Materials Science and Engineering Commons^™

Developing A Novel Methodolgy And Testbed For Fatigue Analysis Of Metal Specimens, Sai Aravind Palepu

Masters Theses

"A prototype of fatigue testing machine was built to determine the fatigue strength of materials. Proposed testing prototype was displacement controlled magnetic type bend fatigue testing machine. Designed prototype was tuned to operate at or near resonance of the specimen in order to amplify excitation displacement. Low maintenance i.e. zero wear of the parts was achieved, there were no moving components in the prototype machine. Crucial components used to build were: DC power supply, solenoid, Arduino UNO, supports and laser displacement sensor. DC source used to pass current through solenoid producing magnetic field; mosfet and Arduino generated square waves of …

Development Of Two Color Imaging Pyrometer For Studying Thermal History Of Laser Metal Deposition, Niroop Matta

Masters Theses

"The laser aided manufacturing process is a process in which parts are built by adding material into the melt pool created by a laser. This process involves a complex thermal history which is important in determining the quality of the parts built. The objective of this study is to develop a high resolution two color imaging pyrometer which can measure the temperature of an object without the dependence of spectral emissivity of the material at an economical price. An 8.8 MP CMOS sensor is used as an imaging sensor. The visible spectrum of light is used for temperature measurement. The …

Hybrid Manufacturing Process Of SicF/Sic Composite Using Preceramic Polymer, Robert Raymond Meinders

Masters Theses

"Continuous fiber-reinforced silicon carbide (SiC_f/SiC) ceramic composites have been increasingly used due to their high temperature strength and graceful failure mechanisms. A disadvantage is the high cost and lengthy production processes that are required to develop these materials. Polymer infiltration and pyrolysis (PIP) is one of the most attractive fabrication processes for composites due to shape flexibility, mass production and relatively low cost; however, the quality of material obtained by this method has been considered insufficient due to the microstructure defects of the material obtained. This study investigated a hybrid of multiple polymer manufacturing processes to maximize quality …

Material | Adventure, Diana Wagner

Masters Theses

With the generous support of the RISD Grad Studies|Grant I traveled to London, England to deepen my thesis research of material libraries. This opportunity allowed me to visit the resources that inspired my enthusiasm for materials and to challenge the questions I posed in my thesis research, How we, artists and designers, learn from materials in the context of the library? The sources explored within this book highlight a growing community of academic and research based material collections in London, along with some exceptional exhibitions of materials and process in the context of the museum and archive.

Replacement Of Solvent Based Ink By Water Based Inks For Gravure Presses With Low Efficiency Ink Driers, Viraj Suresh Dalvi

Masters Theses

Rotogravure printing of decorative laminates, wall coverings, or vinyl floorings process often uses solvent based inks. The main constraining factor with solvent based ink is presence of volatile organic compounds (VOC’s). Due to the environmental norms on Volatile Organic Compounds (VOCs), and restrictions on using solvent based inks, the ink industry came up with water based ink as more environmentally friendly alternative. Organizations which print decorative laminates, wall coverings, or vinyl floorings with solvent based inks have gravure printing infrastructure, which is often equipped with low efficiency driers capable of drying solvent based inks. In order to comply with environmental …

Self-Supported Printed Multi-Layer Capacitors, Michael James Joyce

Masters Theses

The increasing demand for miniaturized electronic devices has increased the need for rechargeable micro-power sources. Although lithium and lithium ion batteries have been utilized in these applications since the late 1990s, other energy harvesting technologies, such as thermal, mechanical, and solar, are now being used to augment batteries to enable systems to be self-powered. However, the lifetime of any battery is finite, which may be a major problem when the application is in a permanent structure or medical implant device. For power or significant energy storage applications, printed multilayer capacitors or supercapacitors are being explored as an enhancement, or replacement …

Electroplating Of Nanoengineered Polymer Substrate, Brandon Voelker

Masters Theses

The development of a polyethylene based polymer with metallic inclusions, a nanoengineered polymer, has recently opened up great potential for many new commercial and industrial applications. The major advantage of developing these nanoengineered polymers is to be able to tailor the resistance and other properties by varying the composition of the polymer. The industrial usage of this polymer benefits from the addition of an electrically conductive, metallic coating. This research develops methods of electroplating nickel and copper layers on to the polymer substrates using DC and pulsed techniques.

