Mechanical Engineering Commons^™

Edge Fracture Prediction Of Dual Phase Steels With Consideration Of Microstructures, Ming Wen

Wayne State University Dissertations

In recent years, Advanced High Strength Steels (AHSS) have been used for the lightweight structural design and manufacturing in automotive industry. This class of sheet metals are prone to edge fracture during stamping production, and the fracture often occurs at much lower strain than that predicted based on the forming limit curves. The uncertainty in predicting edge fracture represents a great challenge in the application of AHSS. This dissertation is focused on the better understanding of edge fracture phenomenon through experimental observation and computer modeling with the consideration of microstructure effect.

In this dissertation, Hole Expansion (HE) test was used …

An Investigation Of The Effect Of Direct Metal Deposition Parameters On The Characteristics Of The Deposited Layers, Tarak A. Amine, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

Multilayer direct laser deposition (DLD) is a fabrication process through which parts are fabricated by creating a molten pool into which metal powder is injected as particles. During fabrication, complex thermal activity occurs in different regions of the build; for example, newly deposited layers will reheat previously deposited layers. The objective of this study was to provide insight into the thermal activity that occurs during the DLD process. This work focused on the effect of the laser parameters of newly deposited layers on the microstructure and mechanical properties of the previously deposited layers in order to characterize these effects to …

Redox Stable Anodes For Solid Oxide Fuel Cells, Guoliang Xiao, Fanglin Chen

Faculty Publications

Solid oxide fuel cells (SOFCs) can convert chemical energy from the fuel directly to electrical energy with high efficiency and fuel flexibility. Ni-based cermets have been the most widely adopted anode for SOFCs. However, the conventional Ni-based anode has low tolerance to sulfur-contamination, is vulnerable to deactivation by carbon build-up (coking) from direct oxidation of hydrocarbon fuels, and suffers volume instability upon redox cycling. Among these limitations, the redox instability of the anode is particularly important and has been intensively studied since the SOFC anode may experience redox cycling during fuel cell operations even with the ideal pure hydrogen as …

Bridging The Nano- And Macro-Worlds: Thermal Property Measurement Using Thermal Microscopy And Photothermal Radiometry – Application To Particle-Irradiation Damage Profile In Zirconium Carbide, Colby Bruce Jensen

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

Multiscaled experimental investigations of heat transfer from nanoscales to macroscales are requisite to progress in energy technologies. In nuclear applications, material properties can undergo significant alteration due to destructive interaction with irradiating particles at microstructural levels that affect bulk properties. This study expands the current knowledge base regarding thermal transport in ion-irradiated materials through the use of a multiscaled experimental approach using four complementary thermal wave methods. For the first time, the in-depth thermal conductivity profile of an ion-irradiated sample is measured directly.

Influence Of Crystal Structure On The Electrochemical Performance Of A-Site-Deficient Sr1-SNb0.1Co0.9O3-Δ Perovskite Cathodes, Yinlong Zhu, Ye Lin, Xuan Shen, Jaka Sunarso, Wei Zhou, Shanshan Jiang, Dong Su, Fanglin Chen, Zongping Shao

Faculty Publications

The creation of A-site cation defects within a perovskite oxide can substantially alter the structure and properties of its stoichiometric analogue. In this work, we demonstrate that by vacating 2 and 5% of Asite cations from SrNb_0.1Co_0.9O_3-δ (SNC1.00) perovskites (Sr_1-sNb_0.1Co_0.9O_3-δ,s = 0.02 and 0.05; denoted as SNC0.98 and SNC0.95, respectively), a Jahn–Teller (JT) distortion with varying extents takes place, leading to the formation of a modified crystal lattice within a the perovskite framework. Electrical conductivity, electrochemical performance, chemical compatibility and microstructure of Sr_1-sNb_0.1Co …

Microstructure, Quasi-Static, And High-Strain Rate Dynamic Characterization Of Metakaolin And Fly Ash Based Geopolymers For Structural Applications, Damian Lee Stoddard

Electronic Theses and Dissertations

Geopolymers are a class of rapid setting cementing systems that have been used as mortar or additives in concrete mixes to improve properties. Several types of geopolymer systems such as metakaolin and fly ash based geopolymers are widely used, and are available in different mixture proportions [1, 2]. Metakaolin (Al2Si2O7), a dehydroxylated form of Kaolinite (Al2Si2O5(OH)4) clay readily available from many sources, provides several benefits whenadded to a concrete mix design or used as a mortar system, including durability, freeze/thaw, acid resistance, and high temperature resistance [3]. Class F fly ash-based mortar geopolymers provide added fire retardation, reduces crack formation, …

