Laser surface modification involves rapid melting and solidification is an elegant technique used for locally tailoring the surface morphology of alumina in order to enhance its abrasive characteristics. COMSOL Multiphysics® based heat transfer modeling and experimental approaches were designed and used in this study for single and multiple laser tracks to achieve densely-packed multi-facet grains via temperature history, cooling rate, solidification, scanning electron micrographs, and wear rate. Multi-facet grains were produced at the center of laser track with primary dendrites extending toward the edge of single laser track. The multiple laser tracks study indicates the grain/dendrite size increases as the laser energy density increases resulting in multiplying the abrasive edges which in turn enhance the abrasive qualities.

In this study an initial assessment of the composition – microstructure – property relationships in binary and ternary Ti – based systems are made possible using LENSTM technology. Laser Engineering Net Shaping (LENSTM), a rapid prototyping, directed laser deposition methodology of additive manufacturing (AM) was used to create bulk homogenous specimens that are compositionally graded. Compositionally graded specimens were made possible by incorporating elemental blends of powder during the LENSTM process. While there have been numerous studies assessing the influence of common elements (e.g., V, Mo, Al, and Cr) on the resulting microstructure in titanium alloys, other elements have been neglected. A systematic study of the Ti – Fe – Al ternary system based upon varying compositions of the eutectoid former, Fe with Al to stabilize the a and b phases respectively has also been neglected. This research effort focuses on exploiting the LENSTM process by rapidly assessing the composition – microstructure – property relationships in a combinatorial approach for the Ti – W, Ti – Fe, and Ti – Fe – Al systems. Compositionally graded specimens of Ti – xW (0<x<40wt.%(14.79at.%)), Ti – xFe (0<x<35wt.%(36.37at.%)), and Ti – xFe – yAl (0<x<40wt.%(36.37at.%)), y=5,10, 15wt.%) have been heat treated to …

Metal fatigue is a recurring problem for metallurgists and materials engineers, especially in structural applications. It has been responsible for many disastrous accidents and tragedies in history. Understanding the micro-mechanisms during cyclic deformation and combating fatigue failure has remained a grand challenge. Environmental effects, like temperature or a corrosive medium, further worsen and complicate the problem. Ultimate design against fatigue must come from a materials perspective with a fundamental understanding of the interaction of microstructural features with dislocations, under the influence of stress, temperature, and other factors. This research endeavors to contribute to the current understanding of the fatigue failure mechanisms. Cast aluminum alloys are susceptible to fatigue failure due to the presence of defects in the microstructure like casting porosities, non-metallic inclusions, non-uniform distribution of secondary phases, etc. Friction stir processing (FSP), an emerging solid state processing technique, is an effective tool to refine and homogenize the cast microstructure of an alloy. In this work, the effect of FSP on the microstructure of an A356 cast aluminum alloy, and the resulting effect on its tensile and fatigue behavior have been studied. The main focus is on crack initiation and propagation mechanisms, and how stage I and stage II cracks …

Magnesium alloys exhibit desirable properties for use in transportation technology. In particular, the low density and high specific strength of these alloys is of interest to the aerospace community. However, the concerns of flammability and susceptibility to corrosion have limited the use of magnesium alloys within the aircraft cabin. This work studies a magnesium alloy containing rare earth elements designed to increase resistance to ignition while lowering rate of corrosion. The microstructure of the alloy was documented using scanning electron microscopy. Specimens underwent salt spray testing and the corrosion products were examined using energy dispersive spectroscopy.

Sintering parameter effects on the microstructure of boron carbide and boron carbide/titanium diboride composites are investigated. The resulting microstructure and composition are characterized by scanning electron microscopy (SEM), x-ray microscopy (XRM) and x-ray diffraction (XRD). Starting powder size distribution effects on microstructure are present and effect the mechanical properties. Reactive spark plasma sintering introduces boron nitride (BN) intergranular films (IGF's) and their effects on fracture toughness, hardness and flexural strength are shown. Mechanical testing of Vickers hardness, 3-point bend and Chevron notch was done and the microstructural effects on the resulting mechanical properties are investigated.

