Ceramic Materials Commons^™

Numerical Simulation Of The Influence Of Ceramic Preform On The Infiltration Process Of Metal Matrix Composites, Chang-Chun Dong, Jian-Xin Zhou, Ya-Jun Yin, Xu Shen

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

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.

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 …

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 …

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.

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. …

Design And Testing Of A Top Mask Projection Ceramic Stereolithography System For Ceramic Part Manufacturing, Dylan Robert De Caussin

Master's Theses

Ceramic manufacturing is an expensive process with long lead times between

the initial design and final manufactured part. This limits the use of ceramic as a viable material unless there is a large project budget or high production volume associated with the part. Ceramic stereolithography is an alternative to producing low cost parts through the mixing of a photo curable resin and ceramic particles. This is an additive manufacturing process in which each layer is built upon the previous to produce a green body that can be sintered for a fully dense ceramic part.

This thesis introduces a new approach …

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

Faculty Publications, Mechanical Engineering

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. The results compared …

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

Faculty Publications, Mechanical Engineering

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.

Power Maximization For Pyroelectric, Piezoelectric, And Hybrid Energy Harvesting, Murtadha A. Shaheen

Theses and Dissertations

The goal of this dissertation consists of improving the efficiency of energy harvesting using pyroelectric and piezoelectric materials in a system by the proper characterization of electrical parameters, widening frequency, and coupling of both effects with the appropriate parameters.

A new simple stand-alone method of characterizing the impedance of a pyroelectric cell has been demonstrated. This method utilizes a Pyroelectric single pole low pass filter technique, PSLPF. Utilizing the properties of a PSLPF, where a known input voltage is applied and capacitance C_p and resistance R_p can be calculated at a frequency of 1 mHz to 1 Hz. …

Effects Of Temperature On Aqueous Freeform Extrusion Fabrication, Jie Li, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An experimental study was conducted to investigate the effect of temperature on ceramic parts produced by paste extrusion based additive manufacturing followed by sintering. A computer-controlled gantry system equipped with a piston extruder was used to extrude aqueous alumina paste. The system includes a temperature control subsystem that allows for freeform extrusion fabrication inside a low-temperature (<0°C) chamber. It can also be used for fabricating parts on a hot plate at ambient or higher temperatures (≥20°C). Test specimens were fabricated from aqueous aluminum pastes at -20°C in the low-temperature chamber and also on the hot plate at 40°C. The minimum angles achievable by these two processes for part fabrication, without use of support material, were compared. Also compared were the relative density and mechanical properties of the parts obtained after sintering. Microstructures were examined via scanning electron microscopy in order to obtain a deeper understanding of the effect of fabrication temperature.

Freeform Extrusion Fabrication Of Titanium Fiber Reinforced Bioactive Glass Scaffolds, Albin Thomas, Krishna C. R. Kolan, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Although implants made with bioactive glass have shown promising results for bone repair, their application in repairing load-bearing long bones is limited due to their low fracture toughness and fairly fast degradation response in vivo. In this paper, we describe our investigation of freeform extrusion fabrication of silicate based 13-93 bioactive glass scaffolds reinforced with titanium fibers. A composite paste was prepared with 13-93 bioactive glass filled with titanium fibers (~16 µm in diameter and aspect ratio of ~250) having a volume fraction of 0.4 vol. %. This paste was then extruded to fabricate scaffolds with an extrudate diameter …

Electrochemical Capture Of Co2 From Natural Gas Using A High-Temperature Ceramic-Carbonate Membrane, Jingjing Tong, Lingling Zhan, Jie Fang, Minfang Han, Kevin Huang

Faculty Publications

This study reports the first investigation of using a ceramic-carbonate dual-phase membrane to electrochemically separate CO₂ from a simulated natural gas. The CO₂ permeation flux density was systematically studied as a function of temperature, CO₂ partial pressure and time. As expected, the flux density was observed to increase with temperature and CO₂ partial pressure. Long-term stability test showed that flux density experienced an initial performance-improving “break-in” period followed by a slow decay. Post-test microstructural analysis suggested that a gradual loss of carbonate during the test could be the cause of the flux-time behavior observed.

