Materials Science and Engineering Commons^™

Lunar Manufacturing Systems And The Role Of Additive Recycling Technologies, Camille A. Newman

Honors Theses

Renewed international interest in sustained lunar exploration has created a growing demand for technologies to support long-duration space exploration. Part of the recent Artemis missions and the Moon to Mars initiative is to improve key mission capabilities and fill critical gaps necessary to sustain lunar habitation. Waste management, recycling systems, and manufacturing systems have been identified as critical technologies that need further development before a sustained mission is possible. This thesis explores the feasibility of an additive manufacturing and recycling system designed to process plastic waste generated during extended lunar habitation. Initial research focused on existing manufacturing and recycling technologies …

Field-Assisted Post-Processing Of Cold-Sprayed Pure Copper, Alan Hensley

Theses and Dissertations--Mechanical and Aerospace Engineering

The properties of materials processed through cold spray, and many other AM processes, are non-uniform and unpredictable. In most cases, post-processing is required to achieve desired properties and better uniformity. In cold spray, the typical method is an annealing heat treatment (AHT), which can improve bond strength, reduce porosity, and restore ductility, among other effects. AHT alone, however, is unable to completely remedy any of the unfavorable properties. In addition, long treatments at high temperatures are often needed for satisfactory results. This increases energy consumption and extends production times for products made by the process. For these reasons, numerous investigations …

Made On Mars: Design And Manufacturing Of Structural Polymer-Regolith Composites, Pailey M. Vitale

Williams Honors College, Honors Research Projects

Human exploration of Mars is constrained by harsh environmental conditions and the prohibitive cost of transporting materials from Earth. Long-term sustainability requires the local production of mechanical and structural components using resources available on Mars, thereby minimizing payload mass. This project investigates polymer–regolith composites derived from atmospheric CO₂ and mineral-rich regolith as a pathway toward in-situ manufacturing. These composites, when compatible with additive manufacturing, could replace imported plastics, enable on-demand fabrication, and support closed-loop recycling systems. The objective is to design and evaluate polymer–regolith composites that maintain mechanical integrity and environmental resistance under Martian conditions, including extreme temperature swings, radiation …

Fused Filament Fabrication Additive Manufacturing Of 17-4 Ph Stainless Steel: Process–Structure–Property Relationships In Magnetic Materials, Maanav Patel

Theses and Dissertations

Additive manufacturing (AM) enables the fabrication of complex metallic components through layer-by-layer processing directly from digital models. Among AM techniques, material extrusion–based processes such as fused filament fabrication (FFF) provide an accessible method for producing metal parts using filament feedstocks composed of metal powders and polymer binders. When applied to precipitation-hardening stainless steels such as 17-4 PH, the processing route and heat treatments can influence the resulting microstructure and functional properties. This work investigates the magnetic behavior of 17-4 PH stainless steel fabricated using FFF and evaluates how heat treatment conditions influence measured magnetic properties. Samples were produced and analyzed …

Mechanical Behavior Of Additively Manufactured Ti-6al-4v Eli Parts: Effects Of Laser Parameter Selection, Samuel Lopez

UNF Graduate Theses and Dissertations

Additive manufacturing (AM) of TI-6AL‑4V Extra‑Low Interstitial (ELI) enables complex geometries for fatigue‑critical medical device applications, yet fatigue performance remains sensitive to process‑induced defects. This work investigates the effect of laser process parameter selection on the microstructure, mechanical properties, and fatigue behavior of TI- 6AL‑4V ELI fabricated via laser powder bed fusion (L‑PBF) using a Renishaw RenAM system. The influence of laser parameters was isolated by holding powder chemistry, build orientation, scan strategy, sub‑transus annealing, and post‑processing constant between a non‑optimized baseline and an optimized parameter set selected based on tensile performance.

Optical microscopy showed the optimized condition exhibited improved …

Anisotropic Residual Stress Measurements In Additively Manufactured 316 Stainless Steel Parts, Rajeshree Varma, Donovan Stumpf, Paul R. Mort

15th International Conference on Shot Peening

Additive manufacturing (AM) using laser powder bed fusion (L-PBF) is increasingly used to produce complex parts for industries like aerospace and medical devices. The intrinsic characteristics of AM – layer-wise deposition and rapid thermal cycling – generate significant, anisotropic, residual stresses that can compromise part quality and performance. Recent studies highlight how these stresses are strongly influenced by process parameters and build orientation. X-ray diffraction (XRD) techniques, including sin²ψ and advanced two-dimensional approaches, have become the preferred methods for non-destructive, directionally resolved measurement of residual stress in AM metals. This review surveys advancements in XRD residual stress methods with a …

