The corrosion resistance under elevated temperature of additively manufactured 316L stainless steel made by directed energy deposition was studied. Test samples were prepared in a hybrid additive manufacturing machine using standard deposition parameters recommended by the manufacturer. Control samples were cut from wrought material to compare the results. The test was performed under a corrosive atmosphere with a solution of water with 3.5 % in weight of salt (NaCl). The total duration of the test was 635 hours, divided in five stages of 12, 24, 48, 226, and 325 hours to analyze the samples between each stage. The samples were analyzed quantitatively measuring weight loss and surface topography, and qualitatively by macroscopic inspection with digital photography, and microscopic inspection with optical and scanning electron microscopy. The results show a higher corrosion rate for the additively manufactured samples compared to the control samples. An evident increase in the size of pits initially present on the samples was observed and quantified on the additively manufactured. Although the additively manufactured samples were more aggressively attacked by corrosion, they still presented a shiny surface finish at the end of the test, reinforcing the idea of the formation of a passive oxide layer and suggesting …

Non-imaging Fresnel lenses have been playing an important role in improving the efficiency of the solar energy systems. Many researchers and scientists have devoted their research to optimize the design of the Fresnel lenses. Before it can contribute to energy efficiency increase, a Fresnel lens with optimized design will first need to be fabricated with the most cost-effective method as well as the best quality fabrication as possible. If targeted in a commercial market, feasibility of mass production with a minimum fabrication time would also be a consideration. To bring the design optimization of a Fresnel lens from a conceptual theory to a real-life increase in energy efficiency, the lens needs to be fabricated, tested, compared, and analyzed. This research thesis is intended to explore the performance of the lenses with optimized design through experimental investigations. The design optimization was achieved by a previous PhD student at UNT. A total of six lenses fabricated with four different methods along with two purchased lenses were tested with two different approaches. Multiple testing routes were conducted within a 10-month period to observe the effects of material decomposition and degradation on the lens performance. The resulting experimental data has provided a solid base …

The interest toward Mars exploration has been considerably increasing due to also the successful deployment of the Perseverance rover and the continuous tests developed by SpaceX's launch vehicle, Starship. While the Mars 2020 mission is currently in progress, the first controlled flight on another planet have been proven in April 2021 with the vertical take-off and landing of the Ingenuity rotorcraft on Mars. In addition, the rotorcraft Dragonfly is expected to achieve the same endeavor in Titan, the largest moon of Saturn, by 2036. Continuous efforts have been oriented toward the development of new technologies and aircraft configurations to improve the performance of current proposed designs to achieve powered flight in different planetary bodies. This thesis work is a preliminary study to develop a comprehensive analysis over the generation of optimum airfoil geometries to achieve vertical flight in environments where low Reynolds numbers and Mach number equal to 0.2 and 0.5.

This thesis details the creation and application of a generalized process plan for the hybrid manufacturing of AISI 316L stainless steel, using direct energy deposition (DED) and ball-nose end-mill machining, that includes the inspection and measurement of objects created by that hybrid manufacturing process plan. The proposed process plan progresses through the selection of substrate thickness, single-track, multi-track, and multi-layer depositions, then on to machining processing. A manufacturers' recommended set and range of DED parameters were used to create a designed experiment that aided in the analysis of objects created in each of the DED process planning steps; those objects were then machined in the same enclosure using a set of machining parameters screened from industry recommendations for ball-nose milling of stainless steel, after which measurements were taken for surface roughness, some material characteristics, and for tool deterioration. The results, analyses, and discussions collected herein show that the proposed process plan can provide models for geometrical outputs for each step in the plan, some improvements in substrate stability, surface roughness, tool deterioration, and material porosity due to voids. Current research in hybrid manufacturing does not show generalized process planning influences. The process plan as demonstrated by the work in this …

Recently, 3D printing has received increasing attention for the fabrication and assembly of electrodes for batteries due to the freedom of creating structures in any shape or size, porosity, flexibility, stretchability, and chemistry. Particularly, zinc ion batteries (ZIBs) are favored due to high safety, cheap materials cost, and high volumetric capacity (5,849 mAh/cm3), however, rapid evaporation of Zn due to low melting temperature has limited its 3D printability via conventional laser-based additive manufacturing technique. Here, we develop a printable ink for the fabrication of flexible and 3D printed Zn anode with varied surface areas using the direct ink writing (DIW) method. Our 3D printed porous and high surface area Zn anode structures effectively suppressed the dendrite growth while providing high Zn ion diffusion towards the cathode to significantly enhance the performance of ZIB. By varying filament distancing and path, we 3D printed zinc anode structures with different active surface areas, surface area to volume ratio, porosity, flexible and multiple layer structures that can be incorporated on any device. Carbon in the composite improved conductivity, and mechanical stability of 3D printed zinc anode. Our 3D printed composite anodes allowed flexible designing of batteries surpassing conventional battery designs such as coin cells …

This thesis describes the experimental and numerical investigation of a novel cold-formed steel 48ft and 54ft long span truss. The truss we designed was to be used as the roofs of large buildings, such as warehouses, hangars, sports arenas. The investigation includes both experimental and numerical testing, the experimental testing of the truss under uniform loads (increasing loads) to determine its deflection and load carrying capacity. The numerical test included developing a finite element model of the truss in SolidWorks and using a finite element model of the truss in ABAQUS to simulate the experimental tests. The findings of this study can be used to improve the design of cold-formed steel long span trusses. The study also provides valuable information for future studies on the modeling of trusses with different cold-formed steel members and the behavior of trusses under load.