Materials Science and Engineering Commons^™

Synthesis And Applications Of Ceramic (Silicon Carbide And Silicon Nitride), Metallic (Cobalt(0)) And Polymeric (Polyurethane) Aerogels, Parwani M. Rewatkar

Doctoral Dissertations

"A new method has been demonstrated for the synthesis of monolithic ceramic and purely metallic aerogels from xerogel powder compacts, and the use of polyurethane aerogels based on cyclodextrins as efficient desiccants.

I. Highly porous ( > 80%) monolithic SiC and Si₃N₄, aerogels were prepared from compressed compacts of polyurea-crosslinked silica xerogel powders. The process is time efficient as solvent-exchange through powders is fast, and energy efficient as it bypasses drying with supercritical fluids. The final ceramic objects were chemically pure, sturdy, with compressive moduli at 37 ±7 MPa and 59 ± 7 MPa, and thermal conductivities …

Near-Field Electrospinning Of A Polymer/Bioactive Glass Composite To Fabricate 3d Biomimetic Structures, Krishna C. R. Kolan, Jie Li, Sonya Roberts, Julie A. Semon, Jonghyun Park, D. E. Day, Ming-Chuan Leu

Biological Sciences Faculty Research & Creative Works

Bioactive glasses have recently gained attention in tissue engineering and three-dimensional (3D) bioprinting because of their ability to enhance angiogenesis. Some challenges for developing biological tissues with bioactive glasses include incorporation of glass particles and achieving a 3D architecture mimicking natural tissues. In this study, we investigate the fabrication of scaffolds with a polymer/bioactive glass composite using near-field electrospinning (NFES). An overall controlled 3D scaffold with pores, containing random fibers, is created and aimed to provide superior cell proliferation. Highly angiogenic borate bioactive glass (13-93B3) in 20 wt.% is added to polycaprolactone (PCL) to fabricate scaffolds using the NFES technique. …

Microstructural Evolution Of Zirconium Carbide (Zrcₓ) Ceramics Under Irradiation Conditions, Raul Florez

Doctoral Dissertations

A comprehensive understanding of the microstructural evolution of Zirconium Carbide (ZrC₂) ceramics under irradiation conditions is required for their successful implementation in advanced Gen-IV gas-cooled nuclear reactors. The research presented in this dissertation focusses on elucidating the ion and electron irradiation response of ZrC₂ ceramics. In the first part of the research, the microstructural evolution was characterized for ZrC₂ ceramics irradiated with 10 MeV Au³⁺ ions up to doses of 30 displacement per atom (dpa) at 800 ºC. Coarsening of the defective microstructure, as a function of dose, was revealed by transmission electron microscopy analysis. …

Biomaterials For Bone Regeneration, Youqu Shen

Doctoral Dissertations

"The purpose of this Ph.D. research is to investigate and improve two classes of hydroxyapatite (HA)-based biomaterials for bone repair: calcium phosphate microspheres and bioactive silicate glass scaffolds. These biomaterials were prepared with modified compositions and microstructures and then were evaluated for bone regeneration.

The open HA microspheres with dense convex surfaces and rough and porous concave surfaces were obtained by sectioning closed hollow HA microspheres. Bone regeneration with the open HA microspheres was greater than with the closed HA microsphere at 12 weeks. Hollow biphasic calcium phosphate (BCP) microspheres have been prepared with different fractions of HA and β-TCP …

Development Of Castrip Dual Phase Steel, Brenton Allen Hrebec

Masters Theses

“Thermomechanical processing necessary to produce DP 980 steel using CASTRIP hot band was investigated. The resultant steel has an ultimate tensile strength of 1038 MPa, yield strength of 744 MPa, and total elongation of 8.6%. These mechanical properties were achieved by batch annealing the hot band at 649°C for 48 hours and cold rolling to a 20% reduction. The steel was continuously annealed to simulate a galvanization cycle with an intercritical temperature of 810°C. The possibility of improving the texture of the steel by warm rolling under dynamic strain aging conditions was investigated. Dynamic strain aging in the CASTRIP hot …

