Manufacturing Commons^™

Development Of Multifunctional Wood Composites With Integrated Phase Change Materials For Enhanced Thermal Management, Self-Healing, And Sustainability., Emmanuel Igbokwe

LSU Master's Theses

Abstract

This study focused on incorporating self-healing, flame retardancy, and energy harvesting capabilities into the wood composite to contribute to more sustainable and energy-efficient building practices. Oriented strand board has been widely used as sheath for roofing or dry walls in residential buildings. Residential buildings account for a large portion of energy consumption. Therefore, an oriented strand board with energy harvesting capability is highly desired. Additionally, flame retardancy and damage self-healing and end-of-life recycling are also critical features for buildings.

In this study, we prepared a novel oriented strand board by constructing sandwich structures. The face sheets of the sandwich …

A Manufacturing-To-Response Pathway For Manufacturing Optimization Of Carbon Fiber Reinforced Polymer Composite Structures, Madhura Limaye

All Dissertations

Over the past decade, there has been an increased adoption of thermoplastic and thermoset based continuous carbon fiber reinforced polymer (CFRP) composites for structural applications in several industries. Among the different manufacturing methods, thermoforming process for thermoplastic based continuous CFRP’s offer a major advantage in reducing cycle times for large scale productions. Similarly, out-of-autoclave curing process for thermoset based continuous CFRP’s using heated tooling enables production of large composite structures. However, these manufacturing processes can have a significant impact on the structural performance of parts by inducing undesirable effects. These effects include inhomogeneous fiber orientations, thickness variations, and residual stresses …

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

LSU Doctoral Dissertations

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

Balsa Bridge, Caleb T. Lovett

All Undergraduate Projects

The problem presented throughout this report was to create a small-scale bridge made entirely out of balsa wood and glue, that could withstand substantial force, as well as perform a lifting/lowering cycle. Other requirements associated with the bridge were properties of weight, deflection, size, and shape. This problem presented a challenge that tested the mathematical side of engineering, being strongly reliant on statics, mechanics of materials, and mechanical design analyses.

To approach this problem, the first step was to complete in depth calculations of the chosen design. With this done, manufacturing and assembly was able to be completed. With a …

Kissing Bond Assessment In Adhesive Bonded Carbon Fiber Reinforced Composites Using Dielectric Spectroscopy, Minhazur Rahman

Mechanical and Aerospace Engineering Dissertations - Archive

The widespread use of fiber-reinforced composites in industries such as space, aviation, automobiles, and construction necessitates the formation of robust composite joints between critical structural components. Although adhesive-bonded joints are superior with improved load distribution and reduced weight, they are often overlooked in favor of bolted joints and mechanical fasteners due to the lack of reliable Non-Destructive Evaluation (NDE) techniques for adhesive-bonded composites. The anisotropic nature of the substrate and the intricate interfacial interactions between the adherend and adhesive material present significant challenges for conventional NDE methods. Moreover, weak adhesive bonds can result from uncontrolled manufacturing parameters, such as accidental …

Fatigue Resistant Cast Steel Railcar Couplers Produced By Wire-Arc Additive Manufacturing (Waam), Samuel Vellequette

Dissertations, Master's Theses and Master's Reports

Every year, approximately 90,000 cast steel railcar coupler knuckles are replaced preemptively to avoid fatigue failure. The coupler geometry has been in service since the early 1930s, so geometry changes are restricted to maintain compatibility with the existing fleet. Defects from the casting process, decarburization during heat treatment, and in-service exposure to corrosive environments combine to promote fatigue crack nucleation in high-stress regions of the knuckle. Wire-arc additive manufacturing (WAAM), which uses traditional welding techniques to build material to near-net shapes, was employed to deposit higher-strength materials in critical regions. By replacing the cast steel in the high-stress region of …

Extending Trailer, Alex Grove

Williams Honors College, Honors Research Projects

The goal of this research project is to revolutionize the convenience in towable transportation. This innovative design aims to enhance the versatility of pull-behind trailers by incorporating an extendable feature, allowing users to effortlessly adjust the length according to their specific needs. Whether navigating tight spaces or accommodating extra cargo, our trailer adapts to diverse situations, providing unmatched flexibility. In addition to its adjustable length, the trailer is engineered to be compactable, addressing the storage constraints often faced by users with limited space. The collapsible design ensures easy storage without compromising on functionality, making it an ideal solution for individuals …

