Other Materials Science and Engineering Commons^™

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%), …

Areosense, Josephine Turney

Williams Honors College, Honors Research Projects

The AeroSense growing system is designed to make indoor aeroponic gardening easy and accessible for everyone. By combining sensors, automation, and AI, the system can monitor and adjust humidity, lighting, and nutrient levels to help plants thrive without requiring expert knowledge. The goal is to create a self-regulating garden that takes the guesswork out of growing fresh herbs and vegetables at home. The project involves building a working aeroponic prototype equipped with misters, pumps, and environmental sensors, all managed by a Raspberry Pi. Using computer vision and machine learning, AeroSense will be able to assess plant health and respond automatically …

The Effects Of Shot Peening Highly Loaded Compression Springs, David J. Breuer

15th International Conference on Shot Peening

The compression spring in this test study is typical of one used in a demanding off-road vehicle suspension. The cyclic loads applied during fatigue tests were severe enough to cause failure in approximately 11,000 cycles without shot peening.

The objectives of this study were the following: (1) Design a compression spring similar to those used in the off-road recreational industry. (2) Design & manufacture a fatigue test stand that could withstand high loads for months of testing. (3) Generate a matrix of shot peening treatments to produce different amounts of residual compressive stress. (4) Measure the shot peening residual compressive …

Thermal Modeling Techniques For Additively Manufactured Porous Metals, Lucas D. Rambo

Master's Theses

Advances in additive manufacturing have enabled the creation of metallic components with tailored porosity, offering design flexibility for thermal, structural, and fluid transport applications. This thesis investigates the effective thermal conductivity (ETC) of porous Inconel 625 (IN625) and Inconel-ceramic composites (IN625-RAM2) fabricated by Laser Powder Bed Fusion (LPBF) using Elementum 3D’s PermiAM technology. Experimental measurements of thermal conductivity using the laser flash method are compared to numerical models built from micro-computed tomography data. Simulations were performed using both finite element (FE) and finite volume (FV) methods to evaluate thermal transport in real microstructures. The study investigates the effects of micro- …

Ultrafast Laser Surface Structuring For Wettability Control On Copper, Akshay Arvind Nagvenkar

All Theses

Wettability is a crucial surface property influencing various phenomena, including heat transfer, cell adhesion, and corrosion. Engineering devices can achieve superior performance by precisely manipulating surface wettability. As a result, extensive research has focused on developing surfaces that exhibit either extreme water attraction (superhydrophilic) or strong water repellency (superhydrophobic). Tailoring surface wettability paves the way for numerous applications, such as drag reduction in marine vessels, controlled drug delivery, efficient water collection, advanced liquid transport systems, oil-water separation, anti-corrosion coatings, friction reduction, and self-cleaning materials. Ultrafast laser surface structuring is a promising approach for engineering multifunctional surfaces, effectively modifying material properties …

Development Of Planetary Drive System For Formula Sae Electric Race Car, Brian Wong, Bradley Maruoka, Joshua Charles Fine, Madison Kai

Mechanical Engineering

Hub motors are compact electric motors mounted directly on each outboard wheel hub. Utilized in Formula SAE and Formula Student vehicles, this configuration offers several advantages over traditional drivetrains, including packaging optimization within the chassis, vehicle traction, and improved efficiency. Although hub motors are not yet common in 4WD vehicles, they are being explored for use in EVs and may become more common in the future. Every year, Cal Poly Racing FSAE designs and builds a formula-style race car. To improve drivetrain performance, the team is investigating the achievability of a hub motor 4WD drivetrain, requiring extensive research, development, and …

Effect Of Build Orientation On Tensile Properties And Fractography Of Additive Manufactured Inconel 718 Alloy, Ajay Kumar Maurya, Amit Kumar, Swarnambuj Suman

ASEAN Journal on Science and Technology for Development

The additive manufacturing (AM) technique “Direct Metal Laser Sintering (DMLS)” is used to create 3D objects directly from 3D design data. A lightweight and complexity-free part without any expensive tooling can be fabricated easily using this method, but it is still challenging to achieve the desired mechanical strength from AM parts, as the mechanical properties of AM-produced parts vary with orientation, scan strategy, and process parameters. Inconel 718 alloy is most commonly utilized in the aerospace and automotive industries, because of its high resistance to corrosion and excellent mechanical qualities. This work presents a study to investigate the orientation-based mechanical …

