Manufacturing Commons^™

Sla Elastic Resin Curing Test Data, Richard Amesimenu, Johnson Nwogu, Haijun Gong

Datasets

3D printing via stereolithography (SLA) enables high-resolution polymer components, but as-printed parts may exhibit incomplete polymerization and reduced mechanical performance. This study investigates the effects of UV post-curing time on SLA-printed elastic photopolymer resin. Specimens were evaluated using Differential Scanning Calorimetry (DSC), uniaxial tensile testing (ASTM D412 Type C), and Durometer Type M hardness testing. Results show that increased post-curing enhances crosslink density, tensile strength, elastic modulus, and hardness, while extended curing may reduce ductility. An optimal post-curing window balancing stiffness and flexibility was identified. Testing datasets include DSC (dsc/), tensile testing (tensile/), and hardness testing (hardness/) results for uncured …

Analysis Of Tower Stringset Replacement From 33 Kv To 66 Kv Considering Sagging Clearance, Muhammad Lazuardi Azzura, Anne Zulfia Syahrial, Julius Purnama Eka Kartika

Journal of Materials Exploration and Findings

Efforts to increase the capacity of transmission networks are often undertaken by uprating the operating voltage of existing lines rather than building entirely new infrastructure. Such uprating typically involves the replacement of tower insulator stringsets to withstand higher voltages, while also ensuring that mechanical performance remains adequate. This paper presents an analysis of uprating the Parakan–Sunyaragi transmission line from 33 kV to 66 kV, with particular emphasis on conductor sagging and the resulting clearance from the ground. The methodology employed includes calculations based on catenary equations, analysis of conductor tensile forces, and a comparative evaluation of two widely used insulator …

Additive Manufacturing Of Metals: Mechanical Properties And Their Implications, Sean Chih

Discovery Day - Daytona Beach

Additive manufacturing of metals is a relatively new and groundbreaking approach to manufacturing high-performance components. However, variability in mechanical properties from the process creates a barrier before this manufacturing technique can be widely applied. Understanding when and where to use this manufacturing is also important to create components with efficiency and without harmful defects. The objective of this research is to evaluate the effects of build orientation, printing parameters, internal defects, thermal history, and residual stresses, post-processing heat treatments, and fatigue behavior on additively manufactured components. Literature-based research is conducted on commonly used metals for additive manufacturing, such as stainless …

Structural Design And Finite Element Analysis Of A 54 Ton Freight Wagon Bolster Test Rig Under Vertical Center Plate Load, Shandy Dwi Prayoga, I Dewa Gede Ary Subagia, I Ketut Adi Atmika, Abdul Rohman Farid, Yunior Lanang Satrio

Journal of Mechanical Engineering Science and Technology (JMEST)

Bolster is one of the bogie's components that receives direct loading from the car body and freight movement. One of the problems that occurs in the bolster is permanent deflection during vertical and transversal static loading. Therefore, a static loading test is required to evaluate the structural strength of the bolster. During the static loading test, a rig is required to hold the bolster so that the bolster is in a fixed position. The rig owned by PT. INKA (Persero) showed a plastic deformation at the vertical center plate load (VCP 5.22P). Therefore, a modified design of the rig is …

Optimization Of Aluminum Coating Deposition Parameters To Enhance The Performance Of Automotive Headlamps, Gulirano Saidakhmedova, Giovanni Maizza

Technical science and innovation

The paper investigates the influence of the optical characteristics of functional coatings applied to automotive reflectors on vehicle active safety parameters, with a focus on the range and intensity of road illumination. The study examines the mathematical relationship between the maximum luminous intensity of a headlamp, the object detection distance, and the reflection coefficient  of an aluminium layer deposited via vacuum thermal evaporation. The main factors driving the degradation of surface reflectivity (including oxidation, thermal degradation of the base coat, and surface roughness) are analysed. It is demonstrated that a decrease in the reflection coefficient during operation directly impairs the …

Magnetic Field-Induced Transformation In Polycrystalline Ni2mnal Heusler Type Magnetic Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely, Laura N. Bartlett

