiency.

This research explores mixed metal selenides containing Fe-Ni, Fe-Co and RhSe which were hydrothermally synthesized and/or electrodeposited and tested for OER and ORR …

Enhanced Electrochemical Performance Of Li-Ion Battery Cathodes By Atomic Layer Deposition, Yan Gao

Doctoral Dissertations

”Li-ion battery now plays an irreplaceable role in supplying green and convenient energy. In this work, atomic layer deposition (ALD) was used to modify Li-ion battery cathode particles for performance enhancement.

An ultrathin and conductive CeO₂ ALD film was deposited on Li-rich layered cathode particles, of which the specific capacity and cyclic stability were significantly improved. On the same cathode particles, FeO_x ALD and post-annealing resulted in a stable and conductive surface spinel phase to improve the performance.

Synergetic TiN coating and Ti doping were performed on a LiFePO₄ (LFP) cathode and extended its cycle life. The …

Understanding The Deformation Mechanisms In Ni-Based Superalloys With Using Crystal Plasticity Finite Element Method, Tianju Chen

Doctoral Dissertations

“Ni-based superalloy is considered as a good candidate due to its excellent resistance to elevated temperature deformation for long term period application. Understanding the deformation and failure mechanisms of Ni-Based superalloys is very helpful for providing design guidelines for processing Ni-based superalloys. Experimental characterization indicates that the deformation mechanisms of Ni based superalloy is strongly microstructure dependent. Besides, damage transform from the void nucleation to the macro cracks by voids growth leading to the failure of the Ni-based superalloys are also showing strong microstructure sensitivity. Therefore, this work focuses on the prediction and comprehension of the deformation and void growth …

Densification Of Ultra-Refractory Transition Metal Diboride Ceramics, William Fahrenholtz, Greg Hilmas, Ruixing Li

Materials Science and Engineering Faculty Research & Creative Works

The densification behavior of transition metal diboride compounds was reviewed with emphasis on ZrB₂ and HfB₂. These compounds are considered ultra-high temperature ceramics because they have melting temperatures above 3000°C. Densification of transition metal diborides is difficult due to their strong covalent bonding, which results in extremely high melting temperatures and low self-diffusion coefficients. In addition, oxide impurities present on the surface of powder particles promotes coarsening, which further inhibits densification. Studies prior to the 1990s predominantly used hot pressing for densification. Those reports revealed densification mechanisms and identified that oxygen impurity contents below about 0.5 wt% …

Modeling Of Scrap Dissolution In Molten Iron For The Case Of Heat Transfer-Controlled Process By Different Approaches And Comparison Of Their Accuracies, Ajay Kumar Shukla, Brahma Deo, D. G.C. Robertson

Materials Science and Engineering Faculty Research & Creative Works

Dissolution of steel scrap in molten iron is studied by using analytical as well as numerical approaches for the case of a heat transfer-controlled process. The approaches used are Green's function approach, quasi-static approach, integral profile method (IPM) (with parabolic profile), and finite difference methods (FDM). Application of FDM explicit and FDM implicit with fixed grid and variable grid is described. Accuracy of all the approaches is compared in terms of total dissolution time evaluated from overall heat balance criterion. The selection rule of time step and deciding the suitable approach for achieving minimum error for different operating conditions, represented …

In-Situ X-Ray Imaging Of The Selective Laser Melting Process, Meelap M. Coday

Masters Theses

"Fusion-based metal additive manufacturing (AM) has garnered much interest in recent decades. Despite the popularity of fusion-based AM technologies such as selective laser melting (SLM), there are still fundamental questions and uncertainties that need to be addressed. In this work, we focus on the understanding of the undercooling in the SLM process and the uncertainties induced by the laser beam size, power, and scan speed. First, we report the estimation of undercooling in the SLM process from the solidification rate measured by in-situ high-speed synchrotron x-ray imaging, based on the dendrite growth velocity model. The undercooling changes as a function …

Prediction Of Crack Propagation In Zrb₂-Carbon Based Composites Using The Extended Finite Element Method, Leiren Danielle Jarvis

Masters Theses

“The ultra-high temperature ceramic, zirconium diboride (ZrB₂) has long been researched for applications in extreme environments. Its high strength (> 400 MPa) and thermal conductivity (> 100 W/m•K) make it a candidate for use in hypersonic fight, but a low fracture toughness (< 3 MPa•m^1/2) limits this use. In order to increase the fracture toughness without compromising the strength and thermal conductivity, experimental research has focused on the viability of engineered architectures using multiple materials to create a macrostructure. These architectures allow for the increase of fracture toughness thru crack deflection in the material.

