Metallurgy Commons^™

Minimizing Leakage In Thin Walled Structures Printed Through Selective Laser Melting, Andrew Spencer Yap

Master's Theses

In this project, the scan strategy of selective laser melting (SLM) for thin walled structures was investigated by changing laser parameters and tool path. Producing thin walled structures is difficult due to defects such as warpage and porosity. A layer on the SLM 125 consists of hatch volume, fill contours, and borders, however, for thin walls, hatch volume can become unavailable, resulting in a solely border/fill contour laser tool path.

Three central composite designs (CCD) were created to optimize the laser parameters of borders to minimize leakage rate and porosity. The two factors changed were border laser power and scanning …

Effect Of Distal Core Flattening On 304 Stainless Steel Guide Wires, Khanh Phan

Materials Engineering

Abbott Vascular produces a variety of medical guide wires to accommodate a wide array of minimally invasive medical procedures. Certain types of these wires have the distal core flattened to improve specific properties such as flexibility and steerability. However, it is unknown how this affects the other mechanical properties of the wire. Abbott Vascular provided two types of wire to test the effects of distal core flattening on the mechanical performance of the wires. One group of wires was made from 304 single spring stainless steel with no flattening performed. The other group of wires was made from 304 triple …

Newly Developed Antifouling Coating Alloys For Hydraulic Cylinder Applications, Christopher Liam Fahey, Robin Ashley Payne

Materials Engineering

In a marine environment solid surfaces are subject to corrosion and fouling, which is the buildup of unwanted material such as algae and barnacles, that can impede the functionality of components. The application that this project focuses on are hydraulic cylinders. Eight alloys, including three newly developed alloys, were tested for marine fouling performance. Three of the alloys were primarily NiCr, these included Inconel 625, Metco 1720, and P105-X3. Four alloys contained varying amounts of Cu, and these were Monel 400, CuproNickel, Monel 450, and P76-X24. Finally, one sample of a Co-based alloy was also tested, Ultimet. Of the samples …

Effect Of Dissolved Oxygen On Corrosion Of Carbon And 13cr Steel In A Brine Environment, Kevin Peter Iu, Andy Zhou

Materials Engineering

Oxygen corrosion is a major threat to seawater injection systems that are part of offshore drilling operations. Seawater is typically deoxygenated to an industry standard of(DO) by injection through a deaeration column followed by treatment with oxygen scavenging chemicals. Commercial simulation software like OLI Studio: Corrosion Analyzer predicts high corrosion rates when injection seawater contains high DO levels, justifying deoxygenation. However, a notable lack of experimental data exists concerning the effect of varying levels of dissolved oxygen on corrosion rate. The goal of this project is to measure the effect of three dissolved oxygen levels (0, 62, and 620 ppb) …

Strengthening Of 7175 Aluminum Alloy Through Multi-Step Aging Process, Colin E. Masterson, Ryland W. Jolliffe

Materials Engineering

7175 is a heat-treatable aluminum alloy commonly used in aerospace forgings. This alloy is aged with a multi-step heat treatment. This treatment must balance strength with stress corrosion cracking resistance through a degree of overaging. The team was tasked by Weber Metals to increase the strength of this treatment without sacrificing stress corrosion cracking resistance. Both two-step and retrogression and reaging treatments were tested in experiments to find a heat treatment that could increase the yield and tensile strength by 1-2 ksi while maintaining a minimum electrochemical conductivity equivalence of 38% relative to copper. Two-step aging is the more conventional …

Fabricating Tinicu Ternary Shape Memory Alloy By Directed Energy Deposition Via Elemental Metal Powders, Yitao Chen, Xinchang Zhang, Mohammad Masud Parvez, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In this paper, a TiNiCu shape memory alloy single-wall structure was fabricated by the directed energy deposition technique with a mixture of elemental Ti, Ni, and Cu powders following the atomic percentage of Ti50Ni45Cu5 to fully utilize the material flexibility of the additive manufacturing process to develop ternary shape memory alloys. The chemical composition, phase, and material properties at multiple locations along the build direction were studied, using scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, Vickers hardness test-ing, tensile testing, and differential scanning calorimetry. The location-dependent compositions of martensitic TiNi and austenitic TiNi phases, mechanical properties, and functional properties …

Metallurgical And Thermal Processing Investigation Of Additively Manufactured Superalloys Jbk-75 And Nasa-Hr-1, Allyse Birken, Derek Noel

