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 …

Waste-heat-to-power (WHP) recovers electrical power from exhaust heat emitted by industrial and commercial facilities. Waste heat is available in enormous quantities. The U.S. Department of Energy estimates 5-13 quadrillion BTUs/yr with a technical potential of 14.6 GW are available and could be utilized to generate power by converting the heat into electricity. The research proposed here will define a system that can economically recover energy from waste heat through a thermal regenerative electrochemical system. The primary motivation came from a patent and the research sponsored by the National Renewable Energy Laboratory (NREL). The proposed system improves on this patent in four major ways: by using air/oxygen, rather than hydrogen; by eliminating the cross diffusion of counter ions and using a dual membrane cell design; and by using high concentrations of electrolytes that have boiling points below water. Therefore, this system also works at difficult-to-recover low temperatures. Electrochemical power is estimated at 0.2W/cm2, and for a 4.2 M solution at 1 L/s, the power of a 100 kW system is 425 kW. Distillation energy costs are simulated and found to be 504 kJ/s for a 1 kg/s feed stream. The conversion efficiency is then calculated at 84%. The Carnot efficiency for …

The objective of this research is to determine how the sandwich's physical characteristics have an impact on the mechanical properties, determine under what conditions the specimens will be lighter and mechanically stronger, and determine if the use of an aluminum honeycomb sandwich as a construction material is feasible. The research has aimed at the use of aluminum sandwiches as light and strong material. The study of the structural layers' damage resistance and tolerance demonstrated that the top and bottom layers play a crucial role. The thesis presents three test results from aluminum honeycomb sandwich compression horizontal, compressive vertical, and bending tests. Also, each group was displayed mechanically and simulated in Abaqus. The study determines the mechanical properties such as maximum elastic stress-strain, ultimate stress-strain, fracture point, density, poison ration, young modulus, and maximum deflection was determined. The energy absorbed by the FEA, such modulus of elasticity, resilience, and toughness, the crack propagation, the test's view shows aluminum honeycomb behaved like a brittle material with both compression test. And the maximum deflection, crack propagation, shear forces, bending moment, and images illustrated that the layers play a crucial role in the 3-point bend test.

This thesis project investigates, analyzes, designs, simulates, constructs and tests a dual-axis solar tracker system to track the sun and concentrates the heat of the sunlight, using a Fresnel lens, into a small area, which is above of an evaporator, to increase the temperature of the seawater to convert it into freshwater. The dual-axis solar tracker was designed with the main objectives that the structure was portable, dismountable, lightweight, low cost, corrosion resistant, wires inside pipes, accurate, small size, follow the sun automatically, off-grid (electrical), use green energy (solar powered), and has an empty area right below of the lens. First, a 500 mm diameter flat Fresnel lens was selected and simulated based on an algorithmic method achieved by a previous PhD student at UNT using MATLAB®, to give the optimization lens dimensions. The lens profile was drawn with AutoCAD®, then output profile lens was simulated in COMSOL Multiphysics®. The objective was to provide the high efficiency, optimum and high precision of the focal rays and heat to the receiver of the evaporator. A novel dual-axis solar tracker system was then designed that is portable, dismountable, lightweight and corrosion resistant. The solar tracker tracks the sun in two axis of …

Corrosion in underground and submerged steel pipes is a global problem. Coatings serve as an impermeable barrier or a sacrificial element to the transport of corrosive fluids. When this barrier fails, corrosion in the metal initiates. There is a critical need for sensors at the metal/coating interface as an early alert system. Current options utilize metal sensors, leading to accelerating corrosion. In this dissertation, a non-conductive sensor textile as a viable solution was investigated. For this purpose, non-woven zinc (II) oxide-polyvinylidene fluoride (ZnO-PVDF) nanocomposite fiber textiles were prepared in a range of weight fractions (1%, 3%, and 5% ZnO) and placed at the coating/steel interface. Electrochemical impedance spectroscopy (EIS) testing was performed during the immersion of the coated samples to validate the effectiveness of the sensor textile. In the second part of this dissertation, an accelerated thermal cyclic method has been applied to determine sensor's reliability in detecting corrosion under actual service condition. The results suggested that the coating is capable of detecting corrosion under harsh conditions. Moreover, the addition of ZnO decreases the error in sensor textile and improved coating's barrier property. In the next phase, experiments were conducted to detect the type of corrosion (pitting or uniform) underneath …

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.

In order to better understand the changes occurring in the internal environment of the pyrolysis process a method of monitoring the internal environment in real time is the key objective of this study. To accomplish this objective four tasks were laid out in order to develop an effective way of monitoring the changes in gases present as pyrolysis is occurring as well as in material activation processing. For all processing the self-activation process was used which combines pyrolysis and thermal activation into a single step process. In the first task 10 hard wood species were activated and the resulting properties were compared to see the impact of wood species on the resulting carbon structures. In order to understand the impact of gas concentration on the resulting carbons the second task developed a gas sensor array which effectiveness was corroborated using GC-MS and then comparisons of the changes in the resulting were made. For the third task the gas sensor array was used to analyze the production of CO2 gas and a triple Gaussian model was developed to model the changes in gas production throughout processing. H2 gas production was modeled in the fourth task using the same Gaussian model as …

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 …

Motivated by previous relevant research on phononics including both active and passive phononics, the interest of faster turnability and more functions of the active phononics of further study led to this proposing research topic: magnetic field tunable active functional phononics. The first design of magnetic field tunable reciprocal--non-reciprocal transmission acoustic device was established, material was characterized, and numerical simulation has been performed. The simulation results show clear T-symmetric breaking non-reciprocity due to energy level splitting effect with Doppler effect – an acoustic Zeeman effect. Inspired by this preliminary work, further experiments were planned to demonstrate this effective Zeeman effect in phononics and effectively charged phonons in water based ferro-fluid. The objectives of this work as the next series of tasks were to illustrate acoustic Zeeman effect and acoustic Landau levels in various strength of magnetic field to investigate a design non-reciprocal sound device with magnetic field switching, which could be controlled on the amount of non-reciprocity with the strength of magnetic field. Once this new field first discovered by the proposed study tasks, more active tunable magnetic field phononics devices could be designed and exemplified in terms of both simulations and experiments. Faster and more controllable active phononic devices could …