Materials Science and Engineering Commons^™

Toward Understanding Commercial Additives For Zincate Electrogalvanizing, Margaret Scott

Masters Theses

"Cyanide zinc electrogalvanizing has been used for many years to produce high quality and uniform zinc coatings. Due to toxicity concerns, a significant amount of research has occurred to remove the use of cyanide while still producing a similar deposit. One of the resulting plating chemistries is the alkaline zincate bath.

Alkaline zincate plating has the advantages of low startup cost, low toxicity, and low corrosion rate. Despite these advantages, alkaline bath conditions do not produce acceptable zinc deposits without the use of plating additives, which can promote lustrous, smooth deposits. This research aims to: (1) generate fundamental electrochemical data …

The Effects Of Rigid Polyurethane Foam As A Confinement Material On Breaching Charge Detonations, Nathan Franz Paerschke-O'Brien

Masters Theses

"The effects of a rigid polyurethane foam used as a confinement material on four types of breaching explosives were tested, focusing on the changes in shockwave peak pressures, detonation load compression forces, and brisance cratering abilities. The Plate Dent testing procedure was modified to incorporate a load cell force sensor, and two air overpressure sensors were included adjacent to the blast to quantify each test result. The testing variables focused on the polyurethane foam cure times and thickness volumes around the breaching explosives to determine the breaching charges' optimal energy output capabilities when confined by the foam material. The rigid …

Prediction Of Isotropic Strain Hardening Material Properties Using Gradient Boosted Regression Tree Method And Hyperparameter Optimization, Darren R. Promer

Masters Theses

In this study a new technique is proposed for the determination of elastic-plastic stress-strain relations for isotropic materials using the force-displacement output from an instrumented indentation test, finite element simulation, and machine learning methods. This non-destructive testing methodology has promising potential for industry implementation. Applications to benefit from this method include the characterization of localized material properties on surface engineered components, and the post-manufacturing assessment of material properties for items such as additively manufactured metallic components and load-bearing welded joints.

Currently, the capability of the instrumented indentation test for determining material properties is limited to the elastic modulus and surface …

A Multiscale Thermomechanical Metal Additive Manufacturing Simulation And The Impact Of Geometry On Residual Stress And Distortion, Luis Fernando Silva Velasco

Masters Theses

Metal additive manufacturing is an enabling technology for the rapid prototyping and manufacturing of geometrically complex parts that would otherwise be difficult or impossible to manufacture. However, the manufacturing process can produce undesired residual stresses and distortions. The first part of the work describes the implementation of a multiscale, thermo-mechanical simulation modeling the metal powder bed fusion additive manufacturing process. NASA’s Micromechanics Analysis Code was is to incorporate the microscale effects of an evolving material porosity on the predicted macroscale residual fields. The simulation shows that modeling an evolving material porosity, as the material transitions from a metal powder to …

Investigation Of Selective Laser Melting Fabricated Internal Cooling Channels, Colin Jack

Masters Theses

Channels where coolant is run to cool a system are common in injection mold tooling. Conventionally, these channels are machined into the mold. This has limited the design of mold cooling systems to the constraints of traditional machining processes, where straight circular channels machined from cast material are typical. The transfer of heat away from the part cavity into these cooling channels has a large effect on the cooling time of the injection mold cycle. In this investigation, laser powder bed fusion processes were used to create non-circular cooling channels. To compare cooling performance, elliptical and circular channels of equal …

Cellulose Based Separator For High-Performance Lithium-Ion Batteries, Akshit Vaidya

Masters Theses

During the past two decades, lithium-ion batteries (LIBs) have gained great success in the field of portable devices, and currently, are penetrating to the market of vehicles. Compared to the fast development of LIBs, little efforts have been dedicated to the separator, which is one of the most important components of LIBs. Primarily, the lithium-ion battery separator has two functions, one is to prevent direct contact between the positive and negative electrodes, and the other is to provide a path for effective ionic transportation. Currently, the separator market of LIBs is dominated by polyolefin materials such as polypropylene, polyethylene, and …

Verification Of Effectiveness Of Spot-Heating Technique In Reducing Spread Of Weld Lines In Injection Molded Plastic Products, Shah Ashikul Abed Sakar

Masters Theses

In producing a plastic part in an injection molding machine many physical factors related to the machine, such as injection pressure, holding pressure, heater temperature, etc. play their roles in the overall quality of the produced part. There are many aspects of the quality of a plastic part, such as part strength, part dimensions, and part surface finish. If any of those aspects gets compromised, the part is considered to have some defects. Of all defects found in injection-molded plastic parts, one most common defect is the presence of weld lines.Weld lines are formed when the flow of the molten …

