Mechanical Engineering Commons^™

Research On Additive Manufacturing Of Metallic Glass Alloy, Yiyu Shen

Doctoral Dissertations

"The required rapid cooling has limited the dimension of the Bulk Metallic glasses (BMGs) produced by traditional method, and hence has seriously limited their applications, despite their remarkable mechanical properties. In this present project, a detailed study is conducted on the methodology and understanding of manufacturing large Zr- based metallic glass part by laser based additive manufacturing technology, which breaks the size limitation. The first research issue proposes and develops a new additive manufacturing technology, named Laser-Foil-Printing (LFP). Sheet foils of LM105 (Zr_52.5Ti₅Al₁₀Ni_14.6Cu_17.9 (at. %)) metallic glass are used as feed …

Investigation Of Microstructure And Mechanical Properties By Direct Metal Deposition, Jingwei Zhang

Doctoral Dissertations

"Microstructure and properties of Direct Metal Deposition (DMD) parts are very crucial to meeting industrial requirements of parts quality. Prediction, and control of microstructure and mechanical properties have attracted much attention during conventional metal manufacturing process under different conditions. However, there is few investigations focused on microstructure simulation and mechanical properties control under different process parameters during DMD process. This dissertation is intended to develop a multiscale model to investigate Ti6Al4V grain structure development and explore Ti6Al4V based functionally graded material (FGM) deposit properties during DMD process. The first research topic is to investigate and develop a cellular automaton-finite element …

Monitoring Of Hybrid Manufacturing Using Acoustic Emission Sensor, Haythem Gaja

Doctoral Dissertations

"The approach of hybrid manufacturing addressed in this research uses two manufacturing processes, one process builds a metal part using laser metal deposition, and the other process finishes the part using a milling machining. The ability to produce complete functioning parts in a short time with minimal cost and energy consumption has made hybrid manufacturing popular in many industries for parts repair and rapid prototyping. Monitoring of hybrid manufacturing processes has become popular because it increases the quality and accuracy of the parts produced and reduces both costs and production time. The goal of this work is to monitor the …

Development And Management Of Advanced Batteries Via Additive Manufacturing And Modeling, Jie Li

Doctoral Dissertations

"The applications of Li-ion batteries require higher energy and power densities, improved safety, and sophisticated battery management systems. To satisfy these demands, as battery performances depend on the network of constituent materials, it is necessary to optimize the electrode structure. Simultaneously, the states of the battery have to be accurately estimated and controlled to maintain a durable condition of the battery system. For those purposes, this research focused on the innovation of 3D electrode via additive manufacturing, and the development of fast and accurate physical based models to predict the battery status for control purposes. Paper I proposed a novel …

Modeling And Experimental Investigations On Particle Dynamic Behaviors In Laser 3d Printing With Blown Powder, Wei Li

Doctoral Dissertations

"Pre-mixed powder is frequently-used powder supply to fabricate Functional Gradient Material (FGM) by Laser 3D printing, which is also called Laser Metal Deposition (LMD). The deposited FGM composition is expected to be similar or same as supplied powder mixture. However, because pre-mixed powder has different particle densities and particle sizes, the caused particle acceleration differences can result in the separation in powder mixture. Up to now, there was no study focused on pre-mixed powders' flow behavior in LMD. The current research aims to investigate the flow behaviors of pre-mixed powder supplied for LMD through both experimental and modeling approaches. In …

High Temperature Polymer Composites Using Out-Of-Autoclave Processing, Sudharshan Anandan

Doctoral Dissertations

"High performance polymer composites possess high strength-to-weight ratio, corrosion resistance, and have design flexibility. Carbon/epoxy composites are commonly used aerospace materials. Bismaleimide based composites are used as a replacement for epoxy systems at higher service temperatures. Aerospace composites are usually manufactured, under high pressure, in an autoclave which requires high capital investments and operating costs. In contrast, out-of-autoclave manufacturing, specifically vacuum-bag-only prepreg process, is capable of producing low cost and high performance composites. In the current study, out-of-autoclave processing of high temperature carbon/bismaleimide composites was evaluated. The cure and process parameters were optimized. The properties of out-of-autoclave cured laminates compared …

Modeling And Characterization Of Thermo-Oxidative Behavior Of Bismaleimide Composites, Rafid Muhammad Hussein

