Materials Science and Engineering Commons^™

Silk As A Biomaterial Paste For Biomimetic Composite, Sang Hyun Park

McKelvey School of Engineering Graduate Student Theses & Dissertations

Silk is a highly promising biomaterial with unique bio-physicochemical properties, such as excellent mechanical and optical properties, biocompatibility and programmable biodegradability. Among many different types, silk from domesticated silkworm, bombyx mori has received wide attention owing to its availability in virtually unlimited quantities and ease of extraction. In this study, we investigated silkworm silk as a protein glue to realize nacre-like composites. We have employed spin assisted layer-by-layer technique to fabricate ultrathin free-standing biocomposite films. Two different composites have been studied: (i) graphene oxide (GO)/silk and (ii) chitin/silk. From our prior work, it is known that the adsorption of amphiphilic …

Nonaffine Rearrangements Of Atoms In Deformed And Quiescent Binary Glasses, Nikolai V. Priezjev

Mechanical and Materials Engineering Faculty Publications

The influence of periodic shear deformation on nonaffine atomic displacements in an amorphous solid is examined via molecular dynamics simulations. We study the three-dimensional Kob-Andersen binary mixture model at a finite temperature. It is found that when the material is periodically strained, most of the atoms undergo repetitive nonaffine displacements with amplitudes that are broadly distributed. We show that particles with large amplitudes of nonaffine displacements are organized into compact clusters. With increasing strain amplitude, spatial correlations of nonaffine displacements become increasingly long-ranged, although they remain present even in a quiescent system due to thermal fluctuations.

Properties Of Partially Stabilized Zirconia Components Fabricated By The Ceramic On-Demand Extrusion Process, Wenbin Li, Amir Ghazanfari, Devin Mcmillen, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The Ceramic On-Demand Extrusion (CODE) process is a novel additive manufacturing process for fabricating dense ceramic components from aqueous pastes of high solids loading. In this study, 3 mol% Y₂O₃ stabilized tetragonal zirconia polycrystal (3Y-TZP) parts were fabricated using the CODE process. The parts were then dried in a humidity controlled environmental chamber and sintered under atmospheric pressure. Mechanical properties of the sintered parts were examined using ASTM standard test techniques, including density, Young’s modulus, flexural strength, Weibull modulus, fracture toughness and Vickers hardness. The microstructure was analyzed, and grain size was measured using scanning electron microscopy. …

3d Printing Of A Polymer Bioactive Glass Composite For Bone Repair, Caroline Murphy, Krishna C. R. Kolan, M. Long, Ming-Chuan Leu, Julie A. Semon, D. E. Day

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A major limitation of synthetic bone repair is insufficient vascularization of the interior region of the scaffold. In this study, we investigated the 3D printing of adipose derived mesenchymal stem cells (AD-MSCs) with polycaprolactone (PCL)/bioactive glass composite in a single process. This offered a three-dimensional environment for complex and dynamic interactions that govern the cell’s behavior in vivo. Borate based bioactive (13-93B3) glass of different concentrations (10 to 50 weight %) was added to a mixture of PCL and organic solvent to make an extrudable paste. AD-MSCs suspended in Matrigel was extruded as droplets using a second syringe. Scaffolds measuring …

Powders For Additive Manufacturing Processes: Characterization Techniques And Effects On Part Properties, Austin T. Sutton, Caitlin S. Kriewall, Ming-Chuan Leu, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Powder-bed based Additive Manufacturing is a class of Additive Manufacturing (AM) processes that bond successive layers of powder by laser melting to facilitate the creation of parts with complex geometries. As AM technology transitions from the fabrication of prototypes to end-use parts, the understanding of the powder properties needed to reliably produce parts of acceptable quality becomes critical. Consequently, this has led to the use of powder characterization techniques such as scanning electron microscopy (SEM), laser light diffraction, x-ray photoelectron spectroscopy (XPS), and differential thermal analysis (DTA) to both qualitatively and quantitatively study the effect of powder characteristics on part …

Designed Extrudate For Additive Manufacturing Of Zirconium Diboride By Ceramic On-Demand Extrusion, Devin Mcmillen, Wenbin Li, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This work describes a process by which zirconium diboride (ZrB2) parts may be fabricated using the Ceramic On-Demand Extrusion (CODE) process. An oxide-carbide-nitride system consisting of ceramic powders and pre-ceramic organics, designed to yield ZrB₂ after reaction sintering, has been developed to produce an aqueous-based extrudate for subsequent processing in the CODE system. Pressurelessly sintered test specimens containing 1 wt% PVA binder achieve high relative density ≥ 99%. The viscoelastic response of the extrudate was characterized via spindle rheometry with a small sample adapter. Batches with 1 wt% PVA and 0.5 wt% Methocel show strong shear thinning characteristic, under …

A Novel Extrusion-Based Additive Manufacturing Process For Ceramic Parts, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical density is introduced in this paper. In this process, an aqueous paste of ceramic particles with a very low binder content ( < 1 vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Several sample parts for various applications were produced using this process and their properties were obtained. The results indicate that the proposed method enables fabrication of large, dense ceramic parts with complex geometries.

