Materials Science and Engineering Commons^™

Chemistry Of Inclusions By Size In Three Primary Copper Anodes, Charles Campbell, Michael Moats

Materials Science and Engineering Faculty Research & Creative Works

Three copper anodes from different commercial electro refineries were characterized to measure inclusion chemistry, size (diameter), and morphology. An automated scanning electron microscope (SEM) paired with energy-dispersive X-ray spectroscopy (EDS) was used to examine hundreds of inclusions near the mold and set sides of each anode. The investigation revealed that in the two anodes with less impurities (99.65% Cu and 99.75% Cu), many of the inclusions were Cu2O with an average diameter of 2 microns. The greater impurity anode (99.05% Cu, 4076 ppm Pb, 1939 ppm As, 635 ppm Bi) contained significant numbers of complex oxide inclusions, averaging 4.6 microns …

Tensile Performance Sensitivity To Variations Of Standard 17-4 Ph Heat Treatments On Lpbf-Produced Material, Ben Brown, Cory Read, Joseph Newkirk, Frank Liou

Materials Science and Engineering Faculty Research & Creative Works

Standard heat treatments for metals of a particular composition are typically designed with the assumption of a conventional starting microstructure, such as that produced by casting or wrought processing. When applied to metals fabricated by Laser Powder Bed Fusion (LPBF) metal additive manufacturing (AM), these heat treatments can produce inconsistent performance due to the unique as-built microstructures. This study investigates how modifications to standard heat treatments for 17-4 PH steel influence the microstructure and mechanical properties of LPBF-fabricated material. Specimens were produced and subjected to varying solutionizing and homogenizing treatments followed by standard aging treatments. Microstructures were characterized using optical …

Melting Behavior Of Direct Reduced Iron Pellets With Different Carbon Content In Molten Steel And Molten Slag, Fabian Andres Calderon Hurtado, Joseph Govro, Arezoo Emdadi, Ronald J. O'Malley

Materials Science and Engineering Faculty Research & Creative Works

This study investigates the melting behavior of direct reduced iron (DRI) pellets in molten slag and steel baths, focusing on how the carbon content influences the melting rate through the stirring effects of gas evolution on heat transfer. A computational model using COMSOL Multiphysics 6.1 is developed to simulate the temperature profile at the pellet's core and the gas evolution resulting from the reaction between FeO and carbon within the pellet. The model is validated using experimental data from this study as well as literature on the DRI pellet–molten slag system. Results indicate that, despite the increased enthalpy demand associated …

Selective Nickel Leaching And Preparation Of Battery-Grade Nickel Carbonate From Copper-Rich Industrial Intermediate, Janaka Jayamini Wijenayake, Michael S. Moats, Lloyd Masuzyo Mseteka, Lana Alagha

Materials Science and Engineering Faculty Research & Creative Works

The rising demand for electric vehicles (EVs) has driven a significant increase in nickel consumption, a critical element in EV battery production. An industrially viable hydrometallurgical process was developed for the selective recovery of nickel from a copper-rich industrial intermediate, containing approximately 70 wt.% Cu and 6 wt.% Ni, predominantly as sulfides alongside minor impurities. Approximately 90% of nickel was selectively extracted via single-stage atmospheric pressure leaching using HCl and H2O2 at 95 °C for 12 h, with the majority of copper retained in the leach residue, which can be utilized as a valuable feedstock for copper smelters. The selectivity …

Laboratory Investigation Of High-Temperature Preformed Particle Gels For Fluid Control In Granite Cores For Geothermal Applications, K. Caleb Darko, Yanbo Liu, Thomas P. Schuman, Mingzhen Wei, Baojun Bai

