Matching Items (67)
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Description
Gallium-based liquid metals are of interest for a variety of applications including flexible electronics, soft robotics, and biomedical devices. Still, nano- to microscale device fabrication with these materials is challenging because of their strong adhesion to a majority of substrates. This unusual high adhesion is attributed to the formation of

Gallium-based liquid metals are of interest for a variety of applications including flexible electronics, soft robotics, and biomedical devices. Still, nano- to microscale device fabrication with these materials is challenging because of their strong adhesion to a majority of substrates. This unusual high adhesion is attributed to the formation of a thin oxide shell; however, its role in the adhesion process has not yet been established. In the first part of the thesis, we described a multiscale study aiming at understanding the fundamental mechanisms governing wetting and adhesion of gallium-based liquid metals. In particular, macroscale dynamic contact angle measurements were coupled with Scanning Electron Microscope (SEM) imaging to relate macroscopic drop adhesion to morphology of the liquid metal-surface interface. In addition, room temperature liquid-metal microfluidic devices are also attractive systems for hyperelastic strain sensing. Currently two types of liquid metal-based strain sensors exist for inplane measurements: single-microchannel resistive and two-microchannel capacitive devices. However, with a winding serpentine channel geometry, these sensors typically have a footprint of about a square centimeter, limiting the number of sensors that can be embedded into. In the second part of the thesis, firstly, simulations and an experimental setup consisting of two GaInSn filled tubes submerged within a dielectric liquid bath are used to quantify the effects of the cylindrical electrode geometry including diameter, spacing, and meniscus shape as well as dielectric constant of the insulating liquid and the presence of tubing on the overall system's capacitance. Furthermore, a procedure for fabricating the two-liquid capacitor within a single straight polydiemethylsiloxane channel is developed. Lastly, capacitance and response of this compact device to strain and operational issues arising from complex hydrodynamics near liquid-liquid and liquid-elastomer interfaces are described.
ContributorsLiu, Shanliangzi (Author) / Rykaczewski, Konrad (Thesis advisor) / Alford, Terry (Committee member) / Herrmann, Marcus (Committee member) / Hildreth, Owen (Committee member) / Arizona State University (Publisher)
Created2015
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Description
Recently, nanostructured metamaterials have attracted lots of attentions due to its tunable artificial properties. In particular, nanowire
anohole based metamaterials which are known of the capability of large area fabrication were intensively studied. Most of the studies are only based on the electrical responses of the metamaterials; however, magnetic response, is

Recently, nanostructured metamaterials have attracted lots of attentions due to its tunable artificial properties. In particular, nanowire
anohole based metamaterials which are known of the capability of large area fabrication were intensively studied. Most of the studies are only based on the electrical responses of the metamaterials; however, magnetic response, is usually neglected since magnetic material does not exist naturally within the visible or infrared range. For the past few years, artificial magnetic response from nanostructure based metamaterials has been proposed. This reveals the possibility of exciting resonance modes based on magnetic responses in nanowire
anohole metamaterials which can potentially provide additional enhancement on radiative transport. On the other hand, beyond classical far-field radiative heat transfer, near-field radiation which is known of exceeding the Planck’s blackbody limit has also become a hot topic in the field.

This PhD dissertation aims to obtain a deep fundamental understanding of nanowire
anohole based metamaterials in both far-field and near-field in terms of both electrical and magnetic responses. The underlying mechanisms that can be excited by nanowire
anohole metamaterials such as electrical surface plasmon polariton, magnetic hyperbolic mode, magnetic polariton, etc., will be theoretically studied in both far-field and near-field. Furthermore, other than conventional effective medium theory which only considers the electrical response of metamaterials, the artificial magnetic response of metamaterials will also be studied through parameter retrieval of far-field optical and radiative properties for studying near-field radiative transport. Moreover, a custom-made AFM tip based metrology will be employed to experimentally study near-field radiative transfer between a plate and a sphere separated by nanometer vacuum gaps in vacuum. This transformative research will break new ground in nanoscale radiative heat transfer for various applications in energy systems, thermal management, and thermal imaging and sensing.
ContributorsChang, Jui-Yung (Author) / Wang, Liping (Thesis advisor) / Phelan, Patrick (Committee member) / Wang, Robert (Committee member) / Yu, Hongbin (Committee member) / Hildreth, Owen (Committee member) / Arizona State University (Publisher)
Created2017
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Description
Additive manufacturing (AM) describes an array of methods used to create a 3D object layer by layer. The increasing popularity of AM in the past decade has been due to its demonstrated potential to increase design flexibility, produce rapid prototypes, and decrease material waste. Temporary supports are an