Synthesis, Microstructure And Performance Evaluation Of Gadolinium Incorporated Cobalt Ferrite Ceramics, Md Taibur Rahman

Open Access Theses & Dissertations

Spinel structured ferrites exhibit remarkable properties and phenomena, which are attractive for application in sensors and actuators, magneto-electronics, and electrochemical energy storage devices. Among spinel ferrites, cobalt ferrite CoFe₂O₄ (CFO) has attracted remarkable attention and widely studied because of their electro-magnetic properties, chemical stability and mechanical hardness. The properties and phenomena of CFO ceramics are dependent on microstructure and chemistry, which in turn depend on the synThesis processes and conditions employed for fabrication. Generally exact chemical composition, processing temperature, reactive or processing atmosphere (if any) and the ions that substitute Fe³⁺/Fe²⁺ ions dictate the …

An Investigation Into The Mechanisms Of Formation Of The Hard Zone In Fsw X65, Jacob D. Allred

Theses and Dissertations

Friction stir welding (FSW) of HSLA steel commonly produces a hard zone (HZ) on the advancing side (AS) of the weld. Despite its detrimental effects on weld toughness, the mechanisms of its formation have not been thoroughly investigated and are not well understood. This paper investigates the various mechanisms in FSW believed to affect the weld HZ, namely: strain, strain-rate, peak temperature and cooling rate. Gleeble tests indicate that strain and strain rate have negligible effects on weld HZ with cooling rate and peak temperature as dominant effects. Jominy tests resulted in cooling rate having 270% greater influence than peak …

Probabilistic Simulation Of Solidification Microstructure Evolution During Laser-Based Metal Deposition, Jingwei Zhang, Frank W. Liou, William Seufzer, Joseph William Newkirk, Zhiqiang Fan, Heng Liu, Todd E. Sparks

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A predictive model, based on a Cellular Automaton (CA) - Finite Element (FE) method, has been developed to simulate microstructure evolution during metal solidification for a laser based additive manufacturing process. The macroscopic FE calculation was designed to update the temperature field and simulate a high cooling rate. In the microscopic CA model, heterogeneous nucleation sites, preferential growth orientation and dendritic grain growth kinetics were simulated. The CA model was able to show the entrapment of neighboring cells and the relationship between undercooling and the grain growth rate. The model predicted the dendritic grain size, structure, and morphological evolution during …

The Effect Of Cooling Rate Of Friction Stir Welded High Strength Low Alloy Steel, Scott Anthony Rose

Theses and Dissertations

The friction stir welding of steel has produced a hard zone in several different alloys. Despite its detrimental effects on weld toughness, the reasons behind neither its formation nor a method of reducing its size or effects have been explored. Recent advances in process control allow for direct heat input control, which combined with the use of backing plates of different thermal conductivity allows for an expansion of the process window. These control methods also affect the HAZ cooling rate by providing greater range (a 60% increase compared to a fixed backing plate) and control (five welds within 16 °C/s). …

Enhanced Tribological Properties Of Surfaces Patterned With Su8/Dlc Microstructures, Luke Osborn

Inquiry: The University of Arkansas Undergraduate Research Journal

In tribology (the study of friction, wear, and lubrication), it is known that micro-textured surfaces can reduce friction due to decreased contact area between two surfaces. The problem with many micro-textures, however, is their inability to withstand significant amounts of wear, thus limiting their potential uses and overall effectiveness. In this study, connected and isolated microstructures of SU8, a negative tone photoresist, coated with and without diamond-like carbon (DLC), were designed to investigate the effects of these microstructures and DLC coating on the tribological performance of a surface. Friction and wear studies were conducted using a tribometer; surface topography and …

The Effect Of Isostatic Pressing On The Dielectric Properties Of Screen Printed Ba0.5Sr0.5Tio3 Thick Films, Siwei Wang, Lingling Zhang, Jiwei Zhai, Fanglin Chen