Enhancing High Cycle Fatigue Perfomance Of Electron Beam Melted Ti6al4v: A Study On Shot Peening And Hot Isostatic Pressing, Naghmeh M. Mojib, Dwayne D. Arola, Ramulu Mamidala

15th International Conference on Shot Peening

The qualification of electron beam powder bed fusion (PBF-EB) for safety-critical applications is hindered by variability in high cycle fatigue performance, largely due to surface roughness and internal defects. While Hot Isostatic Pressing (HIP) effectively reduces internal porosity, it does not address surface-initiated fatigue failures. This study investigated the combined effects of HIP and shot peening on enhancing the fatigue performance of PBF-EB Ti6Al4V. Over 50 specimens, including both vertical and horizontal build orientations, underwent high cycle fatigue testing per ASTM E466. X-Ray computed tomography confirmed decrease in defect distribution following HIP, while shot peening resulted in a more uniform …

In-Situ Defect Detection In Selective Laser Melting Using Convolutional Neural Networks, Ethan Gaigalas

Master's Theses

This thesis develops and trains a convolutional neural network (CNN) to classify defects in metal parts produced by selective laser melting (SLM) using acoustic emission (AE) data. The model successfully identified porosity and standard build layers with high accuracy but consistently struggled to classify lack of fusion (LOF) defects, regardless of input type, normalization, or class count. These results suggest that while AE signals contain distinguishable features for certain defect types, LOF signals may be too subtle or inconsistent for reliable detection. The study addresses the ongoing challenge of in-situ quality monitoring in metal additive manufacturing, where defects like cracks, …

Thermal Modeling Techniques For Additively Manufactured Porous Metals, Lucas D. Rambo

Master's Theses

Advances in additive manufacturing have enabled the creation of metallic components with tailored porosity, offering design flexibility for thermal, structural, and fluid transport applications. This thesis investigates the effective thermal conductivity (ETC) of porous Inconel 625 (IN625) and Inconel-ceramic composites (IN625-RAM2) fabricated by Laser Powder Bed Fusion (LPBF) using Elementum 3D’s PermiAM technology. Experimental measurements of thermal conductivity using the laser flash method are compared to numerical models built from micro-computed tomography data. Simulations were performed using both finite element (FE) and finite volume (FV) methods to evaluate thermal transport in real microstructures. The study investigates the effects of micro- …

Exploring Metal Additive Manufacturing In Martian Atmospheric Environments, Zane Mebruer

Mechanical Engineering Undergraduate Honors Theses

On-surface manufacturing is key to the success of a planetary colonization, especially that of Mars. However, traditional subtractive manufacturing processes are equipment, energy, and material intensive, meaning novel additive manufacturing (AM) processes must be pursued for this end. Selective laser melting, one of the most effective and versatile AM methods, would be incredibly beneficial to a Martian mission but requires an artificial argon atmosphere to create effective parts. The purpose of this study was to examine if carbon dioxide, the gas that makes up over 95% of Mars’ surface atmosphere, would be a sufficient substitute for argon in SLM fabrication. …

Phase-Field Modeling Of Rapid Solidification Processes, Nima Najafizadeh

Doctoral Dissertations

"Many advanced manufacturing processes such as additive manufacturing utilize rapid solidification of alloys, as it enables the formation of exotic non-equilibrium microstructure and thus improved properties. However, the interrelationship between the processing parameters and the resulting microstructure in rapid solidification is yet to be fully understood. We aim to investigate the microstructure evolutions during the rapid solidifications using phase-field modeling. The phase-field method assumes a diffuse interface, which avoids tracking the moving interface and hence enables efficient numerical simulations for complex microstructure evolution. A phase-field model with coupled solute-thermal diffusion and solute trapping effect is developed to investigate the rapid …

Electro-Mechanical Behavior Of Core-Shell Carbon Grease-Silicone Fibers Fabricated Via Coaxial Direct Ink Writing, Fahrettin Kilic

Graduate Theses, Dissertations, and Problem Reports (ETD)

Highly stretchable strain sensors are essential components in soft electronics, enabling integration of sensing and signal transmission into deformable systems. This thesis explores the fabrication and characterization of coaxial core–shell fibers composed of a conductive carbon grease core and an elastomeric silicone shell. These fibers were produced using coaxial direct ink writing (DIW), a versatile additive manufacturing technique that allows continuous deposition of multi-material filaments. The goal was to achieve mechanically compliant yet electrically stable fibers capable of withstanding large deformations, suitable for applications in wearable electronics and soft robotics.
The printed fibers were systematically examined through mechanical tensile testing, …

