Mechanical Engineering Commons^™

Development Of In-Situ Radiometric Inspection Methods For Quality Assurance In Laser Powder Bed Fusion, Cody S. Lough

Doctoral Dissertations

“Laser Powder Bed Fusion (LPBF) metal Additive Manufacturing (AM) fabricates 3D metal parts layer-by-layer. The process enables production of geometrically complex parts that are difficult to inspect with traditional methods. The LPBF parts experience significant geometry driven thermal variations during manufacturing. This creates microstructure and mechanical property inhomogeneities and can stochastically cause defects. Mission critical applications require part qualification by measuring the defects non-destructively. The layer-to-layer nature of LPBF permits non-intrusive measurement of radiometric signals for a part’s entire volume. These measurements provide thermal features that correlate with the local part health. This research establishes Optical Emission Spectroscopy (OES) and …

Additively Manufactured Metallic Cellular Structures, Okanmisope Aziel Fashanu

Doctoral Dissertations

"Cellular structures are lightweight structures with excellent mechanical, thermal, and acoustic properties. They offer promise in a series of applications, including lightweight applications, sandwich cores, mechanical damping, acoustic absorption, strain isolation, and thermal management. The manufacturing of these complex cellular structures is expensive and time-consuming, which hinders the adoption of these structures in many industries. Advancement in manufacturing technologies, such as additive manufacturing (AM), however, have changed this. AM allows for the rapid and less expensive manufacturing of complex cellular structures. This work aimed to investigate the performance of additively manufactured cellular structures for lightweight and sandwich core applications. In …

Advanced Battery Modeling For Interfacial Phenomena And Optimal Charging, Yaqi Zhu

Doctoral Dissertations

"Lithium-ion batteries are one of the most promising energy storage systems for portable devices, transportation, and renewable grids. To meet the increasing requirements of these applications, higher energy density and areal capacity, long cycle life, fast charging rate and enhanced safety for lithium-ion battery (LIBs) are urgently needed. To solve these challenges, the relevant physics at different length scale need to be understood. However, experimental study is time consuming and limited in small scale’s study. Modeling techniques provide us powerful tools to get a deep understanding of the relevant physics and find optimal solutions. This work focuses on studying the …

Prediction Of Battery Health Dynamics, Damola Martins Ajiboye

Doctoral Dissertations

"The successful market penetration of lithium-ion batteries in the last 30 years has ushered in a new dawn in energy applications. Notwithstanding their widespread use, lithium-ion batteries are affected by a plethora of fundamental issues — safety, cycle life, performance, and cost. In this work, advanced modeling techniques are developed to tackle some of these issues. This dissertation is subdivided into four parts, the first is introduction while the remaining are dedicated to the development of computational techniques for predicting battery health dynamics.

In the second part of this work, we developed fast and accurate algorithms for modeling essential battery …

Sources Of Quality Uncertainty In Laser Powder Bed Fusion Metal Additive Manufacturing, Zachary Young

Doctoral Dissertations

"Powder based additive manufacturing (AM) exhibits tremendous uncertainties, where variations in build quality is present despite utilizing similar build processing parameters. First, this work reports the features and formation mechanisms of five unique types of spatter during the LPBF process by in-situ high-speed, high-energy x-ray imaging. The unique physical characteristics of spatter are determined. The effect of laser scan speed and laser power on spatter formation, ejection, and mitigation are determined. Second, this work addresses the uncertainty challenge by identifying the sources of uncertainty in SLM by in-situ characterization due to variations from the additive manufacturing processing parameters needed for …

Novel Piezo Actuators For Surface Cleaning, Yezad H. Anklesaria

Doctoral Dissertations

"Optical cameras are becoming increasingly common and are used in a variety of applications. With recent progress and transition toward more autonomous systems, the usage of optical systems will be common and widespread. Applications of the optical systems range from autonomous vehicles, home security systems, aviation, extraterrestrial vehicles, spacecraft, and satellites. Imaging systems are used in decision-making in many of these applications. Fouling of the field of view of the imaging system can impede the decision process. An active autonomous cleaning method for the optical surface of the optical systems reliably would be advantageous. The research work focuses on developing …