Design And Development Of A Rapid Tensile Quench Rig, Tyler Jewell, Justin Naylor

Williams Honors College, Honors Research Projects

This report outlines the design process and implantation of a tensile quenching rig that incorporated forced convection and a frequency generator. When any metal is quenched, a vapor barrier forms around it. When this happens, it limits the heat flux that may occur until the barrier turns into just nucleate boiling. The vapor barrier acts as an insulator and causes the heat flux to fluctuate, causing uneven hardening which would limit the use of some materials. To combat this effect, we are trying to use forced convection, and something new, which is adding high frequency waves into the quenching process. …

High Energy Density Lithium-Ion Battery Materials., Rachel Dewees

Electronic Theses and Dissertations

Growth of the EV industry has created an increased demand for Li-ion battery electrode materials, and support of a robust lithium-ion battery supply chain is a national imperative. For mainstream acceptance in the American market, the range of EVs must be improved, i.e., the energy density of the battery must be increased. Increasing the specific capacity of the electrode materials is the most direct strategy for increasing the energy density of the battery. Silicon anode materials have a theoretical capacity of over 3700 mAh·g^-1 - an order of magnitude beyond that of the graphitic materials which are currently implemented. …

Predicting The Ductility Of Tungsten Based Bcc Refractory High Entropy Alloys: A Computational Science Driven Study, Akshay Korpe

All Theses

Bcc refractory high entropy alloys (HEAs) are a relatively new category of metallic alloys that promise excellent irradiation resistance and strength retention at high temperatures but exhibit brittle behavior at room temperatures limiting their formability. Understanding the deformation mechanisms and predicting their ductility at room temperature is a topic of interest in contemporary research.

In this work, multiple independent ductility criteria for quantifying the ductility of these HEAs were studied, calculated and compared using Density Functional Theory (DFT) calculations and continuum mechanics frameworks. These ductility parameters were calculated for various W-Ta-Cr-V alloys and the trends were analyzed for each criteria …

On The Structure, Energy, And Segregation Behavior Of Grain Boundaries In Metallic Systems, Yasir Mahmood

All Dissertations

Nearly all structural metallic systems are multi-component polycrystalline aggregates; their microstructures are composed of crystalline grains that are internally joined at grain boundaries (GBs). This thesis focuses on GB structure, energy, and chemistry, as these greatly influence many material properties and processes, including boundary dynamics during processing treatments or under operating conditions.

Using atomistic simulations, we examine the impact of metastable GB structures on solute segregation. A wide range of GB geometries and metastable structures are used in our study. The Al-Mg alloy is used because it is of interest for light weighting. The atomistic simulation results are used to …

A Study On High-Frequency Bending Fatigue, Microhardness, Tensile Strength, And Microstructure Of Parts Made Using Atomic Diffusion Additive Manufacturing (Adam) And Additive Friction Stir Deposition (Afsd), Hamed Ghadimi

LSU Doctoral Dissertations

This dissertation reports the findings of several studies on the mechanical and microstructural properties of parts made using atomic diffusion additive manufacturing (ADAM) and additive friction stir deposition (AFSD). The design of a small-sized bending-fatigue test specimen for an ultrasonic fatigue testing system is reported in Chapter 1. The design was optimized based on the finite element analysis and analytical solution. The stress–life (S–N) curve is obtained for Inconel alloy 718. Chapter 2 presents the findings of ultrasonic bending-fatigue and tensile tests carried out on the ADAM test specimens. The S-N curves were created in the very high-cycle fatigue regime. …

Thermo-Mechanical Instabilities In Next-Generation Friction Materials In High-Speed Sliding Systems, Kingsford Koranteng

Electronic Theses and Dissertations

For centuries, the manufacturing industry has incorporated metals like copper into friction materials to enhance thermal properties and minimize thermo-mechanical instabilities (TMI) in high-speed sliding systems. Unfortunately, these metals have adverse environmental effects due to the emission of hazardous particulate matter. As a result, there is a growing movement towards adopting next-generation friction materials as an alternative solution.

