Materials Science and Engineering Commons^™

Understanding The Deformation Mechanisms In Nanostructured Metals By A Novel Discrete Crystal Plasticity Finite Element Model, Rui Yuan

Doctoral Dissertations

"Implementation of nanostructured metals and alloys for use in engineering applications requires a detailed knowledge of the underlying deformation mechanisms in these materials. It is well known that plastic deformation in metals and alloys is mainly mediated by dislocation activities. Nonetheless, TEM observations and atomistic simulations indicate that dislocation-mediated plasticity in nanostructured metals and alloys is significantly different from that in their coarse-grained counterparts. Therefore, this dissertation focuses on the exploration of the deformation mechanisms in nanostructured metals via crystal plasticity finite element modeling and simulation.

A statistical grain boundary dislocation source model accounting for dislocation nucleation and slip events …

Experimental And Computational Investigation Of Multi-Principal Element Alloys, Mohsen Beyramali Kivy

Doctoral Dissertations

"Multi-principal element (MPE) alloys, unlike traditional alloys, consist of five or more principal elements with near equi-atomic compositions creating a large new compositional space for exploring new alloy possibilities. However, designing MPE alloys with the desired phases, microstructures and properties is challenging task, and there is a demand for basic research for a better understanding of structure-processing-property relations in these alloys.

In this Ph.D. research, different computational models and experiments were integrated to study phase formations, and mechanical properties of different MPE alloys. Density functional theory (DFT) and ab initio molecular dynamics (AIMD) simulations were used to determine crystal structures, …

Dirac Surface States Of Magnetic Topological Insulators, Seng Huat Lee

Doctoral Dissertations

"Magnetic topological insulator (TI) has been theoretically proposed to be a platform for inducing magnetic monopole and exhibit fascinating quantum phenomena, whereas topological superconductor can host Majorana fermions, particles that are their own antiparticles, which can be manipulated for topological quantum computing. In this dissertation, we experimentally demonstrated that by intercalation of different transition metals in the van der Waals gaps of Bi₂Se₃ TI, magnetism and even superconductivity can be induced. In Fe_xBi₂Se₃, antiferromagnetism is induced with a transition temperature at ~ 100 K. Coexistence of the Dirac surface state with …

Processing And Properties Of Wc-Based Cu-Ni-Mn-Zn Metal Matrix Composites Produced Via Pressureless Infiltration, Paul M. Brune

Masters Theses

"This research focuses on the processing and properties of tungsten carbide-based (WC-based) Cu-Ni-Mn-Zn metal matrix composites (MMCs) fabricated by pressureless infiltration. The first goal of this project was to test the wettability of Cu-Ni-Mn and Cu-Ni-Mn-Zn on various carbides. The sessile drop technique was employed to determine if they were suitable candidates for pressureless infiltration. The carbides investigated were TaC, WC, B₄C, and SiC. It was determined that both alloys had contact angles of less than 70⁰ on TaC, WC, and B4C, which is one requirement for pressureless infiltration. However, both alloys reacted with B₄C to …

Mold Flux Crystallization And Mold Thermal Behavior, Elizabeth Irene Peterson

Masters Theses

"Mold flux plays a small but critical role in the continuous casting of steel. The carbon-coated powder is added at the top of the water-cooled copper mold, over time it melts and infiltrates the gap between the copper mold and the solidifying steel strand. Mold powders serve five primary functions: (1) chemical insulation, (2) thermal insulation, (3)lubrication between the steel strand and mold, (4) absorption of inclusions, and (5)promotion of even heat flux. All five functions are critical to slab casting, but surface defect prevention is primarily controlled through even heat flux. Glassy fluxes have high heat transfer and result …

Evaluation Of Non-Chromate Passivations On Electroplated Γ-Phase Zinc Nickel, Steven Michael Volz

Masters Theses

"This research focused on the corrosion response and electrochemical behavior of electroplated low hydrogen embrittlement alkaline γ-phase zinc nickel with passivation layers. The motivation was the need to replace hexavalent chromium conversion coatings in military grade electrical systems with a more environment friendly alternative. The passivation layers were employed for the purpose of mitigating corrosion attack while maintaining low contact resistance. Trivalent chromium-based passivations and cerium-based passivations were compared against the currently used hexavalent chromium conversion coating. The coating systems were compared using electrochemical impedance spectroscopy, cyclic potentiodymanic scans, salt spray exposure testing, electrical resistance measurements, microstructure analysis, and compositional …

