Ceramic Materials Commons^™

Simulated Lunar Gravity Testing Of A Magnetic And Electrostatic System For Beneficiating Lunar Regolith, Blake A. Coffman, Gabriel Porter, Lindsay Manteufel, Mitchell Cottrell, Jeffrey D. Smith, David J. Bayless, William Shonberg, Frank D. Han, Fateme Rezaei, Kirby Runyon

Materials Science and Engineering Faculty Research & Creative Works

We present the design and testing of a lunar regolith beneficiation device that utilizes magnetic and electrostatic separation methods to concentrate desired minerals by removing unwanted material, such as the mineral anorthite, from bulk lunar regolith. The beneficiated materials would have value for downstream in-situ resource utilization (ISRU) processes such as metal extraction, oxygen extraction, and metal oxide additive manufacturing processes. The apparatus uses a dual-strength magnet system with N52 and N42 neodymium magnets to separate particles by magnetic susceptibility. The electrostatic separation system, which acts like a sieve, sorts the regolith simulant by particle size using a single-phase 50% …

Multiphysics Simulation And Experimental Validation Of Phase Transformation And Hardness In Jominy End-Quenched Low-Alloy Steels, J. S. Alabi, E. Heidari, M. F. Buchely, K. Chandrashekhara, S. N. Lekakh, R. J. O'Malley, V. A. Athavale, A. Kumar

Materials Science and Engineering Faculty Research & Creative Works

High-volume industrial continuous hot-rolled steel heat treatment processes involve sophisticated multi-phase modeling. The performance of a given process can be optimized by coupling phase transformation kinetics with the cooling conditions of the process. This study develops a multiphysics model to simulate an intensive quenching process for steel, which is inherently transient and highly dependent on numerous parameters. The simulated object was a Jominy end-quenched specimen geometry using two commercial steels, AISI 4130 and AISI 4140, with the goal of transferring a verified methodology to the heat treatment process for industrial heavy-section products (bars, slabs). The simulation employs thermal, mechanical, and …

In-Situ Investigations Of Calcium-Magnesium-Aluminosilicates (Cmas) Infiltration Effects On Thermal Barrier Coatings Under Extreme Environments Replicating Jet Engines, Zachary Stein

Doctoral Dissertations and Master's Theses

Calcium-magnesium-aluminosilicate (CMAS) particulates, such as sand or volcanic ash, are ingested by gas turbine jet engines during operation. When operating within high abundance regions, these particulates negatively interact and degrade the high temperature thermal barrier coatings (TBC) protecting underlying superalloy turbine blades vital to engine operation. These CMAS particulates melt within the engine and infiltrate into the ceramic coatings. In electron-beam physical vapor deposited (EB-PVD) TBCs, the CMAS within the intercolumnar gaps stiffens the coatings and causes thermomechanical induced high stress concentrations, risking crack formation. While molten, the CMAS thermochemically alters and destabilizes the coating, also risking coating failure. Premature, …

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 …

Extraction Of Aluminum From Lunar Regolith Through Molten Salt Electrolysis, Jacob N. Ortega, Todd P. Sander, Jeffrey D. Smith, Fateme Rezaei, David J. Bayless, William Schonberg, Daniel S. Stutts, Frank D. Han

Materials Science and Engineering Faculty Research & Creative Works

This paper presents the methodology, development, and results of an end-to-end regolith-to-metal concept for producing aluminum in-situ on the lunar surface, namely, the Lunar In-Situ Aluminum Production through Molten Salt Electrolysis (LISAP-MSE) method. Using electrolytic reduction, aluminum oxide (i.e., alumina) can be reduced into aluminum and oxygen via electrolysis in a molten salt bath. A steady supply of hydrogen chloride could allow this in-situ resource utilization (ISRU) method to supply several necessary materials consumed in the electrolytic reduction step of the process to produce bulk aluminum metal, oxygen, water, and silica from anorthite abundant in lunar highland regions. In this …

Tensile Creep Of A Hybrid Polymer-Matrix/Ceramic-Matrix Composite At Elevated Temperature, Waleed S. Alshehri

