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Advanced material systems refer to materials that are comprised of multiple traditional constituents but complex microstructure morphologies, which lead to their superior properties over conventional materials. This dissertation is motivated by the grand challenge in accelerating the design of advanced material systems through systematic optimization with respect to material microstructures

Advanced material systems refer to materials that are comprised of multiple traditional constituents but complex microstructure morphologies, which lead to their superior properties over conventional materials. This dissertation is motivated by the grand challenge in accelerating the design of advanced material systems through systematic optimization with respect to material microstructures or processing settings. While optimization techniques have mature applications to a large range of engineering systems, their application to material design meets unique challenges due to the high dimensionality of microstructures and the high costs in computing process-structure-property (PSP) mappings. The key to addressing these challenges is the learning of material representations and predictive PSP mappings while managing a small data acquisition budget. This dissertation thus focuses on developing learning mechanisms that leverage context-specific meta-data and physics-based theories. Two research tasks will be conducted: In the first, we develop a statistical generative model that learns to characterize high-dimensional microstructure samples using low-dimensional features. We improve the data efficiency of a variational autoencoder by introducing a morphology loss to the training. We demonstrate that the resultant microstructure generator is morphology-aware when trained on a small set of material samples, and can effectively constrain the microstructure space during material design. In the second task, we investigate an active learning mechanism where new samples are acquired based on their violation to a theory-driven constraint on the physics-based model. We demonstrate using a topology optimization case that while data acquisition through the physics-based model is often expensive (e.g., obtaining microstructures through simulation or optimization processes), the evaluation of the constraint can be far more affordable (e.g., checking whether a solution is optimal or equilibrium). We show that this theory-driven learning algorithm can lead to much improved learning efficiency and generalization performance when such constraints can be derived. The outcomes of this research is a better understanding of how physics knowledge about material systems can be integrated into machine learning frameworks, in order to achieve more cost-effective and reliable learning of material representations and predictive models, which are essential to accelerate computational material design.
ContributorsCang, Ruijin (Author) / Ren, Yi (Thesis advisor) / Liu, Yongming (Committee member) / Jiao, Yang (Committee member) / Nian, Qiong (Committee member) / Zhuang, Houlong (Committee member) / Arizona State University (Publisher)
Created2018
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Description
Stiffness and flexibility are essential in many fields, including robotics, aerospace, bioengineering, etc. In recent years, origami-based mechanical metamaterials were designed for better mechanical properties including tunable stiffness and tunable collapsibility. However, in existing studies, the tunable stiffness is only with limited range and limited controllability. To overcome these challenges,

Stiffness and flexibility are essential in many fields, including robotics, aerospace, bioengineering, etc. In recent years, origami-based mechanical metamaterials were designed for better mechanical properties including tunable stiffness and tunable collapsibility. However, in existing studies, the tunable stiffness is only with limited range and limited controllability. To overcome these challenges, two objectives were proposed and achieved in this dissertation: first, to design mechanical metamaterials with metamaterials with selective stiffness and collapsibility; second, to design mechanical metamaterials with in-situ tunable stiffness among positive, zero, and negative.In the first part, triangulated cylinder origami was employed to build deployable mechanical metamaterials through folding and unfolding along the crease lines. These deployable structures are flexible in the deploy direction so that it can be easily collapsed along the same way as it was deployed. An origami-inspired mechanical metamaterial was designed for on-demand deployability and selective collapsibility: autonomous deployability from the collapsed state and selective collapsibility along two different paths, with low stiffness for one path and substantially high stiffness for another path. The created mechanical metamaterial yields unprecedented load bearing capability in the deploy direction while possessing great deployability and collapsibility. The principle in this prospectus can be utilized to design and create versatile origami-inspired mechanical metamaterials that can find many applications. In the second part, curved origami patterns were designed to accomplish in situ stiffness manipulation covering positive, zero, and negative stiffness by activating predefined creases on one curved origami pattern. This elegant design enables in situ stiffness switching in lightweight and space-saving applications, as demonstrated through three robotic-related components. Under a uniform load, the curved origami can provide universal gripping, controlled force transmissibility, and multistage stiffness response. This work illustrates an unexplored and unprecedented capability of curved origami, which opens new applications in robotics for this particular family of origami patterns.
ContributorsZhai, Zirui (Author) / Nian, Qiong (Thesis advisor) / Zhuang, Houlong (Committee member) / Huang, Huei-Ping (Committee member) / Zhang, Wenlong (Committee member) / Liu, Yongming (Committee member) / Arizona State University (Publisher)
Created2021
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Description
A Compact Linear Fresnel Reflector (CLFR) is a simple, cost-effective, and scalable option for generating solar power by concentrating the sun rays. To make a most feasible application, design parameters of the CLFR, such as solar concentrator design parameters, receiver design parameters, heat transfer, power block parameters, etc., should be

