Metallurgy Commons^™

A Spatially Distributed Fiber-Optic Temperature Sensor For Applications In The Steel Industry, Muhammad Roman, Damilola Balogun, Yiyang Zuang, Rex E. Gerald Ii, Laura Bartlett, Ronald J. O'Malley, Jie Huang

Materials Science and Engineering Faculty Research & Creative Works

This paper presents a spatially distributed fiber-optic sensor system designed for demanding applications, like temperature measurements in the steel industry. The sensor system employed optical frequency domain reflectometry (OFDR) to interrogate Rayleigh backscattering signals in single-mode optical fibers. Temperature measurements employing the OFDR system were compared with conventional thermocouple measurements, accentuating the spatially distributed sensing capability of the fiber-optic system. Experiments were designed and conducted to test the spatial thermal mapping capability of the fiber-optic temperature measurement system. Experimental simulations provided evidence that the optical fiber system could resolve closely spaced temperature features, due to the high spatial resolution and …

A Multiscale Thermomechanical Metal Additive Manufacturing Simulation And The Impact Of Geometry On Residual Stress And Distortion, Luis Fernando Silva Velasco

Masters Theses

Metal additive manufacturing is an enabling technology for the rapid prototyping and manufacturing of geometrically complex parts that would otherwise be difficult or impossible to manufacture. However, the manufacturing process can produce undesired residual stresses and distortions. The first part of the work describes the implementation of a multiscale, thermo-mechanical simulation modeling the metal powder bed fusion additive manufacturing process. NASA’s Micromechanics Analysis Code was is to incorporate the microscale effects of an evolving material porosity on the predicted macroscale residual fields. The simulation shows that modeling an evolving material porosity, as the material transitions from a metal powder to …

Effects Of Ring Rolling On Grain Size In Inconel 718 And Waspaloy, David Webster

Materials Engineering

Carlton Forge Works, an industry leader in the manufacture of rolled rings, has observed anomalous grain structures in parts made from Inconel 718 and Waspaloy. These take the form of unusually large grains at the surface of the rings, causing them to fail industry grain size standards. Grain size testing is a critical part of evaluating parts before they are used as grain size and structure control many mechanical properties including creep resistance, low and high cycle fatigue life, and yield strength. These unusually large grains are only present within the first tenth of an inch of the surface of …

Microstructure And Tensile Properties Of Close-Die Forged Ti-6al-4v Aircraft Engine Mount, Renee Roeder, Nick Chen, Michael Viksne

Materials Engineering

The microstructural characteristics of a Ti-6Al-4V close-die forging that passes yield strength specifications are examined and found to be consistent with literature recommendations. Originally, the intent was to compare the microstructure of a forging that passed specification to the microstructure of a forging that did not pass specifications using the imaging software ImageJ. Due to time and safety constraints considering the COVID-19 pandemic, the data that is presented is incomplete data on only the forging that passes specifications. There are no comparisons between the forging that did not pass and the forging that passed.

Pitting Corrosion Of Oerlikon’S Abrasion Resistant Ferritic Stainless Steels, Matthew P. Nalty, Emma Wagstaff

Materials Engineering

Existing hardfacing coatings for hydraulic cylinders and brake disc applications crack during use leaving the components susceptible to corrosion. To address this problem, Oerlikon has designed three new alloys to be abrasion and corrosion resistant. This paper reviews the literature necessary to understand and quantify pitting resistance of stainless-steel alloys. It documents one round of testing ASTM G48 method A: Ferric Chloride Pitting Test of Stainless Steels on the new alloys P72-X9, P72-X13, P129-X9, as well as samples of 431, 316, and 2205 stainless steels. This paper also discusses improvements to the G48 testing method and industry use of the …

Alternative To Custom 450© Stainless Steel For Use In Investment Cast Golf Club Heads, William Henry Armstrong Iv, Davis Martin Loen

Materials Engineering

This investigation seeks to improve on the mechanical property of yield strength, while maintaining 10% elongation prior to fracture observed with of Custom 450 stainless steel in an air-melted investment casting operation. Improving this performance includes an additional heat treatment step of homogenization, as well as replacing the alloy. After identifying and downselecting available high strength stainless steels, a trial of Custom 455 stainless steel is recommended due to its high strength compared to the other alternative alloys. A trial has been developed to analyze the effect air melting has on the chemical composition and mechanical properties of Custom 455 …

Failure Analysis Of Investment Cast Near-Alpha Titanium Alloys, Garrett Ryan Bader, Jonathan Anton Linquist