Theses and Dissertations

Advanced aerospace systems require structural materials that can perform reliably in high-temperature environments for long durations. The performance of standard polymer matrix composites (PMCs) in these conditions is often limited by their susceptibility to time-dependent deformation, such as creep. The objective of this research is to characterize the high-temperature creep behavior of a novel unitized material system comprising a polymer matrix composite (PMC) and a ceramic matrix composite (CMC) co-cured together. The PMC part consists of the polyimide matrix reinforced with laminated carbon fibers woven in an eight harness satin weave (8HSW). The CMC part consists of a zirconia-based ceramic …

Mno2 Nanoscale Interface Modification, Alexander C. Skoppe

Doctoral Dissertations and Master's Theses

Interface modification of carbon fibers has been shown to improve the mechanical performance of composites. In addition, interface modification of carbon fiber composites can impart multifunctionality into the resulting composite. This work will explore ZnO and MnO2 as interface modifications for use on carbon fibers. When exposed to high temperatures, carbon fibers undergo fiber degradation, leading to the need for low-temperature hydrothermal processes. This work will develop and characterize a nanoscale ZnO and MnO2 interface modification for use on carbon fibers. These nanomodifications will be developed with low-temperature processes, minimizing the fiber degradation that the fibers undergo. Fourier transform infrared …

Fabrication Of Ultra High-Temperature Compact Heat Exchanger By Extrusion-Based Ceramic Additive Manufacturing, Abid Hasan Rafi, David W. Lipke, Jeremy Lee Watts, Greg Hilmas, Ming-Chuan Leu

Miners Solving for Tomorrow Research Conference

No abstract provided.

Ground Testing Of A Magnetic-Electrostatic Separation System For Lunar Regolith Beneficiation, Peter Bachle, Charles Wood, Jeffrey Smith, Fateme Rezaei, David Bayless, William Schonberg, Daoru Han

Materials Science and Engineering Faculty Research & Creative Works

The separation of lunar regolith by mineral composition and size category is useful forin-situ resource utilization (ISRU). The research presented herein discusses the designing and development of equipment that has the potential to separate lunar regolith into aluminum, iron-titanium, and magnesium-iron ores. Along with the metal ore separation, this equipment shows the potential to separate regolith by size categories. The combined effect of these separation methods generates output that is valuable to subsequent use in metal and oxygen extraction, additive manufacturing, and regolith sintering processes. The designed equipment uses a dual-strength magnet system with N42 and N52 neodymium magnets for …

Novel Design And Fabrication Of A High-Speed Transient Heat Flux Sensor For Application To Rotating Detonation Engines, Zachary Todd Tallman

Graduate Theses, Dissertations, and Problem Reports (ETD)

Rotating detonation engine (RDE) combustion systems have been a topic of interest in the pressure gain combustion community for their benefits over traditional gas turbine engine combustors. However, cooling requirements for these engines are significantly higher and less predictable than those of non-detonating engines. To understand and quantify the high-speed heat transfer dynamics within an RDE, a novel high-frequency heat flux sensor is presented. This study aims to design a robust, single-sided sensor that can withstand the high temperature and harsh environment of an RDE for extended durations. Screen printing is used to deposit a layered, platinum-yttria-stabilized zirconia (YSZ) film …

Kinetic Modeling Of Dust Grain Dynamics In Electrostatic Sieving, Aaron Berkhoff, Easton Ingram, Fateme Rezaei, Jeffrey Smith, David Bayless, William Schonberg, Daoru Han

Chemical and Biochemical Engineering Faculty Research & Creative Works

A new kinetic particle modeling framework was developed to investigate electrostatic transport of lunar regolith dust particles with applications to the concept of electrostatic sieving. the new approach is based on kinetic particle dynamics and includes major modules of sampling the particle size distribution, solving electric fields, and tracking motion of charged dust grains. a case study for a concept of electrostatic sieving was chosen to validate the new model. the simulation achieved similar performance of particle size classification as reported in the literature. the new model is computationally efficient (takes a few minutes on a PC-type laptop computer) so …