A Compact Linear Fresnel Reflector (CLFR) is a simple, cost-effective, and scalable option for generating solar power by concentrating the sun rays. To make a most feasible application, design parameters of the CLFR, such as solar concentrator design parameters, receiver design parameters, heat transfer, power block parameters, etc., should be optimized to achieve optimum efficiency. Many researchers have carried out modeling and optimization of CLFR with various numerical or analytical methods. However, often computational time and cost are significant in these existing approaches. This research attempts to address this issue by proposing a novel computational approach with the help of increased computational efficiency and machine learning. The approach consists of two parts: the algorithm and the machine learning model. The algorithm has been created to fulfill the requirement of the Monte Carlo Ray tracing method for CLFR collector simulation, which is a simplified version of the conventional ray-tracing method. For various configurations of the CLFR system, optical losses and optical efficiency are calculated by employing these design parameters, such as the number of mirrors, mirror length, mirror width, space between adjacent mirrors, and orientation angle of the CLFR system. Further, to reduce the computational time, a machine learning method is used to predict the optical efficiency for the various configurations of the CLFR system. This entire method is validated using an existing approach (SolTrace) for the optical losses and optical efficiency of a CLFR system. It is observed that the program requires 6.63 CPU-hours of computational time are required by the program to calculate efficiency. In contrast, the novel machine learning approach took only seconds to predict the optical efficiency with great accuracy. Therefore, this method can be used to optimize a CLFR system based on the location and land configuration with reduced computational time. This will be beneficial for CLFR to be a potential candidate for concentrating solar power option.
ContributorsLunagariya, Shyam (Author) / Phelan, Patrick (Thesis advisor) / Kwon, Beomjin (Committee member) / Zhuang, Houlong (Committee member) / Arizona State University (Publisher)
Created2021
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Description
Laser powder bed fusion (LPBF) additive manufacturing (AM) has received widespread attention due to its ability to produce parts with complicated design and better surface finish compared to other additive techniques. LPBF uses a laser heat source to melt layers of powder particles and manufactures a part based on the

Laser powder bed fusion (LPBF) additive manufacturing (AM) has received widespread attention due to its ability to produce parts with complicated design and better surface finish compared to other additive techniques. LPBF uses a laser heat source to melt layers of powder particles and manufactures a part based on the CAD design. This process can benefit significantly through computational modeling. The objective of this thesis was to understand the thermal transport, and fluid flow phenomena of the process, and to optimize the main process parameters such as laser power and scan speed through a combination of computational, experimental, and statistical analysis. A multi-physics model was built using to model temperature profile, bead geometry and elemental evaporation in powder bed process using a non-gaussian interaction between laser heat source and metallic powder. Owing to the scarcity of thermo-physical properties of metallic powders in literature, thermal conductivity, diffusivity, and heat capacity was experimentally tested up to a temperature of 1400 degrees C. The values were used in the computational model, which improved the results significantly. The computational work was also used to assess the impact of fluid flow around melt pool. Dimensional analysis was conducted to determine heat transport mode at various laser power/scan speed combinations. Convective heat flow proved to be the dominant form of heat transfer at higher energy input due to violent flow of the fluid around the molten region, which can also create keyhole effect. The last part of the thesis focused on gaining useful information about several features of the bead area such as contact angle, porosity, voids and melt pool that were obtained using several combinations of laser power and scan speed. These features were quantified using process learning, which was then used to conduct a full factorial design that allows to estimate the effect of the process parameters on the output features. Both single and multi-response analysis are applied to analyze the output response. It was observed that laser power has more influential effect on all the features. Multi response analysis showed 150 W laser power and 200 mm/s produced bead with best possible features.
ContributorsAhsan, Faiyaz (Author) / Ladani, Leila (Thesis advisor) / Razmi, Jafar (Committee member) / Kwon, Beomjin (Committee member) / Nian, Qiong (Committee member) / Zhuang, Houlong (Committee member) / Arizona State University (Publisher)
Created2021
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Description
Magnetic liquids called ferrofluids have been used in applications ranging from audio speaker cooling and rotary pressure seals to retinal detachment surgery and implantable artificial glaucoma valves. Recently, ferrofluids have been investigated as a material for use in magnetically controllable liquid droplet robotics. Liquid droplet robotics is an emerging technology