Materials Engineering

In this project, fracture surfaces of three titanium investment castings were studied as part of a failure analysis on a TaylorMade metalwood. The crack formation occurred between investment cast Ti 9-1-1 and rolled Ti 6-4 joined by laser beam welding. The microstructure of the Ti 9-1-1 contained alpha colonies in large prior beta grains, while the Ti 6-4 was primarily Widmanstätten in basket weave morphology, refined with subsequent rolling. Over a period of cyclic loading, cracking occurred at the face-sole transition in the metalwoods that had been cast from a certain supplier B, while metalwoods that had undergone similar treatment …

Effects Of Surface Finish On High Cycle Fatigue Of Inconel 718, Jessica A. Mcroskey, Matthew Busse

Materials Engineering

Inconel 718 is a nickel-based superalloy and commonly used rocket engine material due to its excellent properties at elevated temperatures. Its fatigue life relies heavily on the surface roughness, as fatigue introduces and propagates cracks at the surface. Part standards set by Aerojet Rocketdyne typically necessitate surface roughness values from 64 to 125 Ra. However, surface topography and residual stresses incurred from the finishing process also affect the fatigue performance. The specific goal of the project is to perform a literature review and write experimental methods to determine how the surface roughness, topography, and residual stresses from turning, grit blasting, …

The Effect Of Distal Core Flattening And Heat Treatment On 304 Stainless Steel Guide Wires, Andrew Spencer Yap, Bryce Eric Veit, Matthew Frederick Lopez Villena

Materials Engineering

The mechanical response of 304 stainless steel guide wires due to different temper conditions and amounts of flattening is to be explored in this project. For this specific project, there is no public literature on the mechanical properties of guide wires with the above conditions through tensile testing or Turns to Failure Testing. To address this, the project with Abbott Vascular will measure the mechanical properties of guide wires using the aforementioned factors. Due to a lack of previous literature on this research topic, there are no quantitative goals for the project, however, any new research compiled in this area …

Effects Of New And Recycle Flux On The Mechanical Properties Of Submerged Arc Welded (Saw) Line Pipe Grade X52m And X65m, Taib Meor Mohd Adli

Student Works (2020-2029)

Two line pipe grade X52M and X65M were manufactured using submerged arc welding process. For each grade, two different welding flux condition were simulated, i.e. 100% new flux and 100% recycle flux. The flux used was aluminate basic type trade name OP 132. The outside diameter and wall thickness for X52M was 610mm x 12.7mm and for X65M was 762mm x 14.3mm. Lower weld re-entrant angle and higher weld bead height were observed in recycle flux condition. Lower weld manganese content recorded in recycle flux condition. And lower mechanical tests (i.e. tensile, impact, and hardness) value reported for recycle flux …

Experimental Performance Evaluation Of A Hyper-Branched Polymer Electrolyte For Rechargeable Li-Air Batteries, Susanta K. Das, Joel Berry, Abhijit Sarkar

Mechanical Engineering Publications

A hyper-branched polymer (HBP) electrolyte is synthesized for rechargeable lithium-air (Li-air) battery cell and experimentally evaluated its performance in actual battery cell environment. Several real-world battery cells were fabricated with synthesized HBP electrolyte, pure lithium metal as anode and an oxygen permeable air cathode to evaluate reproducibility of the rechargeable Li-air battery cell. The effect of various conditions such as various HBP based electrolytes, discharge current −0.1~0.5 mA, cathode preparation processes and carbon contents on the battery cell performance were experimentally evaluated using the fabricated battery cells under dry air condition. Detailed HBP electrolyte synthesis procedures and experimental performance evaluation …

Materials-Processing Relationships For Metal Fused Filament Fabrication Of Ti-6al-4v Alloy., Paramjot Singh

Electronic Theses and Dissertations

Additive manufacturing (AM) is at the mainstream to cater the needs for rapid tooling and small-scale part production. The metal AM of complex geometries is widely accepted and promoted in the industry. While several metal AM technologies exist and are matured to a level where expectation in terms of design and properties are possible to realize. But the metal AM suffers from the heavy expense to acquire equipment, isotropic property challenges, and potential hazards to work with loose reactive metal powder. With this motivation, the dissertation aims to develop the fundamental aspects to print metal parts with bound Ti-6Al-4V powder …

Selective Laser Melting 17-4 Ph Stainless Steel And The Effect Of Varied Thermal Treatments On Fatigue Behavior., Sean Daniel Dobson