Tension–Compression Fatigue Of A Hybrid Polymer-Matrix/Ceramic-Matrix Composite At Elevated Temperature, Marina B. Ruggles-Wrenn, Joshua Schmidt

Faculty Publications

Fully reversed tension–compression fatigue of a hybrid material comprising polymer matrix composite (PMC) co-cured with a ceramic matrix composite (CMC) was investigated. The PMC portion had a polyimide matrix reinforced with 15 plies of carbon fibers woven in an eight-harness satin weave (8HSW). The CMC portion had three plies of a quartz-fiber 8HSW fabric in a zirconia-based ceramic matrix. The hybrid PMC/CMC was developed for use in aerospace thermal protection systems (TPS). Hence, the experimental setup aimed to simulate the TPS service environment—the CMC side was kept at 329 °C, whereas the PMC side was open to laboratory air. Compression …

Interaction Of Particles With Plasma And Shock Produced By Pulsed Spark Discharge, Shomik Mukhopadhyay

Dissertations

Interactions of powders with high-temperature plasma and shockwaves occur in diverse scenarios, such as nuclear blasts, accidental industrial dust explosions, solid propellant combustion in explosive charges and when removing contaminants from surfaces. Electrostatic Discharge (ESD), known for generating shock and plasma, is a promising lab-scale technique for simulating these interactions. Studies with ESD involved placing powders near a spark-producing gap between electrodes and observing mechanical and chemical processes like particle motion and ignition. A limited range of spark conditions and material properties have been tested, which facilitated the development and validation of preliminary computational models describing this system. Significant gaps …

Influence Of Environmental Barrier Coatings On The Overall Effectiveness Of A Film Cooled Ceramic Matrix Composite Plate, Shane P. Lindsay

Theses and Dissertations

Silicon carbide ceramic matrix composites, a promising new potential upgrade over the conventional metals currently used for jet engine turbine blades, have a propensity to oxidize in a combustion environment. Engine manufacturers often apply environmental barrier coatings to prevent the composites from oxidizing. What is unclear, however, is how environmental barrier coatings effect underlying composite temperatures. This research examined the coatings’ effects by first characterizing the influence of environmental barrier coatings on the underlying temperature of a protected ceramic, then evaluating the significance of lateral conduction for cooling a coated ceramic, and finally comparing cooling results for coated and uncoated …

A Concept Of Producing Aluminum In-Situ On The Moon Through Molten Salt Electrolysis, Jacob N. Ortega, Jeffrey Smith, Fateme Rezaei, David Bayless, William Schonberg, Daniel Stutts, Daoru Han

Materials Science and Engineering Faculty Research & Creative Works

This paper presents a concept of producing aluminum in-situ on the lunar surface, namely, the Lunar In-Situ Aluminum Production through Molten Salt Electrolysis (LISAP-MSE) method developed at Missouri University of Science and Technology. This paper aims to demonstrate the use of electro-deoxidation to reduce aluminum oxide (i.e., alumina) into aluminum and oxygen gas via electrolysis in a molten salt bath for the production of aluminum on the Moon. It is shown that with a steady supply of hydrogen chloride, this in-situ resource utilization (ISRU) method could supply several necessary materials consumed in the electro-deoxidation process except hydrogen chloride to produce …

Phenolic Polymer Infiltration And Pyrolysis Process For Additively Manufactured Carbon/Peek Composites To Produce Carbon–Carbon Composites, S. Weiler, H. A. Haffner, K. Chandrashekhara, J. Watts, G. E. Hilmas, J. Bayldon, L. M. Rueschhoff

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Carbon–carbon composites are carbon fibers reinforced with carbon matrix and are classified as advanced materials well suited for high-temperature structural applications. Carbon–carbon composites are characterized by maintaining excellent mechanical properties and structural stability at high temperatures and have been used in aerospace application as nozzles, heatshields, and leading edge. However, conventional methods to manufacture carbon–carbon composites are costly and time-consuming. the aim of this work is to develop a method for creating additively manufactured (AM) carbon–carbon composites using a high-pressure re-infiltration process. in doing so, less infiltration cycles are required compared to a low-pressure re-infiltration, reducing the total manufacture time. …