Performance Of One-Part And Two-Part Class C Fly Ash-Based Alkali Activated Mortars, Cedric Chani Kashosi

Masters Theses

“Seeking an eco-friendly concrete, researchers have conducted studies to fully replace ordinary Portland cement (OPC) with fly ash (FA) producing alkali-activated concrete (AAC). Results showed better performance of AAC in terms of high early compressive strength, and durability compared to conventional concrete. However, much is still unknown about the behavior of AAC. From the type of materials used, the curing procedure, and long-term strength development of these binders; a thorough investigation is needed in order to fill the existing gap from previous studies and thus make a step forward to the safely use of AAC in the construction industry. The …

Removal Of Antimony And Bismuth From Copper Electrorefining Electrolyte By Two Proprietary Solvent Extraction Extractants, Andrew Artzer

Masters Theses

"Antimony and bismuth are two of the most problematic impurities in copper electrorefining (ER). Because of this, much research has been done investigating the ways to remove them. Processes that are currently being used industrially include anode additions, liberators, ion exchange (IX), and solvent extraction (SX). Of these, liberators and anode additions are the most common while SX is the least, mostly being used for arsenic removal. There are other methods that have been evaluated, but are not in commercial use. These include the use of various electrolyte additives, and adsorbents such as bentonite clay and heavy metal sulfates.

Two …

Melt Property Variation In Gese2-As2se3-Pbse Glass Ceramics For Infrared Gradient Refractive Index (Grin) Applications, Anupama Yadav, Andrew Buff, Myungkoo Kang, Laura Sisken, Charmayne Smith (Lonergan), Jason Lonergan, Cesar Blanco, Michael Antia, Megan Driggers, Andrew Kirk, Clara Rivero-Baleine, Theresa Mayer, Andrew Swisher, Alexej Pogrebnyakov, A. R. Hilton, Greg Whaley

Materials Science and Engineering Faculty Research & Creative Works

Melt size-dependent physical property variation is examined in a multicomponent GeSe₂-As₂Se₃-PbSe chalcogenide glass developed for gradient refractive index applications. The impact of melting conditions on small (40 g) prototype laboratory-scale melts extended to commercially relevant melt sizes (1.325 kg) have been studied and the role of thermal history variation on physical and optical property evolution in parent glass, the glass' crystallization behavior and post heat-treated glass ceramics, is quantified. As-melted glass morphology, optical homogeneity and heat treatment-induced microstructure following a fixed, two-step nucleation and growth protocol exhibit marked variation with melt size. These attributes …

Improving Base Metal Electrowinning, Charles Ebenezer Abbey

Doctoral Dissertations

"In zinc electrowinning, Mn oxidizes to form MnO₂ on Pb-Ag anodes, cell walls and pipes. MnO₂ reduces anode corrosion but also leads to short circuits and maintenance issues. MnO₂ is thought to interact with chloride ions and produce oxidized chlorine species. The interactions between Mn and Cl are not well understood. Bench scale experiments were conducted to investigate the effects of the manganese to chloride ratio on anode corrosion rate and electrolyte chemistry using rolled Pb-Ag anodes. Increasing the average Mn/Cl^- ratio from ~7:1 to ~11:1 reduced the anode corrosion rate. Anode scales produced with Mn/Cl …

Nanomorphology Dependent Optical And Mechanical Properties Of Aerogels, Chandana Mandal

Doctoral Dissertations

"Aerogels are very low density, light weight open pore materials. A hypothesis that is under intense current investigation by the scientific community states that the mechanical properties of nanostructured polymers depend on their nanomorphology. Aerogels are nanostructured ultra-lightweight nanoporous materials with skeletal frameworks that can display a wide range of nanomorphologies. Thereby aerogels comprise a suitable platform for testing not only that hypothesis but also a wide range of other properties such as light scattering for applications, for example, in thermally insulating windows.