Cathodic Protection Measurement Through Inline Inspection Technology Uses And Observations, Briana Ley Ferguson

Masters Theses

"This research supports the evaluation of an impressed current cathodic protection (CP) system of a buried coated steel pipeline through alternative technology and methods, via an inline inspection device (ILI, CP ILI tool, or tool), in order to prevent and mitigate external corrosion. This thesis investigates the ability to measure the current density of a pipeline's CP system from inside of a pipeline rather than manually from outside, and then convert that CP ILI tool reading into a pipe-to-soil potential as required by regulations and standards. This was demonstrated through a mathematical model that utilizes applications of Ohm's Law, circuit …

In-Situ Control Of Substrate Temperature In Additive Manufacturing To Homogenize Micro-Hardness Of Laser Clad Deposits Using Thermo-Electric Cooling, Raghu Ram Kolla

Masters Theses

”Nickel hard-surfacing alloys are replacing hard Chromium coatings due to their excellent wear and corrosion-resistant properties. In laser cladding of these alloys, however, these properties can vary across the height of the deposit due to an accumulation of excess heat generated in the deposit during the process. This may result in uneven wear of the clad parts which can be detrimental for practical purposes. The research objective is to develop an in-situ cooling system that works in line with the laser deposition system to extract the excess heat buildup and reduce the variation in the hardness of the Ni-based clad …

An Investigation Of Borax For Sealing Inflow From Berea Sandstone, Tri-Tris Bao Nguyen

Masters Theses

"Well inflow control is a major challenge for the oil and gas industry. Erle Haliburton revolutionized well inflow control with his patent for cementing oil wells in 1921. Soon after, cement became the accepted material to establish well integrity and has been ever since. Cement is used in all phases of the well life cycle, and it is expected to hold indefinitely once set. Yet based on the nature of cement and the placement techniques, flow pathways may develop from improper cementing jobs or from cement degradation over time. Well integrity is especially crucial for wellbore plugging and abandonment, since …

Overview Of Co₂ Leakage Problems And Sealants For Co₂ Leakage Remediation, Shudai Peng

Masters Theses

"Excessive Carbon Dioxide (CO₂) emission has become a serious issue and caused lots of environmental problems. Carbon Capture and Storage (CCS) program has been developed to reduce the CO₂ content in the atmosphere. CO₂ storage has been targeted mainly on depleted oil or gas reservoirs and deep saline aquifers. However, leakage could occur through wellbores, cap rocks, formation faults, and fractures during and after CO₂ injection. To minimize the risk, different types of sealants have been investigated to prevent CO₂ leaks. The aim of this thesis is to provide a comprehensive review of the materials which could be used as …

3d Bioprinting Of Stem Cells And Polymer/Bioactive Glass Composite Scaffolds For Bone Tissue Engineering, Caroline Murphy, Krishna Kolan, Wenbin Li, Julie A. Semon, D. E. Day, Ming-Chuan Leu

Biological Sciences Faculty Research & Creative Works

A major limitation of using synthetic scaffolds in tissue engineering applications is insufficient angiogenesis in scaffold interior. Bioactive borate glasses have been shown to promote angiogenesis. There is a need to investigate the biofabrication of polymer composites by incorporating borate glass to increase the angiogenic capacity of the fabri-cated scaffolds. In this study, we investigated the bioprinting of human adipose stem cells (ASCs) with a polycaprolac-tone (PCL)/bioactive borate glass composite. Borate glass at the concentration of 10 to 50 weight %, was added to a mixture of PCL and organic solvent to make an extrudable paste. ASCs suspended in Matrigel …

Super-Strong Materials For Temperatures Exceeding 2000 ⁰C, Laura Silvestroni, Hans Joachim Kleebe, William Fahrenholtz, Jeremy Lee Watts

Materials Science and Engineering Faculty Research & Creative Works

Ceramics based on group IV-V transition metal borides and carbides possess melting points above 3000⁰C, are ablation resistant and are, therefore, candidates for the design of components of next generation space vehicles, rocket nozzle inserts, and nose cones or leading edges for hypersonic aerospace vehicles. As such, they will have to bear high thermo-mechanical loads, which makes strength at high temperature of great importance. While testing of these materials above 2000⁰C is necessary to prove their capabilities at anticipated operating temperatures, literature reports are quite limited. Reported strength values for zirconium diboride (ZrB₂) ceramics can exceed 1 GPa …

Control Of Columnar To Equiaxed Transition In Solidification Macrostructure Of Austenitic Stainless Steel Castings, Semen Naumovich Lekakh, Ronald J. O'Malley, Mark C. Emmendorfer, Brenton Hrebec