Electrostatic Sorting Of Lunar Regolith Simulants For Sustainable Resource Utilization: Modeling And Characterization Of Particle Size Distribution, Abdullah Al Moinee, Peter Bachle, Kyle Newport, William Schonberg, David Bayless, Jeffrey Smith, Daoru Han, Fateme Rezaei

Civil, Architectural and Environmental Engineering Faculty Research & Creative Works

In pursuit of sustainable resource utilization on the Moon, this paper delves into modeling and characterization of particle size distribution (PSD) of lunar regolith simulants in an electrostatic system. A prototype electrostatic sieve was built and tested with four sample simulants mirroring properties of lunar mare and highland regolith. An alternating four-phase (90 degrees, 180 degrees, 270 degrees, 360 degrees) traveling square-wave was utilized for particle-directed transport to model the diverse trajectories of the particles. Numerically, we scrutinized how the distribution functions of the particles are manifested as the electrostatic field propagates, with a focus on three distinct particle ranges …

Kinetic Modeling Of Electrostatic Sieving For Lunar Regolith Beneficiation: Case Studies, Easton Ingram, Emmanuela Amen Eze, Jeffrey Smith, Fateme Rezaei, David Bayless, William Schonberg, Daoru Han

Materials Science and Engineering Faculty Research & Creative Works

A new kinetic particle modeling framework was developed to investigate electrostatic transport of lunar regolith particles with applications to the concept of electrostatic sieving. the new approach is based on kinetic particle dynamics and includes major modules of sampling the particle size distribution, solving electric fields, and tracking motion of charged dust grains. Case studies for a concept of electrostatic sieving were chosen to validate the new model. the simulation achieved similar yields reported in previous works, which served as validation of the model. the new model is computationally efficient and could serve as a design, analysis, and optimization tool.

Progress Of Lisap-Mse: A Concept Of Producing Aluminum In-Situ On The Moon Through Molten Salt Electrolysis, Jacob N. Ortega, David Bayless, Daniel Stutts, Daoru Han, Todd P. Sander, Jeffrey Smith, Fateme Rezaei, William Schonberg

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper presents a concept of producing aluminum in-situ on the lunar surface, namely, the Lunar In-Situ Aluminum Production through Molten Salt Electrolysis (LISAP-MSE) method developed at Missouri University of Science and Technology. This paper aims to demonstrate the use of electro-deoxidation to reduce aluminum oxide (i.e., alumina) into aluminum and oxygen gas via electrolysis in a molten salt bath for the production of aluminum on the Moon. It is shown that with a steady supply of hydrogen chloride, this in-situ resource utilization (ISRU) method could supply several necessary materials consumed in the electro-deoxidation process except hydrogen chloride to produce …

Electrostatic Sorting Of Lunar Regolith Simulants For Sustainable Resource Utilization: Modeling And Characterization Of Particle Size Distribution, Abdullah Al Moinee, Peter Bachle, Kyle Newport, William Schonberg, David Bayless, Jeffrey Smith, Daoru Han, Fateme Rezaei

Civil, Architectural and Environmental Engineering Faculty Research & Creative Works

In pursuit of sustainable resource utilization on the Moon, this paper delves into modeling and characterization of particle size distribution (PSD) of lunar regolith simulants in an electrostatic system. a prototype electrostatic sieve was built and tested with four sample simulants mirroring properties of lunar mare and highland regolith. an alternating four-phase (90 degrees, 180 degrees, 270 degrees, 360 degrees) traveling square-wave was utilized for particle-directed transport to model the diverse trajectories of the particles. Numerically, we scrutinized how the distribution functions of the particles are manifested as the electrostatic field propagates, with a focus on three distinct particle ranges …