In-Plane Anisotropic Third-Harmonic Generation From Germanium Arsenide Thin Flakes, Huseyin Sar, Jie Gao, Xiaodong Yang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A newly introduced two-dimensional (2D) layered germanium arsenide (GeAs) has attracted growing interest due to its promising highly in-plane anisotropic crystal structure and electronic properties for photonic and optoelectronic applications. The potential of 2D layered GeAs for many applications such as anisotropic photodetection, electronics, superconductivity and thermoelectricity is being investigated in recent studies. However, the intrinsic nonlinear optical properties of 2D layered GeAs have not been explored yet. Here, thickness- and incident polarization-dependent in-plane anisotropic third-harmonic generation (THG) from the mechanically exfoliated thin GeAs flakes is reported. Furthermore, the effect of the flake thickness on the THG conversion efficiency is …

Modular Framework For Implementation And Analysis Of Recursive Filters With Considered And Neglected Parameters, Kyle J. Demars, Kari C. Ward

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper develops novel covariance and square-root factor formulations of a consider-neglect Kalman filter for navigation applications. The proposed filter partitions system parameters into three distinct categories: those to be estimated by the filter, those whose contribution to the system are considered without being explicitly estimated, and those with sufficiently low effect on the system such that their contribution can be neglected altogether. Discussion on appropriate selection of parameters to be considered and neglected is provided with specific attention given to descent-to-landing navigation. Monte Carlo simulations and analysis are performed to assess the performance of the developed square-root consider-neglect filter …

Additive Manufacturing-Enabled Design, Manufacturing, And Lifecycle Performance, Tao Peng, Yi Zhu, Ming Leu, David Bourell

Mechanical and Aerospace Engineering Faculty Research & Creative Works

No abstract provided.

Vibration Analysis Of Simultaneous Drilling And Reaming Bha, Mohammed F. Al Dushaishi, Daniel S. Stutts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The drillstring used in the oil and gas exploration is a complex structure due to the different forces acting on it. One of the primary sources of drillstring vibrations is the cutting forces caused by the drill bit contact with the rock formation. In some drilling applications, such as hole enlargement and underreaming, the source of the cutting action originates from the drill bit as well as the reamer which increases the dynamic complexity of the drillstring. This paper’s objective is to investigate the torsional vibration behaviors of the bottom hole assembly (BHA) under simultaneous drilling and reaming. More specifically, …

Coalescence Speed Of Two Equal-Sized Nanobubbles, Eric Bird, Jun Zhou, Zhi Liang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In This Work, We Use Molecular Dynamics (MD) Simulations Coupled with Continuum-Based Theoretical Analysis to Study the Coalescence Dynamics of Two Equal-Sized Nanobubbles (NBs). We First Derive a Governing Equation for the Evolution of the Capillary Bridge Radius between Two Coalescing NBs from the Axisymmetric Navier-Stokes Equation. to Verify the Prediction from the Governing Equation, We Carry Out MD Simulations of the Coalescence of Two NBs in a Lennard-Jones Fluid System and Directly Measure the Bridge Radius, Rb, as a Function of Time, T. by Varying the Bubble Diameter, We Change the NB Ohnesorge Number from 0.46 to 0.33. in …

Explosive Compaction Of Additively Manufactured Material, Phillip R. Mulligan, Cody Lough, Douglas A. Bristow, Edward Kinzel, Catherine E. Johnson

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective Laser Melting (SLM) is an additive manufacturing (AM) technique that uses a laser to locally fuse material in a metal-powder bed. The process is performed in layers enabling significant geometric freedom over traditional manufacturing techniques. During the deposition process, the metal is locally melted and rapidly self-quenched, leading to rapid solidification with well-defined melt-pool boundaries. Analogies are often drawn to the microstructure created in welding, albeit extending to the entire part. The SLM process parameters are optimized to produce near full density metal parts. The process parameters can also be adjusted to produce local regions that are of unmelted …

Direct 3d Printing Of Silica Doped Transparent Magnesium Aluminate Spinel Ceramics, John M. Pappas, Xiangyang Dong

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Transparent magnesium aluminate spinel ceramics were additively manufactured via a laser direct deposition method in this study. With a minimum porosity of 0.3% achieved, highly transparent spinel samples with the highest total optical transmittance of 82% at a wavelength of 632.8 nm, were obtained by a 3D printing approach. However, cracking was found to be a major issue affecting printed spinel samples. To control prevalent cracking, the effect of silica dopants was investigated. Increased silica dopants reduced average total crack length by up to 79% and average crack density by up to 71%. However, a high dopant level limited optical …