Materials Science and Engineering Faculty Research & Creative Works

The martensitic and magnetic transformations, as well as the mechanical properties, of Ni₂MnAl alloys in as-cast (AC) and heat-treated (HT) conditions were investigated. Magnetic-field-induced strain was evaluated via magnetostriction, with reversible strains of 0.14% and 0.2% achieved in the martensitic phase at 2 K for the AC and HT alloys, respectively. Transformation temperatures and Curie temperatures were determined under constant applied magnetic field, revealing that γ-phase inclusions in the AC microstructure suppress antiferromagnetic domain response, yielding a lower magnetization (∼8.4 emu g⁻¹) compared to the HT alloy (∼13.4 emu g⁻¹). Both alloys exhibited hysteretic behavior in the martensitic state and …

Direct Ink Writing Of Functional Fiber/Granular Composites, Zhuoyuan Yang

Doctoral Dissertations and Master's Theses

Direct ink writing provides a versatile manufacturing route for fabricating functional fiber and granular composites with controlled architecture, tunable interfaces, and customized material distributions. Fiber reinforced composites offer high stiffness, strength, fatigue resistance, and functional anisotropy, while granular composites provide scalable access to particle based structures with high material efficiency and broad resource compatibility. However, the additive manufacturing of these composite systems remains challenging. For fiber based composites, precise control of fiber placement, matrix impregnation, interfacial bonding, and freestanding deposition is difficult to achieve during printing. For granular composites, stable particle flow, controllable packing, binder infiltration, and shape retention are …

The Effect Of Mwcnt-Oil Impregnation Of Sintered Components On Their Wear And Corrosion Resistance, Maha Khaled Abdelfadeel

Theses and Dissertations

Powder Metallurgy (PM) offers an advantageous route for manufacturing complex and near net-shape components. Their inherent interconnected porosity that promotes the action of self lubrication compromises their structural integrity by creating pathways for corrosion and excessive wear. This research investigates the efficacy of Multi-Walled Carbon Nanotubes (MWCNTs) as a nano additive within the impregnating base oil (SN-150 base oil). An experimental matrix was designed to evaluate the influence of MWCNTs with different concentrations of 0.05, 0.1, and 0.2 wt.% and ultrasonic dispersion with varying sonication times of 30 and 60 minutes on the tribological and electrochemical performance of sintered steel …

Rapid-Prototyping Nanofabrication: Lcd-Based Projection Lithography And Physical Vapor Deposition, Sabeel Saleem Mohammmed

University Honors Theses

The semiconductor industry's continued growth, driven in large part by demand for artificial intelligence hardware, has highlighted the need for greater workforce development in regions adjacent to major fabrication centers like Oregon's Silicon Forest. This capstone project lays the groundwork for a small scale and student led semiconductor fabrication lab at Portland State University by demonstrating two of the core steps in chip manufacturing: photolithography and thin film deposition. Rather than relying on conventional fixed reticles, this work explores a unique, low cost approach to patterning that uses an ultraviolet-compatible liquid crystal display (LCD) as a programmable reticle, allowing arbitrary …

Effects Of Niobium On The Mechanical And Oxidation Properties Of Additively Manufactured Tungsten, Alexander Lesieur, Cayla Eckley, Ryan A. Kemnitz

Faculty Publications

Although additive manufacturing presents a novel and customizable approach to fabricating tungsten (W) alloys, the layer-by-layer production technique presents a unique set of processing challenges which are further exacerbated by the metal’s refractory properties. In this study, additions of niobium (Nb) were found to improve the mechanical properties and oxidation resistance of additively manufactured W. Microstructural investigation revealed the effect of Nb on the cracking, grain size, and texture in the as-built material. Mechanical compression testing showed significant improvement in ductility with increasing Nb content. The low concentrations of Nb used did not induce large changes in the yield strength …

Lunar Manufacturing Systems And The Role Of Additive Recycling Technologies, Camille A. Newman

