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Surface Mechanical Attrition Treatment (SMAT) of 7075 Aluminum Alloy to Induce a Protective Corrosion Resistant Layer

Description

This paper investigates Surface Mechanical Attrition Treatment (SMAT) and the influence of treatment temperature and initial sample surface finish on the corrosion resistance of 7075-T651 aluminum alloy. Ambient SMAT was performed on AA7075 samples polished to 80-grit initial surface roughness.

This paper investigates Surface Mechanical Attrition Treatment (SMAT) and the influence of treatment temperature and initial sample surface finish on the corrosion resistance of 7075-T651 aluminum alloy. Ambient SMAT was performed on AA7075 samples polished to 80-grit initial surface roughness. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) tests were used to characterize the corrosion behavior of samples before and after SMAT. Electrochemical tests indicated an improved corrosion resistance after application of SMAT process. The observed improvements in corrosion properties are potentially due to microstructural changes in the material surface induced by SMAT which encouraged the formation of a passive oxide layer. Further testing and research are required to understand the corrosion related effects of cryogenic SMAT and initial-surface finish as the COVID-19 pandemic inhibited experimentation plans.

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2020-05

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Evaluation of an Original Design for a Cost-Effective Wheel-Mounted Dynamometer for Road Vehicles

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This thesis evaluates the viability of an original design for a cost-effective wheel-mounted dynamometer for road vehicles. The goal is to show whether or not a device that generates torque and horsepower curves by processing accelerometer data collected at the

This thesis evaluates the viability of an original design for a cost-effective wheel-mounted dynamometer for road vehicles. The goal is to show whether or not a device that generates torque and horsepower curves by processing accelerometer data collected at the edge of a wheel can yield results that are comparable to results obtained using a conventional chassis dynamometer. Torque curves were generated via the experimental method under a variety of circumstances and also obtained professionally by a precision engine testing company. Metrics were created to measure the precision of the experimental device's ability to consistently generate torque curves and also to compare the similarity of these curves to the professionally obtained torque curves. The results revealed that although the test device does not quite provide the same level of precision as the professional chassis dynamometer, it does create torque curves that closely resemble the chassis dynamometer torque curves and exhibit a consistency between trials comparable to the professional results, even on rough road surfaces. The results suggest that the test device provides enough accuracy and precision to satisfy the needs of most consumers interested in measuring their vehicle's engine performance but probably lacks the level of accuracy and precision needed to appeal to professionals.

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2018-05

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Development and Evaluation of an Electrical Engineering and Math Curriculum Module for High School Students

Description

Parents in STEM careers are more apt to guide their kids towards STEM careers (Sherburne-Michigan, 2017). There are STEM programs and classes for students who are interested in related fields, but the conundrum is that students need to be interested

Parents in STEM careers are more apt to guide their kids towards STEM careers (Sherburne-Michigan, 2017). There are STEM programs and classes for students who are interested in related fields, but the conundrum is that students need to be interested in order to choose to participate. The goal of this creative project was to introduce engineering concepts in a high school class to reveal and investigate the ways in which engineering concepts can be successfully introduced to a larger student populace to increase interest in engineering programs, courses, and degrees. A lesson plan and corresponding materials - including circuit kits and a simulated ball launching station with graphical display - were made to accomplish this goal. Throughout the lesson students were asked to (1) use given materials to accomplish a goal, (2) predict outcomes based on conceptual understanding and mathematical calculations, (3) test predictions, (4) record data, and (5) analyze data to generate results. The students first created a simple circuit to understand the circuit components and learn general electrical engineering concepts. A simple light dimmer circuit let students demonstrate understanding of electrical concepts (e.g., voltage, current resistance) before using the circuit to a simulated motor in order to launch a ball. The students were then asked to predict the time and height of a ball launched with various settings of their control circuit. The students were able to test their theories with the simulated launcher test set up shown in Figure 25 and collect data to create a parabolic height versus time graph. Based on the measured graph, the students were able to record their results and compare calculated values to real-world measured values. The results of the study suggest ways to introduce students to engineering while developing hands-on concept modeling of projectile motion and circuit design in math classrooms. Additionally, this lesson identifies a rich topic for teachers and STEM education researchers to explore lesson plans with interdisciplinary connections to engineering. This report will include the inspiration for the product, related work, iterative design process, and the final design. This information will be followed by user feedback, a project reflection, and lessons learned. The report will conclude with a summary and a discussion of future work.