Molecular Modeling Of Phenolic Resin For Carbon-Carbon Composites, Ivan Gallegos

Dissertations, Master's Theses and Master's Reports

One of the most difficult challenges associated with space exploration is terrestrial atmospheric reentry due to the high thermal loads generated. Carbon carbon (C/C) composites have been used as heat shielding materials due to their high strengthto- weight ratio and thermal properties and their applications include heat shielding for various high temperature environments. C/C composites are manufactured by polymer-infiltration pyrolysis (PIP) via cycles of curing and pyrolysis of a prepreg which can be costly and take up to several days. Thus, C/C composites ideal candidates for computationally-driven optimization techniques, such as a multiscale Integrated Computational Materials Engineering (ICME) approach, by …

Bioprinting With Adipose Stem Cells And Hydrogel Modified With Bioactive Glass, Krishna C.R. Kolan, Apurv Saxena, Bradley A. Bromet, Lesa B. Steen, August T. Bindbeutel, Julie A. Semon, Delbert E. Day, Ming C. Leu

Biological Sciences Faculty Research & Creative Works

Bioprinting research is focused on utilizing growth factors and multiple cell types to create clinically relevant three-dimensional (3D) tissue models using hydrogels. Rheological and biological challenges are two main factors that limit the creation of extrudable bioactive hydrogels. In this study, we investigate incorporation of fast dissolving and bioactive borate glass in different weight to volume percentages (0.075 to 0.6%) to alginate-gelatin (1:1) hydrogel to improve rheological properties and enable bioprinting with bioactive glass. The addition of glass improved the stiffness of the hydrogel. Human adipose-derived mesenchymal stem cells (ASCs) were uniformly mixed in this bioink at 1 x 106 …

Oxidation Of Additively Manufactured Zrb2–Sic In Air And In Co2 At 700–1000 °C, Marharyta Lakusta, Nicholas M. Timme, Abid H. Rafi, Jeremy Lee Watts, M. (Ming) C. (Chuan) Leu, Gregory E. Hilmas, William G. Fahrenholtz, David W. Lipke

Materials Science and Engineering Faculty Research & Creative Works

Oxidation behavior of additively manufactured zrb2–sic in air and in co2 is reported in the temperature range of 700–1000 °c. Observed scale morphologies in air and in co2 were similar, featuring an outer borosilicate layer and an inner porous zirconia layer containing partially oxidized silicon carbide particles and remnant borosilicate products. Oxide scale thicknesses and parabolic scaling constants in air were approximately twice those observed in co2 across all studied temperatures. Activation energies for oxidation of 140 ± 20 kj/mol in air and 110 ± 20 kj/mol in co2 were determined, indicating similar diffusion processes that appear to be rate-limiting. …

Beneficiation Of Lunar Regolith Simulants Through Electrostatic Sieving And Magnetic Separation, Peter Bachle, Jeffrey Smith, Fateme Rezaei, David Bayless, William Schonberg, Daoru Han

Materials Science and Engineering Faculty Research & Creative Works

In the light of future development of lunar structures, in-situ feldspar beneficiation is imperative for metal extraction. This research incorporates the tandem use of electrostatic sieving and magnetic separation for collecting a specific size range and mineral composition from lunar soil that optimizes subsequent chemical processing. While earlier works focused on silt-sized particles, this work expands that range up to medium-grained sand with a greater variety of potential lunar regolith compositions. This work shows that a 2.5 kV, 7 Hz to 30Hz frequency, single-phase square wave can lift silt and fine sand for collection. This lifting is successful directly from …

Kinetic Modeling Of Electrostatic Sieving For Lunar Regolith Beneficiation: Case Studies, Easton Ingram, Emmanuela Amen Eze, Jeffrey Smith, Fateme Rezaei, David Bayless, William Schonberg, Daoru Han

Materials Science and Engineering Faculty Research & Creative Works

A new kinetic particle modeling framework was developed to investigate electrostatic transport of lunar regolith particles with applications to the concept of electrostatic sieving. The new approach is based on kinetic particle dynamics and includes major modules of sampling the particle size distribution, solving electric fields, and tracking motion of charged dust grains. Case studies for a concept of electrostatic sieving were chosen to validate the new model. The simulation achieved similar yields reported in previous works, which served as validation of the model. The new model is computationally efficient and could serve as a design, analysis, and optimization tool.