A commercial epoxy was modified by adding fluorinated poly (aryl ether ketone) and in turn metal micro powders (Ni, Al, Zn, and Ag) and coated on mild steel. Two curing agents were used; triethylenetetramine (curing temperatures: 30 oC and 70 oC) and hexamethylenediamine (curing temperature: 80 oC). Variation in tribological properties (dynamic friction and wear) and surface energies with varying metal powders and curing agents was evaluated. When cured at 30 oC, friction and wear decreased significantly due to phase separation reaction being favored but increased when cured at 70 oC and 80 oC due to cross linking reaction being favored. There was a significant decrease in surface energies with the addition of modifiers.

This paper deals with various topics in micro electromechanical systems (MEMS) technology beginning with microactuation, MEMS processing, and MEMS design engineering. The fabrication and testing of three separate MEMS devices are described. The first two devices are a linear stepping motor and a continuous rotary motor, respectively; and were designed for the purpose of investigating the frictional and wear properties of silicon components. The third device is a bi-stable microrelay, in which electrical current conducts through a secondary circuit, via a novel probe-interconnect mechanism. The second half focuses on engineering a carbon nanotube / SU-8 photoepoxy nanocomposite for fabricating MEMS devices. A processing method for this material as well as the initial results of characterization, are discussed.

The effect of incorporation of montmorillonite layered silicate (MLS) on poly (ethylene terephthalate) (PET) matrix was investigated. MLS was added in varying concentration of 1 to 5 weight percent in the PET matrix. DSC and polarized optical microscopy were used to determine the crystallization effects of MLS addition. Non isothermal crystallization kinetics showed that the melting temperature and crystallization temperature decrease as the MLS percent increases. This delayed crystallization along with the irregular spherulitic shape indicates hindered crystallization in the presence of MLS platelets. The influence of this morphology was related with the fracture toughness of PET nanocomposites using essential work of fracture coupled with the infra red (IR) thermography. Both the essential as well as non essential work of fracture decreased on addition of MLS with nanocomposite showing reduced toughness.

Polymeric coatings are being used in a growing number of applications, contributing to protection against weather conditions and localized corrosion, reducing the friction and erosion wear on the substrate. In this study, various polypropylene (PP) coatings were applied onto steel substrates by compression molding. Chemical modification of PP has been performed to increase its adhesion to metallic surfaces by grafting of maleic anhydride (MAH) onto PP in the presence of dicumyl peroxide (DCP). Influence of different concentrations of MAH and DCP on the properties of resulting materials have been examined. The coated steel samples are characterized by scanning electron microscopy (SEM), shear adhesion testing, FTIR and tribometry. The coatings with 3 wt. % MAH have shown the maximum adhesion strength due to maximum amount of grafting. The wear rates increased with increasing the amount of MAH due to simultaneous increase in un-reacted MAH.

Thermoelectric (TE) devices can undergo degradation from reactions in corrosive environments and at higher operating temperatures by sublimation and oxidation. To prevent the degradation, we have applied two high temperature polymers (HTPs) as coatings for TE materials. Sintering temperatures were from 250°C to 400°C. We explain why dip coating is better technique in our study and had two potential HTPs for tests. By applying TGA (thermogravimetric analysis), we were able to figure out which HTPs have better thermal resistivity. Besides, TGA also help us to find proper curing cycles for HTPs. EDS and SEM results show that the coatings prevent oxidation and sublimation of TE materials. We also shorten HTP curing cycle time and lower the energy costs.

Recent commercial developments have created a need for alternative materials and methods for imparting oil/grease resistance to paper and/or paperboard used in packaging. The performance of a novel grease resistant functional coating comprised of polyvinyl alcohol (PVA), sodium tetraborate pentahydrate (borate) and acetonedicarboxylic acid (ACDA) and the application of said coating by means of flexographic press is presented herein. Application criteria is developed, testing procedures described, and performance assessment of the developed coating materials are made. SEM images along with contact angle data suggest that coating performance is probably attributable to decreased mean pore size in conjunction with a slightly increased surface contact angle facilitated by crosslinking of PVA molecules by both borate ions and ACDA.