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2018-05

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In situ SEM Testing for Fatigue Crack Growth: Mechanical Investigation of Titanium

Description

Widespread knowledge of fracture mechanics is mostly based on previous models that generalize crack growth in materials over several loading cycles. The objective of this project is to characterize crack growth that occurs in titanium alloys, specifically Grade 5 Ti-6Al-4V,

Widespread knowledge of fracture mechanics is mostly based on previous models that generalize crack growth in materials over several loading cycles. The objective of this project is to characterize crack growth that occurs in titanium alloys, specifically Grade 5 Ti-6Al-4V, at the sub-cycle scale, or within a single loading cycle. Using scanning electron microscopy (SEM), imaging analysis is performed to observe crack behavior at ten loading steps throughout the loading and unloading paths. Analysis involves measuring the incremental crack growth and crack tip opening displacement (CTOD) of specimens at loading ratios of 0.1, 0.3, and 0.5. This report defines the relationship between crack growth and the stress intensity factor, K, of the specimens, as well as the relationship between the R-ratio and stress opening level. The crack closure phenomena and effect of microcracks are discussed as they influence the crack growth behavior. This method has previously been used to characterize crack growth in Al 7075-T6. The results for Ti-6Al-4V are compared to these previous findings in order to strengthen conclusions about crack growth behavior.

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2018-05

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An Examination of the Impact of Support Design on 316 Stainless Steel Supports

Description

The removal of support material from metal 3D printed objects is a laborious necessity for the post-processing of powder bed fusion printing (PBF). Supports are typically mechanically removed by machining techniques. Sacrificial supports are necessary in PBF printing to relieve

The removal of support material from metal 3D printed objects is a laborious necessity for the post-processing of powder bed fusion printing (PBF). Supports are typically mechanically removed by machining techniques. Sacrificial supports are necessary in PBF printing to relieve thermal stresses and support overhanging parts often resulting in the inclusion of supports in regions of the part that are not easily accessed by mechanical removal methods. Recent innovations in PBF support removal include dissolvable metal supports through an electrochemical etching process. Dissolvable PBF supports have the potential to significantly reduce the costs and time associated with traditional support removal. However, the speed and effectiveness of this approach is inhibited by numerous factors such as support geometry and metal powder entrapment within supports. To fully realize this innovative approach, it is necessary to model and understand the design parameters necessary to optimize support structures applicable to an electrochemical etching process. The objective of this study was to evaluate the impact of block additive manufacturing support parameters on key process outcomes of the dissolution of 316 stainless steel support structures. The parameters investigated included hatch spacing and perforation, and the outcomes of interests included time required for completion, surface roughness, and effectiveness of the etching process. Electrical current was also evaluated as an indicator of process completion. Analysis of the electrical current throughout the etching process showed that the dissolution is diffusion limited to varying degrees, and is dependent on support structure parameters. Activation and passivation behavior was observed during current leveling, and appeared to be more pronounced in non-perforated samples with less dense hatch spacing. The correlation between electrical current and completion of the etching process was unclear, as the support structures became mechanically removable well before the current leveled. The etching process was shown to improve surface finish on unsupported surfaces, but support was shown to negatively impact surface finish. Tighter hatch spacing was shown to correlate to larger variation in surface finish, due to ridges left behind by the support structures. In future studies, it is recommended current be more closely correlated to process completion and more roughness data be collected to identify a trend between hatch spacing and surface roughness.

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2018-05

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Analog-to-Digital Converter Reliability Testing in Hostile Environments

Description

Analog to Digital Converters (ADCs) are a critical component in modern circuit applications. ADCs are used in virtually every application in which a digital circuit is interacting with data from the real world, ranging from commercial applications to crucial military

Analog to Digital Converters (ADCs) are a critical component in modern circuit applications. ADCs are used in virtually every application in which a digital circuit is interacting with data from the real world, ranging from commercial applications to crucial military and aerospace applications, and are especially important when interacting with sensors that observe environmental factors. Due to the critical nature of these converters, as well as the vast range of environments in which they are used, it is important that they accurately sample data regardless of environmental factors. These environmental factors range from input noise and power supply variations to temperature and radiation, and it is important to know how each may affect the accuracy of the resulting data when designing circuits that depend upon the data from these ADCs. These environmental factors are considered hostile environments, as they each generally have a negative effect on the operation of an ADC. This thesis seeks to investigate the effects of several of these hostile environmental variables on the performance of analog to digital converters. Three different analog to digital converters with similar specifications were selected and analyzed under common hostile environments. Data was collected on multiple copies of an ADC and averaged together to analyze the results using multiple characteristics of converter performance. Performance metrics were obtained across a range of frequencies, input noise, input signal offsets, power supply voltages, and temperatures. The obtained results showed a clear decrease in performance farther from a room temperature environment, but the results for several other environmental variables showed either no significant correlation or resulted in inconclusive data.