Chemistry Faculty Research & Creative Works

To understand the applicability of high-temperature preformed particle gel (HT-PPG) for control of short-circuiting in enhanced geothermal systems (EGSs), core flooding experiments were conducted on fractured granite cores under varying fracture widths, gel particle sizes and swelling ratios. Key parameters such as injection pressure, water breakthrough pressure, and residual resistance factor were measured to evaluate HT-PPG performance. The gel exhibited strong injectability, entering granite fractures at pressure gradients as low as 0.656 MPa/m; HT-PPG yields a superior sealing performance by significantly reducing the permeability; and dehydration occurs during HT-PPG propagation, with a dehydration ratio ranging from 4.71% to 11.36%. This …

Additive Manufacturing Of Multi-Material Aircraft Sandwich Structures, Dhriti Mandalam Surendranath Kumar, Cody Van Dyck

College of Engineering Summer Undergraduate Research Program

This SURP proposal is centered around the exploration of the application of 3D printing composite part processing techniques to produce multi-material sandwich structures for high performance applications such as civilian and military aircraft. These processing techniques have the potential to significantly reduce the costs and the environmental impact of existing conventional autoclave composite processing techniques. The exploration of new ‘out-of-autoclave’ composite part processing techniques may help to reduce processing costs and the environmental impact of processing, as well as broaden the engineering applications of cellular core materials beyond their existing engineering applications. 3D printing directly onto sandwich core materials will …

Engaging Students In Materials Engineering Through A Marble-Based Property Ranking Game, Nathan Cloughley, Alyssa Felix

College of Engineering Summer Undergraduate Research Program

This SURP proposal is centered on the design and development of a Materials Marbles Game, an educational tool designed to introduce students to materials science and materials selection through tactile interaction and hands-on experimentation. The game will incorporate measurement of key material properties—such as mechanical, thermal, electrical, and mass density—using spherical marbles made from different materials. These measurements will then be used to construct a physical Material Property Chart (Ashby-Cebon plot) on a game board, fostering a hands-on, embodied understanding of how different materials behave. The game will also illustrate the thought process behind materials selection, a critical aspect of …

Characterization Of Zwitterion/Salt Electrolyte Blends For Organic Solid Electrolytes In Lithium-Ion Batteries, Sage Alling, Will Vasser

College of Engineering Summer Undergraduate Research Program

Progress toward durable and energy-dense lithium-ion batteries has been hindered by instabilities at electrolyte–electrode interfaces, leading to poor cycling stability, and by safety concerns associated with energy-dense lithium metal anodes. Organic Solid electrolytes (OSEs) can help mitigate these issues; however, OSE conductivity is often limited by sluggish dynamics through rubbery domains. Recent work has suggested that zwitterionic OSEs can self-assemble into superionically conductive domains, permitting decoupling of ion motion and liquid rearrangement timesscales. Although crystalline domains are conventionally detrimental to ion conduction in SPEs, we this work suggests that properly designed semicrystalline OSEs with labile ion–ion interactions and tailored ion …

Active Measurement Of A Micron-Order Gap Under High-Speed And High-Temperature Conditions, Andrew Becker

Doctoral Dissertations and Master's Theses

The hypersonic regime poses numerous challenges that researchers face in the development of hypersonic flight vehicles. Due to their excellent thermomechanical properties, ultra-high-temperature ceramics (UHTCs) have risen as a promising solution to act as a protective barrier between the harsh environment and surface materials of these flight bodies. The mechanical operation of a portable hypersonic simulation device was developed in-house and tested at Argonne National Laboratories (ANL) to gather in-situ material response of prospective UHTC samples when exposed to a hypersonic regime. An edge detection-based algorithm was developed and used in LabVIEW to monitor the health and operation of the …

Machine Learning Classification Of Eeg Responses To Pain-Related Vs Non-Pain-Related Stimulus In Preterm Infants, Lojain Hamwi, Hang Du, Sara Jasim, Xiaogang Wang, Vibhuti Shah, Carol Cheng, Lorenzo Fabrizi, Maria Fitzgerald, Judith Meek, Nicole Racine, Ian Stedman, Rebecca Pillai Riddell