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

Masters Theses

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

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

Masters Theses

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

Two architectures in particular, …

Intrinsic Mechanical Properties Of Zirconium Carbide Ceramics, Nicole Mary Korklan

Masters Theses

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

Inclusion Control In Steel Castings, Koushik Karthikeyan Balasubramanian

Masters Theses

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

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

Masters Theses

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

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

Masters Theses

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

The Transcriptional Response Of Phanerochaete Chrysosporium And Trametes Versicolor To Growth On Stems Of Helianthus Argophyllus (Silverleaf Sunflower), Nadh Hamoud Alsubaie

Masters Theses

Traditional physicochemical and physicomechanical pretreatment technologies have improved the deconstruction of lignocellulose, but often require high energy inputs and added chemical reagents. Recent studies have demonstrated the use of white-rot fungi as alternative biological pretreatment agents that can mitigate these concerns. Although, white-rot fungi have been shown to grow on a variety of non-woody substrates, they have not been explored with respect to sunflower, which has the potential to provide raw materials for both biodiesel and bioethanol. In the present study, Silverleaf sunflower stems (Helianthus argophyllus) were used as substrates for the white-rot fungi Phanerochaete chrysosporium and Trametes …

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 …

Characterization Of The Surface Condition In Aa6061 Resulting From Deep Rolling As A Function Of Common Industrial Parameters, Andrew Kenneth Layer

Masters Theses

"Roller burnishing is widely used in industry to improve the surface finish and fatigue life of components. As weight reduction continues to grow in the automotive and transportation industries, deep rolling can help maintain product performance by mitigating the increase in component stresses resulting from lower weight systems. Deep rolling parameters such as tool, applied angle, feed rate, spindle speeds, and relative tool direction all affect cycle time, product performance, and appearance. The effects of common industrial parameters on the resultant surface roughness and residual stress profiles were studied in this investigation. The samples were manufactured on a CNC lathe …

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 …

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 …

Inclusion Engineering In Femnal Steels, Rairu Vaz Penna

Masters Theses

"Low density high Mn and Al steels, or FeMnAl steels, show great promise for military vehicles and automotive applications in which high strength and toughness is a requirement. However, these steels are subject to processing challenges including development of oxide and nitride inclusions during melting and casting as well as a large as-cast grain size and heavy interdendritic segregation. This can lead to non-uniform heat treatment response and cracking during subsequent hot rolling. Adding up to 10%Al lowers the density of these steels by as much as 15%, unfortunately, this also results in large amounts of hard and faceted AlN …

Corrosion Performance Of Zirconium-Based Passivations On Electroplated Zinc Nickel, Madison Morgan Reed

Masters Theses

“Performance requirements for Department of Defense (DoD) electrical components include corrosion and electrical contact resistance. Historically, electroplated cadmium with a chromate conversion coating (CrCC) has been used to meet corrosion and contact resistance standards. However, replacements are needed for these materials because they are toxic and carcinogenic. Electroplated γ-ZnNi has been identified as an acceptable alternative to Cd. This study evaluated commercially available Zr-based thin films and sealers as passivations for potential replacement of CrCCs. Ten different passivations were tested and compared with bare γ-ZnNi. X-Bond and Zircobond passivations were found to provide some improvement to the bare ZnNi corrosion …

Facile Synthesis Of Nanostructured Metal Borides And Composites For Applications In Sustainable Energy, Maalavan Arivu

Masters Theses

"Electrocatalytic water splitting is a promising solution for sustainable energy generation since one of the half reactions lead to the formation of H₂ which is a clean fuel. The other half of the reaction leading to O₂ evolution is an energy intensive process necessitating the need for an electrocatalyst to break the activation barrier for the commencement of the reaction. In this work we will focus on expanding the family of non-oxidic OER electro-catalysts, especially borides, whereby, apart from facilitating delocalization of electron cloud on the catalytically active transition metal site, low anion electronegativity and increased covalency in …

Grain Refinement Of High Alloy Stainless Steels In Sand And Directionally Solidified Castings, Dustin Alan Arvola

Masters Theses

"The goal of this research project is to develop an industrially viable melting process that will control the crystallization macrostructure of austenitic grades of cast steels. Titanium nitride (TiN) has proven to be an effective grain refiner of austenite. Theoretical simulation and experimental application has led to the development of a repeatable grain refining melt process for austenitic stainless steel alloys.