To study the mechanical properties of nanostructured matter as a function of nanomorphology, various shape-memory polyurethane aerogels …

Development And Characterization Of Nanostructured Steels And High Entropy Alloys For Nuclear Applications, Andrew Kalevi Hoffman

Doctoral Dissertations

"Nuclear reactor materials are subjected to a harsh environment including high temperatures and radiation fluences. In order to extend the lifetime of current light water reactors (LWRs) and realize the development of advanced Gen IV nuclear reactors new materials must be developed which can withstand such an environment. This thesis involves two approaches to solving this materials problem: advanced manufacturing of current commercial alloys using severe plastic deformation (SPD) and the development of new advanced high entropy alloys (HEAs).

Because SPD is effective at achieving grain refinement, this technique was used to obtain material having a high volume fraction of …

The Effect Of Cell Size And Surface Roughness On The Compressive Properties Of Abs Lattice Structures Fabricated By Fused Deposition Modeling, Leah Hope Mason

Masters Theses

"Postprocessing is an important step in many manufacturing methods, but it is especially important for additive manufacturing. Researchers looking to improve the surface roughness of acrylonitrile butadiene styrene (ABS) parts fabricated by fused deposition modeling (FDM) have determined that acetone smoothing not only achieves improved surface roughness but increases compressive strength as well. This could be very beneficial to lattice structures, which are known for already having an excellent strength to weight ratio. If the compressive strength of ABS lattice structures could be improved even further using acetone smoothing, it could expand the applications for plastic lattice structures and improve …

The Effects Of Silica On The Properties Of Vitreous Enamels, Signo Tadeu Dos Reis, Mike Koenigstein, Liang Fan, Genda Chen, Luka Pavic, Andrea Mogus-Milankovic

Materials Science and Engineering Faculty Research & Creative Works

Ground coat enamels for low carbon steel that contain silica as a mill addition have been developed to study the changes of their properties. Acid-resistant commercial enamel where silica addition was varied from 0 to 10.0 wt % was used for this investigation. The effects of the addition on the corrosion resistance, thermal properties, electrical properties, and mechanical adherence of the enamel to low carbon steel were studied. The corrosion resistance of the steel enameled coupons was tested using a salt spray (fog) apparatus for time periods reaching 168 h at room temperature. It was found that, although the density …

A Note Of Thanks To John Halloran, William Fahrenholtz

Materials Science and Engineering Faculty Research & Creative Works

No abstract provided.

Phonon Signature Of Charge Inhomogeneity In High Temperature Superconductors Yba2cu3o6+X, Y. Petrov, T. Egami, R. J. Mcqueeney, Mohana Yethiraj, Herbert A. Mook

Materials Science and Engineering Faculty Research & Creative Works

Temperature and composition dependences of high-energy longitudinal optical (LO) phonons in YBa₂Cu₃O_6+x, studied by inelastic neutron scattering measurements, provide clear evidence for temperature dependent spatial inhomogeneity of doped charges. The measurements indicate that charge doping increases the volume fraction of the charged regions, while the local charge density remains unchanged. For the optimally doped sample the charge distribution changes sharply near the superconducting transition temperature, with stronger charge inhomogeneity below TC. The remarkable magnitude of the phonon response to charge suggests strong involvement of phonons in charge dynamics.

A High-Entropy Alloy With Hierarchical Nanoprecipitates And Ultrahigh Strength, Zhiqiang Fu, Lin Jiang, Haiming Wen, For Full List Of Authors, See Publisher's Website.

