Materials Science and Engineering Commons^™

Plastic Strain Accommodation And Acoustic Emission During Melting Of Embedded Indium Particles In Aluminum, Michael M. Kuba

Masters Theses

"Melting of micron-sized (0.2 to 3 µm diameter) indium particles embedded in an aluminum matrix was discovered to produce acoustic emission. Melting of embedded immiscible particles produces a pure dilation during the phase transformation and has no long-range diffusion field to control the speed of transformation. It was found that acoustic emission can no longer be considered as a criterion of displacive transformations and that melting of micron-sized embedded particles is strain energy controlled. Acoustic emission was confirmed to result from the rapid relaxation of aluminum around indium particles embedded on grain boundaries. Prismatic punching of dislocation loops is proposed …

The Effect Of Sulfur On Structure And Conversion Of Bioactive Borate Glasses, Ali Mohammadkhah

Masters Theses

"The effect of sulfur on glass structure and the conversion process of bioactive CaO-LI₂O-B₂O₃ glasses were studied. One glass without and two glasses with different amounts of sulfur were made using conventional melting and dry quenching techniques. These glasses reacted with a phosphate solution and converted to hydroxyapatite. Particles (150-355µm) were reacted in 0.25 and 0.5 molar K₂HPO₄ solutions at 37⁰C for 2 to 96 hours. The weight loss of the particles and the final pH of the solution were measured. The weight loss measurements indicated that the reaction rate increases with …

Sputter Deposition Of Thin-Film Capacitors Onto Low Temperature Co-Fired Ceramic Substrates, Jack Murray

Masters Theses

"Single layer thin film capacitor structures were fabricated on the surface of low temperature co-fired ceramic (LTCC) substrates using sputter deposition. The capacitor structures had areas between ~10⁴ µm² to ~10⁶ µm² and featured ~200 nm Al or Pt electrodes with 150-1500 nm Al₂O₃ dielectric layers. Impedance analysis and current-voltage testing were carried out to determine the effect of electrode material and dielectric thickness upon capacitor performance. Capacitance values for devices with Al electrodes ranged from ~10 to ~700 pF, depending on capacitor area and dielectric thickness, and the fit to expected values was better than devices with Pt or …

Effect Of Nickel On Castability Of Chromium Molybdenum Steel & The Dynamic Fracture Toughness Of Hy-130, Abhilash Dash

Masters Theses

"The fill lengths of Ni alloyed Cr-Mo steels obtained from fluidity studies (Paper 1) varied linearly with superheat. A 5% Ni steel showed a maximum fill length compared to other steels tested. Ni decreased the liquidus, solidus, and dendritic coherency temperature, but it did not have any significant effect on volume fraction (0.27-0.31) of the solid phase at the dendrite coherency point. The filling time obtained experimentally at 150 C⁰ superheat for 5% Ni steel (HY 130) was close to 1.4 s. For similar conditions, the predicted fill time using a Magmasoft model was close to 1.9 s. Modeling results …

Thermo-Physical Properties Measurement And Steel - Ceramic Shell Interactions In Investment Casting, Chirag Mahimkar

Masters Theses

"Investment casting is a process in which a ceramic shell is prepared on a wax or foam pattern. The wax is melted out or the foam is burnt out and the shell is sintered to have sufficient strength to withstand casting conditions. The investment casting process is very important as it produces near net shape castings which reduce the need for subsequent operations of castings like machining etc. Investment casting shells are subjected to a number of heating cycles during pattern removal, firing, preheating before pouring and finally during solidification. The thermo-physical properties of the shell play an important role …

Crack Formation In Investment Casting Ceramic Shells, W. A. Everhart

Masters Theses

"This thesis is a collection of papers that discuss shell cracking in investment casting during pattern removal. The application of rigid polymeric foam for large investment casting patterns with complex geometries can improve the dimensional tolerances and the surface quality of the casting. However, these pattern materials have a tendency to promote crack formation in investment casting shells during pattern removal by firing.