Electronic Theses and Dissertations

Fatigue failure is the leading source of loss in industry. In order for new means of manufacturing to move towards mainstream use a complete understanding of material and mechanical behavior must be gained. This endeavor seeks to aide in that task by observing the fatigue behavior of selective laser melting (SLM) additive manufacturing (AM) specimens and the effect of differing thermal treatment conditions for an optimized AM process. Stainless steel 17-4 PH specimens were fabricated using SLM AM and thermally treated to three conditions: as-built, solutionized and hardened, and direct hardened. These specimens were characterized for material (powder quality, density, …

Discontinuous Grain Boundaries Of Forged René 41, Aaron Rabin, Bryce Bitter

Materials Engineering

Certain nickel-based alloys, particularly René 41, characteristically have many low-angle grain boundaries (grain arrangements of less than 15 degrees), present in the microstructure of an in-use component. Frequently, these low-angle grain boundaries are not optically visible after the etching process, leading to the phenomena of discontinuous grain boundaries. There exists a risk for René 41 grain boundary characterization; since one cannot assume that a grain boundary continues beyond a discontinuity, the grain size requirements become difficult to meet. Despite favorable characteristics of René 41, such as the corrosion and oxidation resistance coupled with excellent strength at high temperatures, the risks …

Spherical Cavity Expansion Approach For The Study Of Rigid-Penetrator’S Impact Problems, Mario Buchely, Alejandro Marañon

Materials Science and Engineering Faculty Research & Creative Works

In recent years, Spherical Cavity Expansion (SCE) theory has been extensively utilized to model dynamic deformation processes related to indentation and penetration problems in many fields. In this review, the SCE theory is introduced by explaining the different mathematical features of this theory, its solution, and a potential application to model the penetration of a rigid penetrator into a deformable target. First, a chronologically literature review of the most common models used to study this kind of penetration problems is introduced, focusing on the SCE theory. Then, the engineering model of penetration is presented using the SCE approach. The model …

Defect Characterization Of Additively Manufactured Parts, Sabrina D'Alesandro, Joy Gockel, Andrew Harvey

Celebration of Undergraduate & Graduate Research, Scholarship, and Creative Activities Materials

This document describes various image processing techniques to be used for defect characterization of additively manufactured parts. This will help the reader gain knowledge of materials science engineering and the nuances in analyzing data from image processing software.

Additive manufacturing is shaping the manufacturing world through simplistic household printers’ to more complex metal printers used for a variety of applications. Specifically, laser powder bed fusion (LPBF) is an additive manufacturing process that deposits metal powder over the build plate and melts it with a laser in the shape of the build part. In order to make LPBF more efficient with …

A Novel Method For Making Titanium Dioxide For Photocatalytic Applications, Gary Wilson

Graduate Theses & Non-Theses

Titanium dioxide possesses near-ideal properties for large-scale application as a photocatalyst. It is cheap and abundant, nontoxic, and environmentally safe. However, it still suffers from logistical problems preventing its application in industry: namely, rapid electron-hole recombination and inability to utilize visible light. For nearly five decades researchers in this booming field have made numerous attempts to address these problems, doping and combining titanium dioxide with a wide range of materials. A novel ambient-temperature approach to synthesis and doping/modification of anatase-form titanium dioxide was attempted using both oxygen-rich and oxygen deprived synthetic routes. Reactants were exposed to various wavelengths of ultraviolet …

Effect Of Frother Strength And Solids On Gas Dispersion In A Cavitation Sparger Measured By Electrical Resistance Tomography, Philip Holdsworth

Graduate Theses & Non-Theses

Gas dispersion in column flotation is critical for optimizing particle-bubble interaction and maximizing recovery. The effect of various flotation frothers on axial gas dispersion rates in a column flotation cell were measured using electrical resistance tomography (ERT). Tests included two-phase (gas-liquid) and three-phase (gas-liquid-solid) to determine the effect of mechanical parameters and the presence of solids on gas dispersion. Gas holdup can be measured using ERT and utilized in the determination of axial gas dispersion rate in the column. The ERT is constructed with two sensor planes making it possible to simultaneously capture gas holdup values at one cm and …

Effects Of Collision Damage On The Ultimate Strength Of Fpso Vessels, Muhammad Zubair Muis Alie, Dian Ramasari, Taufiqur Rachman, Ristiyanto Adiputra

Makara Journal of Technology

Floating production storage offloading (FPSO) vessels are movable offshore structures. These structures are designed with large dimensions, and their decks are loaded with several types of equipment. During collision damage, the hull and deck parts loaded with equipment are severely affected. Therefore, the ultimate strength of FPSO vessels should be thoroughly checked and evaluated. The objective of the present study is to analyze the ultimate strength of FPSO vessels against collision damage characterized by hogging and sagging under longitudinal bending. The cross section of an FPSO vessel is modeled with elements composed of stiffened and unstiffened plates. The vessel length …