Materials Science and Engineering Faculty Research & Creative Works

High-entropy alloys (HEAs) are a class of metallic materials that have revolutionized alloy design. They are known for their high compressive strengths, often greater than 1 GPa; however, the tensile strengths of most reported HEAs are limited. Here, we report a strategy for the design and fabrication of HEAs that can achieve ultrahigh tensile strengths. The proposed strategy involves the introduction of a high density of hierarchical intragranular nanoprecipitates. To establish the validity of this strategy, we designed and fabricated a bulk Fe₂₅Co₂₅Ni₂₅Al₁₀Ti₁₁₅ HEA to consist of a principal face-centered cubic …

Ultralow Dispersion Multicomponent Thin-Film Chalcogenide Glass For Broadband Gradient-Index Optics, Myungkoo Kang, Andrew M. Swisher, Alexej V. Pogrebnyakov, Liu Liu, Andrew Kirk, Stephen Aiken, Laura Sisken, Charmayne Lonergan, Justin Cook, Teodor Malendevych, Fedor Kompan, Ivan Divliansky, Leonid B. Glebov, Martin C. Richardson, Clara Rivero-Baleine, Carlo G. Pantano

Materials Science and Engineering Faculty Research & Creative Works

A novel photothermal process to spatially modulate the concentration of sub-wavelength, high-index nanocrystals in a multicomponent Ge-As-Pb-Se chalcogenide glass thin film resulting in an optically functional infrared grating is demonstrated. The process results in the formation of an optical nanocomposite possessing ultralow dispersion over unprecedented bandwidth. The spatially tailored index and dispersion modification enables creation of arbitrary refractive index gradients. Sub-bandgap laser exposure generates a Pb-rich amorphous phase transforming on heat treatment to high-index crystal phases. Spatially varying nanocrystal density is controlled by laser dose and is correlated to index change, yielding local index modification to ≈+0.1 in the mid-infrared.

Recyclability Of 304l Stainless Steel In The Selective Laser Melting Process, Austin T. Sutton, Caitlin S. Kriewall, Ming-Chuan Leu, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

During part fabrication by selective laser melting (SLM), a powder-bed fusion process in Additive Manufacturing (AM), a large amount of energy is input from the laser into the melt pool, causing generation of spatter and condensate, both of which have the potential to settle in the surrounding powder-bed compromising its reusability. In this study, 304L stainless steel powder is subjected to five reuses in the SLM process to assess its recyclability through characterization of both powder and mechanical properties. Powder was characterized morphologically by particle size distribution measurements, oxygen content with inert gas fusion analysis, and phase identification by X-ray …

Characterization Of Impact Toughness Of 304l Stainless Steel Fabricated Through Laser Powder Bed Fusion Process, Sreekar Karnati, Atoosa Khiabhani, Aaron Flood, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In this research, the impact toughness of powder bed based additively manufactured 304L stainless steel was investigated. Charpy specimens were built in vertical, horizontal and inclined (45⁰) orientations to investigate the variation in toughness with build direction. These specimens were tested in as-built and machined conditions. A significant difference in toughness was observed with varying build directions. The lowest toughness values were recorded when the notch was oriented in line with the interlayer boundary. The highest toughness was recorded when the notch was perpendicular to the interlayer boundary. A significant scatter in toughness values was also observed. The variation and …

Fabricating Functionally Graded Materials By Ceramic On-Demand Extrusion With Dynamic Mixing, Wenbin Li, Austin J. Martin, Benjamin Kroehler, Alexander M. Henderson, Tieshu Huang, Jeremy Lee Watts, Greg Hilmas, Ming-Chuan Leu

Materials Science and Engineering Faculty Research & Creative Works

Ceramic On-Demand Extrusion (CODE) is an extrusion-based additive manufacturing process recently developed for fabricating dense, functional ceramic components. Presented in this paper is a further development of this process focusing on fabrication of functionally graded materials (FGM). A dynamic mixing mechanism was developed for mixing constituent ceramic pastes, and an extrusion control scheme was developed for fabricating specimens with desired material compositions graded in real time. FGM specimens with compositions graded between Al₂O₃ and ZrO₂ were fabricated and ultimately densified by sintering to validate the effectiveness of the CODE process for FGM fabrication. Energy dispersive spectroscopy …

Fiber-Fed Printing Of Free-Form Free-Standing Glass Structures, John M. Hostetler, Jason E. Johnson, Jonathan T. Goldstein, Douglas A. Bristow, Robert G. Landers, Edward C. Kinzel

