Metallurgy Commons^™

Analysis Of Tower Stringset Replacement From 33 Kv To 66 Kv Considering Sagging Clearance, Muhammad Lazuardi Azzura, Anne Zulfia Syahrial, Julius Purnama Eka Kartika

Journal of Materials Exploration and Findings

Efforts to increase the capacity of transmission networks are often undertaken by uprating the operating voltage of existing lines rather than building entirely new infrastructure. Such uprating typically involves the replacement of tower insulator stringsets to withstand higher voltages, while also ensuring that mechanical performance remains adequate. This paper presents an analysis of uprating the Parakan–Sunyaragi transmission line from 33 kV to 66 kV, with particular emphasis on conductor sagging and the resulting clearance from the ground. The methodology employed includes calculations based on catenary equations, analysis of conductor tensile forces, and a comparative evaluation of two widely used insulator …

Additive Manufacturing Of Metals: Mechanical Properties And Their Implications, Sean Chih

Discovery Day - Daytona Beach

Additive manufacturing of metals is a relatively new and groundbreaking approach to manufacturing high-performance components. However, variability in mechanical properties from the process creates a barrier before this manufacturing technique can be widely applied. Understanding when and where to use this manufacturing is also important to create components with efficiency and without harmful defects. The objective of this research is to evaluate the effects of build orientation, printing parameters, internal defects, thermal history, and residual stresses, post-processing heat treatments, and fatigue behavior on additively manufactured components. Literature-based research is conducted on commonly used metals for additive manufacturing, such as stainless …

Magnetic Field-Induced Transformation In Polycrystalline Ni2mnal Heusler Type Magnetic Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely, Laura N. Bartlett

Materials Science and Engineering Faculty Research & Creative Works

The martensitic and magnetic transformations, as well as the mechanical properties, of Ni₂MnAl alloys in as-cast (AC) and heat-treated (HT) conditions were investigated. Magnetic-field-induced strain was evaluated via magnetostriction, with reversible strains of 0.14% and 0.2% achieved in the martensitic phase at 2 K for the AC and HT alloys, respectively. Transformation temperatures and Curie temperatures were determined under constant applied magnetic field, revealing that γ-phase inclusions in the AC microstructure suppress antiferromagnetic domain response, yielding a lower magnetization (∼8.4 emu g⁻¹) compared to the HT alloy (∼13.4 emu g⁻¹). Both alloys exhibited hysteretic behavior in the martensitic state and …

The Effect Of Mwcnt-Oil Impregnation Of Sintered Components On Their Wear And Corrosion Resistance, Maha Khaled Abdelfadeel

Theses and Dissertations

Powder Metallurgy (PM) offers an advantageous route for manufacturing complex and near net-shape components. Their inherent interconnected porosity that promotes the action of self lubrication compromises their structural integrity by creating pathways for corrosion and excessive wear. This research investigates the efficacy of Multi-Walled Carbon Nanotubes (MWCNTs) as a nano additive within the impregnating base oil (SN-150 base oil). An experimental matrix was designed to evaluate the influence of MWCNTs with different concentrations of 0.05, 0.1, and 0.2 wt.% and ultrasonic dispersion with varying sonication times of 30 and 60 minutes on the tribological and electrochemical performance of sintered steel …

Electropulse Annealing: Phase Composition Of Tial6v4, Vaughn Eckhardt, Ethan Croke, Ian Baker, Russ Taylor

Wetterhahn Science Symposium Posters

Titanium alloy TiAl6V4 is the most ubiquitous titanium alloy used for dental care, aerospace manufacturing, and for high performance vehicles. The material typically undergoes a thermal heat  treatment, but electropulse annealing is another process that involves sending current through the material to heat it up at a quicker rate. The rate of post-annealing cooling is high, and around the material's critical point, its two components, alpha and beta phase, change in relative concentration. After testing multiple current densities and temperatures, in general, as the current density that the sample received during electropulse annealing decreased, both the alpha and beta phases …

Cast In Steel: Horseman's Axe, Sam A. Morris

Create@State

Cast in Steel is a competition between universities across North America started by the Steel Founders Society of America. The competition is centered around giving students the opportunity to learn about casting and the steel industry in general. A prompt of a weapon or tool with some level of historical significance is given to all the teams. The prompt for the 2026 Arkansas State University team, was a Horseman’s Axe. The team designed their rendition of a horseman’s axe, worked with Southern Cast Products as their local industry parter, and fabricated a finished axe to represent Arkansas State University as …

A Sustainable Approach To Tensile Property Enhancement In Sand Casting Via Metal Chip–Sand Composite Molds, Maaruf Isyaku, Danjuma Saleh Yawas, Mathew Olatunde Afolayan, Terva Ause