Two architectures in particular, …

Inclusion Control In Steel Castings, Koushik Karthikeyan Balasubramanian

Masters Theses

“Non-metallic inclusions are mainly comprised of oxides, sulfides, and nitrides, and are formed in liquid steel during the melting and refining process, as a result of reoxidation, worn-out refractories, or entrained slag. The notch toughness of high strength steels is particularly susceptible to the type, number, size, and distribution of non-metallic inclusions. High manganese and aluminum austenitic steels, or Fe-Mn-Al steels, have gained much interest in the military and automotive sector because of their excellent combinations of high strength and toughness. However, these steels are subject to both oxide bifilms and aluminum nitride, AlN, inclusions which form during melting and …

Performance Evaluation Of Alsi10mg Fabricated By A Selective Laser Melting Process, David Michael Murphy

Masters Theses

“Selective laser melting is becoming a widely used additive manufacturing technique that melts metal powder in a layer by layer process in order to build a desired part or geometry. Like many additive processes, selective laser melting allows for fabrication of parts with complex geometries. In order to fabricate a fully dense part there are a number of variables to take into account including: powder characteristics, laser parameters, and environmental parameters. Each of these variables can affect the microstructure and thus the mechanical performance of an additively manufactured part. In this work, the aluminum alloy AlSi10Mg was investigated. AlSi10Mg is …

Intrinsic Mechanical Properties Of Zirconium Carbide Ceramics, Nicole Mary Korklan

Masters Theses

“This research focuses on the processing and mechanical properties of zirconium carbide ceramics (ZrC_x). The first goal of this project was to densify near stoichiometric (i.e., x as close to 1 as possible) and nominally phase pure ZrC_x. The maximum stoichiometry achieved for the ZrC_x (C/Zr ratio of 0.92) was measured using gas fusion analysis. Hot pressing was used to obtain dense ZrC_x. Archimedes was used to determine the relative density of hot pressed ZrC_x at > 95%. Scanning electron microscopy (SEM) was used to determine the overall microstructure of the hot pressed …

On The Investigation Of Hot Tearing Behavior Of Continuous Cast Steel, Yanru Lu

Masters Theses

”Hot tearing has long been recognized as a major problem that plagues the development of the continuous casting process and results in low-quality products. Understanding of the mechanisms and the required conditions for the hot tearing formation is important for industries but has not been well-established yet. Thus, this research focuses on the hot tearing issue observed in continuous cast steel, by providing a summary of the current research progress and then introducing a new laboratory method to determine the thermo-mechanical properties relevant to hot tearing of different steel grades under different solidification conditions. In this method, an apparatus was …

Aging Response On The Stress Corrosion Cracking Behavior Of Wrought Precipitation-Hardened Magnesium Alloy, G. R. Argade, S. K. Panigrahi, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Constant immersion testing and slow strain rate testing (SSRT) are conducted on wrought magnesium alloy in a 3.5 wt.% NaCl solution. After solution annealing (SA) at 525 °C for 8 h, the alloy was isothermally aged at 210 °C for 15 h, 48 h, and 144 h to obtain underaged (UA), peak-aged (PA), and overaged (OA) microstructures, respectively. After 32 days of constant exposure in chloride solution, the SA and UA samples showed the lowest (~ 0.10 mg cm−2 day−1) and the highest (~ 0.20 mg cm−2 day−1) weight loss, respectively. SSRT was carried out at an initial strain rate …