The first two papers discuss the factors affecting shell cracking and methods to prevent it. Experimental methods were combined with finite element modeling to predict stress in the shell. A 3D nonlinear finite element model was developed …

Calcium Wire Ladle Treatment To Improve Cleanliness Of Centrifugal Cast Steel, Edith Yolanda Martinez Silva

Masters Theses

"Centrifugal casting provides the opportunity of combining large centrifugal forces and directional solidification to reduce non-metallic inclusions in the cast steel product. Calcium treatment in the ladle has the potential of reducing and modifying non-metallic inclusions to achieve better machinability and mechanical properties. The objective of this research is to analyze the combined effects of calcium wire ladle treatment and centrifugal casting on the number, size, composition and morphology of non-metallic inclusions in centrifugally cast steel products.

All experiments were completed at an industrial foundry. The experiments involved feeding calcium wire into the ladle after argon oxygen decarburization (AOD) and …

Experimental Study On Thermal Treatment Of Used Printed Wiring Boards (Pwbs), Xiangjun Zuo

Masters Theses

The availability of cheaper and better electronic products as a result of the rapid innovation in technology in past decades has driven the production of e-waste forward. Printed wiring board (PWB) is a component made of one or more layers of insulating material with electrical conductors. The existing processes of recycling PWBs use pyrometallurgical or hydrometallurgical methods, which generate atmospheric pollution. Green recycling has obvious benefits to decrease the amount of PWBs. Green recycling includes two features, 1) little or zero pollution of toxic gases and heavy metals, and 2) efficient (quick and economical) recycling.

The aim of this work …

Zinc Iron Phosphate Glasses For Enameling Applications, Sagnik Saha

Masters Theses

"New compositions of low temperature black glasses were developed that are suitable as frits for enameling soda-lime silicate (S-L-S) glass substrates. Zinc iron phosphate glasses are of interest for this application because they possess dilatometric low softening points (under 600ºC) and have coefficients of thermal expansion that are compatible with S-L-S glass (in the range 90-110x10⁻⁷/ºC). The development of compositions with excellent chemical durability, particularly in acidic conditions, is also desired. Compositional modification were made to the (Na₂O+K₂O)·ZnO·MnO·Fe₂O₃·P₂O₅ glass system using design of experiments. The compositional boundaries used in the design were based on earlier work at Missouri S&T. The …

Foundry Parameters For Casting High-Aluminum Lightweight Steel In Complex Shapes, Angella Marie Schulte

Masters Theses

"This work investigated the liquid metal treatment and molding practices for Fe- 30wt.%Mn-9wt.%Al-1wt.%Si-0.9wt.%C-0.5wt.%Mo steel. The goal of this research was to determine the process conditions that would produce a tough Fe-Mn-Al-C alloy and the appropriate mold design to produce a defect-free P900 plate.

Notch toughness of age-hardenable Fe-Mn-Al-C alloys decreases as phosphorus increases. Thermodynamic calculations and experimental work show that additions of Ca followed by Ce can be used to mitigate the deleterious effects of phosphorus, and the addition of Ar-stirring can be used to decrease the number of harmful aluminum nitride inclusions. In the solution-treated and aged condition (Brinell …

The Properties And Structure Of Tin Phosphate Glasses Modified With Other Oxides, Jong Wook (Austin) Lim

Masters Theses

"The main objective of this research was to evaluate the properties and structures of glasses from the stannous (SnO) phosphate system for possible use in low temperature optical applications. Glasses in the binary xSnO-(100-x)P₂O₅ system (50 ≤ x ≤ 70) were prepared and their thermal and optical properties were evaluated. Differences in glass transition temperatures (T_g) measured here and reported in the literature were explained by differences in the residual water content in the glasses, as determined by infrared spectroscopy. In general, increasing the SnO content of the binary glasses increased the refractive index and the glass transition …

Resistance Switching In Electrodeposited Magnetite Thin Films, Samantha Glen Matthews