Faculty Publications

Ba_0.5Sr_0.5TiO₃ thick films with B₂O₃–Li₂O glass sintering aid were prepared by the screen printing method on Al₂O₃ substrates. A 200 MPa isostatic pressure was applied to the films before sintering. After being sintered at 950^∘C, lower porosity and denser microstructure was obtained compared with the films without isostatic pressing. The dielectric constant and dielectric loss were 238 and 0.0028, respectively. A tunability of 61.7% was obtained for the isostatic pressed films, a 27.8% enhancement compared to unpressurized films. These results suggest that isostatic pressing …

A Hybrid Bishop-Hill Model For Microstructure Sensitive Design, Ribeka Takahashi

Theses and Dissertations

A method is presented for adapting the classical Bishop-Hill model to the requirements of elastic/yield-limited design in metals of arbitrary crystallographic texture. The proposed Hybrid Bishop-Hill (HBH) model, which will be applied to ductile FCC metals, retains the `stress corners' of the polyhedral Bishop-Hill yield surface. However, it replaces the `maximum work criterion' with a criterion that minimizes the Euclidean distance between the applicable local corner stress state and the macroscopic stress state. This compromise leads to a model that is much more accessible to yield-limited design problems. Demonstration of performance for the HBH model is presented for an extensive …

Study On The Fracture Toughness Of Friction Stir Welded Api X80, Allan M. Tribe

Theses and Dissertations

High strength low alloy (HSLA) steels have been developed to simultaneously have high yield strength and high fracture toughness. However, in practical applications steel must be welded. Traditional arc welding has proven detrimental to the fracture toughness of HSLA steels. Friction stir welding has recently shown mixed results in welding HSLA steels. The range of welding parameters used in these recent studies however has been very limited. With only a few welding parameters tested, the effect of spindle speed, travel speed, and heat input on the fracture toughness of friction stir welded HSLA steel remains unknown. To understand how the …

Microstructure Selection Of Sm–Co–Al Alloys To Increase Magnetization, Brian Dick

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

An ever increasing demand for higher performing magnets drives the need for new and innovative methods to achieve this goal. Sm-Co rare earth permanent magnets have a unique eutectic microstructure that, through refinement, could become a two-phase magnet which would significantly increase their energy product. The eutectic structure of Sm₈Co₉₂ is comprised of αCo rods embedded within a Sm₂Co₁₇ matrix. If the rods are small enough to encourage exchange coupling and the matrix is smaller than the single domain limit, then an efficient two-phase magnet is created.

Refining the Co rods and matrix size …

A New Eulerian-Based Double Continuity Model For Predicting The Evolution Of Pair Correlation Statistics Under Large Plastic Deformations, Sadegh Ahmadi

Theses and Dissertations

A new model using a double-continuity relation for predicting the evolution of pair-correlation functions (PCFs) is presented. The proposed model was developed using statistical continuum theory and is employed to predict the viscoplastic behavior of polycrystalline materials. This model was built based upon the continuity relations and a double divergence law that guarantees the conservation of both orientation and mass; and also satisfies the field equations (equilibrium, constitutive, and compatibility) at every point of the polycrystalline material throughout the deformation process. In the presented model, motion of particles in the real space and rotation of crystallographic orientations in the Euler …

A Novel Image Processing Platform Development For Preprocessing Images With Two-Phase Microstructures Containing Isolated Particles, Yuxiu Zhang

Wayne State University Theses

A novel image processing platform is developed in this thesis for pre-processing the images of two-phase microstructures containing isolated particles based on Matlab®. The two phases in this work represent martensite particles and ferrite matrix in Dual Phase steels that are developed for lightweight automotive body structures. An automated image processing tool is useful for obtaining statistical microstructure characteristics, important for better understanding material's deformation and fracture behavior. However, a generalized commercial software can not automatically realize the microstructural features of special interest, and a user-specified pre-processing tool is needed.

This platform utilizes the Matlab® GUI technique, Matlab image processing …

Effect Of Free-Edges On Melt Pool Geometry And Solidification Microstructure In Beam-Based Fabrication Methods, Joy Elizabeth Davis

Browse all Theses and Dissertations

Laser and electron beam-based additive manufacturing of Ti-6Al-4V are under consideration for application to aerospace components. A critical concern for these processes is the ability to obtain a consistent and desirable microstructure and corresponding mechanical properties of the deposit. Based on the Rosenthal solution for a moving point-heat source, recent work has developed simulation-based process maps for the thermal conditions controlling microstructure (grain size and morphology) in beam-based deposition of semi-infinite geometries, where a steady-state melt pool exists away from free-edges. In the current study, the Rosenthal solution is modified to include the effects of free-edges. This is accomplished by …