Magnetic Separation Of Lunar Regolith Simulants With Applications To In Situ Resource Utilization On The Moon, Peter Bachle, Jeffrey Smith, Fateme Rezaei, David Bayless, William Schonberg, Daoru Han

Materials Science and Engineering Faculty Research & Creative Works

The development of in situ resource utilization (ISRU) for metal extraction is imperative as a steppingstone for habitation construction in lunar and non-terrestrial environments. Separation of minerals by chemical composition is important to optimize metal and oxygen liberation from lunar ore. to this effect, devices capable of separating aluminum bearing minerals from iron-bearing minerals from the lunar regolith simulants have been developed. Twenty-eight different simulants have been used in this study. a dual-belt separator was designed to reduce middlings. Para-magnetic minerals were reliably separated using a neodymium N52-magnet-separator system. Effective separation of aluminum-bearing minerals from iron-bearing minerals was greater than …

A Concept Of Producing Aluminum In-Situ On The Moon Through Molten Salt Electrolysis, Jacob N. Ortega, Jeffrey Smith, Fateme Rezaei, David Bayless, William Schonberg, Daniel Stutts, Daoru Han

Materials Science and Engineering Faculty Research & Creative Works

This paper presents a concept of producing aluminum in-situ on the lunar surface, namely, the Lunar In-Situ Aluminum Production through Molten Salt Electrolysis (LISAP-MSE) method developed at Missouri University of Science and Technology. This paper aims to demonstrate the use of electro-deoxidation to reduce aluminum oxide (i.e., alumina) into aluminum and oxygen gas via electrolysis in a molten salt bath for the production of aluminum on the Moon. It is shown that with a steady supply of hydrogen chloride, this in-situ resource utilization (ISRU) method could supply several necessary materials consumed in the electro-deoxidation process except hydrogen chloride to produce …

Ambient Temperature Strength Degradation Of A Ceramic Matrix Composite Due To Solid Particle Erosion, Jonathan Clawson

Williams Honors College, Honors Research Projects

Solid particle erosion (SPE) is an issue for aircraft exposed to hard, fine particles, such as sand or dust, that can be ingested into the engine at a high velocity without reaching their melting point, resulting in material removal. SPE can be attributed to the intake of particulate debris from the runway or from airborne particulates. The cumulative mass loss from SPE damage affects the structural integrity and performance of the engine; however, its effects on ceramic matrix composites (CMCs), that are being employed in the aerospace industry, are not well understood in literature. The limited SPE research studies that …

Lunar In-Situ Aluminum Production Through Molten Salt Electrolysis (Lisap-Mse), Jacob Ortega, Jeffrey D. Smith, Fateme Rezaei, David Bayless, William P. Schonberg, Daniel S. Stutts, Daoru Frank Han

NASA-Missouri Space Grant Consortium

The goal of Artemis is to establish a sustained presence on the Moon. To achieve so, numerous resources are necessary. The Moon contains several essential elements needed to sustain human presence. Most of those elements are trapped in the form of minerals. To refine those minerals into useful materials, reduction methods are needed. Most reduction methods on Earth require large amounts of mass and power which is unrealistic for early stages of building a lunar base. To solve this problem, we are developing a concept of Lunar In-Situ Aluminum Production through Molten Salt Electrolysis (LISAP-MSE).

The LISAP-MSE project, if successful, …

Development Of Novel Turbomachinery Manufacturing Methods, Timothy P. Winkler

Theses and Dissertations

Compact turbine engines are of increasing interest as a means of propulsion for small, lightweight, low cost, unmanned aerial systems. This study looks to leverage advancements in novel manufacturing technology to produce turbomachinery components while simultaneously reducing costs and manufacturing time. To determine the feasibility of drop-in replacements for stock components this study focused on several research areas. This included materials research on both polymer-reinforced and ceramic materials, specimen tensile testing to determine temperature-dependent material properties, finite element analysis of multiple candidate materials, design and fabrication of a spin test rig, and physical spin testing of manufactured components to predict …