Materials Engineering

Aerojet Rocketdyne is investigating the use of directed energy deposition (DED), an additive manufacturing process, to reduce cost and lead time for manufacturing complex rocket engine components for their RS-25 engines. JBK-75 and NASA-HR-1, two Fe-Ni-base, age-hardenable (γ′) superalloys, are used for nozzle structural jackets and hot gas manifolds. Currently, these parts are produced using traditional forging or casting methods followed by intensive machining operations. Additionally, these alloys were designed for use in the wrought condition and require a different set of post-processing heat treatments when produced using DED due to their dendritic, segregated microstructure in the as-built condition. Homogenization …

Experimental Study Of Hollow-Core Slab Containing Waste Pet Bottles, Mulia Orientilize, Josia Irwan Rastandi, R. M. Dimas Aries C., Marsha Niken P., Krisna Adi S.S., Abimantrana Abimantrana

Makara Journal of Technology

This study investigated the utilization of plastic-waste concrete as an effort to reduce urban waste problems. The waste plastic bottles were utilized to form the hollows of the hollow-core slabs (HCSs). The bottles were made of polyethylene terephthalate (PET). As a part of green research to reuse waste material, shredded PET was also added to the concrete mixture to improve the HCS strength. The cast-in-site HCS could be constructed without any difficulties. Three parameters were investigated: the effects of void content, shredded PET content, and steel-fiber (SF) content on the HCS ultimate bending capacity (Mu). Fifteen specimens were tested under …

Improving The Intellectual And Social Development Of Children With Autism: Design Of A Training Center For Autism, Hasti Jalalian

Makara Journal of Technology

Research on the relationship between the role of architecture and the psychology of children with autism, which indicates that appropriate environments for these children can have a significant effect on their healthcare process, has been recently conducted. However, statistics show that autism spectrum disorders are pervasive, and its extent in Iran has been increasing. Moreover, centers that are specifically designed for children with autism are limited, and paradigms are made without considering the mood of these children. Given the role of architecture in designing a suitable space for these children, an investigation that can identify the specific requirements of these …

Numerical Study Of A Buckling Restrained Brace (Brb) In Steel Structures And Comparison With A Convergent Ordinary Brace (Ocb) Under Static And Dynamic Loading, Fatemeh Habibpour

Makara Journal of Technology

Bulk metallic glass (BMG) has good mechanical strength, high hardness, wear resistance, and corrosion resistance with promising application in various industries. However, for the industrial production of BMG, the main issue is how to overcome limitations of joining with other materials. The present study focuses on solder processing at low operating temperature to avoid exceeding the recrystallization temperature. A feasible joining process for BMG was developed using lead-free solders. The BMG surface is pre-plated with copper, nickel, or titanium as a wetting layer. The reaction temperature is set between the glass transition temperature of BMG and the melting point of …

Analysis Of The Interfacial Reaction Between Bulk Metallic Glass Coated Copper, Nickel, And Titanium With Lead-Free Solders, Andromeda Dwi Laksono, Yee-Wen Yen, Rifqi Aulia Tanjung, Teodoro A. Amatosa, Ruki Harwahyu

Makara Journal of Technology

Bulk metallic glass (BMG) has good mechanical strength, high hardness, wear resistance, and corrosion resistance with promising application in various industries. However, for the industrial production of BMG, the main issue is how to overcome limitations of joining with other materials. The present study focuses on solder processing at low operating temperature to avoid exceeding the recrystallization temperature. A feasible joining process for BMG was developed using lead-free solders. The BMG surface is pre-plated with copper, nickel, or titanium as a wetting layer. The reaction temperature is set between the glass transition temperature of BMG and the melting point of …

Design Of Ac Microgrid Topology With Photovoltaic Uncertainties In A Rural Village, Vannak Vai

Makara Journal of Technology

Energy needs are increasing day by day, especially for developing countries, due to population growth and changing lifestyles. A suitable microgrid topology with renewable energy integration is considered to fulfill the people and society’s needs. This paper focuses on the design of AC microgrid topology for a nonelectrified village with the integration of PV uncertainties in both sitting and sizing. The development of an optimal algorithm based on the conductor use minimization and unbalanced load improvement is proposed. The shortest path is proposed to search for the minimum conductor use. Then, the algorithm for improving the unbalanced load with two …