Honors Theses

Renewed international interest in sustained lunar exploration has created a growing demand for technologies to support long-duration space exploration. Part of the recent Artemis missions and the Moon to Mars initiative is to improve key mission capabilities and fill critical gaps necessary to sustain lunar habitation. Waste management, recycling systems, and manufacturing systems have been identified as critical technologies that need further development before a sustained mission is possible. This thesis explores the feasibility of an additive manufacturing and recycling system designed to process plastic waste generated during extended lunar habitation. Initial research focused on existing manufacturing and recycling technologies …

Lunar Manufacturing Systems And The Role Of Additive Recycling Technologies, Camille A. Newman

Honors Theses

Renewed international interest in sustained lunar exploration has created a growing demand for technologies to support long-duration space exploration. Part of the recent Artemis missions and the Moon to Mars initiative is to improve key mission capabilities and fill critical gaps necessary to sustain lunar habitation. Waste management, recycling systems, and manufacturing systems have been identified as critical technologies that need further development before a sustained mission is possible. This thesis explores the feasibility of an additive manufacturing and recycling system designed to process plastic waste generated during extended lunar habitation. Initial research focused on existing manufacturing and recycling technologies …

Quantitative Phase-Field Modeling Of Nonequilibrium Microstructural Evolution In Rapid Solidification For Additive Manufacturing, Leiji Li, Fei Xiao, Ying Zhou, Xiaorong Cai, Chongfeng Zhang, Jinzhong Gao, Xiaopeng Shen, Tianchi Zhu, Sihan Wang, Yijia Gu, Xuejun Jin

Materials Science and Engineering Faculty Research & Creative Works

Fusion-based metal additive manufacturing (AM) relies on layer-by-layer deposition and rapid solidification, where the material transitions swiftly from liquid to solid. A key phenomenon during this process is solute trapping, a nonequilibrium effect governed by a velocity-dependent partition coefficient, which critically influences microstructure kinetics, morphology, and phase formation. In this study, we employ a recently proposed quantitative phase field (PF) model to systematically explore solute trapping, solute drag, and their impacts on pattern formation during rapid solidification at AM-relevant velocities, in both one and two dimensions. Our simulations reveal a growth mode transition from planar to cellular to dendritic, and …

Direct Ink Writing Of Shear Exfoliated Two-Dimensional Nanomaterial- Elastomeric Multifunctional Nanocomposite, Md Abdur Rahman Bin Abdus Salam, Asif Hasan Ridoy, A K M Abirul Haque, Muhammad Shahbaz Rafique, Md Arafat Hossain, Md Shahriar Forhad, Matthew G. Boebinger, Farid Ahmed, Karen Lozano, Ali Ashraf

Manufacturing & Industrial Engineering Faculty Publications

Direct ink writing (DIW) of polymer nanocomposites with high loadings of two-dimensional (2D) nanofillers (graphene and hexagonal boron nitride (hBN)) is challenging because of potential clogging, use of hazardous solvents, and agglomeration. Here, in this work, a shear exfoliation and sieving method to prepare DIW ink with high loading of nanofillers produced from low-cost bulk layered materials such as graphite and bulk hBN powder for successful DIW printing without the use of any solvents, binders, or plasticizers. The single-step exfoliation technique resulted in a composite with substantial layer reduction along the c-axis, as confirmed by SEM, TEM, XRD, and Raman …

Detecting And Repairing Conflicting Constraints In Co-Trained Physics-Informed Neural Networks For Composite Curing Processes, Cooper J. Evans

Dissertations, Master's Theses and Master's Reports

Composite materials have become a critical component of modern manufacturing, especially in the automotive and aerospace industries. The curing process for these composites has been modeled using a variety of partial differential equations representing the heat transfer and composite curing kinetics. Optimizing the applied temperature profile is critical for maximizing the efficiency and capacity of composite part manufacturers. Constraints must be placed on the inputs and outputs of the model, including but not limited to, the applied temperature profile, part temperature, and final degree of cure. Conflicting sets of constraints are easy to unknowingly impose due to the highly coupled …