Effect Of Build Orientation On Tensile Properties And Fractography Of Additive Manufactured Inconel 718 Alloy, Ajay Kumar Maurya, Amit Kumar, Swarnambuj Suman

ASEAN Journal on Science and Technology for Development

The additive manufacturing (AM) technique “Direct Metal Laser Sintering (DMLS)” is used to create 3D objects directly from 3D design data. A lightweight and complexity-free part without any expensive tooling can be fabricated easily using this method, but it is still challenging to achieve the desired mechanical strength from AM parts, as the mechanical properties of AM-produced parts vary with orientation, scan strategy, and process parameters. Inconel 718 alloy is most commonly utilized in the aerospace and automotive industries, because of its high resistance to corrosion and excellent mechanical qualities. This work presents a study to investigate the orientation-based mechanical …

Affordable And Sustainable: Innovating Filament Extrusion For Recycled Materials, Turab S. Rizvi

Undergraduate Research Posters

The chemical stability, toxicity and non-biodegradability of the polymers pose a significant environmental threat. Addressing end-of-life treatment sustainability is crucial for mitigating these issues. The customized Lyman filament extruder in the Advanced Magnetic Materials Processing Laboratory represents an innovative approach to advancing sustainability in renewable energy production and CO₂ mitigation. Redesigning the thermal system and screw operation will tackle key challenges, including precise temperature control, consistent material flow to handle diverse recycled materials. Integrating an advanced thermal regulation system will reduce the energy consumption by maintaining optimal thermal conditions, thereby lowering the CO₂ footprint of the recycling process. The optimized …

Development And Testing Of Irradiation-Tolerant High-Entropy Alloys, Matthew John Luebbe

Doctoral Dissertations

"High entropy alloys (HEAs) are a novel class of alloys made of multiple principal elements in near equal proportions. They have been observed to possess an array of useful engineering properties, such as good ductility and fracture toughness, high temperature strength, oxidation and corrosion resistance and irradiation resistance. This makes them promising candidates for harsh environments, especially nuclear reactors. These properties could potentially realize advanced Gen IV nuclear reactor designs. However, most HEA compositions contain Co, which activates under irradiation, generating safety and waste management concerns. This work studies three compositions of Co-free HEAs whose strength and microstructures are evaluated …

Dielectric Performance Of Fused Filament Fabricated Ultem 9085 For Naval Radome Application, Carson Rogers

UNF Graduate Theses and Dissertations

ULTEM 9085 is a high-performance thermoplastic used in the fused filament fabrication (FFF) additive manufacturing process. It has found use in applications where mechanical strength, chemical integrity, and thermal stability are of paramount importance. In this thesis, the effects of process parameters, annealing, and weathering on the mechanical and dielectric properties of FFF ULTEM 9085 have been investigated.

The first part reviews existing research on how printing parameters such as nozzle temperature, chamber temperature, print speed, infill, and layer height affect the mechanical performance of FFF ULTEM 9085. Data from the manufacturer of commonly used ULTEM 9085 filament, Stratasys, has …

Using Additive Manufacturing To Characterize Effects Of Sparse Infill Density And Sparse Infill Pattern On The Compressive Properties Of Short Strand Carbon Fiber Infused Petg, Luke C. Salisbury

Honors Theses

The advent of additive manufacturing has revolutionized the prototyping, design, and manufacturing of new and innovative products. Through the use of Fused Deposition Modeling (FDM), parts can be manufactured using different sparse infill percentages (the percentage of void space within a printed object) and sparse infill patterns (the lattice structure of material within the object). Through the manipulation of these variables, the same material and part can have different compressive and flexural properties. In addition to sparse infill, the thermoplastics used in fused deposition modeling can be reinforced with carbon fiber strands to create a printable composite material capable of …

Innovations In Additive Manufacturing For Socket Fabrication: An Overview, Linda Ziyadatul Faiza, Wahyu Caesarendra, Wahyu Dwi Lestari

Journal of Mechanical Engineering Science and Technology (JMEST)

Additive Manufacturing (AM) has transformed the prosthetics industry, particularly in socket production, which plays a critical role in the comfort, fit, and functionality of prosthetic limbs. This article examines the latest advancements in AM technologies and their applications in socket fabrication. Key techniques like stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM) have facilitated the production of highly personalized, lightweight, and durable prosthetic sockets. These methods not only improve design precision but also allow for the use of biocompatible, flexible materials, enhancing both comfort and functionality. Digital design tools have streamlined the production process, reducing lead times …