Experimental Investigation Of Liquid Metal Embrittlement In Hot-Dip Galvanized Structural Steel, Amelia Mcnamee

College of Graduate Studies: Theses & Dissertations

This research investigated the liquid metal embrittlement (LME) of hot-dipped galvanized structural steel. The relationship between stress and failure time was analyzed to evaluate the potential presence of a critical stress threshold beyond which LME may occur. A testing apparatus to induce axial stress was designed and assembled in-house. A36 low carbon steel was tested in this study. Different deadweight loadings were applied to the testing sample along the axial direction. The test temperature was maintained by a programmable furnace while the sample gauge section was submerged in a molten zinc bath. Failure time and total displacement of the steel …

Impact Of Quenching Intensity Conditions On Using A Finite Element Model To Investigate The Microstructure And Hardenability Of Low-Alloy Steel, J. S. Alabi, E. Heidari, M. F. Buchely, K. Chandrashekhara, S. N. Lekakh, R. J. O'Malley, V. Athavale, A. Kumar

Materials Science and Engineering Faculty Research & Creative Works

Quenching is one of the primary processes to improve mechanical properties in steels, particularly hardness. Quenching is well established for different geometries of individually treated steel components; while in-steam quenching of large diameter continuously cast steel bar has several specific features which are difficult and costly to experimentally optimize. the end-quench Jominy test has been used extensively to study the hardenability of different steel grades. Different numerical, analytical, and empirical models have been developed to simulate the Jominy process and to understand quenching of steels. However, it is not straight forward to translate experimental data from Jominy test on instream …

Impact Of Quenching Intensity Conditions On Using A Finite Element Model To Investigate The Microstructure And Hardenability Of Low-Alloy Steel, J. S. Alabi, E. Heidari, M. F. Buchely, K. Chandrashekhara, S. N. Lekakh, R. J. O'Malley, V. Athavale, A. Kumar

Materials Science and Engineering Faculty Research & Creative Works

Quenching is one of the primary processes to improve mechanical properties in steels, particularly hardness. Quenching is well established for different geometries of individually treated steel components; while in-steam quenching of large diameter continuously cast steel bar has several specific features which are difficult and costly to experimentally optimize. The end-quench Jominy test has been used extensively to study the hardenability of different steel grades. Different numerical, analytical, and empirical models have been developed to simulate the Jominy process and to understand quenching of steels. However, it is not straight forward to translate experimental data from Jominy test on instream …

Mechanical Characterization Of Functionally Graded M300 Maraging Steel Cellular Structures, Bradley Jay Sampson

Theses and Dissertations

Traditional methods for increasing the energy absorption of a structure involve using a stronger material or increasing the volume of the structure, resulting in a higher cost or additional weight. Additive manufacturing (AM) can be used to maximize the energy absorption of materials with the ability to create complex geometries such as cellular structures. Previous work has shown that the energy absorption of additively manufactured parts can be improved through functionally graded cellular structures; however, this strategy has not been applied to ultra-high strength steel materials. This work characterizes the effect of multiple functional-grading strategies (e.g. uniform, rod-graded, size-graded) on …

Implementation Of Experimental Static Recrystallization Of High Strength Steel Into Computational Simulation Of Multi-Pass Slab Hot Rolling, S. K. Dasari, S. Ganguly, A. Abutunis, K. Chandrashekhara, M. F. Buchely, S. N. Lekakh, R. J. O'Malley, T. Natarajan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Microstructural changes and softening due to static recrystallization have a critical influence on thermo-mechanical behavior of high strength steels during industrial multi-pass hot rolling. Numerical simulation using finite element analysis (FEA) can be used to accurately predict the softening behavior during the hot rolling process. Therefore, the implementation of an experimentally defined static recrystallization model into FEA is necessary to get realistic simulation prediction. in this study, the extent of softening during static recrystallization in Si and Mn alloyed high strength steel was measured using double hit tests. a Gleeble™ thermo-mechanical simulator was used to perform the double hit tests …