Mechanical Behavior Of Additively Manufactured Ti-6al-4v Eli Parts: Effects Of Laser Parameter Selection, Samuel Lopez

UNF Graduate Theses and Dissertations

Additive manufacturing (AM) of TI-6AL‑4V Extra‑Low Interstitial (ELI) enables complex geometries for fatigue‑critical medical device applications, yet fatigue performance remains sensitive to process‑induced defects. This work investigates the effect of laser process parameter selection on the microstructure, mechanical properties, and fatigue behavior of TI- 6AL‑4V ELI fabricated via laser powder bed fusion (L‑PBF) using a Renishaw RenAM system. The influence of laser parameters was isolated by holding powder chemistry, build orientation, scan strategy, sub‑transus annealing, and post‑processing constant between a non‑optimized baseline and an optimized parameter set selected based on tensile performance.

Optical microscopy showed the optimized condition exhibited improved …

Thermal Transformations And Mechanical Properties Of All-D-Metal Mn2fecu Heusler-Type Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely

Materials Science and Engineering Faculty Research & Creative Works

All-d-metal Heusler alloys are emerging functional materials in which magnetic ordering, lattice distortion, and mechanical behavior are strongly coupled through d–d electronic interactions. This study systematically investigates the structural, thermal, magnetic, and mechanical properties of Mn₂FeCu synthesized within a Heusler-type compositional framework. SEM/EDS revealed a dual-phase FCC-based microstructure consisting of Mn–Fe–rich and Mn–Cu–rich domains, while XRD confirmed FCC symmetry with compositional partitioning rather than full L2₁ ordering. Differential scanning calorimetry identified partial melting of the Cu-rich phase near ~ 900 °C. Dilatometry showed a thermoelastic FCC → FCT transformation at ~ 770–780 °C with a recoverable strain of ~ 0.067%. …

Field-Assisted Post-Processing Of Cold-Sprayed Pure Copper, Alan Hensley

Theses and Dissertations--Mechanical and Aerospace Engineering

The properties of materials processed through cold spray, and many other AM processes, are non-uniform and unpredictable. In most cases, post-processing is required to achieve desired properties and better uniformity. In cold spray, the typical method is an annealing heat treatment (AHT), which can improve bond strength, reduce porosity, and restore ductility, among other effects. AHT alone, however, is unable to completely remedy any of the unfavorable properties. In addition, long treatments at high temperatures are often needed for satisfactory results. This increases energy consumption and extends production times for products made by the process. For these reasons, numerous investigations …

The Effects Of Mold Flux Contamination On Oxide Scale Formation And Hydro-Descaling Efficiency During Steel Processing, Tochukwu Princewill Ojiako, Richard Osei, Mario Buchely, Haiming Wen, Simon Lekakh, Ronald O'Malley

Materials Science and Engineering Faculty Research & Creative Works

Oxide scale formation during thin-slab continuous casting has a complex structure, which is influenced by mold flux contamination, that modifies interfacial reactions during solidification, subsequent reheating, and descaling. While individual aspects of the oxidation behavior of carbon steel have been previously examined, the synergetic effects of mold flux contamination during continuous casting and subsequent reheating on scale modification and the efficiency of hydraulic descaling remain inadequately studied. This study quantitatively examines the effect of flux composition on oxide scale evolution, adhesion, and hydraulic removal in low-carbon steel under simulated industrial conditions. Slab samples with as-cast, cleaned, and flux-coated surfaces were …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Parts, Logan Trimmer

Harrisburg University Other Works

Presentation covering the broad strokes of the project. The goal was to prove the viability of hybrid/additive manufacturing for high stress automotive applications. This project focused on recreating a piston from an old engine to examine if hybrid manufacturing could be used for such applications. On a small scale, hybrid manufacturing was able to be more cost effective if the costs of the equipment and electricity were ignored. The decision to ignore those costs came from the inability to find accurate prices for industrial casting.