Utilization Of Sodium Flame Synthesis For The Formation And Deposition Of Pure Metal Materials For Applications In Additive Manufacturing, Zachariah Wargel

McKelvey School of Engineering Graduate Student Theses & Dissertations

Advanced material classes, such as high temperature alloys, ceramics, and refractory materials have become a key area of focus for expansion in the realm of additive manufacturing. Factors such as high melting points, material homogeneity, and physical properties such as ductility limit the application of popular additive manufacturing methods to these material classes. By utilizing sodium flame synthesis and deposition (SFD) technology, nanoparticle materials can be synthesized via combustion in a laminar co-flow diffusion burner and impacted such that the deposits can be used to manufacture designed components. By using the applicable precursor materials of metal chlorides and elemental sodium …

Predicting Rheology Of Uv-Curable Nanoparticle Ink Components And Compositions For Inkjet Additive Manufacturing, Cameron D. Lutz

Master's Theses

Inkjet additive manufacturing is the next step toward ubiquitous manufacturing by enabling multi-material printing that can exhibit various mechanical, electronic, and thermal properties. These characteristics are realized in the careful formulation of the inks and their functional materials, but there are many constraints that need to be satisfied to allow optimal jetting performance and build quality when used in an inkjet 3-D printer. Previous research has addressed the desirable rheology characteristics to enable stable drop formation and how the metallic nanoparticles affect the viscosity of inks. The contending goals of increasing nanoparticle-loading to improve material deposition rates while trying to …

Additive Manufacturing With Bioresorbable Polymers: Process-Structure-Property Relationships For Biomimetic Tissue Scaffolds, Clayton Joseph Culbreath

All Dissertations

Tissue engineering has a base requirement of scaffold structures to support cell growth, proliferation, and regeneration. However, attempts to use artificial scaffold structures have often fallen short of clinical needs to justify the change away from the established, biologic-based current standard of care. Based on the limited number of successful tissue scaffolds produced by material extrusion modes of additive manufacturing, fused filament 3d printing and electrospinning, critical design specifications for a tissue scaffold are six minimum requirements: 1) biocompatibility, 2) porosity, 3) mechanical properties, 4) bioresorbable medical grade materials, 5) bioactivity, and 6) appropriately scaled production methods compliant with medical …

A Comparison Of Beamforming Characteristics In Isotropic And Composite Plate Structures For Use In Structural Health Monitoring, Sarah Ketchersid

Doctoral Dissertations and Master's Theses

Structural health monitoring in plate-like simple structures using phased array beamsteering of guided Lamb waves is useful in damage detection and evaluation efforts. Lamb waves can be effectively used for beamsteering using a linear array. The experimentation primarily focuses on beamsteering in the aluminum panel, which involves developing a simulation based on extracted data to visualize the dispersion of waves across the panel. By evaluating parameters such as slowness, velocity, and amplitude direction and variation for a specific metallic plate, the wavefront generated by a single wave source can be represented as a function of propagation angle and distance from …

Microstructural Investigation Of The Influence Of Geometry On The Mechanical Reliability Of Additively Manufactured Metals, Tracy Connor Varney

Theses and Dissertations--Chemical and Materials Engineering

The adoption of additive manufacturing across a wide range of fields is ever-increasing, allowing for solutions that were previously impossible to achieve. This dissertation demonstrates the wide range of macro- and micro- characterization techniques used to investigate several precipitation strengthened AM alloy systems. While AM allows for nearly unlimited design freedom, this brings along its own issues as the interplay between scan strategy and part geometry is less well known. In this work, a novel thin-wall dogbone geometry was utilized to study one type of complex geometry observed in a large portion of AM focused designs. The mechanical behavior of …

Extrusion-Based Additive Manufacturing Of Magnetic Heat Exchange Structures For Caloric Applications, Vaibhav Sharma

Theses and Dissertations

Currently, the commercial building sector accounts for 18% of total U.S. end-use energy consumption, of which almost a third was from on-site combustion of fossil fuels for space and water heating. Magnetic heat pumping (MHP) technology is an energy-efficient, sustainable, environmentally-friendly alternative to conventional vapor-compression cooling technology. Several MHP designs today are predicted to be highly energy efficient, on condition that suitable working materials can be developed. This materials challenge has proven to be daunting due to issues associated with intricate synthesis/post-processing protocols and complications related to shaping the mostly brittle magnetocaloric alloys into thin-walled channeled regenerator structures to facilitate …