The study begins by conducting experimental and numerical investigations to examine the instabilities found in metal-based friction materials. The primary objective is to utilize the insights gained from the investigations to computationally explore effective strategies for mitigating various instabilities that may arise …

Molecular Dynamics Study Of Characterization In Metal-Free Friction Materials, Yizhan Zhang

Electronic Theses and Dissertations

Metallic friction materials currently used in industry may adversely impact the environment. Substitutions for metals in friction materials, on the other hand, can introduce operational safety issues and other unforeseeable issues such as thermal-mechanical instabilities and insufficient strength. In view of it, this dissertation focuses on developing different kinds of materials from simple structure to complex structure and evaluating the material properties with the assistance of molecular dynamics (MD) tools at the nano scale.

First, the concept of the contacted surfaces in friction at the atomic scale was introduced in order to get accurate understanding of the friction process compared …

Accurate Evaluation Of The Direction-Dependent Mechanical Properties Of Ideal Single Crystals: A Comparative Ab Initio Study, Jaylan Ali Elhalawani

Theses and Dissertations

The mechanical properties of a single crystal or a grain in a polycrystalline material are highly dependent on the direction of the applied load. Key properties of interest are the Young’s modulus and the Poisson ratio in the small strain limit, and the ideal tensile strength in the large strain regime. Prior atomistic computations of these properties interchangeably used two approaches. In one approach the stress-strain response is explicitly calculated via a numerical tensile test experiment. In the second approach the second order single crystal elastic constants are computed via small deformations and then used in analytical equations to derive …

Aerosol Synthesis Of Tungsten Bronze Particles For Nir Shielding, Hao Tu

Theses and Dissertations

This dissertation emphasizes the need for efficient energy use in buildings and transportation due to global warming and the energy crisis. It suggests that improving energy efficiency can help reduce energy consumption and emissions and support sustainability. The dissertation introduces various transparent materials that can block near-infrared (NIR) radiation from solar radiation to save energy and money, and it highlights the growing market value of such products. The dissertation compares tungsten bronze with other NIR shielding materials and shows its advantages. The dissertation introduces a cheap and environmentally friendly method for continuously producing tungsten bronze particles via aerosol synthesis. Particle …

Study Of Nanocomposite Materials Using Molecular Dynamics, Prashik Sunil Gaikwad

Dissertations, Master's Theses and Master's Reports

There is an increase in demand for new lightweight structural materials in the aerospace industry for more efficient and affordable human space travel. Polymer matrix composites (PMCs) with reinforcement material as carbon nanotubes (CNTs) have shown exceptional increase in the mechanical properties. Flattened carbon nanotubes (flCNTs) are a primary component of many carbon nanotube (CNT) yarn and sheet materials, which are promising reinforcements for the next generation of ultra-strong composites for aerospace applications. These flCNT/polymer materials are subjected to extreme pressure and temperature during curing process. Therefore there is a need to investigate the evolution of properties during the curing …

Mechanical Design Of A Microwave Imaging Device For Breast Cancer Detection In Mri Scanners, Grace M. Player

Dartmouth College Master’s Theses

This project seeks to develop an updated version of a microwave imaging device for use in conjunction with breast MRI, improving upon existing technology and developing novel concepts for the device. It posits three primary redesign targets for updating the previous system: resizing the system height, making the device more iteration- friendly, and improving the overall manufacturability of the device by replacing custom components with commercially available alternatives. All three of these redesign targets are met in the new design, V2.0. The height is reduced by reducing antenna travel and height, embedding some components, and shortening the tank wall, resulting …

An Application Of Optimized Bistable Laminates As A Low Velocity, Low Impact Mechanical Deterrent, Graham Lancaster

All Theses

This research considers the problem of using bistable laminates as a mechanical deterrent to the impending impact of a particle. The structure will be controlled through an algorithm that will utilize piezoelectric devices to activate them in unison with the bistable laminate to successfully deter. A novel experimental setup will be constructed to ensure that the bistable laminate stays fixed when acting as a mechanical deterrent. Piezoelectricity is the main driving force of the bistable laminate to morph and this study will use a Macro Fiber Composite (MFC) actuator that contains piezoelectric ceramic rods in a patch to transfer electrical …