Thermodynamic Investigations Of Pure And Blended Cement Mixtures, Jonathan Lapeyre

Doctoral Dissertations

” This research is made up of several studies. The first study focused on understanding the reaction kinetics of Ca₃SiO₅ and metakaolin (MK) mixtures compared to Ca₃SiO₅ and silica fume (SF) mixtures. It was shown that MK was a more effective additive than SF at small replacement levels (i.e. ≥ 10% by mass) while higher replacement levels of MK became a detriment due to excess (Al(OH)₄¯) ions preventing the nucleation and growth of C-S-H. In a follow-up study where the MK particle size distribution (PSD) was modified, similar effects were observed but …

Cyclic Regeneration Of Nanostructured Composites For Catalytic Applications, Fatih Dogan

Materials Science and Engineering Faculty Research & Creative Works

A catalyst obtained by first preparing a cermet material with the general formula ABOx, wherein A is selected from the group consisting of Co, Cu, Ni, Ti, and combinations thereof, wherein B is selected from the group consisting of Mo, W, Ce, and combinations thereof, wherein A and B are different elements, and wherein x is a nonzero number ranging from 3 to 7 and represents the moles of O. Next, the cermet is activated in a reducing atmosphere to yield metal particles dispersed within and/or on the cermet.

Publisher Correction: Pore Elimination Mechanisms During 3d Printing Of Metals (Nature Communications, (2019), 10, 1, (3088), 10.1038/S41467-019-10973-9), S. Mohammad H. Hojjatzadeh, Niranjan D. Parab, Wentao Yan, Qilin Guo, Lianghua Xiong, Cang Zhao, Mimglei Qu, Luis I. Escano, Xianghui Xiao, Kamel Fezzaa, Wes Everhart, Tao Sun, Lianyi Chen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The original version of this Article contained an error in Fig. 4. The x-axis labels in Fig. 4a, b were incorrectly labelled 'Diameter (mm)', rather than the correct 'Diameter (µm)'. This has been corrected in both the PDF and HTML versions of the Article.

Multifunctional Lightweight Aggregate Containing Phase Change Material And Water For Damage Mitigation Of Concrete, Wenyu Liao, Aditya Kumar, Kamal Khayat, Hongyan Ma

Materials Science and Engineering Faculty Research & Creative Works

This paper presents an innovative concept of multifunctional lightweight aggregate, which is produced by loading phase change material (PCM) into the interior of lightweight sand (LWS) and sealing the surface pores using water. The PCM loaded in the LWS functionalizes it as a temperature management agent in concrete, and the water in surface pores enables internal curing. It has been found that the particle shape and pore structure of crushed expanded shale LWS makes it an ideal carrier for PCM, loading sufficient PCM and maintaining better (compared to natural sand) mechanical interlocking. When coupled with the internal curing effect, the …

Grain Refinement In Iron-Based Materials, Simon Naumovich Lekakh, Von Richards, Ronald J. O'Malley, Jun Ge

Materials Science and Engineering Faculty Research & Creative Works

A process for manufacturing an iron-based alloy comprising forming targeted fine oxide and/or carbide dispersoids in a melt, and sequentially precipitating transition-metal nitrides on the dispersoids for heterogeneous nucleation of equiaxed grains. An iron-based cast alloy having a highly equiaxed fine grain structure.

Rare But Conceivable: Determining The Likelihood Of Meteors And Other Infrequent Events, Michael S. Schmidt, Maria Vega-Westhoff

Engineering Management and Systems Engineering Faculty Research & Creative Works

In the aftermath of a rare but devastating disaster, there is a tendency to overestimate how frequent such an event may be, hence a tendency to overestimate the risk associated with such an event. Those concerned with process safety will acknowledge that though rare, events like meteors, hurricanes, and airplane crashes that can impact chemical plants are conceivable. Typically, though, they have nothing more than feelings to decide whether these events are likely enough to be considered "credible." This compiles data from the literature for several "meteors," both natural and man-made, that often become a cause of general concern after …

Grain Size Effects In Selective Laser Melted Fe-Co-2v, Wesley Everhart, Joseph William Newkirk