Methods Of Extrusion On Demand For High Solids Loading Ceramic Paste In Freeform Extrusion Fabrication, Wenbin Li, Amir Ghazanfari, Ming Leu, Robert Landers

Faculty Publications, Mechanical Engineering

Fabrication of highly dense parts with complex geometry by paste-extrusion-based solid freeform fabrication processes requires a precise control of the extrusion flow rate to dispense material on demand, which is often referred as Extrusion-On-Demand (EOD). The extrusion process for aqueous ceramic pastes is complex and difficult to control due to their non-Newtonian behavior, compressibility and inhomogeneity. In this study, three methods of EOD (based on ram extruder, needle valve, and auger valve) are introduced and investigated for the extrusion of high solids loading (i.e., >50%, volumetric) aqueous alumina paste. Optimal extrusion process parameters for these methods are determined through printing …

Microstructure Development Of Granular System During Compaction, Chen Shang, Marcial Gonzalez

The Summer Undergraduate Research Fellowship (SURF) Symposium

Granular materials is the second most manipulated material in the industry today. They are easy to transport and more and more newly developed materials cannot stand the process of traditional casting, like energetic materials and bio-materials, but will survive the powder compaction process. Having a better understanding of the microstructure development of granular systems during compaction process, especially for particles that will heavily deform under loading, will give an insight of how to better process the powders to produce materials with overall better performance comparing to bulk materials. The main theory and mechanism applied are Hertz law and nonlocal contact …

In Vitro Assessment Of Laser Sintered Bioactive Glass Scaffolds With Different Pore Geometries, Krishna C. R. Kolan, Albin Thomas, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The pore geometry of bioactive glass scaffolds intended for use in bone repair or replacement is one of the most important parameters that could determine the rate of bone regeneration. The pore geometry would also affect the mechanical properties of the scaffolds and their rate of degradation. Scaffolds with five different architectures, having ~50% porosity, were fabricated with silicate (13–93) and borate (13–93B3) based bioactive glasses using a laser sintering process. An established, late-osteoblasts/early-osteocytes cell line was used to perform cell proliferation tests on the scaffolds. The results indicated that the cells proliferate significantly more on the scaffolds which mimic …

Characterization Of 3d Interconnected Microstructural Network In Mixed Ionic And Electronic Conducting Ceramic Composites, William M. Harris, Kyle S. Brinkman, Ye Lin, Dong Su, Alex P. Cocco, Arata Nakajo, Matthew B. Degostin, Yu-Chen Karen Chen-Wiegart, Jun Wang, Fanglin Chen, Yong S. Chu, Wilson K. S. Chiu

Faculty Publications

The microstructure and connectivity of the ionic and electronic conductive phases in composite ceramic membranes are directly related to device performance. Transmission electron microscopy (TEM) including chemical mapping combined with X-ray nanotomography (XNT) have been used to characterize the composition and 3-D microstructure of a MIEC composite model system consisting of a Ce_0.8Gd_0.2O₂ (GDC) oxygen ion conductive phase and a CoFe₂O₄ (CFO) electronic conductive phase. The microstructural data is discussed, including the composition and distribution of an emergent phase which takes the form of isolated and distinct regions. Performance implications are considered …

Design, Fabrication, And Properties Of 2-2 Connectivity Cement/Polymer Based Piezoelectric Composites With Varied Piezoelectric Phase Distribution, Xu Dongyu, Cheng Xin, Sourav Banerjee, Huang Shifeng

Faculty Publications

The laminated 2-2 connectivity cement/polymer based piezoelectric composites with variedpiezoelectric phase distribution were fabricated by employing Lead Zirconium Titanate ceramicas active phase, and mixture of cement powder, epoxy resin, and hardener as matrix phase with a mass proportion of 4:4:1. The dielectric, piezoelectric, and electromechanical coupling properties of the composites were studied. The composites with large total volume fraction ofpiezoelectric phase have large piezoelectric strain constant and relative permittivity, and thepiezoelectric and dielectric properties of the composites are independent of the dimensional variations of the piezoelectric ceramic layer. The composites with small total volume fraction of piezoelectric phase have large …

Effect Of Architecture And Porosity On Mechanical Properties Of Borate Glass Scaffolds Made By Selective Laser Sintering, Krishna C. R. Kolan, Ming-Chuan Leu, Greg Hilmas, Taylor Comte