Materials Science and Engineering Faculty Research & Creative Works

Solidification macrostructure is of great importance for the properties and the quality of castings made from austenitic grade stainless steels (ASS) because there are limited options to change as-cast macrostructure in the solid condition. A typical cast macrostructure of ASS has a fine surface chilled zone followed by an elongated dendrite zone, columnar to equiaxed transition (CET) zone, and centrally located equiaxed crystals. Several castings from ASS were produced to determine the effects of casting geometry, chilling, and grain refinement on CET. The transient thermal field in solidified heavy castings was simulated and used to determine an isotherm velocity (V) …

Optimal Design And Freeform Extrusion Fabrication Of Functionally Gradient Smart Parts, Amir Ghazanfari

Doctoral Dissertations

"An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical density was developed. In this process, an aqueous paste of ceramic particles with a very low binder content (<1 vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Sample parts made of alumina and fully stabilized zirconia were produced using this process and their mechanical properties including density, strength, Young's modulus, Weibull modulus, toughness, and hardness were examined. Microstructural evaluation was also performed to measure the grain size, and critical flaw sizes were obtained. The results indicate that the proposed method enables fabrication of geometrically complex parts with superior mechanical properties. Furthermore, several methods were developed to increase the productivity of the CODE process and enable manufacturing of functionally graded materials with an optimum distribution of material composition. As an application of the CODE process, advanced ceramic components with embedded sapphire optical fiber sensors were fabricated and properties of parts and sensors were evaluated using standard test methods"--Abstract, page iv.

Processing, Microstructure, And Properties Of Engineered Diboride Structures, Connor Charles Wittmaier

Masters Theses

"The mechanical properties and processing parameters of boride ceramics in foam and laminate architectures were evaluated. The ceramic reticulated foam was produced through a polymer substrate replication technique and the hardness and compressive strength were tested. The laminate structure was tested to evaluate the flexure strength and work of fracture as a function of temperature.

The foam architecture was produced using a TiB₂ slurry coating on a polyurethane reticulated foam preform. Foams sintered to 2150⁰C displayed an average grain size of 8.9 ± 7.3 µm, and a hardness of 17.3 ± 2.4 GPa. Crush testing foams were sintered at …

Viscous Sealing Glass Compositions For Solid Oxide Fuel Cells, Cheol-Woon Kim, Richard K. Brow

Nuclear Engineering and Radiation Science Faculty Research & Creative Works

A sealant for forming a seal between at least two solid oxide fuel cell components wherein the sealant comprises a glass material comprising B₂O₃ as a principal glass former, BaO, and other components and wherein the glass material is substantially alkali-free and contains less than 30% crystalline material.

Nonlinear Characterization Of Gesbs Chalcogenide Glass Waveguides, Ju Won Choi, Zhaohong Han, Byoung Uk Sohn, George F.R. Chen, Charmayne Smith (Lonergan), Lionel C. Kimerling, Kathleen A. Richardson, Anuradha M. Agarwal, Dawn T.H. Tan

Materials Science and Engineering Faculty Research & Creative Works

GeSbS ridge waveguides have recently been demonstrated as a promising mid - infrared platform for integrated waveguide - based chemical sensing and photodetection. To date, their nonlinear optical properties remain relatively unexplored. In this paper, we characterize the nonlinear optical properties of GeSbS glasses, and show negligible nonlinear losses at 1.55 μm. Using self - phase modulation experiments, we characterize a waveguide nonlinear parameter of 7 W-1/m and nonlinear refractive index of 3.71 x 10-18 m2/W. GeSbS waveguides are used to generate supercontinuum from 1280 nm to 2120 nm at the -30 dB level. The spectrum expands along the red …

Computational Modelling For Phase Transformation Prediction In Super-Invar Alloys: Analytical And Experimental Data, Alexander S. Zhilin, Valeria R. Ramazanova, Joseph William Newkirk, Tarak A. Amine, Deborah Alvarenga

Materials Science and Engineering Faculty Research & Creative Works

The possibility of using computational modelling to predict phase transformation processes has been shown while examining super-invar samples. Due to the complicity of phase transformation processes in these alloys the correlation between modelling and experimental work has been described. Modelling allows basic background of composition behavior to be predicted but it doesn`t give the real structure components.