Magnetic liquids called ferrofluids have been used in applications ranging from audio speaker cooling and rotary pressure seals to retinal detachment surgery and implantable artificial glaucoma valves. Recently, ferrofluids have been investigated as a material for use in magnetically controllable liquid droplet robotics. Liquid droplet robotics is an emerging technology that aims to apply control theory to manipulate fluid droplets as robotic agents to perform a wide range of tasks. Furthermore, magnetically controlled micro-robotics is another popular area of study where manipulating a magnetic field allows for the control of magnetized micro-robots. Both of these emerging fields have potential for impact toward medical applications: liquid characteristics such as being able to dissolve various compounds, be injected via a needle, and the potential for the human body to automatically filter and remove a liquid droplet robot, make liquid droplet robots advantageous for medical applications; while the ability to remotely control the torques and forces on an untethered microrobot via modulating the magnetic field and gradient is also highly advantageous. The research described in this dissertation explores applications and methods for the electromagnetic control of ferrofluid droplet robots. First, basic electrical components built from fluidic channels containing ferrofluid are made remotely tunable via the placement of ferrofluid within the channel. Second, a ferrofluid droplet is shown to be fully controllable in position, stretch direction, and stretch length in two dimensions using proportional-integral-derivative (PID) controllers. Third, control of a ferrofluid’s position, stretch direction, and stretch length is extended to three dimensions, and control gains are optimized via a Bayesian optimization process to achieve higher accuracy. Finally, magnetic control of both single and multiple ferrofluid droplets in two dimensions is investigated via a visual model predictive control approach based on machine learning. These achievements take both liquid droplet robotics and magnetic micro-robotics fields several steps closer toward real-world medical applications such as embedded soft electronic health monitors, liquid-droplet-robot-based drug delivery, and automated magnetically actuated surgeries.
ContributorsAhmed, Reza James (Author) / Marvi, Hamidreza (Thesis advisor) / Espanol, Malena (Committee member) / Rajagopalan, Jagannathan (Committee member) / Zhuang, Houlong (Committee member) / Xu, Zhe (Committee member) / Arizona State University (Publisher)
Created2022
Description
The study aims to develop and evaluate failure prediction models that accurately predict crack initiation sites, fatigue life in additively manufactured Ti-6Al-4V, and burst pressure in relevant applications.The first part proposes a classification model to identify crack initiation sites in AM-built Ti-6Al-4V alloy. The model utilizes surface and pore-related parameters