Doctoral Dissertations

"High-temperature polymer matrix composites (HTPMCs) are susceptible to thermo-oxidation, which accelerates the composites' degradation and reduces the service life. Mechanical properties of HTPMCs deteriorate due to coupled thermo-oxidation and cross-linking mechanisms. Bismaleimides (BMIs) are commonly used high-temperature resins for aerospace applications. This work presents the viability of using experimental weight loss to model the spatial distribution of oxidation when the oxidized polymer matrix is not discernible. Three tasks are introduced: (1) Anisotropic oxidation prediction using optimized weight loss behavior of bismaleimide composites, (2) A multi-scale modeling of thermo-oxidative effects on the flexural behavior of cross-ply bismaleimide composites, and (3) Thermo-oxidative …

Modeling And Simulation Of Viscoplasticity, Recrystallization, And Softening Of Alloyed Steel During Hot Rolling Process, Xin Wang

Doctoral Dissertations

"Hot rolling is one of the most important and complex deformation processes in steel manufacturing and is essential to final product quality. The objective of this study is to investigate viscoplasticity, dynamic recrystallization, and static softening of alloyed metal during hot rolling process. Gleeble hot compression tests were performed to provide experimental stress-strain curves at different temperatures and strain rates. An inverse finite element analysis was performed to calibrate the experimental curves. Viscoplastic models including a Johnson-Cook (JC) model, a Zerilli-Armstrong (ZA) model, and a combined JC and ZA model were developed. Dynamic recrystallization behavior was investigated and modeled based …

Modeling And Control Of Probe-On-Probe Dynamics In Dual-Probe Atomic Force Microscopy, Ayad Al-Ogaidi

Doctoral Dissertations

“The atomic force microscope (AFM) is a widely used instrument for imaging and direct manipulation of materials and particles at the nanoscale. The AFM uses a probe, which is a microcantilever with a sharp point at the end. Typically, the AFM is constructed with a single probe. The disadvantage of this construction is that it can only be used either for imaging or manipulation in one implementation. An AFM was constructed using two probes, permitting simultaneous imaging and manipulation. A dual-probe AFM (DP-AFM) provides a foundation for feedback controlled manipulation.

Paper I investigates probe-on-probe contact stability and examines the dynamics …

Design For Optical Metamaterial Design For Optical Metamaterial Absorber, Huixu Deng

Doctoral Dissertations

“Optical metamaterlal (MM) absorbers in the visible or near-infrared range have been widely investigated in these years since they are crucial in many promising applications, such as solar energy harvesting systems, thermo-photovoltaic energy conversion devices, thermal imaging and emissivity control. This dissertation aims to design and investigate various optical metamaterial absorbers based on different mechanisms and theories, such as cavity resonance, impedance match, equivalent circuit model and waveguide stop light mode. First, via utilizing the cavity resonance, a tunable narrowband MM absorber/emitter for thermophotovoltaic (TPV) is designed and analyzed based on gold nanowire cavities to improve the overall efficiency of …

Quantitative Phase-Field Modeling Of Crack Propagation In Multi-Phase Materials, Arezoo Emdadi

Doctoral Dissertations

”Research presented in this dissertation is focused on developing and validating a computational framework for study of crack propagation in polycrystalline composite ceramics capable of designing micro-architectures of phases to improve fracture toughness and damage tolerance of ZrB₂-based ultra-high temperature ceramics (UHTCs). A quantitative phase-field model based on the regularized formulation of Griffith’s theory is presented for crack propagation in homogenous and heterogeneous brittle materials. This model utilizes correction parameters in the total free energy functional and mechanical equilibrium equation within the crack diffusive area to ensure that the maximum stress in front of the crack tip is …

Effects Of Milling Methods, Cooling Strategies And End-Mill Coatings On Machinability In High Speed End-Milling Of Inconel- 718 Using Carbide End-Mills, Paras Mohan Jasra

Doctoral Dissertations

“Inconel-718 superalloy is used extensively in aerospace and nuclear industries due to its excellent properties such as: high strength-to-weight ratio, ability to retain its properties at high temperature, high corrosion and creep resistance. However, Inconel-718 is characterized as a “difficult-to-cut metal”, because it poses severe problems during machining such as: high temperature at the cutting zone due to low thermal conductivity, hardening tendency at elevated temperature, high cutting forces, rapid tool wear and high chemical affinity with many cutting tools. Appropriate cooling strategies, milling methods, tool coatings and cutting speeds play important roles in addressing these problems. This research presents …