Atom probe tomography as a 3D atomic-scale characterization tool has seen considerable development in the past decade, both in systems improvement and theoretical understanding. However, the time and expertise required from the outset of experimentation to analyzed results is highly asymmetric between metals and nonmetals. For complex oxides, this difficulty can be exemplified by GdBa2Cu3O7-x based high-temperature superconducting coated conductors. The objective of this dissertation is to further establish the experimental and theoretical knowledge required to effectively, and compositionally, study nanoscale defects in nonmetals using atom probe tomography; specifically, those influencing the electromagnetic properties of RBa2Cu3O7-x high temperature superconducting coated conductors. The results from this dissertation can be applied to other complex oxides, nitrides, carbides, or other nonmetallic systems, through the creation and use of an extensive open-source Python package, APAV.

Tissue engineering merges the disciplines of study like cell biology, materials science, engineering and surgery to enable growth of new living tissues on scaffolding constructed from implanted polymeric materials. One of the most important aspects of tissue engineering related to material science is design of the polymer scaffolds. The polymer scaffolds needs to have some specific mechanical strength over certain period of time. In this work bioresorbable aliphatic polymers (PCL and PLLA) were blended using extrusion and solution methods. These blends were then extruded and electrospun into fibers. The fibers were then subjected to FDA standard in vitro immersion degradation tests where its mechanical strength, water absorption, weight loss were observed during the eight weeks. The results indicate that the mechanical strength and rate of degradation can be tailored by changing the ratio of PCL and PLLA in the blend. Processing influences these parameters, with the loss of mechanical strength and rate of degradation being higher in electrospun fibers compared to those extruded. A second effort in this thesis addressed the potential separation of the scaffold from the tissue (loss of apposition) due to the differences in their low strain responses. This hypothesis that using knit with low tension will …

Aircraft engine components can be subjected to a large number of thermo-mechanical loading cycles and to long dwell times at high temperatures. In particular, the understanding of creep in single crystal superalloy turbine blades is of importance for designing more reliable and fuel efficient aircraft engines. Creep tests on single crystal superalloy specimens have shown greater creep strain rates for thinner specimens than predicted by current theories. Therefore, it is necessary to develop a more predictive description of creep processes in these materials for them to be used effectively. Experimental observations have shown that the crystals have an initial porosity and that the progressive growth of these voids plays a major role in limiting creep life. In order to understand void growth under creep in single crystals, we have analyzed the creep response of three dimensional unit cells with a single spherical void under different types of isothermal creep loading. The growth behavior of the void is simulated using a three dimensional rate dependent crystal plasticity constitutive relation in a quasi-static finite element analysis. The aim of the present work is to analyze the effect of stress traixiality and Lode parameter on void growth under both constant true stress and …

Laser-based additive manufacturing offers a high degree of thermokinetic flexibility that has implications on the structure and properties of the fabricated component. However, to exploit the flexibility of this process, it is imperative to understand the process-inherent thermokinetic evolution and its effect on the material characteristics. In view of this, the present work establishes a fundamental understanding of the spatiotemporal variation of thermokinetics during the fabrication of the non-ferrous alloys using the laser powder bed fusion process. Due to existing limitations of experimental techniques to probe such thermokinetics, a finite element method-based computational model is developed to predict the thermokinetic variations during the process. With the computational approach coupled with experimental techniques, the current work presents the solidification behavior influenced by spatially varying thermokinetics. In addition, it uniquely predicts the process-inherent multi-track multi-layer evolution of thermal cycles as well as thermal stress cycles and identifies their influence on the post-solidification microstructural evolution involving solid-state phase transformation. Lastly, the response of the material with a unique microstructure is recorded under various conditions (static and dynamic), which is again compared with the same set properties obtained for the same material processed via conventional routes.

Current ways to alter the microstructure of materials are usually through heat treatments, alloying, and other physical metallurgical methods. Recent efforts in the 21st century are focused on altering the microstructure of a material without physical contact which can be achieved through exposure to a magnetic field (MF). The motivation of this research is to study the quantum effects by subjecting solid-state metals to exposure of MFs. Many of the popular metals currently used in industry are paramagnetic. The ability to alter the microstructure and thus properties of these paramagnetic materials through a magnetic field would open new avenues to the field of research, including, potentially, a pollution-free, non-contact route. The effects of a magnetic field on the mechanical properties of paramagnetic materials were observed through compression testing of the pure paramagnetic material samples induced in a magnetic field. XRD and PPMS were used to relate flow stress to dislocation density and magnetic property of the samples when exposed to the presence of a static magnetic field. The effects of a magnetic field relative to alloyed paramagnetic materials were observed through the same procedure as pure paramagnetic elements. For this purpose, -Ti alloys were chosen as literature suggests a phase …