Michigan Tech Publications

INTRODUCTION: Unmanaged pain in preterm infants can lead to long-term developmental consequences. Current pain assessment methods lack specificity, resulting in possible pain mismanagement in Neonatal Intensive Care Units (NICUs). This study explores the application of machine learning (ML) to differentiate between pain-related and non-pain-related cortical activity in preterm infants. OBJECTIVE: To evaluate the performance of ML models in distinguishing cortical EEG activity during a painful procedure in preterm infants across different postmenstrual ages (PMAs). METHODS: This observational study was conducted from June 2015 to May 2024 at Mount Sinai Hospital in Toronto, Canada, and University College London Hospital, United Kingdom. …

Characterization Of The Fatigue Threshold Behavior Of Uhmwpe, Bethany B. Smith, Anurag Roy, Robert O. Ritchie, Lisa A. Pruitt

Faculty Journal Articles

Ultra-high-molecular-weight-polyethylene (UHMWPE) has been the material of choice for bearings in total joint replacements (TJRs) for decades as a result of its excellent wear resistance, chemical inertness, energetic toughness, low friction, and biocompatibility. Utilization of this polymer in orthopedic devices requires oxidation, wear, and fatigue resistance. Balancing these important properties by tailoring processing techniques and modulating microstructural features has been an ongoing endeavor in the field. Research into the clinical applications of UHMWPE has primarily focused on the challenges of wear and oxidation while studies into the realm of fatigue have been more limited. Literature gaps exist in fully understanding …

Bridging Materials And Energy Storage Mechanisms In Zn-I2 Batteries, Rong-Qi Liu, Wen-Shuo Shang, Jin-Tao Zhang

Journal of Electrochemistry

Zinc-iodine (Zn-I₂) batteries have emerged as a compelling candidate for large-scale energy storage, driven by the growing demand for safe, cost-effective, and sustainable alternatives to conventional systems. Benefiting from the inherent advantages of aqueous electrolytes and zinc metal anodes, including high ionic conductivity, low flammability, natural abundance, and high volumetric capacity, Zn-I₂ batteries offer significant potential for grid-level deployment. This review provides a comprehensive overview of recent progress in three critical domains: positive-electrode engineering, zinc anode stabilization, and in situ characterization methods. On the cathode side, anchoring iodine to conductive matrices effectively mitigates polyiodide shuttling and enhances …

Series Reports From Professor Wei’S Group Of Chongqing University: Advancements In Electrochemical Energy Conversions (2/4): Report 2: High-Performance Water Splitting Electrocatalysts, Ling Zhang, Wang-Yang Wu, Qiu-Yue Hu, Shi-Dan Yang, Li Li, Rui-Jin Liao, Zi-Dong Wei

Journal of Electrochemistry

The unavailability of high-performance and cost-effective electrocatalysts has impeded the large-scale deployment of alkaline water electrolyzers. Professor Zidong Wei’s group has focused on resolving critical challenges in industrial alkaline electrolysis, particularly elucidating hydrogen and oxygen evolution reaction (HER/OER) mechanisms while addressing the persistent activity-stability trade-off. This review summarizes their decade-long progress in developing advanced electrodes, analyzing the origins of sluggish alkaline HER kinetics and OER stability limitations. Professor Wei proposes a unifying “12345 Principle” as an optimization framework. For HER electrocatalysts, they have identified that metal/metal oxide interfaces create synergistic “chimney effect” and “local electric field enhancement effect”, enhancing selective …

Local Electric Fields Coupled With Cl− Fixation Strategy For Improving Seawater Oxygen Reduction Reaction Performance, Yu-Rong Liu, Miao Zhang, Yan-Hui Yu, Ya-Lin Liu, Jing Li, Xiao-Dong Shi, Zhen-Ye Kang, Dao-Xiong Wu, Peng Rao, Ying Liang, Xin-Long Tian