Direct Printing Of Single-Crystal Silicon By Microscale Nanoparticle Printing And Confined Laser Melting And Crystallization, Wan Shou

Doctoral Dissertations

"The transport and interfacial phenomena in laser melting and crystallization of silicon in micro-/nano-scale confinement lacks sufficient understanding. Uncovering the underlying mechanisms, and hence harness the melting and crystallization processes can help the formation of controllable single-crystal structures or patterns. In this dissertation, a molecular dynamics (MD) simulation was conducted to calculate the interfacial free energy of the silicon system in contact with flat and structured walls. Then the calculated interfacial energies were employed to predict the nucleation mechanisms in a slab of liquid silicon confined by two walls and compared with MD simulation results. Further, in combination with a …

Design, Modeling, Fabrication, And Testing Of A Multistage Micro Gas Compressor With Piezoelectric Unimorph Diaphragm And Passive Microvalves For Microcooling Applications, Shawn Thanhson Le

Doctoral Dissertations

This dissertation investigates the development of a multistage micro gas compressor utilizing multiple pump stages cascaded in series to increase the pressure rise with passive microvalves and piezoelectric unimorph diaphragms. This research was conducted through modeling, simulation, design, and fabrication of the microcompressor and its components. A single-stage and a two-stage microcompressor were developed to demonstrate and compare the performance and effectiveness of using a cascaded multistage design.

Steady fluid flow through static microvalves structure was studied to gain insight on its gas flow dynamics and characteristics. Transient analysis combined with the structure's interaction was investigated with an analytical model …

Processing, Microstructure, And Mechanical Properties Of Zirconium Diboride-Molybdenum Disilicide Ceramics And Dual Composite Architectures, Ryan Joseph Grohsmeyer

Doctoral Dissertations

"This research had two objectives: characterization of processing-microstructure-mechanical property relationships of conventional ZrB₂-MoSi₂ ceramics at room temperature (RT) and 1500⁰C in air, and fabrication of ZrB₂-MoSi₂ dual composite architectures (DCAs) for use near 1500⁰C. Elastic moduli, fracture toughness, and flexure strength were measured at RT and 1500⁰C for 15 ZrB₂-MoSi₂ ceramics hot pressed using fine, medium, or coarse ZrB₂ starting powder with 5-70 vol.% MoSi₂, referred to as FX, MX, and CX respectively where X is the nominal MoSi₂ content. MoSi₂ decomposed during sintering, resulting in …

Additive Manufacturing Of Glass Using A Filament Fed Process, Junjie Luo

Doctoral Dissertations

"There are many scientific and engineering applications of glass including optics, communications, electronics, and hermetic seals, there has been minimal research towards the Additive Manufacturing (AM) of transparent glass parts. The special thermal and optical properties of glasses make them hard to be printed using conventional AM techniques. In this dissertation, two different AM techniques for glass AM were developed, Selective Laser Melting (SLM) and filament fed process.

Semi-transparent parts were printed with SLM process. However, the filament fed process was found to be more robust and promising for printing optically transparent glass parts. Therefore, this dissertation is focused on …

Reliability Prediction In Early Design Stages, Yao Cheng

Doctoral Dissertations

"In the past, reliability is usually quantified with sufficient information available. This is not only time-consuming and cost-expensive, but also too late for occurred failures and losses. For solving this problem, the objective of this dissertation is to predict product reliability in early design stages with limited information. The current research of early reliability prediction is far from mature. Inspired by methodologies for the detail design stage, this research uses statistics-based and physics-based methodologies by providing general models with quantitative results, which could help design for reliability and decision making during the early design stage. New methodologies which accommodate component …

Optimal Design And Freeform Extrusion Fabrication Of Functionally Gradient Smart Parts, Amir Ghazanfari

Doctoral Dissertations

"An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical density was developed. In this process, an aqueous paste of ceramic particles with a very low binder content (<1 vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Sample parts made of alumina and fully stabilized zirconia were produced using this process and their mechanical properties including density, strength, Young's modulus, Weibull modulus, toughness, and hardness were examined. Microstructural evaluation was also performed to measure the grain size, and critical flaw sizes were obtained. The results indicate that the proposed method enables fabrication of geometrically complex parts with superior mechanical properties. Furthermore, several methods were developed to increase the productivity of the CODE process and enable manufacturing of functionally graded materials with an optimum distribution of material composition. As an application of the CODE process, advanced ceramic components with embedded sapphire optical fiber sensors were fabricated and properties of parts and sensors were evaluated using standard test methods"--Abstract, page iv.