The objective of this thesis is to investigate the effects of adding natural fiber (kenaf fiber, retted kenaf fiber, and sugarcane fiber) into polymer materials. The effects are obtained by considering three main parts. 1. Performance in thermoplastic composites. The effect of fiber retting on polymer composite crystallization and mechanical performance was investigated. PHBV/PBAT in 80/20 blend ratio was modified using 5% by weight kenaf fiber. Dynamic mechanical analysis of the composites was done to investigate the glass transition and the modulus at sub-ambient and ambient temperatures. ESEM was conducted to analyze fiber topography which revealed smoother surfaces on the pectinase retted fibers. 2. Performance in thermoset composites. The effect of the incorporation of natural fibers of kenaf and of sugarcane combined with the polyester resin matrix is investigated. A comparison of mechanical properties of kenaf polyester composite, sugarcane polyester composite and pure polyester in tensile, bending, dynamic mechanical thermal analysis (DMA) and moisture test on performance is measured.. 3. Performance in sandwich composites. The comparison of the performance characteristics and mechanical properties of natural fiber composites panels with soft and rigid foam cores are evaluated. A thorough test of the mechanical behavior of composites sandwich materials in tensile, bending …

High entropy alloys (HEAs) are a relatively new class of solid solution alloys that contain multiple principal elements to take advantage of their high configurational entropy, sluggish diffusion, lattice distortion, and the cocktail effect. In recent development, work hardening mechanisms known as twinning induced plasticity (TWIP) and transformation induced plasticity (TRIP) have been found active in Al0.3CoCrFeNi (molar fraction) and Fe50Mn30Co10Cr10 (at %) HEA compositions. Friction-stir processing was done to increase the mechanical properties and improve the microstructure of the alloys for the purpose of high strain rate performance. Quasi-static tensile tests as well as top-hat geometry Split-Hopkinson pressure bar tests were conducted to view the mechanical properties as well as view the microstructural evolution at dynamic strain rates. Overall, the Al0.3CoCrFeNi condition after friction-stir processing and heat treatment has proved to have the best mechanical properties, and selecting from the conditions in this study, Al0.3CoCrFeNi has better shear localization resistance.

In this research, a temperature dependent tribological investigation of selected ternary oxides was undertaken. Based on the promising results of previous studies on silver based ternary oxides, copper based ternary oxides were selected to conduct a comparative study since both copper and silver are located in the same group in the periodic table of the elements. Two methods were used to create ternary oxides: (i) solid chemical synthesis to create powders and (ii) sputtering to produce thin films. X-ray diffraction was used to explore the evolution of phases, chemical properties, and structural properties of the coatings before and after tribotesting. Scanning electron microscopy, Auger scanning nanoprobe spectroscopy, and X-ray photoelectron spectroscopy were used to investigate the chemical and morphological properties of these materials after sliding tests. These techniques revealed that chameleon coatings of copper ternary oxides produce a friction coefficient of 0.23 when wear tested at 430 °C. The low friction is due to the formation of copper tantalate phase and copper in the coatings. All sputtering coatings showed similar tribological properties up to 430 °C.

Our research focuses on re-using a waste a material, cross-linked polyethylene abbreviated XLPE, which is a widely used coating for wires. XLPE is strong and has excellent thermal properties due to its chemical structure - what leads to the significance of recycling this valuable polymer. Properties of XLPE include good resistance to heat, resistance to chemical corrosion, and high impact strength. A wire is usually composed of a metal core conductor and polymeric coating layers. One creates a new coating, including little pieces of recycled XLPE in the lower layer adjacent to the wire, and virgin XLPE only in the upper layer. Industries are often wasting materials which might be useful. Mostly, some returned or excess products could be recycled to create a new type of product or enable the original use. This method helps cleaning the waste, lowers the costs, and enhances the income of the manufacturing company. With the changing of the thickness of the outer layer, the roughness changes significantly. Moreover, different processing methods result in surfaces that look differently.