Fatigue And Fracture Of Electron Beam Melting Ti-6al-4v, William A. Grell

Electronic Theses and Dissertations

For applications in the aerospace field, selection of materials for a given design requires an understanding of critical properties, like fatigue and fracture, in addition to static mechanical and physical properties. With the ongoing advancements in metallic additive manufacturing techniques and the interest in applying the process to aerospace applications, there is a clear need to fully characterize properties. Arguably, the most attractive alloy for applications in aerospace is the Ti-6Al-4V alloy. The current dissertation examines the mechanical properties of the alloy, made by the Electron Beam Melting (EBM) Powder Bed Fusion (PBF) method. As illustrated in this work, the …

A Strong And Ductile Cobalt-Free Solid-Solution Fe30ni30mn30cr10 Multi-Principal Element Alloy From Hot Rolling, Hans Pommerenke, Jiaqi Duan, Nathan Curtis, Victor Delibera, Adam Bratten, Andrew Hoffman, Mario Buchely, Ronald O'Malley, Haiming Wen

Materials Science and Engineering Faculty Research & Creative Works

Most of the face-centered cubic (FCC) multi-principal element alloys (MPEAs) developed thus far contain cobalt. for many applications, it is either required or beneficial to avoid cobalt, since cobalt has long-term activation issue (for nuclear applications), is expensive, and is considered a critical material. in addition, FCC structured solid-solution MPEAs tend to have relatively low strength. an FCC solid-solution Fe30Ni30Mn30Cr10 (at %) MPEA was fabricated via arc melting, followed by homogenization at 1100 °C for 12 h. the alloy was hot rolled at 1100 °C with a total reduction of up to 97 %. the microstructure was characterized, and mechanical …

A High-Strength Precipitation Hardened Cobalt-Free High-Entropy Alloy, Matthew Luebbe, Jiaqi Duan, Fan Zhang, Jonathan Poplawsky, Hans Pommeranke, Maalavan Arivu, Andrew Hoffman, Mario Buchely, Haiming Wen

Materials Science and Engineering Faculty Research & Creative Works

Recent studies on precipitation-hardened high-entropy alloys (HEAs) demonstrate their high strength and thermal stability, making them promising materials for high-temperature structural applications such as nuclear reactors. However, many existing HEAs contain cobalt (Co), which is unsuitable for nuclear applications because of the long-term activation issue of Co. Co is also expensive and considered a critical material for other applications. Therefore, it is desired to exclude Co from the composition. a Co-free (Fe0.3Ni0.3Mn0.3Cr0.1)88Ti4Al8 HEA was developed and studied in this work. in contrast to previous Co-free HEAs, this alloy is close to Equi atomic in its composition and promises a more …

Investigation Of Microstructurally Dependent Mechanical Properties Of Cold Sprayed Copper Using Correlative Microscopy, Quintin Otto

UNF Graduate Theses and Dissertations

This project employs multi-instrument materials characterization to analyze material made with the “Cold Spray” additive manufacturing process. Cold spray is an emerging additive manufacturing technique with unique benefits resulting from its low temperature adhesion process induced by plastic deformation. Metallic powder collides at high speeds creating three dimensional materials and coatings without the need for melting. Copper cold sprayed specimens were analyzed using a series of imaging techniques to characterize the microstructure at varying levels of detail and magnification. Scanning electron microscopy and electron back scattered diffraction were paired with microhardness testing to generate a correlative comparison between microstructure and …

Development Of Inconel 718f And Inconel 718e Powders For Parts Manufacturing Utilizing Binder Jet Three-Dimensional Printing And Compressed Pellet Methods, Duncan Eric Manor Ii

Graduate Theses, Dissertations, and Problem Reports (ETD)

Alloy Inconel 718 is a Ni based superalloy used for high temperature applications including turbine blades, turbocharger rotors and nuclear reactors. Inconel 718 is a popular commercial atomized powder that has limitations in performance for use in additive manufacturing applications due to poor part quality and efficiency of current fabrication methods. Developing new compositions and additive manufacturing (AM) methodologies of IN718 is critical to improve the quality and the efficiency of IN718 parts manufacturing. Developing new additive manufacturing methodology that produces higher quality parts made of IN718 as compared to current methods has the potential to greatly impact industry, academia, …

Bbt Acoustic Alternative Top Bracing Cadd Data Set-Norev-2022jun28, Bill Hemphill

STEM Guitar Project’s BBT Acoustic Kit

This electronic document file set consists of an overview presentation (PDF-formatted) file and companion video (MP4) and CADD files (DWG & DXF) for laser cutting the ETSU-developed alternate top bracing designs and marking templates for the STEM Guitar Project’s BBT (OM-sized) standard acoustic guitar kit. The three (3) alternative BBT top bracing designs in this release are
(a) a one-piece base for the standard kit's (Martin-style) bracing,
(b) 277 Ladder-style bracing, and
(c) an X-braced fan-style bracing similar to traditional European or so-called 'classical' acoustic guitars.