The study aims to develop and evaluate failure prediction models that accurately predict crack initiation sites, fatigue life in additively manufactured Ti-6Al-4V, and burst pressure in relevant applications.The first part proposes a classification model to identify crack initiation sites in AM-built Ti-6Al-4V alloy. The model utilizes surface and pore-related parameters and achieves high accuracy (0.97) and robustness (F1 score of 0.98). Leveraging CT images for characterization and data extraction from the CT-images built STL files, the model effectively detects crack initiation sites while minimizing false positives and negatives. Data augmentation techniques, including SMOTE+Tomek Links, are employed to address imbalanced data distributions and improve model performance. This study proposes the Probabilistic Physics-guided Neural Network 2.0 (PPgNN) for probabilistic fatigue life estimation. The presented approach overcomes the limitations of classical regression machine models commonly used to analyze fatigue data. One key advantage of the proposed method is incorporating known physics constraints, resulting in accurate and physically consistent predictions. The efficacy of the model is demonstrated by training the model with multiple fatigue S-N curve data sets from open literature with relevant morphological data and tested using the data extracted from CT-built STL files. The results illustrate that PPgNN 2.0 is a flexible and robust model for predicting fatigue life and quantifying uncertainties by estimating the mean and standard deviation of the fatigue life. The loss function that trains the proposed model can capture the underlying distribution and reduce the prediction error. A comparison study between the performance of neural network models highlights the benefits of physics-guided learning for fatigue data analysis. The proposed model demonstrates satisfactory learning capacity and generalization, providing accurate fatigue life predictions to unseen examples. An elastic-plastic Finite Element Model (FEM) is developed in the second part to assess pipeline integrity, focusing on burst pressure estimation in high-pressure gas pipelines with interactive corrosion defects. The FEM accurately predicts burst pressure and evaluates the remaining useful life by considering the interaction between corrosion defects and neighboring pits. The FEM outperforms the well-known ASME-B31G method in handling interactive corrosion threats.
ContributorsBalamurugan, Rakesh (Author) / Liu, Yongming (Thesis advisor) / Zhuang, Houlong (Committee member) / Bhate, Dhruv (Committee member) / Arizona State University (Publisher)
Created2023
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Description
Computing the fluid phase interfaces in multiphase flow is a challenging area of research in fluids. The Volume of Fluid andLevel Set methods are a few algorithms that have been developed for reconstructing the multiphase fluid flow interfaces. The thesis work focuses on exploring the ability of neural networks to reconstruct

Computing the fluid phase interfaces in multiphase flow is a challenging area of research in fluids. The Volume of Fluid andLevel Set methods are a few algorithms that have been developed for reconstructing the multiphase fluid flow interfaces. The thesis work focuses on exploring the ability of neural networks to reconstruct the multiphase fluid flow interfaces using a data-driven approach. The neural network model has liquid volume fraction stencils as an input, and it predicts the radius of the circle as an output of the network which represents a phase interface separating two immiscible fluids inside a fluid domain. The liquid volume fraction stencils are generated for randomly varying circle radii within a 1x1 domain using an open-source VOFI library. These datasets are used to train the neural network. Once the model is trained, the predicted circular phase interface from the neural network output is used to generate back the predicted liquid volume fraction stencils. Error norms values are calculated to assess the error in the neural network model’s predicted liquid volume fraction stencils with the actual liquid volume fraction stencils from the VOFI library. The neural network parameters are optimized by testing them for different hyper-parameters to reduce the error norms. So as to minimize the difference between the predicted and the actual liquid volume fraction stencils and errors in reconstructing the fluid phase interface geometry.
ContributorsPawar, Pranav Rajesh (Author) / Herrmann, Marcus (Thesis advisor) / Zhuang, Houlong (Committee member) / Huang, Huei-Ping (Committee member) / Arizona State University (Publisher)
Created2023
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Description
With increasing advance complexity in the structure to be 3D printed, the use of post processing removal of support structures has become more complicated thing due to the need of newer tool case to remove supports in such scenarios. Attempts have been made to study, research and experiment the dissolvable

With increasing advance complexity in the structure to be 3D printed, the use of post processing removal of support structures has become more complicated thing due to the need of newer tool case to remove supports in such scenarios. Attempts have been made to study, research and experiment the dissolvable and recyclable photo-initiated polymeric resin that can be used to build support structure. Vat photo-polymerization method of manufacturing was selected due to wide range of materials that can be selected and researched which can have the potential to be selected further for large scale manufacturing. Deep understanding of the recyclable polymer was done by performing chemical and mechanical property test. Varying light intensities are used to study the curing properties and respective dissolving properties. In this thesis document, recyclable and dissolvable polymeric resin have been selected to print the support structures which can be later dissolved and recycled.The resin was exposed to varying light projections using grayscales of 255, 200 and 150 showing different dissolving time of each structure. Dissolving time of the printed parts were studied by varying the surface to volume ratios of the part. Higher the surface to volume ratios of the printed part resulted in lower time it takes to dissolve the part in the dissolving solution. The mechanical strengths of the recycled part were found to be pretty solid as compared to the freshly prepared resin, good sign of using it for multiple times without degrading its strength. Cactus shaped model was printed using commercial red resin and supports with the recyclable solution to deeply understand the working and dissolving properties of recyclable resin. Without any external efforts, the supports were easily dissolved in the solution, leaving the cactus intact. Further work is carried on printing Meta shaped gyroid lattice structure in effort to lower the dissolving time of the supports while maintaining enough mechanical stress. Future efforts will be made to conduct the rheology test and further lower the dissolving time as much it can to be ready for the commercial large scale applications.
ContributorsNawab, Prem Kalpesh (Author) / Li, Xiangjia (Thesis advisor) / Zhuang, Houlong (Committee member) / Jin, Kailong (Committee member) / Arizona State University (Publisher)
Created2023
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Description
For the past two centuries, coal has played a vital role as the primary carbon source, fueling industries and enabling the production of essential carbon-rich materials, including carbon nanotubes, graphite, and diamond. However, the global transition towards sustainable energy production has resulted in a decline in coal usage for energy