Masters Theses

"The resistance switching phenomenon has been extensively studied in metal oxide thin films for its applications in the non-volatile memory industry. The research presented here focuses on magnetite thin films which have been electrodeposited onto gold-sputtered glass substrates via the electrochemical reduction of a Fe(III)-triethanolamine complex in aqueous alkaline solution. Magnetite was chosen for its usefulness in read/write memory applications, its high Curie temperature, its metal-to-insulator (Verwey) transition, and its half-metallic character and attendant spintronic properties. Resistance switching behavior caused by a reversible redox reaction at the anode was observed in the films, demonstrating that electrodeposited films show the same …

Controlling Strength And Permeability Of Silica Investment Casting Molds, Darryl M. Kline

Masters Theses

"Investment casting is a metal casting process in which a ceramic mold is created around a disposable pattern using dip coating. The fine silica flour making up most of the mold gives the benefits of a smooth internal mold surface and high density. The high density allows for investment casting molds to be thinner and lighter than sand-based molds, but gives substantially smaller gaps between particles for air flow. This research focused on the design and improvement of the formulation for making investment casting molds with customizable physical properties. Properties of the molds, specifically flexural strength, permeability, and physical structure, …

Evaluation Of Alternative Methods For Surface Preparation And Deposition Of Cerium-Based Conversion Coatings On Aluminum Alloys, William J. Gammill

Masters Theses

"This thesis investigates alternative surface preparation and deposition methods for cerium-based conversion coatings (CeCC) on high strength aluminum alloys. Cerium-based conversion coatings are being investigated as a more environmentally friendly replacement for chromium-based conversion coatings. Currently, the alloys are immersed in strong alkaline and acidic solutions to prepare the aluminum surfaces for conversion coating, in which immersion may not be suitable for all situations. Alternatives to this method were investigated, including wipe application of solution, ultrasonic processing in deionized water, and abrasive blasting with alumina. AI 7075-T6 test panels were prepared using each of these methods and compared to a …

Sintering And Microstructural Effects On Mechanical Properties Of Zirconium Carbide-Tungsten Cermets, Melissa M. Giles Craft

Masters Theses

"Zirconium carbide-tungsten cermets were prepared by in situ reaction sintering a mixture of zirconia and tungsten carbide. Tungsten is a refractory metal with a melting point of 3422⁰C; however, its mechanical strength decreases significantly with increasing temperature. One approach to improve the elevated temperature strength is to add ceramic particulates to the matrix. Zirconia and tungsten carbide were compacted and then reacted and sintered in a single step by heating to 2050⁰C. The resulting stoichiometric zirconium carbide-tungsten cermet had a relative density greater than 96%. Cermets with two different grain sizes were produced by altering the final sintering temperature. Sintering …

The Effect Of Near-Surface Metallurgy On The Machinability Of Cast Iron, William Dewey Peach

Masters Theses

"The increasing performance and durability of cutting tool inserts have created metallurgical challenges for production foundries to produce near-net shaped castings within strict dimensional tolerances. In order for foundries to take full advantage of the increased cutting speed capabilities, it becomes necessary to reduce machining allowances and produce much more stable casting surfaces. To accomplish this, a better understanding of the complex microstructures formed within the first 0.120 in. (3 mm) of the mold/metal interface (as-cast surface) is necessary. The goal of the work presented here was to examine the microstructures formed in the near-surface region of gray iron castings, …

Friction Stir Processing Of Laser Metal Deposited Ti-6al-4v, Romy Francis

Masters Theses

"Laser metal deposition (LMD) can form near net shaped components for aerospace applications. Ti-6Al-4V is a widely used aerospace alloy and fabrication of this alloy using LMD is gaining popularity. Improved mechanical properties are always a requirement in aerospace alloys and research is constantly being conducted to improve the properties of components formed from this alloy. Friction Stir Processing (FSP) in the past has been used as a method to change the surface properties of materials through microstructural modifications. The changes in properties can include hardness, corrosion resistance, fatigue strength, etc. The first section of this thesis is based on …