Thermomechanical Fatigue Life Investigation Of An Ultra-Large Mining Dump Truck Tire, Wedam Nyaaba

Doctoral Dissertations

The cost benefits associated with the use of heavy mining machinery in the surface mining industry has led to a surge in the production of ultra-large radial tires with rim diameters in excess of 35 in. These tires experience fatigue failures in operation. The use of reinforcing fillers and processing aids in tire compounds results in the formation of microstructural inhomogeneity in the compounds and may serve as sources of crack initiation in the tire. Abrasive material cutting is another source of cracks in tires used in mining applications. It suffices, then, to assume that every material plane in the …

Event-Triggering Architectures For Adaptive Control Of Uncertain Dynamical Systems, Ali Talib Oudah Albattat

Doctoral Dissertations

"In this dissertation, new approaches are presented for the design and implementation of networked adaptive control systems to reduce the wireless network utilization while guaranteeing system stability in the presence of system uncertainties. Specifically, the design and analysis of state feedback adaptive control systems over wireless networks using event-triggering control theory is first presented. The state feedback adaptive control results are then generalized to the output feedback case for dynamical systems with unmeasurable state vectors. This event-triggering approach is then adopted for large-scale uncertain dynamical systems. In particular, decentralized and distributed adaptive control methodologies are proposed with reduced wireless network …

Characterization And Numerical Simulation Of The Microstructural And Micromechanical Viscoelastic Behavior Of Oil Sands Using The Discrete Element Method, Eric Kofi Gbadam

Doctoral Dissertations

"Oil sands are naturally geologic formations of predominantly quartz sand grains whose void spaces are filled with bitumen, water, and dissolved gases. The electric rope shovel is the primary equipment used for excavating the Athabasca oil sand formations. The equipment's static and dynamic loads are transferred to the formation during excavation and propel. These loads cause ground instability leading to sinkage or rutting, crawler wear, and fracture failures. These problems result in unplanned downtimes, production losses, and high maintenance costs. In order to address these problems, there is a need to develop valid models that capture the behavior and performance …

Continuous Focusing And Separation Of Microparticles With Acoustic And Magnetic Fields, Ran Zhou

Doctoral Dissertations

"Microfluidics enables a diverse range of manipulations (e.g., focusing, separating, trapping, and enriching) of micrometer-sized objects, and has played an increasingly important role for applications that involve single cell biology and the detection and diagnosis of diseases. In microfluidic devices, methods that are commonly used to manipulate cells or particles include the utilization of hydrodynamic effects and externally applied field gradients that induce forces on cells/particles, such as electrical fields, optical fields, magnetic fields, and acoustic fields.

However, these conventional methods often involve complex designs or strongly depend on the properties of the flow medium or the interaction between the …

Numerical And Experimental Study Of New Designs Of All-Vanadium Redox Flow Batteries For Performance Improvement, Mohammed Abdulkhabeer Ali Al-Yasiri

Doctoral Dissertations

"Energy storage is envisioned as a key part of a renewable energy solution incorporated in a grid that overcomes two critical limits of renewable energy: intermittency and uncertainty. Among various technologies, a vanadium redox flow battery (VRFB) offers a promise because of its unique features such as long cycle life, separation of energy and power ratings, and capability of a deep discharge. The remaining challenges, however, include the limited application due to low energy density and complicated geometries. The complex geometry makes it difficult to optimize the performance and can cause a serious concern about leakage of the liquid. The …

