In this thesis, friction stir channeling (FSC) and its process parameters influence on geometry, surface quality and productivity are explored. The probe of the friction stir processing (FSP) tool used to perform these tests was a modified submerged bobbin tool made of MP 159 Co-Ni alloy. The body was made from H13 tool steel. To find the optimal channel conditions for a targeted range of process parameters, multiple 6061 aluminum samples were prepared with a U shape guide to test the effects of different spindle speeds and feed rates. Using a gantry-type computer numerical control (CNC) friction stir welding (FSW) machine, the aluminum coupons were subjected to calibration experiments, force control tests, and an increased production rate to test these effects. It was found through experimentation that the programmed feed rates, spindle speeds and forces produced by the machine had an impact on the channel geometry. It was determined from the force-controlled setup that 8.46 mm/s at 750 RPM was the best combination of results for the four conditions tested on a CNC friction stir processing-machine. It was then tested at 10.58 mm/s at 800 RPM, which had comparable results with the best combination of input parameters from the force-controlled …

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 …

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 …

Lignocellulose is the most abundant biopolymer on earth and offers excellent potential for sustainable manufacturing. Because lignocellulose is structurally complex and resistant to decomposition, innovative degradation strategies are necessary to unlock its value. In this dissertation, a green manufacturing process through enzyme-triggered self-cultured bacteria retting for lignocellulosic fiber was developed and investigated. The mechanism of the lignocellulosic fiber retting at a controlled degradation strategy was studied. This enzymatic degradation strategy utilizes a small amount of enzyme to trigger a large aggregation of specific bacteria to obtain clean fibers. Industrial hemp (Cannabis sativa L.) fiber was successfully retted with this strategy. The degradation of pectin was proved through an environmental scanning electron microscope and reducing sugar analysis. The bacterial successions were identified by 16S rRNA gene metagenomic sequencing. The results showed that Bacillaceae dominated the hemp retting conditions containing 1% pectinase, suggesting that pectinase can manipulate bacterial community succession by changing the nutrients available to bacteria through the degradation of pectin. This degradation strategy has 20-25% less environmental impact than the thermochemical degradation strategy, resulting in better fiber consistency and much shorter processing time (3-5 days) than the traditional water degradation strategy. The study on the degradation of lignin-rich lignocellulose also …

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.

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 …