Creep Behavior Of A Ti-Based Multi-Principal Element Alloy, Benjamin Elbrecht

All Theses

Abstract

The understanding of microstructural damage mechanisms is the foundation of better understanding existing materials and future material development. There are significant challenges to measuring these damage mechanisms in-situ as continuous observation of the state of the microstructure is difficult or impossible for many experimental setups. This thesis presents a method for measuring grain boundary sliding (GBS) and local strain concentrations in-situ via a Heaviside function based algorithm. GBS is the shearing of two grains along their shared grain boundary and is a common damage mechanism in creep which presents as a discontinuity that can be measured with a Heaviside …

Evaluating The Effects Of Granulated Rubber And Glass Fibers In Polymer Concrete As A Structural Material For Wafer Grinding Machines, Kevin Gabriel Kuehn, Philip Randall Streeter

Materials Engineering

Polymer concrete is a composite material used to replace cast iron and steel in wafer grinding machines for vibration damping. During the grinding and lapping processes of manufacturing silicon wafers, excessive vibrations may cause subsurface damage which requires additional polishing and reduces yield. Nine compositions containing various levels of granulated rubber and glass fibers were manufactured. CRM WRF-10 granulated rubber was examined at 0%, 5%, and 10% and Corning Cem-Fil glass fibers were added at 0%, 0.5%, and 1% by weight. Smooth-On EpoxAcast 690 epoxy resin was held constant at 16% for each composition. Crushed granite aggregate from Martin Marietta, …

Challenges And Signal Processing Of High Strain Rate Mechanical Testing, Barae Lamdini

Theses and Dissertations

Dynamic testing provides valuable insight into the behavior of materials undergoing fast deformation. During Split-Hopkinson Pressure Bar testing, stress waves are measured using strain gauges as voltage variations that are usually very small. Therefore, an amplifier is required to amplify the data and analyze it. One of the few available amplifiers designed for this purpose is provided by Vishay Micro-Measurements which limits the user’s options when it comes to research or industry. Among the challenges of implementing the Hopkinson technology in the industry are the size and cost of the amplifier. In this work, we propose a novel design of …

Enhancing Stability Of High-Nickel Cathodes For Lithium-Ion Batteries Through Additive Manufacturing Of Cathode Structure, Matthew Sullivan

Mechanical Engineering Undergraduate Honors Theses

Lithium-ion batteries (LIBs) are currently the best method to store electrical energy for use in portable electronics and electronic vehicles. New cathode materials for LIBs are consistently studied and researched, but few are as promising and attainable as nickel-rich transition metal oxides such as LiNi1-x-yMnxCoyO2 (NMC). NMC materials exist with many different mass ratios, but higher nickel content materials provide higher energy density. With this increase in capacity comes a sacrifice with cyclability, as high-nickel NMC variants are prone to structure collapse, transition metal dissolution, and cracks due to volume change. In this report, mechanical modification of the electrode by …

Branched Chain Amino Acid Strain State Monitoring With Raman Spectroscopy And Plasmonic Bowtie Nanoantenna Devices For Early Disease Detection, Caroline A. Campbell

Theses and Dissertations

This work centers on the development and the down-selection of nano-manufactured devices to be used in conjunction with Raman spectroscopy for probing a branched chain amino acid. The nano-manufactured devices integrate plasmonic nanoantennas for the purpose of amplifying molecular fingerprints, which are otherwise difficult to detect, through Surface Enhanced Raman Spectroscopy (SERS). Plasmonic nanostructures can be utilized for a variety of biomedical and biochemical applications to detect the characteristic fingerprint provided by Raman Spectroscopy. The nano-manufactured devices create an electric field that amplifies minute perturbations and raises the signal above background noise. This may provide a deeper understanding of signal …

Optimization Of 3d Printed Mold Performance For Injection Molding Via Hollow Infill Patterns, Alan Fong

University Honors Theses

The applicability of hollow infill patterns has been explored for its applications in making 3D printed polymer-based injection molds in the additive manufacturing industry. Hollow infill patterns offer a significant reduction in material costs as well as the opportunity for reducing the cooling times via pumping a coolant fluid through the hollow cavity in a similar fashion to traditional conformal cooling channels. A 3D Jacks Support Hollow mold model was determined to be the best performing design. FEA analysis was conducted to determine the maximum reduction in internal volume (percentage of material saved) that could be achieved without exceeding the …

Jcati Carbon Fiber Recycling Shredder, Benjamin Cooley

All Undergraduate Projects

Once carbon fibers are cast into a resin and used in a composite material, retrieving those fibers can be a difficult task. However, it is beneficial to recycle and reuse the fibers from old unneeded components rather than pay the cost of acquiring new ones. The Joint Center for Aerospace Technology Innovation (JCATI) carbon fiber recycling device condenses the multistep process of extracting the fibers by integrating all steps into one automated device. In the previous version of the device, the cutting blades turned the long composite strips into thin fingers but did not sever them across the width.