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The porosity and architecture of bone scaffolds, intended for use in bone repair or replacement, are two of the most important parameters in the field of bone tissue engineering. The two parameters not only affect the mechanical properties of the scaffolds but also aid in determining the amount of bone regeneration after implantation. Scaffolds with five different architectures and four porosity levels were fabricated using borate bioactive glass (13-93B3) using the selective laser sintering (SLS) process. The pore size of the scaffolds varied from 400 to 1300 μm. The compressive strength of the scaffolds varied from 1.7 to 15.5 MPa …

Wetting And Reactive Air Brazing Of Bscf For Oxygen Separation Devices, Richard Ladouceur, Alan Meier, Ph.D.

2013 Undergraduate Research

The goals of this project are to develop a Reactive Air Brazing (RAB) alloy and process for joining Barium strontium cobalt ferrite (BSCF), and to develop a fundamental understanding of the wettability and microstructral development due to reaction kinetics in BSCF/Ag-Me_xO_y systems.

Hydraulic And Thermal Performances Of A High Temperature Ceramic Plate-Fin Heat Exchanger (Pfhe), Vijaisri Nagarajan, Yitung Chen, Qiuwang Wang, Ting Ma

College of Engineering: Graduate Celebration Programs

• Numerical analysis was carried for novel configuration of high temperature PFHE
• Fluid flow and heat transfer properties were studied for various fin configurations
• Ripsaw fin design with thickness of 0.05 mm gives maximum heat transfer with less pressure drop and friction factor
• Validation and parametric study were carried out for all fin configurations

Finite Element Analysis Of The Contact Deformation Of Piezoelectric Materials, Ming Liu

Theses and Dissertations--Chemical and Materials Engineering

Piezoelectric materials in the forms of both bulk and thin-film have been widely used as actuators and sensors due to their electromechanical coupling. The characterization of piezoelectric materials plays an important role in determining device performance and reliability. Instrumented indentation is a promising method for probing mechanical as well as electrical properties of piezoelectric materials.

The use of instrumented indentation to characterize the properties of piezoelectric materials requires analytical relations. Finite element methods are used to analyze the indentation of piezoelectric materials under different mechanical and electrical boundary conditions.

For indentation of a piezoelectric half space, a three-dimensional finite element …

Strength Of Polycrystalline Ceramics Under Shock Compression, Jianbin Zhu

Department of Engineering Mechanics: Dissertations, Theses, and Student Research

Determinations of Some polycrystalline ceramics’ strength properties and inelastic deformation mechanisms in the shocked state are critically important to the design and optimization of armor structures involving these materials. In this work, multiscale modeling and simulations have been carried out to study strength of the effects of polycrystalline microstructure, crystal anisotropy, porosity, and their interactions with microscopic deformation/damage mechanisms on the responses of several polycrystalline ceramics under shock compression and to extract their shock strengths from the wave profiles measured in the related plate impact shock wave experiments.

With a mesoscopic computational model, the roles of intragranular microplasticity and deformation …

Evaluation Of Cathode Materials For Low Temperature (500-700c) Solid Oxide Fuel Cells, Alexander M. Lassman

Master's Theses

Solid oxide fuel cells (SOFC) have gained a great deal of interest, due to their potential for high efficiency power generation and ability to utilize hydrogen fuel, as well as various hydrocarbon-based fuels. A recent trend in SOFC development has been towards lower operating temperatures (500-700°C), which can substantially reduce the cost and complexity of the system. This thesis presents an investigation into state of the art Ba- and La- based cathode materials for use in low temperature (500-700°C) solid oxide fuel cells.

Synthesis of A-site deficient [A=0.97] Ba_0.5Sr_0.5Co_0.8Fe_0.2O₃ (BSCF) was …

Air Plasma Sprayed Thermal Barrier Coatings: Experiments And Finite Element Analysis, Charles H. Thistle

Master's Theses

The purpose of this research was to examine the primary in-service failure mechanism of an air plasma sprayed thermal barrier coating commonly used in combustor applications, and to use that failure mechanism as a basis in developing a life prediction strategy. The research consisted of an experimental phase, in which the failure mechanism was identified and key features of the coating system measured, and a modeling phase, in which the findings of the experimental phase were used to build a system specific finite element model of the coating in order to extract quantitative data relevant to coating life.