Materials Science and Engineering Faculty Research & Creative Works

The material science of additive manufacturing (AM) has become a significant topic due to the unique way in which the material and geometry are created simultaneously. Major areas of research within inorganic materials include traditional structural materials, shape memory alloys, amorphous materials, and some new work in intermetallics. The unique thermal profiles created during selective laser melting (SLM) may provide new opportunities for processing intermetallics to improve mechanical and magnetic performance. A parameter set for the production of Fe-Co-2V material with additive manufacturing is developed and efforts are made to compare the traditional wrought alloy to the AM version of …

Comparison Of Fatigue Performance Between Additively Manufactured And Wrought 304l Stainless Steel Using A Novel Fatigue Test Setup, M. M. Parvez, Y. Chen, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In this research, a novel adaptive controlled fatigue testing machine was designed for bending type high cycle fatigue test. A unique dual gauge section Krouse type mini specimen was designed for simply supported transverse bending. Displacement controlled fatigue tests were implemented using an electromechanical actuator. The variation in the control signal and load observed during the test provides unique insights into realizing the deterioration of the specimen due to fatigue. These analyses were utilized to compare the fatigue performance of wrought and additively manufactured 304L stainless steel. The influence of the build direction on fatigue performance was also investigated by …

Compressive And Bending Performance Of Selectively Laser Melted Alsi10mg Structures, D. Murphy, O. Fashanu, Myranda Spratt, Joseph William Newkirk, K. Chandrashekhara, H. Misak, D. Klenosky

Materials Science and Engineering Faculty Research & Creative Works

Selective laser melting (SLM) is a widely used additive manufacturing technique that effectively manufactures complex geometries such as cellular structures. However, challenges such as anisotropy and mechanical property variation are commonly found due to process parameters. In a bid to utilize this method for the commercial production of cellular structures, it is important to understand the behavior of a material under different loading conditions. In this work, the behavior of additively manufactured AlSi10Mg under compression, bending, and tension loads was investigated. Vertical and horizontal build directions are compared for each type of loading. Specimens were manufactured using the reduced build …

Effective Elastic Properties Of Additively Manufactured Metallic Lattice Structures: Unit-Cell Modeling, Okanmisope Fashanu, David Murphy, Myranda Spratt, Joseph William Newkirk, K. Chandrashekhara, Ben Brown, John Porter

Materials Science and Engineering Faculty Research & Creative Works

Lattice structures are lightweight materials, which exhibit a unique combination of properties such as air and water permeability, energy and acoustic absorption, low thermal conductivity, and electrical insulation. In this work, unit-cell homogenization was used to predict the effective elastic moduli of octet-truss (OT) lattice structures manufactured using selective laser melting (SLM). OT structures were manufactured using a Renishaw AM 250 SLM machine with various relative densities. Compression test was carried out at strain rate 5 x 10^-3 m^-1 using an MTS frame. Finite element analysis was used in the determination of the OT’s effective elastic properties. Results …

Elevated Temperature Mechanical And Microstructural Characterization Of Slm Ss304l, G. R. Hecht, Sriram Praneeth Isanaka, Joseph William Newkirk

Materials Science and Engineering Faculty Research & Creative Works

SLM built SS304L was annealed and water quenched to minimize residual stress and avoid carbide precipitation. Mini-tensile characterization of strength and elongation at temperature conditions up to 800°C, along with observations of the associated microstructural transformations were utilized to understand the changes produced in SLM SS304L. As-built and annealed specimens were found to exhibit decreasing strength and elongation with increasing temperature as expected. Carbide precipitates appeared after short times at high temperatures within both as-built and annealed specimens for all cases, but no brittle intermetallic phase development was observed for any of the temperatures investigated. While the lack of Sigma, …

Ionic Conductivity Behavior By Activated Hopping Conductivity (Ahc) Of Barium Aluminoborosilicate Glass–Ceramic System Designed For Sofc Sealing, M. J. Da Silva, W. M. Pontuschka, J. F. Bartolomé, P. Jasinski, J. Karczewski, Signo Tadeu Dos Reis