Optimization Of Post-Processing Methods For Additively Manufactured Metals, Julia R. Carano

Williams Honors College, Honors Research Projects

Ultrasonic Nanocrystal Surface Modification (UNSM) is a process used to change the surface hardness of flat-faced materials. It is a machining process using a high-powered laser and a blunt-tipped tool at high speeds which aims to improve the uniformity of the surface on most metals. By heating and pressing the surface of the workpiece, the grains of the material become less rounded and more cohesive on a microscopic level. This, ideally, results in a workpiece with improved material properties. The changes were previously observed through hardness testing.

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Components, Logan Trimmer

Harrisburg University Other Works

The goal of this research was to establish the viability of using hybrid manufacturing for automotive applications. By verifying that high-stress components can be created, it can be assumed that any other lower stress part could be made to match the strength requirements. A limiting factor of adoption for hybrid manufacturing is how new the technology is. Studies on time and cost were performed allowing for comparisons with traditional manufacturing technologies (casting, forging, milling) used in automotive applications. This research utilized a Haas Automation UMC750 5-axis CNC mill with a Meltio laser wire direct energy deposition attachment. Fusion 360 was …

Modeling Of Transformation Temperatures In Cast Martensitic Stainless Steels-Ca6nm: Effects Of Composition, Heating Rate, And Grain Size, Ugochukwu Agbedo, Mario Buchely, Laura Bartlett, Caelan Kennedy

Materials Science and Engineering Faculty Research & Creative Works

Accurate prediction of the critical transformation temperatures Ac1 and Ac3 is one of the essential factors in the heat treatment of CA6NM cast martensitic stainless steel. In this study, the influence of alloy composition, heating rate, and prior austenite grain size on the critical temperatures was quantified using dilatometric measurements and statistical modeling. Six heat treatment conditions produced prior austenite grain sizes ranging from ~75 to 247 µm. Experimental results showed that grain size variations produced only minor changes in Ac1 and Ac3, indicating a weak dependence of transformation temperatures on prior austenite grain size within the investigated range. In …

Multiphysics Simulation And Experimental Validation Of Phase Transformation And Hardness In Jominy End-Quenched Low-Alloy Steels, J. S. Alabi, E. Heidari, M. F. Buchely, K. Chandrashekhara, S. N. Lekakh, R. J. O'Malley, V. A. Athavale, A. Kumar

Materials Science and Engineering Faculty Research & Creative Works

High-volume industrial continuous hot-rolled steel heat treatment processes involve sophisticated multi-phase modeling. The performance of a given process can be optimized by coupling phase transformation kinetics with the cooling conditions of the process. This study develops a multiphysics model to simulate an intensive quenching process for steel, which is inherently transient and highly dependent on numerous parameters. The simulated object was a Jominy end-quenched specimen geometry using two commercial steels, AISI 4130 and AISI 4140, with the goal of transferring a verified methodology to the heat treatment process for industrial heavy-section products (bars, slabs). The simulation employs thermal, mechanical, and …

Effect Of Wall Movement On Porosity Formation In Ductile Iron Castings Under Varying Processing Parameters, Shamsul Alam

College of Graduate Studies: Theses & Dissertations

Shrinkage porosity is a major defect that significantly impairs the mechanical properties and overall performance of ductile iron castings. Although graphite formation during solidification induces volumetric expansion, this expansion alone is insufficient to fully compensate for the shrinkage occurring throughout solidification. During the solidification and cooling of ductile iron, multiple phase transformations occur, resulting in dynamic volume changes that exert pressure on mold walls and internal cavities. These pressures can deform mold walls and casting surfaces, leading to defects such as swell and porosity, while also influencing shrinkage formation. This study aims to analyze the mechanisms of porosity formation and …

Critical Parameters Controlling Oxide Scale Formation And Hydro-Descaling Efficiency During Steelmaking, Tochukwu Princewill Ojiako

Doctoral Dissertations

In modern steelmaking, cast slabs are exposed to high-temperature oxidizing environments during secondary cooling, reheating, and hot rolling, resulting in the formation of multilayer oxide scales on the steel surface. These scales interact with mold-flux residues originating from the casting process (CC). The morphology, chemistry, and adhesion of oxide scale strongly influence its removability during high-pressure hydraulic descaling and ultimately determine the surface quality of hot-rolled products. However, the mechanistic relationship between oxide scale evolution, scale-steel interfacial structure, and hydraulic descaling performance remains poorly understood.