Materials Science and Engineering Faculty Research & Creative Works

Additive Manufacturing (AM) of low-profile 2.5D glass structures has been demonstrated using a fiber-fed laser-heated process. In this process, glass fibers with diameters 90-125 μm are supported as they are fed into the intersection of the workpiece and a CO₂ laser beam. The workpiece is positioned by a four-axis CNC stage with coordinated rotational/transitional kinematics. The laser energy at λ = 10.6 μm is coupled to phonon modes in the glass, locally heating it above its working point. The rapid heating and cooling process allows for the deposition of various glasses into free-standing three-dimensional structures such as trusses and …

Effect Of Wall Thickness And Build Quality On The Compressive Properties Of 304l Thin-Walled Structures Fabricated By Slm, Myranda Spratt, Sudharshan Anandan, Rafid M. Hussein, Joseph William Newkirk, K. Chandrashekhara, Heath Misak, Michael Walker

Materials Science and Engineering Faculty Research & Creative Works

The specific strength of lightweight lattice structures built with SLM is of interest to the aerospace industry. Honeycombs were manufactured with increasing wall thicknesses (which increases density) and tested under compression. The optimal strength to density ratio was determined from the resulting data. The build quality was also evaluated to determine how/if the results were influenced by the specimen quality. Differences between the nominal and as-built geometry were identified, but considered to be minimal. Microstructural evaluation of the specimens revealed a possible dependence on the ‘border scan’ properties, as the thickness of the specimens was such that the board scan …

Fast Prediction Of Thermal History In Large-Scale Parts Fabricated Via A Laser Metal Deposition Process, Lei Yan, Tan Pan, Joseph William Newkirk, Frank W. Liou, Eric E. Thomas, Andrew H. Baker, James B. Castle

Materials Science and Engineering Faculty Research & Creative Works

Laser metal deposition (LMD) has become a popular choice for the fabrication of near-net shape complex parts. Plastic deformation and residual stresses are common phenomena that are generated from the intrinsic large thermal gradients and high cooling rates in the process. Finite element analysis (FEA) is often used to predict the transient thermal cycle and optimize processing parameters; however, the process of predicting the thermal history in the LMD process with the FEA method is usually time-consuming, especially for large-scale parts. Herein, multiple 3D FEA models with simple assumptions on the heat source and its loading methods are compared and …

Mechanical Properties Evaluation Of Ti-6al-4v Thin-Wall Structure Produced By A Hybrid Manufacturing Process, Lei Yan, Wenyuan Cui, Joseph William Newkirk, Frank W. Liou, Eric E. Thomas, Andrew H. Baker, James B. Castle

Materials Science and Engineering Faculty Research & Creative Works

The hybrid manufacturing (HM) process combines the precision of computer numerical control (CNC) and the freeform capability of additive manufacturing to expand the versatility of advanced manufacturing. The intent of this paper is to explore the relationship between HM processing parameters and mechanical properties of the final parts manufactured by one type of HM process that combines laser metal deposition (LMD) and CNC milling. The design of experiment (DOE) is implemented to explore the Ti-6Al-4V thin-wall structure fabrication process with different HM build strategies. Vickers hardness, tensile test, and microstructure analyses are conducted to evaluate the mechanical property variance within …

Development Of An Engineering Diagram For Additively Manufactured Austenitic Stainless Steel Alloys, Zachary T. Hilton, Joseph William Newkirk, Ronald J. O'Malley

Materials Science and Engineering Faculty Research & Creative Works

Austenitic stainless steels are the most widely applied types of stainless steels, due to their good weldability and high corrosion resistance. A number of engineering diagrams exist for the purpose of providing insight into the behavior of these steels. Examples of these diagrams are constitution diagrams (aka Schaeffler Diagrams) which are used to approximate the solidification path of the alloy and the amount of retained ferrite in the solidified matrix. Other diagrams are the Suutala diagram, which approximates cracking susceptibility, and microstructural maps, which predict the solidification path by varying a processing parameter, such as cooling rate. By combining these …