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2019-05

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Predicting Mechanical Failure of Vacuum Pumps Using Accelerometer Data

Description

The objective of this paper is to find and describe trends in the fast Fourier transformed accelerometer data that can be used to predict the mechanical failure of large vacuum pumps used in industrial settings, such as providing drinking water.

The objective of this paper is to find and describe trends in the fast Fourier transformed accelerometer data that can be used to predict the mechanical failure of large vacuum pumps used in industrial settings, such as providing drinking water. Using three-dimensional plots of the data, this paper suggests how a model can be developed to predict the mechanical failure of vacuum pumps.

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2019-05

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Around the Corner Imaging: Developing a Graphical User Interface

Description

This Creative Project was carried out in coordination with the capstone project, Around the Corner Imaging with Terahertz Waves. This capstone project deals with a system designed to implement Around the Corner, or Non Line-of-Sight (NLoS) Imaging. This document discusses

This Creative Project was carried out in coordination with the capstone project, Around the Corner Imaging with Terahertz Waves. This capstone project deals with a system designed to implement Around the Corner, or Non Line-of-Sight (NLoS) Imaging. This document discusses the creation of a GUI using MATLAB to control the Terahertz Imaging system. The GUI was developed in response to a need for synchronization, ease of operation, easy parameter modification, and data management. Along the way, many design decisions were made ranging from choosing a software platform to determining how variables should be passed. These decisions and considerations are discussed in this document. The resulting GUI has measured up to the design criteria and will be able to be used by anyone wishing to use the Terahertz Imaging System for further research in the field of Around the Corner or NLoS Imaging.

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2019-05

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Design, Characterization, and Evaluation of a Dynamic Soft Robotic Prosthetic Socket Interface

Description

Prosthetic sockets are a static interface for dynamic residual limbs. As the user's activity level increases, the volume of the residual limb decreases by up to 11% and increases by as much as 7% after activity. Currently, volume fluctuation is

Prosthetic sockets are a static interface for dynamic residual limbs. As the user's activity level increases, the volume of the residual limb decreases by up to 11% and increases by as much as 7% after activity. Currently, volume fluctuation is addressed by adding/removing prosthetic socks to change the profile of the residual limb. However, this is time consuming. These painful/functional issues demand a prosthetic socket with an adjustable interface that can adapt to the user's needs. This thesis presents a prototype design for a dynamic soft robotic interface which addresses this need. The actuators are adjustable depending on the user's activity level, and their structure provides targeted compression to the soft tissue which helps to limit movement of the bone relative to the socket. The engineering process was used to create this design by defining system level requirements, exploring the design space, selecting a design, and then using testing/analysis to optimize that design. The final design for the soft robotic interface meets the applicable requirements, while other requirements for the electronics/controls will be completed as future work. Testing of the prototype demonstrated promising potential for the design with further refinement. Work on this project should be continued in future research/thesis projects in order to create a viable consumer product which can improve lower limb amputee's quality of life.

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2018-05

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Automatic Recording of Children's Activity Within a Classroom: A Study of Levy Flights

Description

The diagnosis for an attention deficit/hyperactivity disorder (ADHD) in children is heavily based on teacher or parent opinion, and not on scientific evidence. This causes children to be wrongly diagnosed with a disorder and be prescribed medicine that they do

The diagnosis for an attention deficit/hyperactivity disorder (ADHD) in children is heavily based on teacher or parent opinion, and not on scientific evidence. This causes children to be wrongly diagnosed with a disorder and be prescribed medicine that they do not need to be taking. This paper discusses a project that was completed for the Child Study Lab (CSL) preschool at Arizona State University (ASU), in which children’s activity within a classroom was automatically recorded using ultra-wideband technology. This project’s goal was to gather location data on the children in the CSL and analyze and assess the collected data for any patterns of behavior. The hope was that if a child’s data displayed a pattern that strayed from the norm, that this analysis could pose as a more objective way to indicate that a child may have an attention deficit problem. Fractal Dimensions and Levy Flights were researched and applied to the data analysis portion of this project.

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2020-05