Repair Of Metallic Components Using Hybrid Manufacturing, Renwei Liu

Doctoral Dissertations

"Many high-performance metal parts users extend the service of these damaged parts by employing repair technology. Hybrid manufacturing, which includes additive manufacturing (AM) and subtractive manufacturing, provides greater build capability, better accuracy, and surface finish for component repair. However, most repair processes still rely on manual operations, which are not satisfactory in terms of time, cost, reliability, and accuracy. This dissertation aims to improve the application of hybrid manufacturing for repairing metallic components by addressing the following three research topics. The first research topic is to investigate and develop an efficient best-fit and shape adaption algorithm for automating 3D models' …

Manufacturing Of Advanced Continuous Fiber Reinforced Composites For High Temperature Applications, James Robert Nicholas

Doctoral Dissertations

"New resin systems have enabled composites to be considered as attractive alternatives in structural applications that require material to be stronger, lighter and/or more resilient to environmental effects. The current work is on the development of processes to produce continuous fiber reinforced materials from two state of the art resin systems. Two processes were developed to produce continuous fiber reinforced ceramic materials from a preceramic polymer. The first was a vacuum forming process developed using the out-of-autoclave polymer composite manufacturing technique in conjunction with the polymer infiltration and pyrolysis process to produce ceramic composite material of zirconium diboride-silicon carbide reinforced …

Volumetric Error Compensation For 5-Axis Machine Tools, Jennifer Ruth Creamer

Doctoral Dissertations

"This work presents a geometric error compensation method for large 5-axis machine tools. The compensation method presented here uses tool tip measurements recorded throughout the axis space to construct a position-dependent geometric error model that can easily be used for error compensation. The measurements are taken using a laser tracker, permitting rapid error data gathering at most locations in the axis space. First two model types are compared for generating table-based error compensation and experimental results are presented. Table-based compensation is then extended to machine tool controller types with restrictions on the number or combination of compensation tables using an …

Control Of Single- And Dual-Probe Atomic Force Microscopy, Muthukumaran Loganathan

Doctoral Dissertations

“Atomic force microscope (AFM) is one of the important and versatile tools available in the field of nanotechnology. It is a type of probe-based microscopy wherein an atomically sharp tip, mounted on the free end of a microcantilever, probes the surface of interest to generate 3D topographical images with nanoscale resolution. An integral part of the AFM is the feedback controller that regulates the probe deflection in the presence of surface height changes, enabling the control action to be used for generating topographical image of the sample. Besides sensing, the probe can also be used as a mechanical actuator to …

Investigation Of Small-Scale Thermal Recovery And Storage Systems, Suvhashis Thapa

Doctoral Dissertations

An approach to recover and store waste heat is presented in this dissertation. The waste heat is the energy that is rejected to the environment without being put to practical use and it is a result of both equipment inefficiency and thermodynamic limitation on the equipment and the process. In a typical Otto cycle, for instance, out of the total energy consumed by the system, only one-third of the energy is converted into useful work and the rest is discharged in the environment as waste heat [1]. For a spark ignition, a 1.4 liters internal combustion engine with the thermal …

Experimental Investigation And Numerical Simulation Of A Copper Micro-Channel Heat Exchanger With Hfe-7200 Working Fluid, Eric Borquist

Doctoral Dissertations

Ever increasing cost and consumption of global energy resources has inspired the development of energy harvesting techniques which increase system efficiency, sustainability, and environmental impact by using waste energy otherwise lost to the surroundings. As part of a larger effort to produce a multi-energy source prototype, this study focused on the fabrication and testing of a waste heat recovery micro-channel heat exchanger. Reducing cost and facility requirements were a priority for potential industry and commercial adoption of such energy harvesting devices. During development of the micro-channel heat exchanger, a new fabrication process using mature technologies was created that reduced cost, …

Kinetic Energy Harvesting Mechanism For Vortex Drop Structures, Mungtra Chusilp

Doctoral Dissertations

Energy recovery from wastewater is gaining significance as utilities work toward achieving energy neutrality and sustainability in their wastewater collection and treatment systems. In this dissertation, kinetic energy harvesting mechanism for vortex drop structures found within the municipal waste and storm water conveyance systems is presented. There are thousands of sewer drop structures installed across the U.S. carrying billions of gallons of sewage each year. A custom micro water turbine is developed in this research which could be retrofitted within the existing drop shafts to harvest the excessive kinetic energy available. This dissertation presents the conceptual design and analysis of …