Effect Of Finite Geometry On Solidification Microstructure In Beam-Based Fabrication Of Thin Wall Structures, Satish C. Kuchi

Browse all Theses and Dissertations

With the advent of Rapid Protyping (RP) in the manufacturing industry, many newtechnologies came into development for quick fabrication of materials. One of the most versatile fabrication process among them is additive manufacturing. Laser based manufacturing (LBM) and electron beam manufacturing (EBM) processes use the energy from a laser or electron beam to build up structures layer by layer directly from powdered metals and wire feed stock. It has been determined from previous work that solidification cooling rate and thermal gradients are the important factors for controlling microstructure (grain size and morphology) and resulting mechanical properties of the deposit. The …

Effects Of Processing Parameters On The Embrittlement Of Self Reacting Friction Stir Welds, David Eric Taylor

LSU Master's Theses

Friction Stir Welding (FSW) has been adopted as one of the major welding processes for joining Aluminum. Many aerospace and marine structures are welded through this novel FSW processes currently. The Lockheed Martin Space Systems (LMSS), Michoud Operations, in New Orleans is continuously pursuing Friction Stir Welding technologies in its efforts to advance fabrication of the external tanks of the space shuttle. Recently, a reduction in mechanical strength (embrittlement) has been observed especially in self-reacting (SR) friction stir welds. This strength reduction was attributed to Residual Oxide Defects (ROD) but the exact reasons for this type of behavior needed to …

Investigation Of Heterogeneity Of Fsw Inconel 718 Coupled With Welding Thermal Cycle, Dong Fang Huang

Theses and Dissertations

In order to develop a better understanding of the property, microstructure evolution and thermal history of FSW Inconel 718's, the strain, strain rate and thermal cycles need to be determined. In order to estimate the strain field of a deformed body, a displacement function needs to be determined. A 3D deformation model was developed to determine the displacement coefficients. A rectangular box created in this model deforms following a linear displacement function. Three orthogonal planes cut this deformed box, which leads to three deformed planes. The shape parameters (L, H, θ¹ and θ²) on the three orthogonal planes can be …

A New Method Of Synthesizing Black Birnessite Nanoparticles: From Brown To Black Birnessite With Nanostructures, Shizhi Qian, Marcos A. Cheney, Pradip K. Bhowmik, Sang W. Joo, Wensheng Hou, Joseph M. Okoh

Mechanical Engineering Faculty Research

A new method for preparing black birnessite nanoparticles is introduced. The initial synthesis process resembles the classical McKenzie method of preparing brown birnessite except for slower cooling and closing the system from the ambient air. Subsequent process, including wet-aging at 7◦C for 48 hours, overnight freezing, and lyophilization, is shown to convert the brown birnessite into black birnessite with complex nanomorphology with folded sheets and spirals. Characterization of the product is performed by X-ray diffraction (XRD), transmission electron microscopy (TEM), high-resolution transmission electron microscopy (HRTEM), thermogravimetric analysis (TGA), and N2 adsorption (BET) techniques. Wet-aging and lyophilization times are shown to …

Titanium Alloyed With Boron, Seshacharyulu Tamirisakandala, Daniel B. Miracle, Raghavan Srinivasan, Jay S. Gunasekera

Mechanical and Materials Engineering Faculty Publications

Small additions of boron to conventional titanium alloys have been found to produce significant changes to the microstructures and associated properties. Grain refinement and improved strength and stiffness are first-order effects, which lead to possibilities for developing novel and affordable processing methodologies and to enhance performance over conventional titanium alloys. In this article, we introduce this new class of titanium alloys and describe unique formability benefits achieved via engineering microstructures.

Evaluation Of Mechanical Properties And Microstructure For Laser Deposition Process And Welding Process, Yaxin Bao, Jianzhong Ruan, Todd E. Sparks, Jambunathan Anand, Joseph William Newkirk, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Aided Manufacturing Process (LAMP) can be applied to repair steel die/molds which are currently repaired using traditional welding process in industry. In order to fully understand the advantages of laser deposition repair process over traditional welded-repair process, the mechanical properties such as tensile strength and hardness of H13 tool steel samples produced by these two processes were investigated. The microstructure and fracture surface of the samples were analyzed using optical microscope and SEM (Scanning Electron Microscope). Moreover, depositions on substrates with different shapes were studied to evaluate the performance of LAMP on damaged parts with complicated geometric shape.