This dissertation investigates oxide scale formation, modification, and removal in low-carbon thin-slab steels produced by …

Overcoming Resolution Vs. Throughput Trade-Offs In Ceramic Material Extrusion Additive Manufacturing Via Viscoelastic Filament Stretching, Abid H. Rafi, David W. Lipke, Jeremy L. Watts, Gregory E. Hilmas, Ming C. Leu

Materials Science and Engineering Faculty Research & Creative Works

Fabricating large, monolithic ceramic parts using material-extrusion additive manufacturing remains challenging due to difficulty maintaining uniform moisture content during printing, which can lead to drying-induced defects such as warping and cracking, especially as part size and print time increase. Fabricated parts have trade-offs among print resolution, high throughput, and structural fidelity. Our study has shown that increasing the ratio of nozzle traverse speed vs. material extrusion speed increases filament stretching in viscoelastic ceramic paste, helping to overcome the trade-offs between resolution and throughput. Using aqueous ZrB2–SiC (70/30 vol.%) as a representative ultra-high temperature ceramic paste, rheological characterisation revealed viscoelastic yield-stress …

Castrip Process Technology: Non-Grain Oriented (Ngo) Si Steels Extension And Carbide-Free Bainitic (Cfb) For Flat Products, Naram Naidu Meesala

Masters Theses

"This research explores the development of advanced steel grades manufactured through Castrip® twin-roll thin strip casting technology, with particular attention to non-grain-oriented electrical Si-Steels (NGOES) and carbide-free bainitic (CFB) steels. The Castrip® process offers a near-net-shape route for producing thin steel strips, which greatly decreases the number of processing stages, lowers energy demand, and reduces carbon dioxide emissions when compared with traditional steel production methods.

In the NGOES part of the study, several industrial Fe–Si steel compositions were cold rolled to final thicknesses ranging from 0.35 mm to 0.15 mm. These materials were then exposed to short-duration continuous annealing at …

Effect Of Complex Alloying Elements On Oxide Scale Formation And Water-Jet Descaling Performance On Continuously Cast Low-Carbon Steels, Tochukwu P. Ojiako, Tsvetkov Dmitry, Mario Buchely, Haiming Wen, Simon N. Lekakh, Ronald J. O'Malley

Materials Science and Engineering Faculty Research & Creative Works

The formation and evolution of oxide scale in contact with mold flux during continuous casting, subsequent reheating, and hydraulic descaling are strongly governed by steel chemistry. To elucidate the effect of complex alloying elements (Si, Mn, and Cr), two industrially produced continuously cast low-carbon steel grades for manufacturing stamped parts (a base and alloyed steel grade) were investigated. The objective was to determine how alloying elements influence oxidation behavior, scale morphology, interfacial adhesion, and water-jet descaling efficiency. Continuously cast slab specimens were subjected to controlled thermal and atmospheric oxidation cycles simulating multistage industrial practice. Three initial surface conditions (industrial as-cast, …

Fused Filament Fabrication Additive Manufacturing Of 17-4 Ph Stainless Steel: Process–Structure–Property Relationships In Magnetic Materials, Maanav Patel

Theses and Dissertations

Additive manufacturing (AM) enables the fabrication of complex metallic components through layer-by-layer processing directly from digital models. Among AM techniques, material extrusion–based processes such as fused filament fabrication (FFF) provide an accessible method for producing metal parts using filament feedstocks composed of metal powders and polymer binders. When applied to precipitation-hardening stainless steels such as 17-4 PH, the processing route and heat treatments can influence the resulting microstructure and functional properties. This work investigates the magnetic behavior of 17-4 PH stainless steel fabricated using FFF and evaluates how heat treatment conditions influence measured magnetic properties. Samples were produced and analyzed …