Simulation Of Cooling Rate Effects On Ti-48al-2cr-2nb Crack Formation In Direct Laser Deposition, Lei Yan, Wei Li, Xueyang Chen, Yunlu Zhang, Joseph William Newkirk, Frank W. Liou, David Dietrich

Materials Science and Engineering Faculty Research & Creative Works

Transient temperature history is vital in direct laser deposition (DLD) because it reveals the cooling rate at specific temperatures, which directly relates to phase transformation and types of microstructure formed in deposit. FEA simulation was employed to study the transient temperature history and cooling rate at different experimental setups in Ti-48Al-2Cr-2Nb DLD process. In this paper, an innovative model was described, which combines a moving Gaussian distribution heat source and element birth and death technology in ANSYS, help to analysis cooling rate control method and guide crack-free deposits build process.

Modeling And Experimental Investigation Of Pre-Mixed Multi-Powder Flow In Fabricating Functional Gradient Material By Laser Metal Deposition Process, Wei Li, Jingwei Zhang, Sreekar Karnati, Yunlu Zhang, Frank W. Liou, Joseph William Newkirk, Karen M. Brown Taminger, W. L. Seufzer

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Metal Deposition (LMD) is an effective process to fabricate Functionally Graded Material (FGM) from pre-mixed powders. Since the supplied multi-powder directly affects the deposited FGM’s composition, investigation on Pre-Mixed Multi-Powder (PMMP) flow during LMD is greatly needed. This paper presents a comprehensive numerical PMMP flow model. By solving discrete particle force balance equations coupled with continuity equations and momentum equations for carrier gas, the dynamic behavior of PMMP flow through powder feeder tube and out of nozzle was calculated. With this model, the particle sizes of multi-powder were optimized to obtain considered FGM composition. To verify the modeling results, …

Elevated Temperature Microstructure Stability Of Slm 304l Stainless Steel, Tarak Amine, Joseph William Newkirk

Materials Science and Engineering Faculty Research & Creative Works

With time at temperature, changes in metallurgical structure can be expected for almost any steel or alloy. In stainless steels, the changes can be grain growth, carbide precipitation, ferrite decomposition, or embrittlement. These phenomena can significantly effect the properties of the steel and would potentially change the functionality of the component. Therefore, to determine component stability, the elevated temperature microstructure stability of additive manufacturing materials was studied. This work investigates the influence of different aging times of additive material stainless steels (304L) fabricated with the Selective Laser Melting (SLM) process on microstructure and mechanical properties. Microstructure and mechanical properties were …

Investigation Of Tensile Properties Of Bulk And Slm Fabricated 304l Stainless Steel Using Various Gage Length Specimens, Sreekar Karnati, I. Axelsen, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The complex solidification dynamics and thermal cycling during Selective Laser Melting process is expected to result in non-equilibrium material characteristics. There is an essential need for characterization techniques which are critical towards the estimation of anisotropies. The current investigation is targeted towards establishing tensile testing methodologies and their relation to differing gage lengths. Dog-bone shaped specimen designs with gage lengths of 1”, 0.3” and 0.12” were employed in this research. The characterization was performed on hot rolled-annealed 304 stainless and SLM fabricated 304L stainless. It was theorized that smaller gage length specimens would be instrumental in mapping material property anisotropy …

Novel Extrusion-Based Additive Manufacturing Process For Ceramic Parts, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical density is introduced in this paper. In this process, an aqueous paste of ceramic particles with a very low binder content (< 1 vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Several sample parts for various applications were produced using this process and their properties were obtained. The results indicate that the proposed method enables fabrication of large, dense ceramic parts with complex geometries.