Journal of Materials Exploration and Findings

The present work focuses on the study of the effect of adding different weight percentages and particle sizes of various metal chips to foundry sand on the tensile strength of aluminum alloy castings, utilizing Taguchi's optimization methodology and regression analysis. Characterization techniques such as X-ray fluorescence (XRF), thermogravimetry, and SEM were also used. The XRF analysis identified aluminum (76.61%), silicon (17.49%), and magnesium (1.28%) as the major elements in the aluminum alloy engine block. For the foundry sand, silicon (89.51%), phosphorus (7.41%), and potassium (1.7%) were found. In contrast, the major constituents in cast iron included iron (88.3%), carbon (3.7%), …

Effect Of Wall Movement On Porosity Formation In Ductile Iron Castings Under Varying Processing Parameters, Shamsul Alam

College of Graduate Studies: Theses & Dissertations

Shrinkage porosity is a major defect that significantly impairs the mechanical properties and overall performance of ductile iron castings. Although graphite formation during solidification induces volumetric expansion, this expansion alone is insufficient to fully compensate for the shrinkage occurring throughout solidification. During the solidification and cooling of ductile iron, multiple phase transformations occur, resulting in dynamic volume changes that exert pressure on mold walls and internal cavities. These pressures can deform mold walls and casting surfaces, leading to defects such as swell and porosity, while also influencing shrinkage formation. This study aims to analyze the mechanisms of porosity formation and …

Multiphysics Modeling Of Melt Pool Dynamics And Powder Bed Stability In Lpbf Of Inconel 718 For A Circular Cavity, Nayan Pundhir, Oluwapelumi O. Adejumo, Kumbla Chandrashekhara, Joseph W. Newkirk, Heath Misak, Cesar Ortiz Rios

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser powder bed fusion (LPBF) is a metal additive manufacturing process in which a concentrated laser beam selectively melts successive powder layers to fabricate components. Final part quality is highly sensitive to process parameters such as hatch spacing, powder bed density, laser power, and scanning speed. In this study, a computational fluid dynamics model employing discrete element method has been developed in FLOW-3D to simulate LPBF of Inconel 718. The modeled powder bed incorporates particle size distribution data obtained from scanning electron microscopy and is evaluated for single-layer, single-track deposition over a circular cavity. The model captured melt pool dynamics …

Electron Beam Irradiation Effects On Bulk Metals: A Comparative Study Of Polycrystalline Versus Single-Crystalline Structures, A. A. Elmustafa, N. A. Sultana, A. H. Al-Allaq, M. Ojha, Y. S. Mohammed, J. Vennekate, H. Baumgart

Mechanical & Aerospace Engineering Faculty Publications

This study investigates the effects of electron beam (e-beam) irradiation on the mechanical and structural properties of eight bulk metallic samples, comprising both polycrystalline (PC) and single-crystalline (SC) forms of Ni, Cr, V, and Ti. These metals were evaluated as potential candidates for beam exit windows in high-power (MW-class) particle accelerators. The primary objective is to identify metals capable of withstanding the conditions of high-power/MW-class e-beam accelerators and serve effectively as exit windows. Selection criteria were based on each metal’s intrinsic properties, power dissipation capability, and irradiation-induced changes in mechanical behavior, including hardness, elastic modulus, and defect density. Comprehensive characterization …

Thermal Transformations And Mechanical Properties Of All-D-Metal Mn2fecu Heusler-Type Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely

Materials Science and Engineering Faculty Research & Creative Works

All-d-metal Heusler alloys are emerging functional materials in which magnetic ordering, lattice distortion, and mechanical behavior are strongly coupled through d–d electronic interactions. This study systematically investigates the structural, thermal, magnetic, and mechanical properties of Mn₂FeCu synthesized within a Heusler-type compositional framework. SEM/EDS revealed a dual-phase FCC-based microstructure consisting of Mn–Fe–rich and Mn–Cu–rich domains, while XRD confirmed FCC symmetry with compositional partitioning rather than full L2₁ ordering. Differential scanning calorimetry identified partial melting of the Cu-rich phase near ~ 900 °C. Dilatometry showed a thermoelastic FCC → FCT transformation at ~ 770–780 °C with a recoverable strain of ~ 0.067%. …

The Effects Of Mold Flux Contamination On Oxide Scale Formation And Hydro-Descaling Efficiency During Steel Processing, Tochukwu Princewill Ojiako, Richard Osei, Mario Buchely, Haiming Wen, Simon Lekakh, Ronald O'Malley