Mean-Shift Object Tracking Algorithm With Systematic Sampling Technique, Yoanes Bandung, Aris Ardiansyah

Makara Journal of Technology

Mean shift is a fast object tracking algorithm that only considers pixels in an object area, hence its relatively small computational load. This algorithm is suitable for use in real-time conditions in terms of execution time. The use of histograms causes this algorithm to be relatively resistant to rotation and changes in object size. However, its resistance to lighting changes is not optimal. This study aims to improve the performance of the algorithm under lighting changes and reduce its processing time. The proposed technique involves the use of sampling techniques to reduce the number of iterations, optimization of candidate search …

Analysis Of Correlation And Mapping Of Chlorophyll-A Concentrations And Sea Surface Temperatures In Coastal Areas Based On Terra Modis Satellite Image Data, Hendrata Wibisana, Bangun Muljo Sukotjo, Umboro Lasminto

Makara Journal of Technology

Ecosystems in aquatic environments are distinct from ecosystems on land. Changes that occur in ecosystems in aquatic environments affect the lives of biota in these waters, including the fish used as a food source in fishing communities in coastal areas. This study aims to determine the role of remote sensing in mapping and analyzing the relationship between the parameters of sea surface temperature and chlorophyll-a concentrations on the coast. The correlation of sea surface temperature with chlorophyll-a concentrations is modeled via linear regression. An analysis of variance test is performed to establish the suitability of the temperature data for the …

Study Of Laser Based Additive Manufacturing For Titanium And Copper Alloys, Congyuan Zeng

LSU Doctoral Dissertations

Material processing by laser is increasingly applied in industrial applications for its outstanding characteristics, such as localized heating, high efficiency, and high manufacturing precision. In this study, two kinds of laser material processing strategies were investigated, namely laser surface engineering and laser-powder-bed fusion additive manufacturing, with pure titanium and copper alloys as target materials, respectively.

For laser surface engineering related studies, the work includes the investigation of the dynamic interactions between titanium and pure nitrogen or ambient air under transient laser processing conditions. Thanks to the in-situ synchrotron X-ray diffraction tests, the high-temperature reaction steps between titanium and pure nitrogen/ambient …

Absorption Of Nitrogen During Pulsed Wave L-Pbf Of 17-4 Ph Steel, Ben Brown, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In the fabrication of 17-4 PH by laser powder bed fusion (L-PBF) the well-documented occurrence of large amounts of retained austenite can be attributed to an elevated concentration of nitrogen present in the material. While the effects of continuous wave (CW) laser processing on in-situ nitrogen absorption characteristics have been evaluated, power modulated pulsed wave (PW) laser processing effects have not. In this study the effects of PW L-PBF processing of 17-4 PH on nitrogen absorption, phase composition, and mechanical performance are explored using commercially available PW L-PBF equipment and compared to samples produced by CW L-PBF. PW L-PBF samples …

Thermodynamic Prediction And Experimental Verification Of Multiphase Composition Of Scale Formed On Reheated Alloy Steels, Richard Osei, Semen Naumovich Lekakh, Ronald O'Malley

Materials Science and Engineering Faculty Research & Creative Works

The structure, phase, and composition of scale formed on a continuously cast steel slab during reheating depend on intrinsic factors (steel chemistry, microstructure, and as-cast surface condition) and extrinsic parameters (temperature, time, composition, and velocity of combustion gas atmosphere). The scale that forms on a slab normally has several layers with differing compositions and phases and knowledge of this scale structure is important in subsequent descaling and hot rolling processing steps. Formation of multiphase scale structures on steel during high temperature oxidation in reheat furnace proceeds according to a local thermodynamic equilibrium, while thickness of layers depends on kinetic conditions …

Modeling And Optimization Of Process Parameters In Face Milling Of Ti6al4v Alloy Using Taguchi And Grey Relational Analysis, Al Mazedur Rahman, S M Abdur Rob, Anil K. Srivastava

Manufacturing & Industrial Engineering Faculty Publications

Titanium alloys are extensively used in aerospace, missiles, rockets, naval ships, automotive, medical devices, and even the consumer electronics industry where a high strength to density ratio, lightweight, high corrosion resistance, and resistance to high temperatures are important. The machining of these alloys has always been challenging for manufacturers. This article investigates the combined effect of radial depth, cutting speed and feed rate on cutting forces, tool life, and surface roughness during face milling of Ti6Al4V alloy. This study focuses on the significance of radial depth of cut on cutting force, tool life and surface roughness compared to that of …