The CADD data set for each of the three (3) top bracing designs includes …

Effects Of Bonding Pressure And Lamina Thickness On Mechanical Properties Of Clt Composed Of Southern Yellow Pine, Cody S. Bates

Theses and Dissertations

This study produced cross-laminated timber panels at a range of four lamina thickness (5/8, 1, 1 1/8, and 1 1/4 inch) and three bonding pressures (50, 125, 200 psi), producing a total of 12 panels for mechanical testing. The goal of this study is to observe how the thickness and pressure trends affect the mechanical properties of CLT. Tests include flatwise bending, flatwise shear, internal-bond, and delamination. Results showed that bending MOE decreases as the panel thickness increases while bonding pressure had no significance. Bending MOR was less significant for the thickness and more significant for pressure compared to the …

Rapid Annealing Of Perovskite Solar Cell Thin Film Materials Through Intense Pulse Light., Amir Hossein Ghahremani

Electronic Theses and Dissertations

Perovskite solar cells (PSCs) have garnered a great attention due to their rapid efficiency improvement using cheap and solution processable materials that can be adapted for scalable high-speed automated manufacturing. Thin film perovskite photovoltaics (PVs) are typically fabricated in an inert environment, such as nitrogen glovebox, through a set of deposition and annealing steps, each playing a significant role on the power conversion efficiency (PCE), reproducibility, and stability of devices. However, atmospheric processing of PSCs would achieve lucrative commercialization. Therefore, it is necessary to utilize materials and methods that enable successful fabrication of efficient PSCs in the ambient environment. The …

Noise Control In Sorting Conveyors, Eyra Herrera

Mechanical Engineering Undergraduate Honors Theses

E-commerce has increased the necessity of effective material handling equipment in warehouses and distribution centers. Sorter conveyors systems facilitate material handling by providing a reliable and automated system to classify and distribute products in a gentle and rapid manner. With the steady increase of speed in sorter conveyors to satisfy today’s industry demand, some systems have started to produce high noise levels that could potentially affect workers’ health. Since decreasing the speed of these conveyors is not a viable option to decrease noise in sorter equipment, industries have opted to find other ways to apply noise control to their equipment. …

Jcati Base Plate, Jacob Atamian

All Undergraduate Projects

Students of the Mechanical Engineering Technology (MET) program at Central Washington University have contributed to an ongoing Carbon Fiber Recycler project funded by the Joint Center for Aerospace Technology Innovation (JCATI). The goal of this project was to modify the existing recycling system to produce a higher success rate of recycled carbon composite material. This report focuses on increasing the rigidity of the crushing gears so that the deflection occurring among the components during operation was below 0.005 inches to ensure proper operating conditions. The operating speed of the crushing gears was 2.5 rpm with a crushing load of 10,500 …

Balsa Wood Bridge, Andrew Harris

All Undergraduate Projects

Faculty at Central Washington University proposed a challenge to mechanical engineering students that could be accomplished in an in-home setting. The goal was to create a balsa wood bridge, weighing no more than 85 grams, that can support a load over an open span and raise above its resting position by means of a mechanical system. To produce a successful solution to the problem, a vertical lift bridge was created consisting of two lifting towers and a load bearing bridge. Using equations of static equilibrium and strength of materials, the required width for each member was determined. Project requirements were …

Mini Rc Baja Car, Jason Schindler

All Undergraduate Projects

Incorporating each aspect of engineering incorporated into a senior project is difficult. That is why an RC Baja car is a great senior project for Mechanical Engineering students. The approach that students must take to design, construct, and test the car is to set parameters, and to make overall goals that can be easily measured. These goals include, but not limited to things like a $700 budget and the ability to withstand a 1-foot drop to a flat surface on all four wheels simultaneously. First, the design must meet the specifications and rules that are set previously. This ensures that …