Observations were …

Effect Of Particle Size, Binder Content And Heat Treatment On Mechanical Properties Of 13-93 Bioactive Glass Scaffolds, Krishna C. R. Kolan, Ming-Chuan Leu, Greg Hilmas, Mariano Garcia Velez

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Particle size, binder content and the post-processing schedule are important parameters that affect the microstructure, and, hence, the mechanical properties of parts produced using the indirect selective laser sintering process. 13-93 bioactive glass, with mean particle sizes ranging from 10 μm to 44 μm, is mixed with different amounts of stearic acid binder to fabricate green scaffolds. Through the design of the post-processing schedule, the time required for postprocessing the green scaffolds is reduced from the initial 80 hrs to 12 hrs. The compressive strength varies from 41 MPa for a part with~60% porosity to 157 MPa for a part …

Freeze Extrusion Fabrication Of 13-93 Bioactive Glass Scaffolds For Bone Repair, Tieshu Huang, Nikhil D. Doiphode, M. N. Rahaman, Ming-Chuan Leu, B. Sonny Bal, D. E. Day

Materials Science and Engineering Faculty Research & Creative Works

There is an increasing demand for synthetic scaffolds with the requisite biocompatibility, internal architecture, and mechanical properties for the bone repair and regeneration. In this work, scaffolds of a silicate bioactive glass (13-93) were prepared by a freeze extrusion fabrication (FEF) method and evaluated in vitro for potential applications in bone repair and regeneration. The process parameters for FEF production of scaffolds with the requisite microstructural characteristics, as well as the mechanical and cell culture response of the scaffolds were evaluated. After binder burnout and sintering (60 min at 700°C), the scaffolds consisted of a dense glass network with interpenetrating …

Selective Laser Sintering Of 13-93 Bioactive Glass, Krishna C. R. Kolan, Ming-Chuan Leu, Greg Hilmas, Mariano Garcia Velez

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Bioactive glasses are more promising than biopolymers in fabricating scaffolds for bone tissue repair because they convert to hydroxyapatite, when implanted in vivo. Both direct and indirect selective laser sintering (SLS) methods of 13-93 bioactive glass were considered in this research to study the feasibility of fabricating scaffolds for bone repair applications. Stearic acid was used as the binder in the indirect method to fabricate the scaffolds. The green scaffolds underwent binder burnout and sintering at various soaking conditions between 675⁰C and 700⁰C, achieving a maximum compressive strength of 23.6 MPa, which is higher than that of the human cancellous …

Hydrogen Fuel Cell Analysis: Lessons Learned From Stationary Power Generation Final Report, Scott E. Grasman, John W. Sheffield, Fatih Dogan, Sunggyu Lee, Umit O. Koylu, Angie Rolufs

Materials Science and Engineering Faculty Research & Creative Works

This study considered opportunities for hydrogen in stationary applications in order to make recommendations related to RD&D strategies that incorporate lessons learned and best practices from relevant national and international stationary power efforts, as well as cost and environmental modeling of pathways. The study analyzed the different strategies utilized in power generation systems and identified the different challenges and opportunities for producing and using hydrogen as an energy carrier. Specific objectives included both a synopsis/critical analysis of lessons learned from previous stationary power programs and recommendations for a strategy for hydrogen infrastructure deployment. This strategy incorporates all hydrogen pathways and …

Studies Of Dynamic Crack Propagation And Crack Branching With Peridynamics, Youn Doh Ha, Florin Bobaru

Department of Engineering Mechanics: Faculty Publications

In this paper we discuss the peridynamic analysis of dynamic crack branching in brittle materials and show results of convergence studies under uniform grid refinement (m-convergence) and under decreasing the peridynamic horizon (δ-convergence). Comparisons with experimentally obtained values are made for the crack-tip propagation speed with three different peridynamic horizons.We also analyze the influence of the particular shape of themicro-modulus function and of different materials (Duran 50 glass and soda-lime glass) on the crack propagation behavior. We show that the peridynamic solution for this problem captures all the main features, observed experimentally, of dynamic crack propagation and branching, as well …