Maximum Evaporating Flux Of Molecular Fluids From A Planar Liquid Surface, Eric Bird, Zhi Liang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In This Work, We Use the Kinetic Theory of Gases (KTG) to Develop a Theoretical Model to Understand the Role of Internal Motions of Molecules on the Maximum Evaporation Flux from a Planar Liquid Surface. the Kinetic Theory is Applied to Study the Evaporation of Molecular Fluids into a Vacuum and Predict the Dimensionless Maximum Evaporation Flux (JR,max, I.e., the Ratio of the Maximum Evaporation Flux to the Molar Flux Emitted from a Liquid Surface). the Key Assumptions Regarding the Velocity Distribution Function (VDF) of Polyatomic Molecules in the Highly Nonequilibrium Vapor Near the Evaporating Surface Are Validated by the …

Review Of Multimode Space Propulsion, Joshua L. Rovey, Christopher T. Lyne, Alex J. Mundahl, Nicolas Rasmont, Matthew S. Glascock, Mitchell J. Wainwright, Steven P. Berg

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Multimode propulsion is the integration of two or more propulsive modes with shared propellant into a single spacecraft propulsion system. Multimode propulsion is emerging as an enabling technology that promises enhanced capabilities for spacecraft and space missions and can therefore play an important role in the future of in-space propulsion. Multimode propulsion has the potential to provide unprecedented flexibility and adaptability to spacecraft as a direct result of shared propellant and can provide mass savings for certain missions. These benefits can apply regardless of spacecraft size. Additional mass savings may be realized by sharing thruster hardware between modes, especially for …

Asymmetric Semiconductor Nanostructures For Particle Manipulation, Jaykob Maser, Joshua Rovey

Mechanical and Aerospace Engineering Faculty Research & Creative Works

We explore how material selection affects the electromagnetic response of closely positioned asymmetric nanostructures. COMSOL Multiphysics is used to model the system, and the materials studied include gold (Au), gallium arsenide (GaAs), indium tin oxide (ITO), and aluminum zinc oxide (AZO). All materials produce average electric field magnitudes on the order of 10 MV/m. We conclude that the ITO and AZO nanostructures produce the most uniform electric field response over the entire domain of incident wavelengths and that GaAs is least thermally stable in a vacuum environment due to its low heat conductivity.

Laser Metal Deposition Of An Alcocrfeniti₀.₅ High-Entropy Alloy Coating On A Ti6al4v Substrate: Microstructure And Oxidation Behavior, Wenyuan Cui, Wei Li, Wei Ting Chen, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Ti6Al4V has been recognized as an attractive material, due to its combination of low density and favorable mechanical properties. However, its insufficient oxidation resistance has limited the high-temperature application. In this work, an AlCoCrFeNiTi_0.5 high-entropy alloy (HEA) coating was fabricated on a Ti6Al4V substrate using laser metal deposition (LMD). The microstructure and isothermal oxidation behaviors were investigated. The microstructure of as-deposited HEA exhibited a Fe, Cr-rich A2 phase and an Al, Ni, Ti-enriched B2 phase. Its hardness was approximately 2.1 times higher than that of the substrate. The oxidation testing at 700⁰C and 800⁰C suggested that the HEA coating …

A Review On Metallic Alloys Fabrication Using Elemental Powder Blends By Laser Powder Directed Energy Deposition Process, Yitao Chen, Xinchang Zhang, Mohammad Masud Parvez, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The laser powder directed energy deposition process is a metal additive manufacturing technique, which can fabricate metal parts with high geometric and material flexibility. The unique feature of in-situ powder feeding makes it possible to customize the elemental composition using elemental powder mixture during the fabrication process. Thus, it can be potentially applied to synthesize industrial alloys with low cost, modify alloys with different powder mixtures, and design novel alloys with location-dependent properties using elemental powder blends as feedstocks. This paper provides an overview of using a laser powder directed energy deposition method to fabricate various types of alloys by …