Modeling Of Rare Earth Solvent Extraction Process For Flowsheet Design And Optimization, Vaibhav Kumar Srivastava

Theses and Dissertations--Mining Engineering

The separation and purification of rare earth elements (REEs) into individual products has been a topic of significant interest for researchers and engineers for many decades. The prime reason for such sustained interest is due to REEs’ demand and application in modern technology, as well as the challenges associated with their separation and purification. The chemical similarity of rare earth group elements is responsible for difficult separability which makes purification of individual elements challenging. Despite associated complications, processes such as solvent extraction (SX) and ion-exchange have been successfully utilized in the separation and production of REEs on pilot and commercial …

Analysis Of Post-Deposition Recrystallization Processing Via Indium Bromide Of Cu(In,Ga)Se2 Thin Films, Deewakar Poudel, Benjamin Belfore, Tasnuva Ashrafee, Shankar Karki, Grace Rajan, Angus Rockett, Sylvain Marsillac

Applied Research Center Publications

Cu(In,Ga)Se₂ (CIGS) thin films were deposited at low temperature (350 °C) and high rate (10 µm/h) by a single stage process. The effect of post-deposition treatments at 400 °C and 500 °C by indium bromide vapor were studied and compared to the effect of a simple annealing under selenium. Structural, electrical, and chemical analyses demonstrate that there is a drastic difference between the different types of annealing, with the ones under indium bromide leading to much larger grains and higher conductivity. These properties are associated with a modification of the elemental profiles, specifically for gallium and sodium.

Toward Understanding Commercial Additives For Zincate Electrogalvanizing, Margaret Scott

Masters Theses

"Cyanide zinc electrogalvanizing has been used for many years to produce high quality and uniform zinc coatings. Due to toxicity concerns, a significant amount of research has occurred to remove the use of cyanide while still producing a similar deposit. One of the resulting plating chemistries is the alkaline zincate bath.

Alkaline zincate plating has the advantages of low startup cost, low toxicity, and low corrosion rate. Despite these advantages, alkaline bath conditions do not produce acceptable zinc deposits without the use of plating additives, which can promote lustrous, smooth deposits. This research aims to: (1) generate fundamental electrochemical data …

The Effects Of Molybdenum, Chromium, And Niobium On Gray Iron For Brake Rotor Applications, Matthew Hasbrouck

Dissertations, Master's Theses and Master's Reports

Brake rotor composition and microstructure must be optimized for thermal and mechanical performance to avoid thermal-mechanical cracking, excessive wear, and to reduce noise. Niobium is an element that increases the strength and wear resistance of gray iron; however, the interaction of niobium with other common alloying elements (chromium and molybdenum) is not well understood. Thirteen gray cast iron alloys were produced with varying levels of carbon equivalent (CE), Cr, Mo, and Nb. Bars with four different diameters (8, 14, 22, and 30 mm) were cast from each alloy and microstructural and physical properties such as graphite flake morphology, pearlite spacing, …

Application Of Laser Assisted Ultrasonic Nanocrystal Surface Modification On Aluminum And 3d Printed Titanium, Eman Hassan, Thomas Crouse

Williams Honors College, Honors Research Projects

A novel surface treatment, laser assisted ultrasonic nanocrystal surface modification (LA-UNSM), has proved effective in increasing surface hardness, and fatigue life. The objective of this research is to determine the effectiveness of this process on components created with additive manufacturing. To accomplish this, we investigated the effectiveness of LA-UNSM treatment on aluminum, a common 3d printed metal, and the effectiveness of LA-UNSM processing on 3d printed titanium. We first conducted our own literature review to assess the practicality of using this same treatment on aluminum. We then treated traditionally manufactured aluminum at varying levels of laser intensity to determine if …

Jominy Hardenability Tester Redesign, Dennis Kopacz, Shadoe Beatty, Thomas Benenati, Jared Mclean, Matthew Yokosuk

Williams Honors College, Honors Research Projects

Our project is Redesigning a Hardenability Tester. The goal of this project is to figure out how to incorporate an intensive quenching system to the current design from last years group. An intensive quench is a new system that is safer to harden steel and it hardens steel more effectively than other quenching processes. This will be achieved through testing the initial design to make sure it is able to run. After that as a group we will take this system through a design process to introduce a safe process of intensive quenching to the tester.