The …

Monitoring Of Overhead Polymer Core Composite Conductors Under Excessive Mechanical Loads Using Fiber Bragg Grating Sensors, Daniel H. Waters

Electronic Theses and Dissertations

This combined experimental and numerical study addresses mechanical effects associated with static and dynamic loading of novel High Temperature Low Sag (HTLS) transmission line polymer core composite conductors. The developed methodology was successfully applied to ACCC® to explain the complex failure mechanisms associated with combined bending and tension loading. Furthermore, the use of Fiber Bragg Grating (FBG) sensors was investigated for the first time to monitor the ACCC® design during installation and in-service.

Transverse low-velocity impacts to the ACCC® conductor having either free or constrained end conditions and large axial tensile loads were performed. It was identified that the most …

Impact Dynamics Of Surfactant-Laden Droplets On Non-Wettable Coatings, Amir Esmaeili

Theses and Dissertations

Owing to their excellent water repellency, non-wettable (superhydrophobic) coatings have gained tremendous attention in the past couple of decades. Alkyl ketene dimer (AKD), an inexpensive polymer frequently used in paper industry as a sizing agent, has shown potentials to become superhydrophobic. The formation of a porous structure after curing the solidified AKD for an extra-long time (4–6 days) results in superhydrophobicity, i.e., a static contact angle with water of >150° and a roll-off angle of <10°. In this work, a facile and low-cost method was used to turn the surface of AKD superhydrophobic in a very short period of time by briefly treating the coatings, obtained from isothermally heated molten AKD at 40 °C for 3 min, with ethanol. The resulting superhydrophobicity is due to the formation of porous, entangled irregular micro/nano textures that create air cushions on the surface leading to droplet state transition from Wenzel to Cassie. As a proof of concept, the same material was applied to the co-sputtered nickel-tungsten thin films, commonly used in micro/nano-electro-mechanical systems, to improve their hydrophobicity. According to the results, at least 20% increase was observed in the dynamic contact angles of the treated substrates.

In addition, this work presents a detailed high-speed imaging analysis of the influence of the molecular weight, concentration and ionic nature of surfactants on droplet …

Development Of Synthetic Coal Char Simulant For Microwave Conversion Studies: A Computationally-Driven Approach, Kevin A. Hager

Graduate Theses, Dissertations, and Problem Reports (ETD)

Recent experimental demonstration of new reaction windows for coal char/methane reactions that are less energy-intensive, provides innovation for modular reactors. However, the correlation of the exact mechanism for the enhancement of these reaction windows is not certain. This study investigates the simplification of these experimental studies by developing a well-characterized coal char simulant. The approach involves using a computational approach to screen macroscopic composition to replicate the dielectric and compositional response of actual char. This study is focused on PRB coal char. A discrete element method (DEM) technique was used to simulate the packing of coal chars to give the …

The Critical Role Of Dynamic Surface Tension Of Surfactants On The Impact Dynamics Of Water Droplets, Amir Esmaeili, Reza Mohammadi

Graduate Research Posters

Due to their time-dependent surface tension, the addition of surface-active agents or surfactants to water for specific applications has made controlling the impact dynamics of these droplets a complex phenomenon. This work investigates the influence of the molecular weight, concentration, and ionic nature of the surfactants as well as the substrate surface characteristics on the impact dynamics of surfactant-laden droplets using a high-speed camera at 10000 frames per second. Sodium dodecyl sulfate, hexadecyltrimethylammonium bromide, and n-decanoyl-n-methylglucamine were used as anionic, cationic, and nonionic surfactants, respectively. We used hydrophilic glass slides, hydrophobic polytetrafluoroethylene, and superhydrophobic alkyl ketene dimer (AKD) as substrates. …