Lateral Migration Of A Ferrofluid Droplet In A Plane Poiseuille Flow Under Uniform Magnetic Fields, Md Rifat Hassan, Cheng Wang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The lateral migration of a two-dimensional (2D) viscous ferrofluid droplet in a plane Poiseuille flow under a uniform magnetic field is studied numerically by using the level set method. Focusing on low droplet Reynolds number flows (Re_d ≤ 0.05), several numerical simulations are carried out to analyze the effects of magnetic field direction and strength, droplet size, and viscosity ratio on the lateral migration behavior of the droplet. The results indicate that the magnetic field direction plays a pivotal role in the trajectory of lateral migration of the droplet and the final equilibrium position in the channel. When the …

Plasmon-Phonon Coupling Between Mid-Infrared Chiral Metasurfaces And Molecular Vibrations, Md Shamim Mahmud, Daniel Rosenmann, David A. Czaplewski, Jie Gao, Xiaodong Yang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Plasmon-phonon coupling between metamaterials and molecular vibrations provides a new path for studying mid-infrared light-matter interactions and molecular detection. So far, the coupling between the plasmonic resonances of metamaterials and the phonon vibrational modes of molecules has been realized under linearly polarized light. Here, mid-infrared chiral plasmonic metasurfaces with high circular dichroism (CD) in absorption over 0.65 in the frequency range of 50 to 60 THz are demonstrated to strongly interact with the phonon vibrational resonance of polymethyl methacrylate (PMMA) molecules at 52 THz, under both left-handed and right-handed circularly polarized (LCP and RCP) light. The mode splitting features in …

Determination Of Effective Parameters Of Fishnet Metamaterials With Vortex Based Interferometry, Wei Cao, Jie Gao, Xiaodong Yang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Metamaterials are artificially engineered structures that have unique properties not usually found in natural materials, such as negative refractive index. Conventional interferometry or ellipsometry is generally used for characterizing the optical properties of metamaterials. Here, we report an alternative optical vortex based interferometric approach for the characterization of the effective parameters of optical metamaterials by directly measuring the transmission and reflection phase shifts from metamaterials according to the rotation of vortex spiral interference pattern. The fishnet metamaterials possessing positive, zero and negative refractive indices are characterized with the vortex based interferometry to precisely determine the complex values of effective permittivity, …

Distributed Adaptive State Estimation And Tracking Scheme For Nonlinear Systems Using Active Passive Sensor Networks, Akhilesh Raj, S. Jagannathan, Tansel Yucelen

Electrical and Computer Engineering Faculty Research & Creative Works

This paper proposes a novel adaptive neural network (NN) based distributed state estimation scheme for a heterogeneous sensor network (HSN), to estimate the state vector of an unknown nonlinear process/target by using sensed output when the target input remains unknown. The active nodes in the HSN can sense the target output based on the detection range. By using a connected graph, the active nodes will communicate their estimated state vector from their adaptive NN observer to other passive nodes in the neighborhood that cannot sense the target, so that they can estimate the target state vector. Next, a subset of …

Effects Of Zirconia Doping On Additively Manufactured Alumina Ceramics By Laser Direct Deposition, John M. Pappas, Aditya R. Thakur, Xiangyang Dong

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The ability to additively manufacture functional alumina ceramics has the potential to lower manufacturing costs and development time for complex components. In this study, the doping effects of zirconia on laser direct deposited alumina ceramics were investigated. The microstructure of the printed samples was analyzed in terms of grain size and composition distribution. The addition of zirconia was found to accumulate along alumina grain boundaries and resulted in significant grain refinement. The zirconia doping largely reduced crack formation during processing compared to that of pure alumina samples. In the case of 10 wt% zirconia, cracking during deposition was nearly completely …

Impulse And Performance Measurements Of Electric Solid Propellant In A Laboratory Electrothermal Ablation-Fed Pulsed Plasma Thruster, Matthew S. Glascock, Joshua L. Rovey, Kurt A. Polzin

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Electric solid propellants are advanced solid chemical rocket propellants that can be controlled (ignited, throttled and extinguished) through the application and removal of an electric current. This behavior may enable the propellant to be used in multimode propulsion systems utilizing the ablative pulsed plasma thruster. The performance of an electric solid propellant operating in an electrothermal ablation-fed pulsed plasma thruster was investigated using an inverted pendulum micro-newton thrust stand. The impulse bit and specific impulse of the device using the electric solid propellant were measured for short-duration test runs of 100 pulses and longer-duration runs to end-of-life, at energy levels …