Grain refinement of the as-cast structure of Cr-Ni stainless steel alloys solidified with primary FCC, BCC and dual FCC/BCC phases was studied experimentally. Refinement was achieved in both cast ferritic and austenitic grades. Dual solidification of …

Designed Extrudate For Ceramic Additive Manufacturing, Devin Mcmillen

Masters Theses

"The objective of this thesis work was to design ceramic paste systems that assist in achieving a high theoretical density ( > 95%) after deposition by a novel additive manufacturing process, i.e. Ceramic On-Demand Extrusion (CODE). The work is encompassed in five main sections: Sections 1 and 2 provide an introduction and literature review of relevant topics for the following sections of experimentation. Section 3 provides an analysis of a reaction chemistry to identify three discrete materials that could be combined via CODE and result in zirconium diboride (ZrB₂) post-sintering. Section 4 describes the development of a high solids …

Research And Development Of Optically Transparent Join With Low Processing Temperatures, Eric Kevin Muskovin

Masters Theses

The purpose of this study was to investigate durable solar cell cover glass joins produced by diffusion bonding with deep eutectic solvents (DES) and to develop a novel process of joining optically transparent materials at low temperatures. A joined PV cell-glass specimen was characterized using Raman, μ-FTIR, SEM-EDS, and thin-film XRD. DESs were created with malonic acid (MAL) and choline chloride (ChCl) of varying composition factors (CF; CF=MAL/ChCl). Joining borosilicate glass coupons was attempted using DESs with CF = 0.65 and 1 at temperatures between 100-150 °C for 20 hours. Joining the glass coupons failed at all temperatures and oxygen …

Effect Of Microstructural Features On Steel Machinability, Mark C. Emmendorfer

Masters Theses

Non-metallic inclusions can have a tremendous impact on the machinability of steel. Some oxide inclusions such as alumina, spinel, and other refractory abrasive oxide inclusions can have a detrimental effect on machinability. Modification of oxide inclusions by calcium treatment can promote the formation of low melting point oxides such as anorthite and gehlenite inclusions that can assist in chip formation and form a lubricating layer on the rake surface of the machine tool. MnS is known to be beneficial to improving the machinability of steel. They assist in chip formation by being heavily deformed in the primary shear zone. Sulfide …

Characterization And Tailoring Of Powder Used In Additive Manufacturing And Plasma Spheroidization, Caitlin S. Kriewall

Masters Theses

"There are many processes that use metal powder as the starting material for the production of parts. With the growth of these manufacturing techniques, more critical part applications are being considered. In order to fully understand the process and create consistent parts, powder properties need to be well understood. Selective laser melting (SLM) is a powder bed-based additive manufacturing process. During processing, heat-affected powders are generated and can deposit within the build area. The current work investigated the characterization of heat-affected 304L stainless steel powder using techniques such as scanning electron microscopy, x-ray diffraction and x-ray photoelectron spectroscopy to detect …

Microstructural Development And Its Effect On Aqueous Corrosion Of A Borosilicate Glass Ceramic For Waste Vitrification, Nicholas Stephen Roberts

Masters Theses

"Waste loadings of reprocessed spent nuclear fuel vitrified into borosilicate glass can be increased by precipitating environmentally stable phases concentrated with waste components in a chemically stable glass matrix. The principal objective of this thesis was to characterize the development of crystalline powellite (CaMoO₄ and related phases) and oxyapatite (Ca₂LN₈Si₆O₂₆) in borosilicate glass-ceramics and to determine how the formation of those phases affected its chemical durability.

Borosilicate glasses provided by PNNL were re-melted and quenched at rates from over 300⁰C/s to ~0.05⁰C/s. Isothermal heat treatment experiments were conducted by quenching melts …

Modulated Photothermal Radiometry: Detector Sensitivity Study And Experimental Setup, Jessica Nicole Seals

Masters Theses

"This thesis outlines the development of a system used for determining the surface thermal diffusivity of both non-irradiated and irradiated materials. The motivation for this work is to establish a modulated photothermal radiometry (PTR) system on the campus of Missouri University of Science and Technology. One of the main efforts described in this thesis is the design and construction of the physical apparatus. Along the way, it was necessary to perform a detailed sensitivity analysis of the system to determine whether the expected signal emitted from the sample falls within the bounds of detectivity for the HgCdTe (MCT) detector used …

The Modification Of A Curtain Coating Formulation: A Study Of Rheology And Surface Tension, And Their Effect On Pitting, Samantha Leigh Schoenfelder

Masters Theses

When an undisclosed recycled fiber mill installed a “two-slotted” curtain coater to replace their air knife coater, a prominent defect arose known as “pitting,” which is also called pinholing or cratering. Pitting occurs when the coating of the sheet has small holes that mar its surface, which, when clustered together or larger in size, can cause print breakup during the printing process.

Through research, pitting is known to be caused by a boundary layer of air that gets laterally pulled in between the coating and board during their initial contact. Thus, rheological properties and the surface tension of the curtain …