Friction Stir Processing Of Magnesium Alloys, Gaurav Bhargava

Masters Theses

"Magnesium alloys have been fast catching up their attention in applications where both lightweight and exceptional strength is desired. But magnesium alloys suffer formability issues which limit their use to cast applications when designing complicated shapes. Friction stir processing (FSP) is technique for, imparting a fine-grained, homogeneous microstructure by which both strength and ductility can be enhanced. The results from the first part of present work showed that AZ31 alloy when employed the use of FSP, yielded significant strength and ductility gains but on the cost of anisotropy. The cause of anisotropy was investigated to be correlated to texture evolution …

The Corrosion Of Ni₃Si Alloys In Sulfuric Acid, Christopher Marc Larson

Masters Theses

"Hydrogen production from water, the world's most renewable natural resource, can provide an economical and sustainable form of energy for the future. One means to achieve this is with a nuclear reactor-based sulfur-iodine (S-I) thermochemical cycle. Currently there are few materials available, other than precious metals like gold and platinum, that possess the corrosion resistance and mechanical properties required for the sulfuric acid decomposition loop of the S-I process. However, alloys based on Ni₃Si show promise to be a more affordable, corrosion resistant materials option for this technology. In this study, the corrosion behavior of NiSi₂₂ and NiSi₂₀(Nb,Ti)₃ alloys in …

Investment Shell Cracking, Edward A. Druschitz

Masters Theses

"Shell cracking is the single greatest problem affecting investment casters. A clearer understanding of the factors affecting the melt profile of the wax can be gained using computational fluid dynamics (CFD) to model the interaction among 1) the thermal conductivity of the wax, 2) the thermal conductivity of the shell, and 3) the temperature of the autoclave during the autoclave de-waxing cycle. The most favorable melt profile results from a high autoclave temperature (438⁰K to 458⁰K) and saturated thermal conductivity of the shell (1.36 to 1.40 Wm⁻¹k⁻¹) in conjunction with a low wax thermal conductivity (0.33 Wm⁻¹k⁻¹). These parameters reduce …

Quench Factor Analysis Of Wrought And Cast Aluminum Alloys, Vishwanath Gandikota

Masters Theses

"Mechanical property variation across the cross section of heat treatable aluminum alloys is a major concern. To minimize such variation, a proper understanding of kinetic transformations and estimation of mechanical properties is required. The Jominy end quench test has been used successfully to study the effect of quench rate on the final heat treated properties of wrought and cast aluminum alloys. This test produces varying cooling rates along the length of a cylindrical sample cooled with water at one end. Jominy bars of wrought and cast aluminum alloys were solutionized, endquenched, and aged to T6 temper condition after delays of …

Synthesis Of Surface Composites Using Friction Stir Processing, Bharat Gattu

Masters Theses

"Composite materials have an edge over monolithic materials due to higher strength/stiffness - to - density ratios, improved fatigue and wear resistance and better high temperature properties. Surface composites provide improved tribological properties such as wear resistance, friction coefficient and corrosion resistance. Friction stir processing (FSP) which originated from friction stir welding (FSW - a method for joining aluminum alloys) is a solid state technique to modify the microstructure of the alloys. During FSP the frictional heat generated at the tool - work piece interface plasticizes the material allowing it to flow around the pin. The combined effect of the …

Inclusion Modification In Steel Castings Using Automated Inclusion Analysis, Vintee Singh

Masters Theses

"The objective of this research is to study the effects of changing the melt and ladle practices (deoxidation, slag, refractory types, etc.) in steel foundries on the cleanliness and toughness of steel castings. This study used an automated inclusion analyzer ASPEX PICA-1020, which provides a rapid and accurate method for determining the composition, size, number, and spacing of the inclusions present in steel samples. The first step in this research was to complete a series of industrial tests to benchmark the current foundry ladle practices with respect to cleanliness of the cast steel. Trials were conducted at steel foundries using …

Fatigue Of Friction Stir Welded Lap Joints With Sealants, Kenneth Doering

Masters Theses

"A lack of understanding of corrosion fatigue in friction stir welded aluminum joints prevents friction stir welding from being implemented in aerospace applications. Fatigue testing reveals a 60-75% reduction in the fatigue life of friction stir welded aluminum lap joints immersed in 3.5% NaCl solution (corrosion fatigue) compared with that of lap joints tested in ambient air. The loss in fatigue life is attributed to accelerated fatigue cracking due to hydrogen environment embrittlement. Two polymer sealant candidates are investigated: silicone rubber and nylon-11. Both sealant candidates can be applied prior to welding and seal the faying surface gaps in lap …