Geckos are famous for the skill of switchable adhesion that they use to stick on various surface while keep their fingers super clean. In the dissertation, a unique mechanism was discovered to explain gecko self-cleaning phenomena. Using atomic force microscopy (AFM), we managed to compare the microparticle-substrate adhesion and the microparticle-seta adhesion with a single seta bonded to the AFM cantilever. A dynamic effect was approved that high pulling-off speed could increase the microparticle-substrate adhesion and thus the self-cleaning appears at high moving speed. Based on the self-cleaning theory, a gecko-inspired N-doped graphene surface with switchable adhesion was achieved, which was designed into a bio-inspired micromanipulator with a success rate over 90%. When electrical bias was applied on this biomimetic surface, the charge concentration induced an electrical double layer (ELD) on the convex surfaces, which attracts polar water molecules to form a water bridge on it, significantly enhancing the adhesion on the wrinkled graphene surface, mimicking the capillary force on beetle feet. Therefore, the bio-inspired adhesive surface can be controlled with speed, electrical bias, humidity and different material surfaces. The water attraction phenomenon on the polarized surface was further tested for the potential application of water collection and evaporation in …

In this dissertation, small and large NaCl particle-derived surfaces (Ra > 40 microns) were generated on 2D Zn materials, and the surfaces were carefully studied concerning topography, corrosion behavior, and bone cell compatibility. Increases in surface roughness accelerated the corrosion rate, and cell viability was maintained. This method was then extended to 3D porous scaffolds prepared by a hybrid AM/casting technique. The scaffolds displayed a near-net shape, an interconnected pore structure, increasing porosity paralleled to an increased corrosion rate, an ability to support cell growth, and powerful antibacterial properties. Lastly, nano/micro (Rz 0.02–1 microns) topographies were generated on 2D Zn materials, and the materials were comprehensively studied with special attention devoted to corrosion behavior, biocompatibility, osteogenic differentiation, immune cell response, hemocompatibility, and antibacterial performance. For the first time, the textured nonhemolytic surfaces on Zn were shown to direct cell fate, and the micro-textures promoted bone cell differentiation and directed immune cells away from an inflammatory phenotype.

This thesis examines the value of using dispersed conductive fillers as a stress/strain sensing material. The effect of the intrinsic conductivity of the filler on the ability to be effective and the influence of filler concentration on the conductivity are also examined. To meet these objectives, nanocomposites of polyvinylidene fluoride (PVDF) with carbon nanofibers (CNFs) and carbon nanotubes (CNTs) were prepared by melt-blending using a twin screw extruder. Since PVDF has a potential to be piezoresistive based on the type of crystalline phase, the effect of CNFs on PVDF crystallinity, crystalline phase, quasi static and dynamic mechanical property was studied concurrently with piezoresponse. Three time dependencies were examined for PVDF/CNTs nanocomposites: quasi-static, transient and cyclic fatigue. The transient response of the strain with time showed viscoelastic behavior and was modeled by the 4-element Burger model. Under quasi-static loading the resistance showed negative pressure coefficient below yield but changed to a positive pressure coefficient after yield. Under cyclic load, the stress-time and resistance-time were synchronous but the resistance peak value decreased with increasing cycles, which was attributed to charge storage in the nanocomposite. The outcomes of this thesis indicate that a new piezoresponsive system based on filled polymers is a viable …

The FeCo-V alloy, commercially referred to as Hiperco, is known for its great soft magnetic properties. However, the high cost of production has limited the usage of this alloy to small-scale applications, where the small volume and high magnetic performance are critical. Additive manufacturing (AM) has the potential to solve the production problems that exist in Hiperco manufacturing. The present research has focused on selective laser melting (SLM) based AM processing of Hiperco. The goal was to perform a detailed examination of SLM processed Hiperco and determine how the process parameters affect the microstructure, mechanical and magnetic properties. While a systematic set of SLM process parameters were employed, the results indicate that the energy density was quite similar for this set of process parameters, resulting in similar properties. Overall, the saturation magnetization (Ms) values were very good, but the coercivity (Hc) values were very high, in the case of all as SLM processed conditions. Additionally, a large variation in porosity was observed in the as SLM processed samples, as a function of process parameters. Interestingly, long-term heat-treatments of these samples in an Ar+H2 atmosphere resulted in substantial decreases in the Hc values. These results are presented and discussed.