The Influence Of Build Parameters On The Compressive Properties Of Selective Laser Melted 304l Stainless Steel, Okanmisope Fashanu, Mario F. Buchely, R. Hussein, S. Anandan, Myranda Spratt, Joseph William Newkirk, K. Chandrashekhara, H. Misak, M. A. Walker

Materials Science and Engineering Faculty Research & Creative Works

Process parameters used during Selective Laser Melting (SLM) process have significant effects on the mechanical properties of the manufactured parts. In this study, the influence of two build parameters (build orientation and hatch angle) on the compressive properties of 304L stainless steel was evaluated. SLM 304L samples were manufactured using three hatch angles, 0°, 67°,105° and two orientations, z-direction and x-direction, and tested using a compression frame according to ASTM E9-09. Bulk density was measured according to ASTM C373-17 before compression. Properties evaluated were the bulk density, yield strength, strength at 15% plastic-strain and strength at 30% plastic-strain. Results showed …

Design Of Lattice Structures With Graded Density Fabricated By Additive Manufacturing, Wenjin Tao, Yong Liu, Austin T. Sutton, Krishna C. R. Kolan, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Lattice structures fabricated by Additive Manufacturing (AM) processes are promising for many applications, such as lightweight structures and energy absorbers. However, predicting and controlling of their mechanical behaviors is challenging due to the complexity of modeling and the uncertainties exist in the manufacturing process. In this paper, we explore the possibilities enabled by controlling the local densities. A set of lattice structures with different density gradients are designed using an implicit isosurface equation, and they are manufactured by Selective Laser Melting (SLM) process with 304L stainless steel. Finite element analysis and compression test are used to evaluate their mechanical properties. …

Repeated Loading Model For Elastic-Plastic Contact Of Geomaterial, Jian Wang, Qimin Li, Changwei Yang, Caizhi Zhou

Materials Science and Engineering Faculty Research & Creative Works

A new nonlinear hysteretic model with considering the loading, unloading, and reloading processes is developed based on Drucker—Prager yield criterion and finite-element analysis. This model can be used for multiple repeated elastic—plastic normal direction contact problems between two identical spherical geomaterials. After examining the influence of material properties, strain hardening, and loading histories, we found that the hysteretic phenomena (represented by residual displacement and plastic work) become weak after the first cycle, and the subsequent cycles step into elastic shakedown state eventually. A critical number of cycles can be used to estimate the state of ratchetting, plastic shakedown, as well …

Detonation Synthesis Of Alpha-Variant Silicon Carbide, Martin Langenderfer, Catherine E. Johnson, William Fahrenholtz, Vadym Mochalin

Mining Engineering Faculty Research & Creative Works

A recent research study has been undertaken to develop facilities for conducting detonation synthesis of nanomaterials. This process involves a familiar technique that has been utilized for the industrial synthesis of nanodiamonds. Developments through this study have allowed for experimentation with the concept of modifying explosive compositions to induce synthesis of new nanomaterials. Initial experimentation has been conducted with the end goal being synthesis of alpha variant silicon carbide (α-SiC) in the nano-scale. The α-SiC that can be produced through detonation synthesis methods is critical to the ceramics industry because of a number of unique properties of the material. Conventional …

Modeling And Simulation Of Mass Flow Of Steel Plate/Slab During Hot Rolling, X. Wang, S. Ganguly, K. Chandrashekhara, Mario F. Buchely, Semen Naumovich Lekakh, David C. Van Aken, Ronald J. O'Malley, D. Bai, Y. Wang, T. Natarajan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The ability to predict mass flow behavior during hot rolling is essential to product quality. In this study, viscoplastic models of the steels from SSAB and U.S. Steel were developed based on experimental stress-strain curves. A three-dimensional nonlinear finite element model was built to simulate a reverse plate hot rolling and a hot strip rolling process. For plate rolling, a seven pass schedule was simulated. The plastic strain distributions during rolling were investigated. The results show that the surface of the plate has larger plastic strain than the center. In the case of hot strip rolling, the simulation predicts that …