Journal of Electrochemistry

Development of robust electrocatalyst for oxygen reduction reaction (ORR) in a seawater electrolyte is the key to realize seawater electrolyte-based zinc-air batteries (SZABs). Herein, constructing a local electric field coupled with chloride ions (Cl⁻) fixation strategy in dual single-atom catalysts (DSACs) was proposed, and the resultant catalyst delivered considerable ORR performance in a seawater electrolyte, with a high half-wave potential (E_1/2) of 0.868 V and a good maximum power density (Pmax) of 182 mW·cm⁻² in the assembled SZABs, much higher than those of the Pt/C catalyst (E_1/2: 0.846 V; Pmax: 150 mW·cm^{−2 …}

Significantly Enhanced Oxygen Reduction Reaction Activity In Co-N-C Catalysts Through Synergistic Boron Doping, Chang Lan, Jing-Sen Bai, Xin Guan, Shuo Wang, Nan-Shu Zhang, Yu-Qing Cheng, Jin-Jing Tao, Yu-Yi Chu, Mei-Ling Xiao, Chang-Peng Liu, Wei Xing

Journal of Electrochemistry

The weak adsorption energy of oxygen-containing intermediates on Co center leads to a considerable performance disparity between Co-N-C and costly Pt benchmark in catalyzing oxygen reduction reaction (ORR). In this work, we strategically engineer the active site structure of Co-N-C via B substitution, which is accomplished by the pyrolysis of ammonium borate. During this process, the in-situ generated NH₃ gas plays a critical role in creating surface defects and boron atoms substituting nitrogen atoms in the carbon structure. The well-designed CoB₁N₃ active site endows Co with higher charge density and stronger adsorption energy toward oxygen species, …

Microstructure Densification In Cement Pastes Enabled By Novel Graphene Types, Sahil Surehali, Taihao Han, Ranjith Divigalpitiya, Aditya Kumar, Narayanan Neithalath

Materials Science and Engineering Faculty Research & Creative Works

The primary barriers hindering graphene's widespread adoption as a performance-enhancing additive in cement-based systems have traditionally been its prohibitive cost and the sustainability concerns associated with conventional manufacturing processes. However, these impediments have recently been mitigated by advancements in detonation synthesis techniques, enabling scalable, cost-effective, and environmentally favorable production of novel graphene types—specifically fractal graphene (FG) and reactive graphene (RG). This paper explores the influence of ultra-low dosages of FG and RG (≤ 0.04 % by mass of cement, which results in ∼20 % increase in compressive strengths) on the pore-structure features of cement pastes. Compared to the control paste, …

Improvement Of Lithium-Metal Electrode All-Solid-State Batteries Performance By Shot Peening And Magnetron Sputtering, Atsuro Okumura, Manabu Kodama

15th International Conference on Shot Peening

To enable fast charging in lithium-metal anode all-solid-state batteries, suppressing lithium dendrite formation at the solid electrolyte (SE) interface is critical. Increasing fracture toughness via shot peening (SP) and improving interfacial contact with Au sputtering can inhibit dendrite growth. However, conventional sputtering may reduce toughness due to localized thermal damage. This study investigated magnetron sputtering as a low-damage, plasma-based Au deposition method. SEs with and without SP were fabricated and coated via normal and magnetron sputtering. Critical current density (CCD) and fracture toughness were evaluated. Without SP, CCD improvement was limited regardless of sputtering method due to poor bonding. With …

Hydrogen Embrittlement In Shot-Peened Steel, Jia-Huei Tien, David R. Johnson, David Bahr

15th International Conference on Shot Peening

This work investigates the role of shot peening on hydrogen embrittlement resistance in quenched and tempered 1070 steel. Thermal desorption spectroscopy results revealed that shot-peened specimens contained nearly twice the hydrogen (H) content of unpeened samples when charged under the same electrochemical conditions, suggesting the introduction of additional trapping sites occur during peening. The mechanism underlying this behavior can be associated with increased dislocation density and is more consistent with the HELP mechanism. Residual stress measurements show a significant relaxation of compressive stresses in shot-peened specimen after H charging, indicating H enhanced dislocation rearrangement. Both unpeened and peened specimens exhibited …