Ionic Conductivity And Electrochemical Properties Of Alginate–Nn4no3-Based Biopolymer Electrolytes For Edlc Application, Norfatihah Binti Mazuki, Nur Muhitul Jalilah Rasali, Bouchta Sahraoui, Ahmad Salihin Samsudin

Makara Journal of Technology

In this work, alginate doped with various contents of ammonium nitrate (NH4NO3) as a solid biopolymer electrolyte (SBE) was prepared via casting by using distilled water as a solvent. Impedance studies on alginate–NH4NO3 SBE films were conducted via impedance spectroscopy. The lowest bulk resistance (Rb) showed that the maximum ionic conductivity of the sample containing 25 wt.% NH4NO3 at ambient temperature (303 K) was 5.56 × 10−5 S cm−1. The temperature dependence of ionic conductivity was evaluated, and results confirmed that electrolytes followed an Arrhenius behavior. The highest conducting sample was fabricated into an electrical double-layer capacitor and characterized in …

Synthesis Of Epoxy Monoethanolamide From Bauhinia Monandra Seed Oil, Adewale Adewuyi, Rotimi A. Oderinde

Makara Journal of Technology

In this study, we synthesized epoxidised monoethanolamide (EMA) from Bauhinia monandra seed oil (BMO) via a simple reaction route. In this process, BMO was transesterified to obtain a mixture of methyl esters, which was subjected to a urea adduct complexation reaction. The unsaturated methyl esters (BME) from the urea adduct complexation reaction were then epoxidised using performic acid produced in situ in a one-pot reaction system. The epoxidised methyl esters were converted to EMA by reacting them with monoethanolamine (1:10). The progression of the reaction was monitored using Fourier transform infrared spectroscopy and proton nuclear magnetic resonance spectroscopy, and the …

Parametric Investigation Of Effect Of Abnormal Process Conditions On Self-Piercing Riveting, Taek-Eon Jeong, Dong-Hyuck Kam, Cheolhee Kim

Mechanical and Materials Engineering Faculty Publications and Presentations

Self-piercing riveting (SPR) is one of the mechanical joining processes, and its application to Al/Fe dissimilar materials combination, which is hard to weld, is expanding in the automotive industry. The main process parameters in SPR are types of rivet and die, setting force, and rivet setting speed. Previously, the relationship between the main process parameters and output parameters such as cross-sectional characteristics and joint strength has been studied to optimize the SPR process. In practical applications, there are unexpected and abnormal process conditions such as poor fit-up, angular misalignment, edge offset distance, and inaccurate setting and pre-clamping forces, and their …

Ethylene Carbonate And Polyethylene Glycol As Efficient Plasticizers In Cmc-Pva-Nh4no3-Based Polymer Electrolyte, Noor Saadiah Mohd Ali, Yuki Nagao, Ahmad Salihin Samsudin

Makara Journal of Technology

This study investigated the influence of plasticizers (polyethylene glycol [PEG] and ethylene carbonate [EC]) on the ionic conduction of CMC-PVA-NH4NO3. Blended biopolymer electrolytes (BBEs) based on carboxymethyl cellulose–polyvinyl alcohol (CMC-PVA) doped with ammonium nitrate (NH4NO3) were obtained via casting solution technique incorporated with PEG and EC, which acted as plasticizers. Electrical impedance spectroscopy (EIS) was conducted to evaluate the effect of plasticization on the ionic conduction properties. The ionic conductivity improved from 1.70 × 10−3 S/cm for un-plasticized BBEs to 3.92 × 10−3 S/cm for plasticized BBEs with EC and 3.00 × 10−3 S/cm for plasticized BBEs with PEG. The …

Current Status Of Hydrothermal Treatment For Energy And Material Recovery Toward A Sustainable Post-Consumer Material Cycle, Baskoro Lokahita, Muhammad Aziz, Fumitake Takahashi

Makara Journal of Technology

The demand for energy-efficient and environmentally friendly municipal solid waste (MSW) processing has increased in developing countries. The thermochemical process offers a fast and reliable solution to reutilize or reduce the volume of MSW. Hydrothermal treatment is a novel MSW treatment technology that is compatible with high-moisture-content feedstock. It involves the thermal degradation of MSW in pressurized water or steam, which promotes the disintegration of cellulosic and polymer materials. Recent advances have shown effective MSW conversion into homogenous solid hydrochar with higher energy density. Alkali and chlorine content, which causes issues in combustors, was successfully removed due to the washing …