For the past two centuries, coal has played a vital role as the primary carbon source, fueling industries and enabling the production of essential carbon-rich materials, including carbon nanotubes, graphite, and diamond. However, the global transition towards sustainable energy production has resulted in a decline in coal usage for energy purposes, with the United States alone witnessing a substantial 50% reduction over the past decade. This shift aligns with the UN’s 2030 sustainability goals, which emphasize the reduction of greenhouse gas emissions and the promotion of cleaner energy sources. Despite the decreased use in energy production, the abundance of coal has sparked interest in exploring its potential for other sustainable and valuable applications.In this context, Direct Ink Writing (DIW) has emerged as a promising additive manufacturing technique that employs liquid or gel-like resins to construct three-dimensional structures. DIW offers a unique advantage by allowing the incorporation of particulate reinforcements, which enhance the properties and functionalities of the materials. This study focuses on evaluating the viability of coal as a sustainable and cost-effective substitute for other carbon-based reinforcements, such as graphite or carbon nanotubes. The research utilizes a thermosetting resin based on phenol-formaldehyde (commercially known as Bakelite) as the matrix, while pulverized coal (250 µm) and carbon black (CB) function as the reinforcements. The DIW ink is meticulously formulated to exhibit shear-thinning behavior, facilitating uniform and continuous printing of structures. Mechanical property testing of the printed structures was conducted following ASTM standards. Interestingly, the study reveals that incorporating a 2 wt% concentration of coal in the resin yields the most significant improvements in tensile modulus and flexural strength, with enhancements of 35% and 12.5% respectively. These findings underscore the promising potential of coal as a sustainable and environmentally friendly reinforcement material in additive manufacturing applications. By harnessing the unique properties of coal, this research opens new avenues for its utilization in the pursuit of greener and more efficient manufacturing processes.
ContributorsSundaravadivelan, Barath (Author) / Song, Kenan (Thesis advisor) / Marvi, Hamidreza (Committee member) / Zhuang, Houlong (Committee member) / Arizona State University (Publisher)
Created2023
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Description
Non-Destructive Testing (NDT) is a branch of scientific methods and techniques

used to evaluate the defects and irregularities in engineering materials. These methods

conduct testing without destroying or altering material’s structure and functionality. Most

of these defects are subsurface making them difficult to detect and access.

SONIC INFRARED (IR) is a relatively new and

Non-Destructive Testing (NDT) is a branch of scientific methods and techniques

used to evaluate the defects and irregularities in engineering materials. These methods

conduct testing without destroying or altering material’s structure and functionality. Most

of these defects are subsurface making them difficult to detect and access.

SONIC INFRARED (IR) is a relatively new and emerging vibrothermography

method under the category of NDT methods. This is a fast NDT inspection method that

uses an ultrasonic generator to pass an ultrasonic pulse through the test specimen which

results in a temperature variation in the test specimen. The temperature increase around

the area of the defect is more because of frictional heating due to the vibration of the

specimen. This temperature variation can be observed using a thermal camera.

In this research study, the temperature variation in the composite laminate during

the SONIC IR experimentation using an infrared thermal camera. These recorded data are

used to determine the location, dimension and depth of defects through SONIC IR NDT

method using existing defect detection algorithms. Probability of detection analysis is

used to determine the probability of detection under specific experimental conditions for

two different types of composite laminates. Lastly, the effect of the process parameters

such as number of pulses, pulse duration and time delay between pulses of this technique

on the detectability and probability of detection is studied in detail.
ContributorsDarnal, Aryabhat (Author) / Liu, Yongming (Thesis advisor) / Zhuang, Houlong (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2019