Strain Phase Separation: Formation Of Ferroelastic Domain Structures, Fei Xue, Yongjun Li, Yijia Gu, Jinxing Zhang, Long-Qing Chen

Materials Science and Engineering Faculty Research & Creative Works

Phase decomposition is a well-known process leading to the formation of two-phase mixtures. Here we show that a strain imposed on a ferroelastic crystal promotes the formation of mixed phases and domains, i.e., strain phase separation with local strains determined by a common tangent construction on the free energy versus strain curves. It is demonstrated that a domain structure can be understood using the concepts of domain/phase rule, lever rule, and coherent and incoherent strain phase separation, in a complete analogy to phase decomposition. The proposed strain phase separation model is validated using phase-field simulations and experimental observations of PbTiO …

Water-Soluble Glass Substrate As A Platform For Biodegradable Solid-State Devices, Shihab Md Adnan, Kwangman Lee, Mohammad Tayeb Ahmad Ghasr, Matthew O'Keefe, D. E. Day, Chang-Soo Kim

Materials Science and Engineering Faculty Research & Creative Works

A biodegradable glass material is utilized as a novel functional element of solid-state devices. A water-soluble borate glass substrate serves as the structural platform on which thin film device is built. The glass substrate completely dissolves in a saline solution in approximately 40 h. Intentional failure of the spiral device (RLC resonator circuit) as a result of rapid structural disintegration by dissolution is demonstrated in DC, AC, and RF ranges that agrees well with simulation. Adopting water-soluble glass elements is expected to be a viable approach to develop reliable all-inorganic biodegradable devices that are fully functional during an intended operational …

Method For Fabricating Biocompatible Porous Titanium, B. Sonny Bal, Tieshu Huang, M. N. Rahaman

Materials Science and Engineering Faculty Research & Creative Works

A method for fabricating porous metal constructs (such as porous Ti constructs) which may be used as implants in bone repair is disclosed. The method employs a new saltbath sintering process coupled with conventional powder metallurgy technology which is capable of fabricating porous metal constructs with controlled porosity and pore size having a lower production cost than conventional powder metallurgy methods.

Thermophysical Properties And Conduction Mechanisms In Asxse1-X Chalcogenide Glasses Ranging From X = 0.2 To 0.5, Jason Lonergan, Charmayne Smith (Lonergan), Devon Mcclane, Kathleen Richardson

Materials Science and Engineering Faculty Research & Creative Works

The arsenic (As) to selenium (Se) ratio in As_xSe_1-x glasses ranging from x = 0.2 to 0.5 was varied in order to examine the effect of chemical and topological ordering on the glass' thermal transport behavior. The fundamental thermal properties of glass transition temperature (T_g), thermal conductivity (k), and heat capacity (c_p) were experimentally measured using differential scanning calorimetry, transient plane source method, and ultrasonic testing. Based on topological constraint theory, inflections in T_g and k were found at the structural coordination number «r» of 2.4, whereas a slight increase in heat …

Computational Fluid Dynamics Study Of Molten Steel Flow Patterns And Particle-Wall Interactions Inside A Slide-Gate Nozzle By A Hybrid Turbulent Model, Mahdi Mohammadi-Ghaleni, Mohsen Asle Zaeem, Jeffrey D. Smith, Ronald J. O'Malley

Materials Science and Engineering Faculty Research & Creative Works

Melt flow patterns and turbulence inside a slide-gate throttled submerged entry nozzle (SEN) were studied using Detached–Eddy Simulation (DES) model, which is a combination of Reynolds–Averaged Navier–Stokes (RANS) and Large–Eddy Simulation (LES) models. The DES switching criterion between RANS and LES was investigated to closely reproduce the flow structures of low and high turbulence regions similar to RANS and LES simulations, respectively. The melt flow patterns inside the nozzle were determined by k–ε (a RANS model), LES, and DES turbulent models, and convergence studies were performed to ensure reliability of the results. Results showed that the DES model has significant …

Protective Conversion Coating On Mixed-Metal Substrates And Methods Thereof, Matthew O'Keefe, Surender Maddela

Materials Science and Engineering Faculty Research & Creative Works

Mixed-metal automotive vehicle bodies-in-white comprising ferrous metal surfaces, zinc surfaces, aluminum alloy surfaces, and magnesium alloy surfaces are cleaned and immersed in an aqueous bath comprising an adhesion promoter and an aqueous electrocoat bath (the adhesion promoter may be in the electrocoat bath. The adhesion promoter, which may be a cerium salt, is selected to react with each metal in the body surfaces to form an oxide layer that provides corrosion resistance for the surface and adherence for the deposited polymeric paint coating. The body is cathodic in the electrocoat deposition.

