Chalcogen-rich transition-metal dichalcogenide (TMD) magnetron sputtering targets were custom manufactured via ball milling and sintering in the interest of depositing p-type chalcogen-rich films. Room temperature radio frequency (RF) magnetron sputtering produced ultra-thin amorphous precursor of WSx and MoSx (where x is between 2-3) on several different substrates. The influence of working pressure on the MoS3 content of the amorphous films was explored with X-ray photoelectron spectroscopy (XPS), while the physical and chemical effects of sputtering were investigated for the WSx target itself. The amorphous precursor films with higher chalcogenide content were chosen for laser annealing, and their subsequent laser annealing induced phase transformations were investigated for the synthesis of polycrystalline 2H-phase semiconducting thin films. The role of laser fluence and the number of laser pulses during annealing on phase transformation and film mobility was determined from Raman spectroscopy and Hall effect measurement, respectively. Hall effect measurements were used to identify carrier type and track mobility between amorphous precursors and crystalline films. The p-type 2H-TMD films demonstrates the ability to produce a scalable processing criterion for quality ultra-thin TMD films on various substrates and in a method which is also compatible for flexible, stretchable, transparent, and bendable substrates.

To design high pressure fuel system components that resist wear and scuffing failure when operated in low viscosity fuels, a comprehensive study on the tribological performance of various existing coating materials is necessary. This thesis aims to provide the relative performance of a variety of coating materials across different fuel environments by testing them in conditions that model those experienced in fuel pumps. The relative performance of these coatings are then indexed across a variety of material properties, including hardness, elastic modulus, wettability, and the interaction between the surface and the various types of fuel molecules.

Ceramics have a wide variety of applications due to their unique properties; however, the low fracture toughness leads the formation and propagation of unpredictable cracks, and reduces their reliability. To solve this problem, self-healing adaptive oxides were developed. The aim of the work is to gain new insights into self-healing mechanisms of ceramics and their application. Binary oxide systems were investigated that are at least partially healed through the extrinsic or intrinsic addition of silver or silver oxide to form ternary oxides (e.g., Nb2O5 + Ag → AgNbO3). Sintered pellets and coatings were tested. For self-healing TBCs, model systems that were studied include YSZ-Al2O3-SiC, YSZ-Al2O3-TiC, YSZ-Al2O3-Nb2O5, and YSZ-Al2O3-Ta2O5. Laser cladded samples and sintered pellets were produced to test. The healing process occurs due to the formation of oxidation products and glassy phases depending on the self-healing mechanism. X-ray diffraction was used to explore phase evolution, chemical compositions, and structural properties of these samples. SEM equipped with EDS was used to investigate the chemical and morphological properties for the cross-sectional area. Pin-on-disc test was applied to test tribology performance for Nb2O5-Ag2O system, and infiltration test was applied to test CMAS-resistance for TBCs at elevated temperature. The improvements in the performance of …

Ti and Ti-based alloys are used in many aerospace and automotive components due to their high strength-to-weight ratio and corrosion resistance. However, room and elevated temperature wear resistance remain an issue, thus requiring some form of secondary hard phase, e.g., refractory carbides and oxides, as well as solid lubrication to mitigate wear. In this study, Ti-TiC (14, 24 and 35 vol% TiC) composite coatings were deposited on mild steel substrates using cold spray with comparisons made to baseline cold-sprayed Ti. The dry sliding friction and wear behavior were studied from 25°C to 575°C and during thermal cycling in this temperature range. While the room temperature friction coefficient of all the coatings remained relatively constant at ~0.5, the wear rate continually decreased from ~1x10-3 to ~2x10-5 mm3/N-m with increasing the TiC loading. Raman spectroscopy measurements determined that the same TiO2 tribochemical phases (rutile and anatase) were present on the room temperature sliding wear surfaces, thus responsible for similar friction coefficients. With increasing sliding temperatures to 575°C, the Ti-35%TiC composite coating exhibited the best overall tribological behavior, i.e., the friction coefficient decreased to ~0.3 along with a negative wear rate of -6.6x10-5 mm3/N-m (material gain on the wear track was recorded due …

Traditional lightweight armor ceramics such as boron carbide (B4C) and silicon carbide (SiC) are used alone or together in varying amounts to create monolithic protective plates. These materials exhibit relatively small differences in hardness, flexure strength, and fracture toughness. Many of the routes taken during the synthesis of the powder and sintering of the plates using traditional ceramic processing techniques have long processing times, tend to leave asperities within the microstructure, and have unwanted secondary phases that lower the performance of these materials. In lieu of the incremental changes in the above properties, it is thought that adding diamond particulates to the ceramic matrix will dramatically improve the mechanical properties and overall performance. With the reduced cost of synthetic diamond and the commercial development of more rapid spark plasma sintering (SPS), this work develops a novel reactive SPS process to fabricate near fully dense SiC-TiC-diamond composites at various processing temperatures with minimal graphitization and full adhesion to the ceramic matrix. It was found that samples with up to ~97% theoretical density can be fabricated with no quantifiable graphite content within the characterization ability using advanced X-ray diffraction and microscopy techniques.

The current work investigates how the interactions among constituent elements in high entropy alloys or complex concentrated alloys (HEA/CCAs) can lead to lattice instability and local chemical ordering which in turn affects the microstructure and properties of these alloys. Using binary enthalpies of mixing, the degree of ordering in concentrated multi-component solid solutions was successfully tailored by introducing Cr, Al and Ti in a CoFeNi HEA/CCA. CoFeNi was selected as the base alloy to achieve a close to random solid solution as indicated by the near-zero binary enthalpies in CoFeNi alloy system. The room temperature tensile properties of these alloys with varied degree of ordering follow a consistent trend where yield stress increased with degree of ordering. This novel approach provides a new alloy design strategy to obtain controlled ordering tendencies and consequently targeted mechanical properties. Further studies on specific alloys have been conducted to utilize this ordering tendency in attaining precipitation strengthening. For this purpose, Al, Ti and Ni were selected to promote ordering and Co, Fe, and Cr were chosen to strengthen the solid solution matrix. In Al0.25CoFeNi HEA/CCA, the ordering tendency between Al and Ni results in a competition between two long-range ordered phases, L12 and B2. …