Electroplating is conducted in a 1000 mL beaker using a specialized plating …

A Novel Silica-Based Nano Pigment As A Titanium Dioxide Replacement, Ryan Stoneburner

Masters Theses

This research focused on the evaluation of a new Silica-based pigment for the replacement of titanium dioxide (TiO₂) in paperboard coatings. The silica-based pigment has shown the ability to be a replacement in terms of functionality and runnability. TiO₂ is currently the highest opacifying pigment used in paper coatings, but it is also the most costly. Finding a less expensive pigment that doesn't reduce effectiveness is critical to reducing the cost of TiO₂ formulations. To evaluate the new pigment, coatings will be applied using a Cylindrical Laboratory Coater (CLC) with varying amounts of TiO₂ and …

Material Potential | Recontextualizing Material Libraries, Diana Wagner

Masters Theses

Material libraries are growing resources that offer an opportunity for artists and designers to discover a variety of materials. These collections are composed in a traditional taxonomy, pairing materials based on composition. Samples are typically commercially made and are displayed independent of context, means of production, cultural significance, and application.

Through making we learn a material’s potential: the transformation it can make, the form it can take, and the new composites we can create. This generative experience lives in the studio and workshop. But how can we introduce this language of process, critical thinking, and making to activate and challenge …

Inorganic Biodegradable Devices For Temporary Implants, Kassan Unda

Masters Theses

"Implantable electronic devices have great potential to benefit many health care technologies. They comprise of two different categories. The first is permanent prosthetic devices like cardiac pacemakers or nerve stimulants. The other category includes temporary devices for interventional medical monitoring and control scenarios, which lose functionality and become unnecessary after their intended operational lifetime. This can cause serious electromagnetic and biomechanical safety concerns if not removed from the body by an additional surgical operation.

This thesis focuses on exploring the feasibility of implantable inorganic bioresorbable thin film resistive devices utilizing bioactive glass as the core structural material. This device will …

Thermal Properties Of Zirconium Diboride - Transition Metal Boride Solid Solutions, Devon Lee Mcclane

Masters Theses

"This research focuses on the thermal properties of zirconium diboride (ZrB₂) based ceramics. The overall goal was to improve the understanding of how different transition metal (TM) additives influence thermal transport in ZrB₂. To achieve this, ZrB₂ with 0.5 wt% carbon, and 3 mol% of individual transition metal borides, was densified by hot-press sintering. The transition metals that were investigated were: Y, Ti, Hf, V, Nb, Ta, Cr, Mo, W, and Re. The room temperature thermal diffusivities of the compositions ranged from 0.331 cm²/s for nominally pure ZrB₂ to 0.105 cm²/s for (Zr,Cr)B₂ and converged around 0.155cm²/s at higher temperatures …

Corrosion Resistance Of Enamel Coating Modified By Calcium Silicate And Sand Particle For Steel Reinforcement In Concrete, Fujian Tang

Masters Theses

"Porcelain enamel has stable chemical property in harsh environments such as high temperature, acid and alkaline, and it can also chemically react with substrate reinforcing steel resulting in improved adherence strength. In this study, the corrosion resistances of enamel coating modified by calcium silicate and sand particles, which are designed for improved bond strength with surrounding concrete, were investigated in 3.5 wt% NaCl solution. It consists of two papers that describe the results of the study.

The first paper investigates the corrosion behavior of enamel coating modified by calcium silicate applied to reinforcing steel bar in 3.5 wt% NaCl solution …

Effect And Interactions Of Commercial Additives And Chloride Ion In Copper Electrowinning, Wenyuan Cui

Masters Theses

"This thesis is to understand and compare the effects and interactions of modified polysaccharide (HydroStar), polyacrylamide (Cyquest N-900) and chloride ion on copper electrowinning. A study of the nucleation and growth was conducted in a synthetic electrolyte (40 g/L Cu, 160 g/L H₂SO₄, 20 mg/L Cl-) with the addition of HydroStar or Cyquest N-900 using potential step measurements. The current responses generated were compared to theoretical models of nucleation and growth mechanisms. The nucleation and growth mechanism changed as function of potential and the presence of organic additives. The nucleation and growth mechanisms were confirmed using scanning electron microscopy (SEM). …