New Horizons For Processing And Utilizing Red Mud, M. Archambo

Dissertations, Master's Theses and Master's Reports

Red mud is an industrial slurry waste that is produced as a byproduct of the Bayer process for alumina. The waste is generated in large quantities, up to a ratio of 2:1 against the valued product alumina. Red mud exhibits many chemical and physical properties that categorize it as a hazardous material. Due to the addition of sodium hydroxide in processing, the pH is typically at values close to 13. Small particle size discourages separation from water for disposal, so drying red mud happens over many years.

The pH of red mud can be reduced with inexpensive reagents. Carbon dioxide …

Thermomechanical Mechanisms That Cause Adhesion Of Aluminum High Pressure Die Castings To The Die, Alex Monroe

Dissertations, Master's Theses and Master's Reports

In high pressure die casting (HPDC) of aluminum, cast material adhering to die is a significant defect. Adhesion occurs in two primary ways. The casting may stick preventing its removal from the die. Aluminum can also adhere to the die and buildup in local areas on the die surface with additional casting cycles. This second form of adhesion is called soldering. Lubricant is the best technology to control all forms of adhesion, but it comes at the cost of casting porosity, blisters, reduced die life, and increased die casting machine wear. New strategies to prevent adhesion are desired to eliminate …

Role Of Eta Phase Evolution On Creep Properties Of Nickel Base Superalloys Used In Advanced Electric Power Generation Plants, Ninad Mohale

Dissertations, Master's Theses and Master's Reports

Advanced fossil energy power generation plants require materials that withstand high temperatures and corrosive environments. One such material that is used in steam turbines is Nimonic 263. It is a nickel-base superalloy that is principally strengthened by gamma primephase (Ni₃(Ti, Al)) and has an L1₂structure. At extended times and at turbine operating temperatures however, eta (Ni₃Ti) phase is known to form at the expense of gamma prime. Eta has a complex DO₂₄structure and is the stable phase between 750°C and 900°C, but with slow kinetics of formation. Little is understood about eta …

Exploring Rapid Solidification And Equal Channel Angular Pressing In The Fabrication Of Mg-Based Alloys For Medical Applications, Emily Tom

Dissertations, Master's Theses and Master's Reports

The development of magnesium bioresorbable implants has become increasingly popular due to the increased need for temporary implants and magnesium’s excellent biocompatibility and suitable elastic modulus. Even though magnesium is an excellent candidate, when alloyed with other metals magnesium’s corrosion rate becomes too rapid for bioresorbable medical applications. The investigation into novel processing techniques to control the formation of precipitates to improve mechanical strength and ductility as well as corrosion rates has become of interest. This work investigates the combination of two nonequilibrium processing techniques, rapid solidification (RS) and equal channel angular pressing (ECAP), and the effects it has on …

Atomistic Monte Carlo Simulation Study Of Phase Transitions In Metal Alloys, Xiaoxu Guo

Dissertations, Master's Theses and Master's Reports

The atomic-scale Monte Carlo simulation study focuses on the intrinsic behaviors of a defect-free crystal that undergoes a cubic-to-tetragonal martensitic transformation. The quasi-spin variable associated with the lattice sites characterizes the local unit cells of the orientation variants of the ground-state martensite phase, which interact with each other through long-range elastic interactions. It is shown that the diffuse scattering in the premartensitic austenite state results from the spatial correlation of the atomic-scale heterogeneous lattice displacements and manifests the displacement short-range ordering. The effects of temperature, elastic anisotropy, and shear modulus softening on the diffuse scattering and displacement short-range ordering are …

Analyzing Variation In Dispersoid Formation In Aluminum Alloys By Minor Changes In Homogenization Temperature, Brendan Treanore

Dissertations, Master's Theses and Master's Reports

The homogenization of billets in the aluminum extrusion industry is a critical step that removes chemical segregation from casting, dissolves low melting point phases, forms nanoscale dispersoid phases, and promotes the beta to alpha transformation of iron particles in the matrix. With ever increasing use of aluminum extrusion in the automotive industry there is a constant need for increased efficiency and consistency in processing of extruded aluminum. The work in this thesis explores the effects of 10°C differences in the homogenization temperature on the formation of dispersoids in 6082 alloys used in the automotive industry. The role of dispersoids is …