Investigation Of Heat-Affected 304l Ss Powder And Its Effect On Built Parts In Selective Laser Melting, Caitlin S. Kriewall, Austin T. Sutton, Ming-Chuan Leu, Joseph William Newkirk, Ben Brown

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective laser melting (SLM) is a powder bed based additive manufacturing process in which a layer of powder is laid over the surface of a substrate and a laser with sufficient energy is employed to selectively melt particles to build a part layer by layer. During the SLM process, dark smoke was observed coming off of the powder bed surface where the laser was interacting with powder. This phenomenon resulted from heat-affected powder that was visibly different than the base powder. Since the concentration of the heat-affected powder differs throughout the build chamber as a result of the recirculating argon …

Effect Of Powder Particle Size On The Fabrication Of Ti-6al-4v Using Laser Metal Deposition From Elemental Powder Mixture, Xueyang Chen, Lei Yan, Wei Li, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Direct Laser Metal Deposition (LMD) was used to fabricate thin-wall Ti-6Al-4V using the powder mixture of Ti-6 wt.%Al-4 wt.%V. Scanning electron microscopy (SEM), optical microscopy (OM) and energy dispersive spectroscopy (EDS) were employed to examine the chemical composition and microstructure of the as-deposited sections. Vickers hardness tests were then applied to characterize the mechanical properties of the deposit samples which were fabricated using pre-mixed elemental powders. The EDS line scans indicated that the chemical composition of the samples was homogenous across the deposit. X-ray diffraction (XRD) was used for the phase identification. After significant analysis, some differences were observed among …

Proposed Hybrid Processes For Part Building Using Fusion Welding And Friction Stir Processing, Megan A. Gegesky, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

It has been shown that a hybrid laser additive manufacturing and friction stir processing can deposit components with forged-like structures. This paper reports a hybrid fusion welding and friction stir process to create parts with quality structures. Combining traditional fusion welding and friction stir processing techniques for non-weldable aluminum alloys could facilitate the joining of difficult geometries in manufactured parts. This research illustrates mechanical property changes for non-weldable and weldable aluminum alloys. The Vickers hardness, and microhardness in the case of AA5052-H32, tensile strength and corrosion resistance of four processing states: base material, fusion welded material, friction stir welded material, …

Design Maps For Fracture Resistant Functionally Graded Materials, Muhammad Ridwan Murshed

Theses and Dissertations

The objective of this research is to generate design maps to identify functionally graded microstructures with enhanced fracture toughness. Several Functionally Graded Materials (FGMs) with an edge crack and membrane loading are considered and the resulting J-integral values are computed numerically using Finite Element Analysis. In order to capture the resulting stress fields accurately, Barsoum elements are used in the vicinity of the crack tip and the simulations are carried out for several crack lengths (a) and material contrasts (κ). The averages of the J-integral values are used to determine the normalized Stress Intensity Factors which are then benchmarked with …

Amine-Thiol Solution Route Method For Fabricating Cdxzn1-Xs Thin Film Solar Cells, Preston D. Fernandez, Xianyi Hu, Carol Handwerker, Rakesh Agrawal

The Summer Undergraduate Research Fellowship (SURF) Symposium

Cadmium zinc sulfide, CdZnS, is a promising material for the buffer layer of thin film solar cells because the alloy is considerably more cost effective and more optimizable than pure cadmium sulfide, CdS, in terms of band gap. The current fabrication methods of the buffer layer often require expensive equipment or produce undesirable impurities in the alloy. This study investigates a cost effective and scalable solution route method to synthesize the CdZnS buffer layer. Molecular precursors of CdZnS were dissolved in varying molecular ratios of cadmium and zinc in a mixture of hexylamine and propanethiol. The resulting alloys produced were …

Radiation Tailored Polymers For Detectors, Adhesive-Coatings And Other Industrial Uses, Anna M. Earley, Alex Bakken, Rusi P. Taleyarkhan

The Summer Undergraduate Research Fellowship (SURF) Symposium

The ever growing importance of humans to depend on renewable resources has shifted the focus of consumers, producers, and even politicians to more sustainable answers. Furthermore, pressure on the oil and natural gas industry has elevated the status of biopolymers in this regard. Polylactic acid (PLA) is unique polymer that offers unique abilities for tailored property derivation; thereby, enabling one to replace many engineered polymers and provide a sustainable solution as a nontoxic renewable resource. As a bioplastic, the tailoring of PLA under various conditions is important to the application and integration into current industry uses. After irradiating high molecular …

Study Of Oxidative-Crosslink Reaction In Polyphenyl Sulfide (Pps) / Carbon Fiber And Its Influence In Additive Manufacturing, Dong Hee Kim, Eduardo Barocio, Bastian Brenken, Anthony Favaloro, Byron Pipes