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 …

From Strain To Stress: Stress Map Testing Of Almen Strips, Donovan Stumpf, Rajeshree Varma, Paul R. Mort

15th International Conference on Shot Peening

Almen strips have long been used to evaluate shot peening intensity, with arc height serving as a proxy for compressive residual stress. Stress mapping tests (SMT) in this work involve the controlled flattening of an Almen test strip onto a spatial pressure sensor, acting as an inferential measurement for the net bending moment caused by the relaxation of the peened strip. This work explores how stress mapping tests add insight into the stress state of Almen strips, potentially offering a fast and practical alternative to residual stress depth profiling. SMT data analysis provides a framework for relating Almen gauge height …

Fourier Analyses Of Optical Profilometry As An Inferential Measurement For Impact Coverage., Langdon Feltner, Paul Mort

15th International Conference on Shot Peening

A critical consideration in peening process design is achieving sufficient impact coverage. Conventional methods for assessing coverage rely on manual inspection, which is time-consuming and poorly suited for automated control. In this work, we investigate the use of frequency-domain analysis to quantify surface modification in peened samples using optical profilometry (OP) data. Three-dimensional surface maps of Almen strips were acquired using a high-resolution OP system and analyzed via fast Fourier transform (FFT) to compute spatial power spectral densities (PSDs). PSD maps and radially averaged profiles reveal consistent amplification of harmonic components similar to the nominal particle size, with increasing intensity …

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 …

Comparison Of Peening Effect Between Additive Manufacutred And Drawing Titanium Alloy, Hitoshi Soyama

15th International Conference on Shot Peening

Although additively manufactured (AM) metals are attractive materials, their remarkable weak fatigue properties are an obstacle to their practical application. Thus, post-processing to improve their fatigue properties is required. In the present study, powder bed fusion using laser sintering titanium alloy, i.e., PBF-LS/Ti6Al4V was treated by shot peening (SP), submerged laser peening (SLP), cavitation peening (CP), and fine particle bombarding (FPB), then the fatigue properties were investigated by a torsional fatigue test, comparing with drawing Ti6Al4V. It was revealed that the fatigue strength at 10⁷ was 446 ± 5 MPa for PBF-LS/Ti6Al4V treated by FPB+CP, 359 ± 9 MPa …

Improvement Of The Fatigue Behaviour Of Additive Manufatured Scalmalloy By Using Surface Improvement Processes, Francisco José Boby Alcaide, Irene Eras, José Manuel De Los Santos, Alejandro Munoz Castro, Antonio Perinan Butrón, Jorge Sogorb

15th International Conference on Shot Peening

The use of light metals such as Aluminum alloys has experienced a remarkable increase for the additive manufacturing (AM) industry, especially in aerospace.

AM Scalmalloy®. (an Al-Mg-Sc alloy) shows outstanding behavior with much higher mechanical performance with respect to other alloys for powder bed fusion laser-based (PBF-LB) process like AlSi10Mg or AlSi7Mg. Recent studies have mainly focused on static loading, with minor attention to cyclic loading despite its vital importance in many applications.

In this work, the fatigue performance of PBF-LB Scalmalloy was investigated considering the effects of surface treatments to identify the set of optimal post-processes. Shot peening with …

Influence On Shot Peening And Blast Polishing For Rotating Bending Fatigue Strength Of Vacuum Carburized Steel With Circumferential Notch, Yuji Kobayashi, Hayato Taniguchi, Kiyotaka Masaki

15th International Conference on Shot Peening

In order to improve fuel efficiency in automobiles, weight reduction is necessary as well as improving engine efficiency. For transmission gears, thickness reduction is necessary for weight reduction. When the thickness is reduced, the cross-sectional area becomes smaller, and the load stress increases. Therefore, higher fatigue strength is required. Most gears carry out carburizing. Shot peening is often used to improve the fatigue strength of carburized heat-treated parts. After shot peening, compressive residual stress is introduced, but at the same time, surface roughness is increased. Therefore, the processing conditions of shot peening are very important. Blast polishing is a processing …