Broad-Spectrum Antibacterial Characteristics Of Four Novel Borate-Based Bioactive Glasses, Megan Ottomeyer, Ali Mohammadkah, D. E. Day, David J. Westenberg

Materials Science and Engineering Faculty Research & Creative Works

Bioactive glasses have been developed for medical applications in the body for bone and tissue repair and regeneration. We have developed a borate-containing bioactive glass (13-93B3, referred to as B3), which is undergoing clinical trials to assess its wound-healing properties. To complement the healing properties of B3, metal ion dopants have been added to enhance its antimicrobial properties. Bioactive glasses doped with silver, gallium or iodine ions were found to have broad spectrum antimicrobial effects on clinically relevant bacteria including MRSA. While the B3 glass alone was sufficient to produce antibacterial effects on select bacteria, adding dopants enhanced the broad-spectrum …

Properties Of Partially Stabilized Zirconia Components Fabricated By The Ceramic On-Demand Extrusion Process, Wenbin Li, Amir Ghazanfari, Devin Mcmillen, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The Ceramic On-Demand Extrusion (CODE) process is a novel additive manufacturing process for fabricating dense ceramic components from aqueous pastes of high solids loading. In this study, 3 mol% Y₂O₃ stabilized tetragonal zirconia polycrystal (3Y-TZP) parts were fabricated using the CODE process. The parts were then dried in a humidity controlled environmental chamber and sintered under atmospheric pressure. Mechanical properties of the sintered parts were examined using ASTM standard test techniques, including density, Young’s modulus, flexural strength, Weibull modulus, fracture toughness and Vickers hardness. The microstructure was analyzed, and grain size was measured using scanning electron microscopy. …

3d Printing Of A Polymer Bioactive Glass Composite For Bone Repair, Caroline Murphy, Krishna C. R. Kolan, M. Long, Ming-Chuan Leu, Julie A. Semon, D. E. Day

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A major limitation of synthetic bone repair is insufficient vascularization of the interior region of the scaffold. In this study, we investigated the 3D printing of adipose derived mesenchymal stem cells (AD-MSCs) with polycaprolactone (PCL)/bioactive glass composite in a single process. This offered a three-dimensional environment for complex and dynamic interactions that govern the cell’s behavior in vivo. Borate based bioactive (13-93B3) glass of different concentrations (10 to 50 weight %) was added to a mixture of PCL and organic solvent to make an extrudable paste. AD-MSCs suspended in Matrigel was extruded as droplets using a second syringe. Scaffolds measuring …

Powders For Additive Manufacturing Processes: Characterization Techniques And Effects On Part Properties, Austin T. Sutton, Caitlin S. Kriewall, Ming-Chuan Leu, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Powder-bed based Additive Manufacturing is a class of Additive Manufacturing (AM) processes that bond successive layers of powder by laser melting to facilitate the creation of parts with complex geometries. As AM technology transitions from the fabrication of prototypes to end-use parts, the understanding of the powder properties needed to reliably produce parts of acceptable quality becomes critical. Consequently, this has led to the use of powder characterization techniques such as scanning electron microscopy (SEM), laser light diffraction, x-ray photoelectron spectroscopy (XPS), and differential thermal analysis (DTA) to both qualitatively and quantitatively study the effect of powder characteristics on part …

Designed Extrudate For Additive Manufacturing Of Zirconium Diboride By Ceramic On-Demand Extrusion, Devin Mcmillen, Wenbin Li, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This work describes a process by which zirconium diboride (ZrB2) parts may be fabricated using the Ceramic On-Demand Extrusion (CODE) process. An oxide-carbide-nitride system consisting of ceramic powders and pre-ceramic organics, designed to yield ZrB₂ after reaction sintering, has been developed to produce an aqueous-based extrudate for subsequent processing in the CODE system. Pressurelessly sintered test specimens containing 1 wt% PVA binder achieve high relative density ≥ 99%. The viscoelastic response of the extrudate was characterized via spindle rheometry with a small sample adapter. Batches with 1 wt% PVA and 0.5 wt% Methocel show strong shear thinning characteristic, under …

A Novel Extrusion-Based Additive Manufacturing Process For Ceramic Parts, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical density is introduced in this paper. In this process, an aqueous paste of ceramic particles with a very low binder content ( < 1 vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Several sample parts for various applications were produced using this process and their properties were obtained. The results indicate that the proposed method enables fabrication of large, dense ceramic parts with complex geometries.