Improving Cast Steel Rail Coupler Fatigue Resistance Through Local Wire-Arc Additive Manufacturing, Andrew M. Bunge

Dissertations, Master's Theses and Master's Reports

Every year, thousands of cast-steel railcar couplers suffer from corrosion-initiated fatigue cracking in similar areas of the coupler’s knuckle; between 2015 and 2018 about 90,000 knuckles were replaced, otherwise these couplers would have been at risk for unexpected failures. These types of couplers have been common in industrial use as early as 1932, hence it is desirable for a countermeasure to the fatigue cracking that does not involve significantly altering the geometry or casting process. Wire arc additive manufacturing (WAM) is a developing technology which boasts the ability to produce complex near-net-shape components; however, less attention has been paid to …

Materials Testing For Large Format 3d Printing, William Jenkins

Williams Honors College, Honors Research Projects

An ABS Carbon Fiber blend was printed into single walled hexagons at a variety of settings on a Cincinnati BAAM large format 3D printer. These hexagons were then cut down into sheets and had tensile and flexural test samples cut out of them, in order for materials testing to be performed. Tensile strength, tensile strain, young’s modulus, flexural strength, deflection and elastic modulus were all determined. A desktop CNC machine and a planer were purchased for the manufacturing of these samples, and an efficient cutting procedure was designed and optimized. After all data collection concluded, this data was thoroughly analyzed, …

Short Strand Carbon Fiber Reinforced Polylactic Acid Filament For Additive Manufacturing, Dale Chenoweth, Lukas Seggi, Luke Phillips

Williams Honors College, Honors Research Projects

In this design project, the additive manufacturing filament of short strand carbon fiber (SSCF) reinforced polylactic acid (PLA) composite was developed. The micro-size, precision cut SSCFs were mixed with the PLA pellets through a melting homogenization process. Through this process the composite material block is cut and divided into pieces for ease of pelletizing. The material block pieces are then pelletized to be fed through the single screw extruder to develop the SSCF-PLA composite filament. The SSCF-PLA filaments were manufactured with a varying amount of SSCF ranging from 0.5% to 10% of the material block's weight. Development of a 1% …

Influence Of Heat Treatment And Shielding Gas Environment On The Very High Cycle Fatigue Behavior Of 17-4 Precipitation Hardened Stainless Steel, Jade Welsh

UNF Graduate Theses and Dissertations

Additive manufacturing (AM) for stainless steel components has proved useful in a variety of industries ranging from aerospace to biomedical engineering. Many of these components are subject to very high cycle fatigue (VHCF) loading and must have tailored mechanical properties to ensure failures do not occur before a service life is reached. Testing the fatigue strength AM materials exposed to VHCF loading is paramount to compare with the expected life cycles of their wrought counterparts. In this thesis, AM 17-4 precipitation hardened (PH) stainless steel (SS) were fabricated using laser powder bed fusion (L-PBF) technique, while the wrought 17-4 PH …

Cobalt Chromium In Biomedical Applications And The Development Of A Pspp Map, Nouralhouda Jamal

BCoE Publications

During the world wars, Cobalt-Chromium (Co-Cr) alloys gained prominence for their use in aircraft engine components, where they exhibited high temperature strength and durability. They are used in a wide range of industries due to their unique set of qualities, particularly strength, corrosion resistance, and biocompatibility. They have emerged as versatile materials with a broad spectrum of applications, from aerospace and automotive components to biomedical implants.

This paper presents a thorough analysis of its composition, processing techniques, microstructure, mechanical properties, and performance characteristics. The primary goal of this project is to develop a PSPP (Process, structure, properties, and performance) map …

An Investigation Into The Challenges Of Contemporary Additive Manufacturing: Insights Into The Metallurgical Response Of Materials And Relevant Solution, Huan Ding

LSU Doctoral Dissertations

Additive Manufacturing (AM) has gained attention in recent years due to its unique capabilities in the fabrication of complex parts. As with any new research, there is still a lack of sufficient understanding in the field of additive manufacturing, and further investigation is needed to solve existing problems. Ultimately, the aim is to enable the widespread use of AM components across various industries.

Chapter One provides a brief introduction to the background and current bottlenecks of additive manufacturing technology. Chapter two focuses on the development of high-strength 7075 aluminum alloy (Al7075) for Fused Deposition Modeling and Sintering (FDMS) technology. Al7075 …