Reduced Order Approach For Peening Stress Field Variability, Langdon Feltner, Paul Mort

15th International Conference on Shot Peening

A common goal in shot peening research is to connect operational parameters to resultant residual stress fields, providing a means to control and optimize the effectiveness of surface treatment. In practice, experimental measurements of residual stresses are often averaged values over regions that are large in comparison to an impact dimple. In fact, the stochastic nature of impact locations leads to residual stress fields that are distributed. Finite element peening simulations confirm this observation. The goal of this report is to connect operational parameters to localized fluctuations in residual stress through probabilistic reasoning (Figure 1). In particular, the development of …

Adaptation Of Shot Peen Parameters For Gear Geometry, David J. Breuer, Beth Matlock

15th International Conference on Shot Peening

Shot peening is a well established process for the surface enhancement of gearing. Gearing is a primary example of a high cycle fatigue application that can benefit from residual stress enhancement. Designing shot peening parameters to specific gear geometry based on material, heat treatment, and surface finish is a more precise way to achieve better performance outcomes. One of the best tools to assist in the optimal shot peening is x-ray diffraction (XRD) and its ability to measure small differences that can result in significant performance outcomes. XRD residual stress measurements are a direct measurement of elastic strain. The diffraction …

Investigations On The Fatigue Strength Of Threads Produced By Different Fabrication Techniques, Philippe Du Maire, Jürgen Hoffmeister, Andreas Öchsner, Michael Johlitz

15th International Conference on Shot Peening

The increasing importance of sustainability in engineering demands the development of long-lasting, high-performance components that reduce material and energy consumption over time. This study investigates how different thread manufacturing processes, i.e., cutting, rolling, and deep rolling, affect the fatigue strength of bolts made from 42CrMo4+QT steel. Cylindrical specimens with M12 threads were subjected to cyclic tensile loading with constant mean stress. Fatigue strength was evaluated using the staircase method, and supporting analyses included X-ray diffraction for residual stress, and full width half maximum examination and Vickers microhardness measurements. Results show that thread rolling significantly improves fatigue strength, achieving 113.8 MPa …

Antibacterial Activity Of Zno/Geopolymer Composite Granules And Their Potential Application In Water Treatment, Ziyan Tirta Maulitia, Putri Nur Angelina, Pipit Erlita Sari, Sri Sugiarti, Irma Isnafia Arief, Zaenal Abidin

Makara Journal of Science

Water pollution has become a major global concern owing to its complexity and widespread impact. Staphylococcus aureus (S. aureus) and Escherichia coli (E. coli) are the most common bacterial contaminants in water sources, which pose significant threats to public health. To mitigate water contamination by these pathogenic microorganisms, developing and implementing effective water treatment technologies are essential. A promising approach involves using antibacterial water filtration systems. Herein, zinc oxide (ZnO) nanoparticles were synthesized via hydrothermal and precipitation methods as antibacterial agents for water treatment. These preparation methods required considerably low synthesis time. A capping agent was …

Effect Of Fine Particle Peening Induced Material Transfer On The Initial Deposition Behavior Of Nickel Electroplating On Aluminum Substrate, Kazuki Iijima, Yutaka Kameyama, Hideaki Sato, Shuhei Kodama

15th International Conference on Shot Peening

Plating on aluminum requires a complex zincate pretreatment. Fine Particle Peening (FPP), using particles ≤200 µm, has gained attention as an alternative due to its ability to transfer particle components onto the surface, potentially improving deposition and adhesion. Previous studies showed enhanced plating on aluminum treated with steel particles. This study investigates the effectiveness of FPP as a pretreatment for nickel electroplating by examining initial deposition behavior. A1050-H24 aluminum was treated using FPP with either steel or glass particles, compared to an untreated specimen. Steel particle FPP created a lamellar microstructure with alternating iron and aluminum phases. EBSD revealed that …