Materials Science and Engineering Faculty Research & Creative Works

Oxide scale formation during thin-slab continuous casting has a complex structure, which is influenced by mold flux contamination, that modifies interfacial reactions during solidification, subsequent reheating, and descaling. While individual aspects of the oxidation behavior of carbon steel have been previously examined, the synergetic effects of mold flux contamination during continuous casting and subsequent reheating on scale modification and the efficiency of hydraulic descaling remain inadequately studied. This study quantitatively examines the effect of flux composition on oxide scale evolution, adhesion, and hydraulic removal in low-carbon steel under simulated industrial conditions. Slab samples with as-cast, cleaned, and flux-coated surfaces were …

Breaking The Vapor Barrier And Scale: Revolutionizing Steel Quenching With Ultrasound Technology, Anthony O. Santos

Williams Honors College, Honors Research Projects

The quenching process is a fundamental heat treatment used to enhance material properties by heating steel to its austenitizing temperature and rapidly cooling it to form high-strength martensite. However, this process is often hindered by two surface barriers: the Leidenfrost effect (vapor blanket) and oxide scale. These cooling limitations restrict the use of steel in high-performance aerospace applications due to inconsistent material properties and unpredictable engineering properties. This research investigates the use of fully submersible, 50-watt 40 kHz ultrasound technology to improve cooling rates in a Jominy test [4]. Through numerical simulations and experimental validation, the study demonstrates that acoustic …

Optimization Of Post-Processing Methods For Additively Manufactured Metals, Julia R. Carano

Williams Honors College, Honors Research Projects

Ultrasonic Nanocrystal Surface Modification (UNSM) is a process used to change the surface hardness of flat-faced materials. It is a machining process using a high-powered laser and a blunt-tipped tool at high speeds which aims to improve the uniformity of the surface on most metals. By heating and pressing the surface of the workpiece, the grains of the material become less rounded and more cohesive on a microscopic level. This, ideally, results in a workpiece with improved material properties. The changes were previously observed through hardness testing.

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

Theses and Dissertations

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

Critical Parameters Controlling Oxide Scale Formation And Hydro-Descaling Efficiency During Steelmaking, Tochukwu Princewill Ojiako

Doctoral Dissertations

In modern steelmaking, cast slabs are exposed to high-temperature oxidizing environments during secondary cooling, reheating, and hot rolling, resulting in the formation of multilayer oxide scales on the steel surface. These scales interact with mold-flux residues originating from the casting process (CC). The morphology, chemistry, and adhesion of oxide scale strongly influence its removability during high-pressure hydraulic descaling and ultimately determine the surface quality of hot-rolled products. However, the mechanistic relationship between oxide scale evolution, scale-steel interfacial structure, and hydraulic descaling performance remains poorly understood.

This dissertation investigates oxide scale formation, modification, and removal in low-carbon thin-slab steels produced by …

Modeling Of Transformation Temperatures In Cast Martensitic Stainless Steels-Ca6nm: Effects Of Composition, Heating Rate, And Grain Size, Ugochukwu Agbedo, Mario Buchely, Laura Bartlett, Caelan Kennedy

Materials Science and Engineering Faculty Research & Creative Works

Accurate prediction of the critical transformation temperatures Ac1 and Ac3 is one of the essential factors in the heat treatment of CA6NM cast martensitic stainless steel. In this study, the influence of alloy composition, heating rate, and prior austenite grain size on the critical temperatures was quantified using dilatometric measurements and statistical modeling. Six heat treatment conditions produced prior austenite grain sizes ranging from ~75 to 247 µm. Experimental results showed that grain size variations produced only minor changes in Ac1 and Ac3, indicating a weak dependence of transformation temperatures on prior austenite grain size within the investigated range. In …

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 …

An Overview Of Biomass-Derived Graphene Oxide And Its Characteristics For Future Sustainable Applications, Afif Wardana, Ahmad Nabil Shahab, Donanta Dhaneswara, Nofrijon Sofyan

Journal of Materials Exploration and Findings

The production of graphene oxide (GO) from biomass presents considerable promise as a sustainable alternative substitute for traditional semiconductors. Biomass waste, abundant and often underutilized worldwide, is distinguished by its high carbon content and regenerative characteristics, rendering it an optimal resource for sustainable material production. By heating its biopolymers, lignocellulosic biomass can be used as a new material to make graphene, which forms three-dimensional turbostratic crystallites. These crystallites, composed of partially defective aromatic carbon sheets with graphite-like characteristics, make it easier to create GO with specialized functions for cutting-edge applications. Its capability underscores the revolutionary potential of biomass waste in …

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 …

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 …

The Effect Of Surface Treatment On The Fatigue Strength Of Sus316l Additive Manufactured Products, Hitoshi Nishijima, Yuji Kobayashi, Toshiya Tsuji, Kiyotaka Masaki