Hydraulic Balsa Wood Rising Bridge, Kaitlyn Greenfield

All Undergraduate Projects

What is the solution to allowing tall vessels to navigate past a vehicle bridge that is less than 10 [ft] above the water? To answer this question, a balsa wood bridge was designed, constructed, and tested. The bridge needed to articulate by mechanical means, allow for travel through the bridge, and be able to withstand ample force while the main structure only being constructed of balsa wood and glue. The project was analyzed in sections. These sections include: the bridge structure and its members, the hydraulic lift, and the pins needed for the bridge and hydraulic lift to operate. The …

Tailoring Texture, Microstructure, And Shape Memory Behavior Of Niti Alloys Fabricated By L-Pbf-Am, Sayed Ehsan Saghaian N.E.

Theses and Dissertations--Mechanical and Aerospace Engineering

Laser Powder Bed Fusion (L-PBF) is one of the most promising Additive Manufacturing (AM) methods to fabricate near net-shape metallic materials for a wide range of applications such as patient-specific medical devices, functionally graded materials, and complex structures. NiTi shape memory alloys (SMAs) are of great interest due to a combination of unique features, such as superelasticity, shape memory effect, high ductility, work output, corrosion resistance, and biocompatibility that could be employed in many applications in automotive, aerospace, and biomedical industries. Due to the difficulties with traditional machining and forming of NiTi components, the ability to fabricate complex parts, tailor …

Formula Sae Monocoque Chassis Development, Kc Egger, Brian Ford, Kyle Nagao, Neal Sharma, Donovan Zusalim

Mechanical Engineering

Formula SAE is a collegiate competition hosted by SAE International with the primary goal being to design, manufacture, and race an open wheel race car. The Cal Poly Racing Formula SAE team strives for improvement every race season and has remained competitive as a result. The 2019-2020 management team determined that further research and development towards the chassis would yield the greatest performance benefit for future seasons, as the previous chassis platform limited packaging and mounting options for vehicle subsystems which interfaced with the chassis.

A redesign of the Cal Poly Racing Formula SAE team’s carbon fiber reinforced polymer monocoque …

Comparison Of Pressure-Assist Silver Sintering To Tin Silver Solder Alloy As Die Attach Material In High Power Semiconductor, Tolentino Erik Nino

Student Works (2020-2029)

The research is focused on pressure-assisted silver sintering material that is compared to tin silver solder alloy paste as used in power electronics. Material characterization, electrical tests, and reliability tests were conducted in the experiment. After drying process, it was observed that the Ag sintering paste height was reduced to approximately 40 percent. Die attach shear test showed that the average reading is about from 200 to 600 grams which are already enough to hold the dice before proceeding to the pressure sintering process. X-ray revealed that the void percent for SnAg paste sample is about 1.5 percent while pressure-assist …

Preventing Delayed Cracks In Sus304 Deep Drawn Cups Using Extreme Blank Holding Forces Aided By Nanolubrication, Ibrahim Muhammad Shafiq

Student Works (2020-2029)

This study was to investigate the formation and reformation of delayed cracks of SUS304 cylindrical drawn cups under elevated blank holding force (BHF) from 8~32 kN with 1~3 wt% SiO2 nanolubricants concentrations. The widest crack-free BHF range i.e. from 29 ~ 31 kN was determined for 2 wt% of SiO2 in the experiment. Delayed cracks were also observed below and beyond this BHF range. There was an increment of frictional force at the cup flange region when entering the crack-free BHF range, as proven by the rebound in sidewall thickness, relative intensity of α′-martensite, elongated height and drawing force beyond …

Microstructural Characteristics And Mechanical Properties Of Sn-Ag-Cu Solders With Minor Additions Of Al And Zn, Yee Mei Leong

Student Works (2020-2029)

Driven by the recent trend towards miniaturization of lead free electronic products, researchers are putting immense efforts to improve the properties and reliability of Sn based solders. Recently, much interest has been shown on low silver (Ag) content solder SAC 105 (Sn-1.0Ag-0.5Cu) solder because of economic reasons and improvement of impact resistance as compared to SAC387(Sn-3.8Ag-0.7Ag). The present work investigates the effect of minor (0.1-0.5wt.%) Aluminium (Al) and Zinc (Zn) addition to SAC105 on the bulk and interfacial structure between solder and copper substrate during reflow and after thermal aging , the mechanical properties of the solder joint and the …