Development And Characterization Of Spiral Additions In A Ceramic Matrix, Andrea Lynn Els

Masters Theses

"A novel spiral architecture was formed using titanium diboride and silicon carbide ceramics as either the spiral or matrix phase. Particulate composites with the same compositions were fabricated to compare to the materials in this study. Spiral additions were formed using powder loaded polymers followed by a single and/or multi-filament co-extrusion. For 25 vol% SiC spiral additions to TiB₂, boron nitride was added to the SiC spiral to alter the bonding at the interface and reduce thermal residual stresses. All samples were hot-pressed to near full density at 1980 ⁰C. Hot pressed multi-filament co-extrusion of 2.4 mm / …

Thermodynamics And Crystallography Of The Γ→Ε→Α' Transformation In Femnalsic Steels, Scott Thomas Pisarik

Masters Theses

"FeMnAlSiC steels which exhibit two-stage transformation induced plasticity (TRIP) behavior characterized by the γ→ε→α' dual stage martensitic transformation promise to take a leading role in the development of 3rd generation advanced high strength steels. The crystallographic orientation relationship of the γ→α' and γ→ε athermal martensitic transformations in these steels has been determined as the Kurdjumov-Sachs and the Shoji-Nishiyama, respectively. Six crystallographic variants of α-martensite consisting of three twin-related variant pairs were observed in ε- bands. A planar parallelism of {0001}ε || {110}α' and a directional relation of α' lying within 1⁰ of ε existed for these variants. Two regular solution …

Use Of Polymer Rapid Tools As Functional Injection Mold Tooling, Sean Derrick

Masters Theses

Conventional tool making for injection molded plastics is expensive, time consuming, and generates a great deal of waste. Presently, industry is waiting for what is commonly referred to as Rapid Tooling (RT). The greatest opportunity for RT implementation would be the use of Additively Manufacturing (AM) technology. Specifically, AM techniques which use a high strength polymer resin substrate.

The following research is an initial feasibility study to determine if Polymer Rapid Tools (PRTs) could be used as functional injection mold tooling. The objective of the research was to determine if a PRT could mold a variety of features to a …

Improved Deinkability Of Lep (Liquid Electrophotography) Digital Prints, Zheng Wei

Masters Theses

Digital printing plays a very important role in the life of modern society. With the development of digital printing technologies, and the increasing market share of digital printing, the amount of digital prints in waste paper is rapidly increasing. Under “green” manufacturing and environmental sustainability, deinking of digital print inks is an urgent problem that needs to be solved. Indigo is a typical series of HP (Hewlett-Packard) digital presses that use a liquid ink named ElectroInk (Liquid Electrophotography or LEP). The particle size of HP ElectroInk is very small, 1-2 microns, which is smaller than dry toners. But, during flotation, …

Liquid Phase Sintering Of 20bi(Zn₀.₅Ti₀.₅)O₃-80batio₃ Dielectrics With Bismuth-Zinc-Borate And Bismuth Borosilicate Glasses, David I. Shahin

Masters Theses

"Dielectrics in the Bi(Zn₀.₅Ti₀.₅O₃-BaTiO₃ system (specifically 20BZT-80BT, in mol%) are promising candidates for high energy density capacitor applications due to broad temperature-dependent dielectric constant maxima and a relatively field-independent permittivity. Bulk samples require sintering temperatures of greater than 1180ºC to reach useful densities. Due to incompatibility of Bi with low-pO₂ processing, BZT-BT-based multilayer capacitors must utilize noble metal electrodes that resist oxidation during sintering. Sintering temperatures must be reduced to allow use of less expensive electrode materials (Cu, etc.). This work studies the reduced temperature sintering behavior and dielectric properties of BZT-BT sintered with 30 Bi₂O₃-30ZnO-40B₂O₃ and 50Bi₂O₃-25B₂O₃-25SiO₂ (mol%) liquid …

The Use Of Elemental Powder Mixes In Laser-Based Additive Manufacturing, Rodney Michael Clayton