The Summer Undergraduate Research Fellowship (SURF) Symposium

Ever since its development in 1980s, Fused Filament Fabrication (FFF) has been an attractive additive manufacturing technology due to its flexibility to create intricate shapes at lower costs and faster manufacturing process than subtractive techniques. These advantages make FFF suitable for printing molds for use in traditional composites manufacturing processes. Combining FFF with high-temperature thermoplastic composites enables producing molds that not only sustain autoclave conditions but also have low coefficient of thermal expansion (CTE). A semi-crystalline polymer, Poly-phenylene Sulfide (PPS), with 50% by weight of carbon fiber is used as feedstock material for FFF. Nonetheless, PPS is sensitive to undergo …

Wearable Piezotronic Devices For Heart Rate Monitoring, Adam J. Miller, Wenzhuo Wu Dr.

The Summer Undergraduate Research Fellowship (SURF) Symposium

Self-powered multifunctional wearable devices that are capable of human-device interfacing are highly desired. Piezotronic devices utilize piezoelectricity and semiconductor properties to enable devices to have seamless interaction between human and device. One important use for piezotronic devices is for pressure sensing. Pressure sensing devices have been employed in smart skins, biomonitoring, gesture recognition, and many more applications. This study aims to create a flexible piezotronic device, specifically for use in pressure sensing to monitor heart rate. ZnO nanowires are grown on a flexible polymer substrate so that they can be made into wearable devices. A p-n heterojunction is formed by …

Development Of A New Nanohub Simulation Tool: Coarse Graining Of Crystalline Nano-Cellulose., Kuo Tian, Mehdi Shishehbor, Pablo Zavattieri

The Summer Undergraduate Research Fellowship (SURF) Symposium

Crystalline Nano-cellulose (CNC) is a general molecular structure obtained from acid hydrolysis of native fiber. They are often very short (100 to 1000 manometers) and the mechanical properties of CNC varies depend on length scale. Due to defect formation of the structure, the mechanical properties of the material composed of such CNC may vary drastically. This study was to provide a numerical tool to integrate a few valid modules and to better understand the mechanical properties of CNC and the overall performance of the bio-inspired material composed of CNC. Our focus is mainly on two type of composite structure [1] …

Photonicstd-2d: Modeling Light Scattering In Periodic Multilayer Photonic Structures, Alexey Bondarev, Shaimaa Azzam, Zhaxylyk Kudyshev, Alexander V. Kildishev

The Summer Undergraduate Research Fellowship (SURF) Symposium

Efficient modeling of electromagnetic processes in optical and plasmonic metamaterials is important for enabling new and exciting ways to manipulate light for advanced applications. In this work, we put together a tool for numerical simulation of propagation of normally incident light through a nanostructured multilayer composite material. The user builds a unit cell of a given material layer-by-layer starting from a substrate up to a superstrate, splitting each layer further into segments. The segments are defined by width and material -- dielectric, metal or active medium. Simulations are performed with the finite difference time domain (FDTD) method. A database of …

Evaluation Of Strain Distortion Correction Protocol Using Scanning Electron Microscopy And Digital Image Correlation, Alexandra Mallory, Alberto Mello, Michael Sangid

The Summer Undergraduate Research Fellowship (SURF) Symposium

Scanning electron microscopy in combination with digital image correlation (SEM-DIC) is a useful technique for measuring strain in materials at the micro-scale. In particular, it can be used to identify micro-scale strain localizations that are the precursor to material failure. While SEM produces high resolution images of the microstructure, the images also contain a large amount of distortion that, during DIC, will result in distorted strain values that require correction. In this project, a nickel-based alloy underwent cyclic mechanical fatigue at three different high temperatures to a targeted maximum strain. Scanning electron microscopy imaging was done on a 200x150μm area …

Characterizing Hmx/Ap Cocrystal Propellant Through Planar Laser Induced Fluorescence, Seth M. Nielsen, Michael S. Powell, Steven F. Son

The Summer Undergraduate Research Fellowship (SURF) Symposium

Energetic cocrystals, or energetic materials that consist of two or more components that form a unique crystalline structure with unique properties, are currently being investigated as a possible method for decreasing the sensitivity of high energy density explosives for use in powerful solid composite propellants. Fuels more powerful than those in current use have not been practical because of their increased safety hazard due to higher sensitivity to being ignited. This has been one of the barriers that has prevented solid composite propellants from seeing significant improvements in performance. This study is an attempt to characterize a cocrystal of HMX …

Rapid Grain Boundary Mobility At Ambient Temperatures, Jarrod M. Lund, R Adam Bilodeau, Rebecca K. Kramer