Object Oriented Cae Software For The Exploration And Design Of Microstructures, Stephen D. Sintay

Theses and Dissertations

Through the use of generalized spherical harmonic basis functions a spectral representation is used to model the microstructure of cubic materials. This model is then used to predict the macroscopic elastic and plastic properties of materials with cubic crystal symmetry and various sample symmetry including triclinic and axial—symmetric. Building on the work of citeN{Barnett-FractureMechanics} the influence that anisotropy has on the fatigue response of the material is also modeled. This is accomplished through using the effective elastic stiffness tensor in the computation of crack extension force G. The resulting material model and macroscopic property calculations are the foundation for …

Recovery Of The Grain Boundary Character Distribution Through Oblique Double-Sectioning, Brent L. Adams, David T. Fullwood, E. R. Homer

Faculty Publications

This work was supported primarily by the MRSEC program of the National Science Foundation under DMR-0079996. A method for the retrieval of the complete grain boundary character distribution by oblique double-sectioning is proposed. The method, which is similar to the recovery of the orientation distribution from sets of incomplete pole-figures, is efficient and provides many advantages as compared to calibrated serial sectioning. As compared to standard stereological approaches, the new methodology retains the advantage of direct measurement of the grain boundary inclination parameters. Solutions to the fundamental equation of oblique double-sectioning are provided in the Fourier space, and some specifics …

An Analysis Of Microstructure And Corrosion Resistance In Underwater Friction Stir Welded 304l Stainless Steel, Tad Dee Clark

Theses and Dissertations

An effective procedure and parameter window was developed for underwater friction stir welding (UWFSW) 304L stainless steel with a PCBN tool. UWFSW produced statistically significant: increases in yield strengths, decreases in percent elongation. The ultimate tensile strength was found to be significantly higher at certain parameters. Although sigma was identified in the UWFSWs, a significant reduction of sigma was found in UWFSWs compared to ambient FSWs. The degree of sensitization in UWFSWs was evaluated using double loop EPR testing and oxalic acid electro-etched metallography. Results were compared to base metal, ambient FSW, and arc welds. Upper and lower sensitization localization …

Two-Dimensional Grain Boundary Percolation In Alloy 304 Stainless Steel, Brent L. Adams, John A. Basinger, David T. Fullwood, E. R. Homer

Faculty Publications

This work was supported by the MRSEC program of the National Science Foundation under Award Number DMR-0079996. An experimentally-obtained percolation threshold for high-angle random grain boundary networks in alloy 304 stainless steel is compared to thresholds predicted by percolation theory. A discrepancy occurs in the two values (0.46 experimental and 0.65 theoretical). Possible reasons for the discrepancy are explored. The grain boundary network appears to be composed of two distinct sub-networks, with the 'outer' network acting as the dominant contributor to the percolating paths.

New Stereology For The Recovery Of Grain-Boundary Plane Distributions In The Crystal Frame, Brent L. Adams, Ryan J. Larsen

Faculty Publications

One of the authors (RJL) is grateful to the Office of Naval Research for fellowship support. BLA acknowledges the support of the NSF through the Materials Research Science and Engineering Center, Carnegie Mellon University (Grant No. DMR-0079996). A new experimental method is given for recovering the probability-distribution function Sv(ns/g). The function Sv(na/g) is the grain-boundary area per unit volume as a function of grain-boundary plane orientation (na), given a lattice misorientation (g) between the adjoining grains. The grain-boundary normal (na) is expressed in the crystal frame in which the misorientation g originates. The proposed method recovers the three-dimensional Sv(na/g) function …

Effects Of Friction Stir Processing On The Microstructure And Mechanical Properties Of Fusion Welded 304l Stainless Steel, Colin J. Sterling

Theses and Dissertations

Friction stir processing (FSP) has been utilized to locally process regions of arc weldments in 304L stainless steel to improve the microstructure and mechanical performance. The cast microstructure and coarse delta-ferrite has been replaced with a fine-grained wrought microstructure. Furthermore, twins were introduced throughout the friction stir processed region. Although sub-surface sigma and carbides were introduced during FSP, their presence is not expected to adversely affect the resulting mechanical or corrosion properties of friction stir processed 304L arc welds. The resulting mechanical properties of FS processed weldments were also an improvement over as-welded arc welds. FSP resulted in an increase …