Masters Theses

"This study examines the use and functionality of laser depositing alloys from mixes of elemental metallic powders. Through the use of laser-based additive manufacturing (LAM), near net-shaped 3-Dimensional metallic parts can be produced in a layer-by-layer fashion. It is customary for pre-alloyed powders to be used in this process. However, mixes of elemental powders can be used to produce alloys that are formed during the deposition process. This alternative technique requires that the elemental powders adequately mix during deposition for a homogeneous deposit to be produced. Cost savings and versatility are among several of the advantages to using elemental powder …

Effects Of Material Variables And Process Parameters On Properties Of Investment Casting Shells, Priyatham Tumurugoti

Masters Theses

"Manufacture of investment casting shells is a complex process. The choice of raw materials - refractory powders or grains, binders and additives - affects the properties of investment casting shells. In this study, different systems of shells were prepared, according to a design of experiments, with commercially available raw materials that differ in chemistry, particle size or particle size distribution. Shell strength was measured in green, fired and cooled, and hot conditions and the results were analyzed for strength-material property relation. Various microstructures of polished cross sections of these shells were characterized using scanning electron microscope. It was determined that …

Processing And Properties Of Zrb₂-Zrsi₂ Matrix Composites Reinforced With Continuous Sic Fiber, Benjamin John Bowin Lai

Masters Theses

"The research presented in this thesis focuses on the processing, microstructure, and mechanical properties of ZrB₂-based composites. The main goal was to develop a process that incorporates high strength continuous SiC fiber in a ZrB₂-based matrix. In order to achieve this, the densification, microstructure, and mechanical properties of ZrB₂-ZrSi₂ monolithic ceramics were characterized along with various SiC fiber reinforced ceramic matrix composites (CMCs) utilizing the same matrix.

There were two main areas of study in this thesis. The initial study demonstrated that additions of ZrSi₂ into a ZrB₂ ceramic increases densification at significantly reduced processing temperatures ≤1600ºC). This study revealed …

Microstructure And Mechanical Properties Of Silicon Carbide-Titanium Diboride Ceramic Composites, Derek Scott King

Masters Theses

"The microstructure, hardness, fracture toughness, Young's modulus, strength and Weibull modulus of silicon carbide-titanium diboride (SiC-TiB₂) ceramics were studied. First, SiC-TiB₂ ceramics with 15 vol.% TiB₂ particles were processed using two green processing methods, spray drying (ST) and ball milling (SiC-15TiB₂). In addition, SiC-TiB2 ceramics with TiB₂ contents ranging from 0 to 100 vol.% were produced to determine a TiB₂ content that produced the best combination of mechanical properties. From spray drying, segregation of the TiB₂ particles in ST led to a granule-like microstructure and spontaneous microcracking in the final ceramic. In ceramics containing 20 and 40 vol.% TiB₂, the …

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 …

Process Simulation And Inclusion Characterization In Stainless Steel Ingot Casting, Jun Ge

Masters Theses

"For the ingot casting process, fluid flow of steel plays an important role in quality control and industrial operations. Using CFD software (FLUENT), this study overviews the fluid flow pattern in the bottom-teeming ingot filling process with three different swirl-modified upgate designs. Turbulent flow and mass transfer are considered main factors in controlling the process. The motion of the slag phase was also considered. In addition to the modeling studies, inclusions in stainless steel poured into ingots with a traditional and a swirl-modified upgate system were investigated using an optical microscope, SEM-EDS and ASPEX automated feature analysis technology. The main …

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 …

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 …

Cerium-Based Conversion Coatings On Cast Aluminum 380 And 413 Alloys, Ci Lin

Masters Theses

"This investigation focused on the deposition and characterization of cerium-based conversion coatings (CeCCs) on cast aluminum alloys. Previous research has shown that CeCCs are viable alternatives to chromate conversion on high strength alloys such as 2024-T3 and 7075-T6. For the casting alloys such as 380 and 413, the presence of Si affects the composition and stability of the native oxide, which means that pretreatment plays an important role for the coating deposition. This thesis consists of two papers that describe the results of the study.

The first paper reports the effect of the final rinsing temperature before coating deposition on …

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 …

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 …

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 …