Friction Stir Form Welding Of Aluminum Structures, Kamini Ashokkumar Gupta

Masters Theses

"The objective of this work was to demonstrate the applicability of friction stir welding (FSW) technology in the automotive industry. Increasing fuel prices, stringent safety and emission norms are continuously striving automakers to make lightweight, fuel efficient vehicles. Automotive engineers are researching for alternate materials in order to meet weight savings targets. Use of aluminum in place of steel in a car has been increasing for making lightweight vehicles. Conventional welding and spot welding are used as preferred joining methods by the automotive industry. However, if aluminum is used in place of steel alternate joining methods are to be researched. …

Evaluation Of Su8 And Ruthenium Oxide Materials For Microfluidic Devices, Margaret Theresa Audrain

Masters Theses

"This thesis investigates two materials, SU8 photoresist and RuO₂, for possible incorporation into a self-calibrating microfluidic biosensor. The negative, epoxy based photoresist SU8 has been widely used in the fabrication of micro-electro-mechanical systems (MEMS) devices. This is due to its many desirable features that make it a suitable material for a wide variety of MEMS applications. The effects cross-linking (exposure dose) and bonding time have on bond strength and plasma modification of the SU8 surface were investigated as well as the bond strength of etched SU8. It was shown that adhesive bonding was an effective method of bonding, with bond …

Modeling And Measurement Of Thermal Residual Stresses And Isotope Effects On Thermo Physical Properties Of Zrb₂-Sic Ceramics, Michael P. Teague

Masters Theses

"Commercially available finite element modeling software (ABAQUS) was used to investigate the internal residual stresses that develop as a result of cooling from processing temperatures in ZrB₂-SiC ceramics. The size and shape of the SiC particles were varied to evaluate their effect on the residual stresses. Results were compared to experimental data and showed similar trends, where increasing SiC particle size increased tensile stress and also decreased strength. Models were used to analyze benefits of novel shaped SiC inclusions and also better understand the short comings of the composites. An attempt to validate the models using neutron diffraction to measure …

Recovery Of Materials From Recycling Of Spent Furnace Linings, Phani Krishna Angara Raghavendra

Masters Theses

"The objective of this research study is to evaluate the technical feasibility of liberating metal entrapped in the spent melting furnace linings obtained from a non-ferrous metal producer and develop an economic technique to recycle all of the materials presently landfilled. Five to six million pounds of spent melting furnace linings are landfilled annually from this non-ferrous producer"--Abstract, page iii.

Thermal Characterization And Vibration Of Solder Alloys, Brandon Lee Brinkmeyer

Masters Theses

"Recent legislation and growing environmental concerns have forced the electronics industry to discontinue the use of tin-lead (SnPb) solder. Although the legislation did not directly affect aerospace and defense industries, future transitions to lead-free (LF) solders are inevitable. Differences exist between these high reliability systems and consumer electronics, first of which is a very small production rate and a long life cycle which often leads to repair or rework procedures which introduce the potential for mixing of SnPb and LF solder. In this study, Sn-3Ag-0.5Cu (SAC305) was mixed with Sn-37Pb solder in amounts of 0, 25, 50, 75, and 100 …

Elevated Temperature Behavior Of A Magnesium Based Bulk Metallic Glass, Neal C. Ross

Masters Theses

"Bulk metallic glasses are a new material set that possess interesting and exceptional engineering properties. Their study has been a major focus of research in metallurgy since the early 1990s, and recently their properties have led to application in specialized applications. Limitations including material cost, maximum attainable cast diameters, and high density have prevented the widespread use of these materials. In particular, the high density of most bulk metallic glasses has significantly reduced their appeal to the aerospace community. In an effort to overcome this, research is being performed on producing lower density glass forming systems based on magnesium and …