Numerical Study On The Temperature-Dependent Viscosity Effect On The Strand Shape In Extrusion-Based Additive Manufacturing, Behrouz Behdani, Matthew Senter, Leah Mason, Ming-Chuan Leu, Joontaek Park

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A numerical model that incorporates temperature-dependent non-Newtonian viscosity was developed to simulate the extrusion process in extrusion-based additive manufacturing. Agreement with the experimental data was achieved by simulating a polylactic acid melt flow as a non-isothermal power law fluid using experimentally fitted parameters for polylactic acid. The model was used to investigate the temperature effect on the flow behavior, the cross-sectional area, and the uniformity of the extruded strand. OpenFOAM, an open source simulation tool based on the finite volume method, was used to perform the simulations. A computational module for solving the equations of non-isothermal multiphase flows was also …

Thermal Transport Across The Interface Between Liquid N-Dodecane And Its Own Vapor: A Molecular Dynamics Study, Eric Bird, Jesus Gutierrez Plascencia, Zhi Liang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

There Are Two Possible Thermal Transport Mechanisms at Liquid-Gas Interfaces, Namely, Evaporation/condensation (I.e., Heat Transfer by Liquid-Vapor Phase Change at Liquid Surfaces) and Heat Conduction (I.e., Heat Exchange by Collisions between Gas Molecules and Liquid Surfaces). using Molecular Dynamics (MD) Simulations, We Study Thermal Transport Across the Liquid-Vapor Interface of a Model N-Dodecane (C12H26) under Various Driving Force Conditions. in Each MD Simulation, We Restrict the Thermal Energy to Be Transferred Across the Liquid-Vapor Interface by Only One Mechanism. in Spite of the Complex Intramolecular Interactions in N-Dodecane Molecules, Our Modeling Results Indicate that the Schrage Relationships, Which Were Shown …

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 …

3d-Printed Biomimetic Bioactive Glass Scaffolds For Bone Regeneration In Rat Calvarial Defects, Krishna C. R. Kolan, Yue-Wern Huang, Julie A. Semon, Ming-Chuan Leu

Biological Sciences Faculty Research & Creative Works

The pore geometry of scaffold intended for the use in the bone repair or replacement is one of the most important parameters in bone tissue engineering. It affects not only the mechanical properties of the scaffold but also the amount of bone regeneration after implantation. Scaffolds with five different architectures (cubic, spherical, x, gyroid, and diamond) at different porosities were fabricated with bioactive borate glass using the selective laser sintering (SLS) process. The compressive strength of scaffolds with porosities ranging from 60% to 30% varied from 1.7 to 15.5 MPa. The scaffold's compressive strength decreased significantly (up to 90%) after …

Fast Reversible Phase Change Silicon For Visible Active Photonics, Letian Wang, Matthew Eliceiri, Yang Deng, Yoonsoo Rho, Wan Shou, Heng Pan, Jie Yao, Costas P. Grigoropoulos

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Both amorphous and crystalline silicon are ubiquitous materials for electronics, photonics, and microelectromechanical systems. On-demand control of Si crystallinity is crucial for device manufacturing and to overcome the limitations of current phase-change materials (PCM) in active photonics. Fast reversible phase transformation in silicon, however, has never been accomplished due to the notorious challenge of amorphization. It is demonstrated that nanostructured Si can function as a PCM, since it can be reversibly crystallized and amorphized under nanosecond laser irradiation with different pulse energies. Reflection probing on a single nano disk's phase transformations confirms the distinct mechanisms for crystallization and amorphization. The …

A Molecular Dynamics Study Of Transient Evaporation And Condensation, Zhi Liang, Anirban Chandra, Eric Bird, Pawel Keblinski

Mechanical and Aerospace Engineering Faculty Research & Creative Works

We Use Molecular Dynamics (MD) Simulations to Study the Transient Evaporation and Condensation of a Pure Fluid Ar in a Nanochannel. in the MD Model, the Evaporation and Condensation of Fluid Ar is Initiated by a Sudden Increase of the Temperature or Periodically Varying the Temperature in the Solid Substrate on One Side of the Nanochannel. in Both Cases, We Find the Transient Evaporation and Condensation Rates Obtained Directly from MD Simulations Are in Good Agreement with the Predictions from the Schrage Relationships. Furthermore, Our Analyses Show that the Kinetics of the Transient Heat and Mass Transfer between the Evaporating …