15th International Conference on Shot Peening

Rotating bending fatigue tests were conducted to investigate the effect of shot peening and barrel finishing on fatigue properties of SUS316L made by laser PBF which was one of additive manufacturing processes. Surface roughness, residual stress, and fatigue strength were investigated for each specimen. As a result, the fatigue strength of the barrel finished specimens was almost same or better than that of the shot peened specimens. Barrel finished specimens increased 4.1 times higher fatigue strength than as-built specimens. The surface roughness of the specimens after barrel finishing was reduced by up to 96% compared to the as-built specimens. On …

Improving Fatigue Strength And Life Of Single Crystal Cmsx-4, Jochen Peter Fuhr, Lloyd Hackel, Nicolau I. Morar, Noah Holtham, Keivan Davami, Montu Sharma, Rajkumar Roy

15th International Conference on Shot Peening

The deep penetration of laser peening (LP) and retention of residual stress at high temperature by LP is significant in improving fatigue life and strength of superalloys exposed to high temperature and corrosion. Single crystal CMSX-4, was evaluated for stress relaxation and both fatigue life and fatigue strength of material that was LP-treated compared to non-LP and shot-peened (SP) specimens. LP was done with multiple layers using a 20 J/pulse laser where the laser high energy enabled using a 5 mm spot size on the metal surface. Stress measurements by the slitting technique showed the plastic penetration depth exceeded SP …

Recent Progress And Scientific Challenges In Wire-Arc Additive Manufacturing Of Metallic Multi-Material Structures, Sainand M. Jadhav, Sambhaji Kusekar, Akash Belure, Satyavan Digole, Abhijeet Mali, Muralimohan Cheepu, Manoj Mugale, Suhas Alkunte, Duckbong Kim

Faculty Articles

Metallic multi-material structures are heterogeneous structures characterized by changing composition, microstructures, and site-specific characteristics, advantageous for numerous applications where multifunctionality is desired. Metallic multi-material structures are known as bimetallic structures (BSs), which are functionally graded materials (FGMs). In recent years, wire-arc additive manufacturing (WAAM) advanced as a promising additive manufacturing process to realize the fabrication of these structures due to its high deposition rate, cost-effectiveness, and material utilization efficiency. This review presents a comprehensive overview of the recent progress, processing strategies, and scientific challenges in WAAM of multi-material structures. The paper begins with an introduction to multi-material structures, followed by …

A Study Of Wear Measurement And Life Prediction Of Insert Chute Liner On Gold Ore Processing, Ferry Ardika Natanael, Nony Maulidya, Dedi Priadi

Journal of Materials Exploration and Findings

Chutes are critical materials handling assets to transport solid particles from one process step to another in mineral processing, coal mining and cement industries. The material transport, because of material characteristics, cause severe wear on internal lining of chutes or bins’ structure. The wear problem on internal lining of bins or chutes needs to be checked to keep production efficiency. Therefore, not checked wear rate causes liner replacement schedule becomes unpredictable. It leads to production loss and highly cost maintenance in industry. This study shows that condition-based maintenance through regular thickness measurement using Ultrasonic Transducer (UT) to predict life service …

Correlation Between Microstructure And Hardfacing Properties With Welding Current Intensity In Reconditioned Low-Alloy Steel Material Using Submerged Arc Welding (Saw) : A Comprehensive Review, Iman Nugraha Asmara, Winarto Winarto

Journal of Materials Exploration and Findings

This review studying the correlation between microstructural transformations and mechanical properties in reconditioned low-allow steel material, focusing on the impact of Submerged Arc Welding (SAW) parameters, especially current, on microstructure . The study highlights how variation on welding parameters, especially current intensity variation, affecting microstructural transformations, hardness, and wear resistance of hardfaced layers. Key aspects such as dilution effect, phases distribution, and carbide formation are reviewed to understanding their impact on mechanical properties. By reviewing insights from existing literature and experimental findings, this review underscores the role of Submerged Arc Welding in enhancing mechanical properties and microstructural of low-alloy steel …

Wear Of High Entropy Alloys: Understanding Effects Of Cryogenic Temperatures And Surface Nitriding On Wear Behavior, Aubrey Yu Tang

Dartmouth College Ph.D Dissertations

Cryogenic tribological applications have become increasingly important with the development and innovation of advanced equipment in aerospace, polar regions, superconductivity, and more. Traditional lubrication methods are not viable under these harsh environments, so metallic materials must be able to maintain excellent mechanical properties and withstand the constant impact and wear alone. High entropy alloys (HEAs) have emerged as potential candidates for these applications because of their wide variety of excellent room temperature properties and apparent improvement of mechanical properties of some HEAs at extremely low temperatures. Despite their promising nature, very limited work has been done on understanding the wear …