The Summer Undergraduate Research Fellowship (SURF) Symposium

Understanding and measuring the influence of grain boundaries (planar defects in the crystalline structure of materials) and their motion has become a dominant aspect in materials research, with applications in additive manufacturing, fatigue prevention, and material modeling. However, modeling grain boundaries and grain boundary mobility (GBM) is difficult due to the high temperatures or external stresses, imaging solutions compatible with the material system, and long time-scales required to create measurable experimental results. In this paper, we introduce a novel material system that allows for easy and fast visualization of GBM. A drop of liquid metal eutectic gallium indium (eGaIn) placed …

Metamodels Of Residual Stress Buildup For Machining Process Modeling, Stuart B. Mccrorie, Michael Sangid

The Summer Undergraduate Research Fellowship (SURF) Symposium

In the process of machining materials, stresses, called residual stresses, accumulate in the workpiece being machined that remain after the process is completed. These residual stresses can affect the properties of the material or cause part distortion, and it is important that they be calculated to prevent complications from arising due to the residual stresses. However, these calculations can be incredibly computationally intensive, and thus other methods are needed to predict the residual stresses in materials for quick decision-making during machining. By using metamodels - a method of representing data where few data points exist - we can achieve an …

Large Scale Monolithic Solar Panel Simulation - A Study On Partial Shading Degradation, Suhas V. Baddela, Xingshu Sun, Muhammad A. Alam

The Summer Undergraduate Research Fellowship (SURF) Symposium

Shadow-induced degradation is a major concern for both power output and long-term reliability in solar cells. Apart from the obvious fact that shading reduces the amount of solar irradiance available to solar panels, it may lead to formation of hot spots, where solar cells are forced to reverse breakdown with localized heating, and potentially, permanent damage. To get a better understanding of shadow-induced degradation, we develop an electro-thermal coupled simulator that can self-consistently solve the electrical and thermal distributions of solar panel under arbitrary shading conditions. The simulation framework consists of two part: a) compact models that can describe the …

Mechanical Investigation Of Phase-Transforming Cellular And Origami Materials, John M. Cleveland, David Restrepo, Yunlan Zhang, Pablo Zavattieri, Nilesh Mankame

The Summer Undergraduate Research Fellowship (SURF) Symposium

Cellular materials, such as honeycombs and metallic foams, have attracted much attention due to their exceptional ability to absorb and diffuse mechanical energy. These materials have a wide range of applications, such as improving vehicle crash safety and helmet impact resistance. However, many of these materials are rendered unusable after one application. Phase-transforming cellular materials (PXCMs) utilize a reversible bistable mechanism to facilitate energy absorption from one-dimensional impacts and loads. These mechanisms have the added benefit over other cell structures of reusability. In this study, various PXCM designs are discussed and examined to determine their energy absorption capabilities.

Three different …

High Strain Rate Experiments Of Energetic Material Binder, Roberto Rangel Mendoza, Michael Harr, Weinong Chen

The Summer Undergraduate Research Fellowship (SURF) Symposium

Energetic materials, in particular HMX, is widely used in many applications as polymer bonded explosives (PBX) and rocket propellant. However, when damaged, HMX is known to be an unstable substance which renders it a hazardous material and in some cases unreliable. Finding critical mechanical conditions at high rates that render various forms of energetic materials as unreliable would be vital to understand the effects that vibrations and compression forces have on energetic materials. A better understanding would enable the ability to develop improvements in the manufacturing of PBX and rocker propellant. The method utilized to evaluate the mechanical properties of …

Characterization Of Suspension Polymerized Polyacrylamide And Poly(Sodium Acrylate-Acrylamide) Copolymer And Their Size Influence On The Properties Of Concrete, Cole R. Davis, Kendra A. Erk, Stacey L. Kelly

The Summer Undergraduate Research Fellowship (SURF) Symposium

Shrinkage leading to cracking and mechanical instability is a major problem for concrete due to the loss of water during the curing process. However, through the addition of Superabsorbent Polymer (SAP) hydrogels, shrinkage can be prevented, increasing the strength of concrete. Characterization of suspension polymerized polyacrylamide (PAM) poly(sodium acrylate-polyacrylamide) (PANa-PAM) copolymer microsphere sizes, morphology and swelling behavior was conducted before adding them to concrete. Size was determined using microscopy paired with ImageJ analysis. Coulter Counter size characterization was also used to determine the particle size distribution. Swelling behavior was determined using the tea bag method as well as size analysis …