Materials Science and Engineering Faculty Research & Creative Works

Non-conducting BaO-B₂O₃ -Al₂O₃ -SiO₂ parent glasses designed for solid oxide fuel cell (SOFC) sealing applications were prepared using the melt-quenching technique. The glass formation region was determined according to phase equilibrium relations and was found to be in the composition range 70BaO-(x) Al₂O₃ -(10−x) B₂O₃ -₂₀SiO₂ where 3.0 < x < 6.0 wt.%. The conductivity values obtained conductivity ranged from 10 −5 to 10 −10 S/cm at temperatures between 600 and 850 °C. The batch compositions presented a threshold of dc conductivity near 70BaO wt% with a quasi linear behavior with the decrease of the BaO content. Different values of conduction activation energy were observed at temperatures above the glass transition temperature (T g ) (up to 700 °C), which were attributed to the thermal bond-breaking of non-bridging oxygen (NBO) defects. The experimental results of the electrochemical characterization by impedance spectroscopy of glass–ceramic interfaces with yttria-stabilized zirconia (YSZ) acting as solid ionic conductor electrolyte are presented and discussed.

Infrared Glass–Ceramics With Multidispersion And Gradient Refractive Index Attributes, Laura Sisken, Myungkoo Kang, Johann M. Veras, Charmayne Lonergan, Andrew Buff, Anupama Yadav, Devon Mcclane, Cesar Blanco, Clara Rivero-Baleine, Theresa S. Mayer, Kathleen A. Richardson

Materials Science and Engineering Faculty Research & Creative Works

Infrared (IR) glass–ceramics (GCs) hold the potential to dramatically expand the range of optical material solutions available for use in bulk and planar optical systems in the IR. Current material solutions are limited to single- or polycrystalline materials and traditional IR-transparent optical glasses. GCs that can be processed with spatial control and extent of induced crystallization present the opportunity to realize an effective refractive index variation, enabling arbitrary gradient refractive index elements with tailored optical function. This work discusses the role of the parent glass composition and morphology on nanocrystal phase formation in a multicomponent chalcogenide glass. Through a two-step …

A Displacement Controlled Fatigue Test Method For Additively Manufactured Materials, Mohammad Masud Parvez, Yitao Chen, Sreekar Karnati, Connor Coward, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

A novel adaptive displacement-controlled test setup was developed for fatigue testing on mini specimens. In property characterization of additive manufacturing materials, mini specimens are preferred due to the specimen preparation, and manufacturing cost but mini specimens demonstrate higher fatigue strength than standard specimens due to the lower probability of material defects resulting in fatigue. In this study, a dual gauge section Krouse type mini specimen was designed to conduct fatigue tests on additively manufactured materials. The large surface area of the specimen with a constant stress distribution and increased control volume as the gauge section may capture all different types …

Braze For Ceramic And Ceramic Matrix Composite Components, Sean E. Landwehr, Scott Nelson, Jeremy Lee Watts, Greg Hilmas, William Fahrenholtz, Derek Scott King

Materials Science and Engineering Faculty Research & Creative Works

In some examples, a technique may include positioning a first part comprising a ceramic or ceramic matrix composite and a second part comprising a ceramic or a CMC adjacent to each other to define a joint region at the interface of the first part and the second part. In some examples, the joint region may be heated using at least one of a laser or a plasma arc source to heat the joint region to an elevated temperature. The first and second parts may be pressed together and cooled to join the first and second parts at the joint region. …

Methods Of Use And Manufacture Of Silver-Doped, Nano-Porous Hydroxyapatite, Cheol-Woon Kim, Richard K. Brow

Nuclear Engineering and Radiation Science Faculty Research & Creative Works

A silver-doped, nano-porous hydroxyapatite material is provided that can be utilized to capture radioactive iodine, ¹²⁹I. Methods of using the silver-doped, nano-porous hydroxyapatite material to remove radioactive iodine, and methods of manufacturing the material are also provided.