Liquefaction Potential Analysis Based On Nonlinear Ground Response On The Coastline Of Bengkulu City, Indonesia, Lindung Zalbuin Mase

Makara Journal of Technology

This paper presents the study of the seismic response and liquefaction potential of the coastal area of Bengkulu City during the September 2007 Sumatra earthquake. The study is conducted by collecting site investigation data (standard penetration test) and applying input motion to observe soil response. Synthetic ground motion is generated by considering the important aspects of earthquakes, including focal depth, epicenter, earthquake source, and site classification. The synthetized ground motion is then used as the input motion in the seismic response analysis. The results of this analysis are spectral acceleration and peak ground acceleration at each depth. The resulting spectral …

Comparison Of Phytoremediation And Filtration For Diamond-Mine-Tailings Water Treatment, M. Hafidhuddin Noor, Mijani Rahman, Akhmad Gazali, Nia Kania, Aulia Rahma, Erdina L.A. Rampun, Amalia E. Pratiwi, Muthia Elma

Makara Journal of Technology

The water pollution caused by diamond mine activities can kill aquatic life. In this work, we used phytoremediation and filtration to treat pond water polluted by the tailings of a diamond mine located in South Kalimantan, Indonesia. Einchhornia crassipes (water hyacinth) was utilized as the biomass for the phytoremediation process. Gravel (10–15 mm) and sand (0.1–1 mm) were used as filter media in the simple filtration setup, using an up-flow system (bottom to top). In the experiment, 16 L of diamond tailing water was poured into five phytoremediation reactors (each 60 L in volume), which were then tested over seven …

Thermally Driven Spin Transport In Ferromagnetic Metals, Wafa Saud Aljuaid

Electronic Theses and Dissertations

Since the discovery in 2008, the spin Seebeck effect has become one of the most active topics in the spin caloritronics research field. It opened a new way to create spin current by a combination of magnetic fields and heat. A temperature gradient in ferromagnetic (FM) metals generates a ow of spin current due to split of spin chemical potential between spin up and spin down electrons. This thermal spin current has been detected using an attached nonmagnetic heavy metal with large spin Hall angle via the inverse spin hall effect (ISHE). A voltage signal is generated since the nonmagnetic …

Additive Manufacturing Of Copper-Based Alloy By Laser Powder Bed Fusion, Binghao Lu

Electronic Theses and Dissertations, 2020-2023

Copper (Cu) and Cu-alloy are good candidates for the engineered components that require good thermal and electrical conductivity. Since industry often needs sophisticated components that cannot be made easily by traditional methods, such as casting, forging and machining, research for additive manufacturing of copper-based alloy is on demand. Therefore, this thesis focuses on the optimization of laser powder bed fusion (LPBF) of Cu-10 wt.% Sn alloy and pure Cu based on their characteristics such as relative density/porosity, surface roughness, phase constitutes, melt pool dimension, and dendrite arm spacings dimension, determined by optical microscopy, X-ray diffraction and Scanning electron microscope. LPBF, …

Lateral Bracing Of Beams Provided By Standing Seam Roof System: Concepts And Case Study, Gengrui Wei, Benjamin Schafer, Michael Seek, Matthew Eatherton

Engineering Technology Faculty Publications

The standing seam roof (SSR) system is the most commonly used roof system for metal buildings due to its superior durability, water tightness, and energy efficiency. In this type of system, SSR panels attach to Z-shaped or C-shaped purlins with clips, and the purlins are in turn connected to rafters (i.e. roof beams). For the design of metal building rafters against lateral torsional buckling, bottom flange braces provide torsional bracing to the rafter and the SSR system provides some lateral bracing. However, the degree to which the SSR system can restrain the rafter against lateral movement has not previously been …

Effect Of Cerium And Magnesium Additions On The Strength And Morphology Of The Intermetallic Compound Layers In Aluminum-Steel Dissimilar Castings, Matt Thomas

Dissertations, Master's Theses and Master's Reports

Dissimilar castings are under investigation due to their light-weighting opportunities within the automotive industry. In this case, dissimilar castings consist of a solid steel core and a poured aluminum component. The strength and integrity of the casting relies on the coherency of the bond between the two components; by optimizing the metallurgical component of the bonding phenomena, the weight and complexity of the insert can be reduced, further increasing the light-weighting opportunities. An interface comprised of intermetallics, generally Fe₄Al₁₃ and Fe₂Al₅, forms between the two components with the latter forming nearest the steel. …