Materials Science and Engineering Commons^™

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 …

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 …

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 …

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 …

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, …

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 …

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 …

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 …

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 …

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 …

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 …

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 …

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 …

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 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 …

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 …

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.

Friction Stir Spot Welding Of Aluminum Alloys, Wei Yuan

Masters Theses

"Efforts to reduce vehicle weight and improve safety performance have resulted in increased application of light-weight aluminum alloys and a recent focus on the weldability of these alloys. Friction stir spot welding (FSSW) is a solid state welding technique (derivative from friction stir welding (FSW), which was developed as a novel method for joining aluminum alloys). During FSSW, the frictional heat generated at the tool-workpiece interface softens the surrounding material, and the rotating and moving pin causes material flow. The forging pressure and mixing of the plasticized material result in the formation of a solid bond region. The present work …

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. …

Synthesis Of Nanostructured Conducting Polymers And Their Application As Gas Sensors, Zhe-Fei Li

Masters Theses

"A single-step, bottom-up technique based on a nanostructured conducting polymer has been used to fabricate sensors. Small amounts of aqueous solutions of aniline, a dopant, and an oxidant were placed on an interdigitated electrode array. Ultraviolet (UV)-irradiation of the solutions enhanced polymerization, yielding a highly porous film of polyaniline nanofibers with mean diameters of around 100 nm and lengths on the order of 1 µm. Solutions that were not irradiated formed bulk-like polyaniline films. Nanofibers and bulk polyaniline sensors were exposed to vapors in an argon carrier gas including: chloroform, a weak proton donor; toluene, a vapor that causes polymer …

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 …

Development Of Knowledge Base Of Concrete Bridge Maintenance System, Bahre Karam

Masters Theses

Bridges are the key elements of any transportation system of a country. Bridges are expensive structures and therefore, it's essential to maintain and repair them on regular basis. Almost one third of the bridges in United States are reported to be in some what deteriorated conditions. This Research presents the development of knowledge base for decision support system for concrete bridges.

During this research various concrete bridge problems are investigated including COlTosion, delamination, cracks, spalling and scour etc. The inspection tools and techniques are addressed in order to identify these problems both for above and below water surface. The various …

Process Development And Applications Of A Dry Film Photoresist, Phaninder R. Kanikella

Masters Theses

"In this study, dry film photoresist was patterned using UV lithography and the sidewall profile was optimized to achieve vertical sidewalls. Sidewall verticality of dry film is very important for better pattern transfer"--Abstract, page iv.

Properties Of Alkaline-Resistant Calcium-Iron-Phosphate Glasses, Jiawanjun Shi

Masters Theses

"The physical properties and alkaline corrosion resistant properties of calcium-iron-phosphate glasses were studied. The addition of Fe₂O₃ decreases the thermal expansion coefficient and increases the glass fiber's Young's modulus in comparison with the addition of CaO. Bulk glass dissolution behavior in alkaline Lawrence solution was studied by weight loss experiments, Raman spectroscopy, and analytical scanning electron microscopy. The corrosion of glass powder in NaOH solution was studied by X-ray diffraction, infrared spectroscopy and high pressure liquid chromatography. The results show that the dissolution rate decreases when the phosphate chain length decreases. Calcium oxide can improve the glass durability in high …

Friction Stir Processing Of Cast Magnesium Alloys, Timothy A. Freeney

Masters Theses

"This thesis investigates the feasibility and benefits of using friction stir processing as a thermo-mechanical microstructural modification tool for local property enhancement or casting repair of magnesium alloys, specifically high strength EV31A and WE43"--Abstract, page iv.