Additive manufacturing (AM) describes an array of methods used to create a 3D object layer by layer. The increasing popularity of AM in the past decade has been due to its demonstrated potential to increase design flexibility, produce rapid prototypes, and decrease material waste. Temporary supports are an inconvenient necessity in many metal AM parts. These sacrificial structures are used to fabricate large overhangs, anchor the part to the build substrate, and provide a heat pathway to avoid warping. Polymers AM has addressed this issue by using support material that is soluble in an electrolyte that the base material is not. In contrast, metals AM has traditionally approached support removal using time consuming, costly methods such as electrical discharge machining or a dremel.

This work introduces dissolvable supports to single- and multi-material metals AM. The multi-material approach uses material choice to design a functionally graded material where corrosion is the functionality being varied. The single-material approach is the primary focus of this thesis, leveraging already common post-print heat treatments to locally alter the microstructure near the surface. By including a sensitizing agent in the ageing heat treatment, carbon is diffused into the part decreasing the corrosion resistance to a depth equal to at least half the support thickness. In a properly chosen electrolyte, this layer is easily chemically, or electrochemically removed. Stainless steel 316 (SS316) and Inconel 718 are both investigated to study this process using two popular alloys. The microstructure evolution and corrosion properties are investigated for both. For SS316, the effect of applied electrochemical potential is investigated to describe the varying corrosion phenomena induced, and the effect of potential choice on resultant roughness. In summary, a new approach to remove supports from metal AM parts is introduced to decrease costs and further the field of metals AM by expanding the design space.
ContributorsLefky, Christopher (Author) / Hildreth, Owen (Thesis advisor) / Chawla, Nikhilesh (Committee member) / Azeredo, Bruno (Committee member) / Rykaczewski, Konrad (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2018
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Description
Fatigue is a degradation process of materials that would lead to failure when materials are subjected to cyclic loadings. During past centuries, various of approaches have been proposed and utilized to help researchers understand the underlying theories of fatigue behavior of materials, as well as design engineering structures so that

Fatigue is a degradation process of materials that would lead to failure when materials are subjected to cyclic loadings. During past centuries, various of approaches have been proposed and utilized to help researchers understand the underlying theories of fatigue behavior of materials, as well as design engineering structures so that catastrophic disasters that arise from fatigue failure could be avoided. The stress-life approach is the most classical way that academia applies to analyze fatigue data, which correlates the fatigue lifetime with stress amplitudes during cyclic loadings. Fracture mechanics approach is another well-established way, by which people regard the cyclic stress intensity factor as the driving force during fatigue crack nucleation and propagation, and numerous models (such as the well-known Paris’ law) are developed by researchers.

The significant drawback of currently widely-used fatigue analysis approaches, nevertheless, is that they are all cycle-based, limiting researchers from digging into sub-cycle regime and acquiring real-time fatigue behavior data. The missing of such data further impedes academia from validating hypotheses that are related to real-time observations of fatigue crack nucleation and growth, thus the existence of various phenomena, such as crack closure, remains controversial.

In this thesis, both classical stress-life approach and fracture-mechanics-based approach are utilized to study the fatigue behavior of alloys. Distinctive material characterization instruments are harnessed to help collect and interpret key data during fatigue crack growth. Specifically, an investigation on the sub-cycle fatigue crack growth behavior is enabled by in-situ SEM mechanical testing, and a non-uniform growth mechanism within one loading cycle is confirmed by direct observation as well as image interpretation. Predictions based on proposed experimental procedure and observations show good match with cycle-based data from references, which indicates the credibility of proposed methodology and model, as well as their capability of being applied to a wide range of materials.
ContributorsLiu, Siying (Author) / Liu, Yongming (Thesis advisor) / Jiao, Yang (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2018
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Description
Reactive inkjet printing (RIJP) is a direct-write deposition technique that synthesizes and patterns functional materials simultaneously. It is a route to cheap fabrication of highly conductive features on a versatile range of substrates. Silver reactive inks have become a staple of conductive inkjet printing for application in printed and flexible

Reactive inkjet printing (RIJP) is a direct-write deposition technique that synthesizes and patterns functional materials simultaneously. It is a route to cheap fabrication of highly conductive features on a versatile range of substrates. Silver reactive inks have become a staple of conductive inkjet printing for application in printed and flexible electronics, photovoltaic metallization, and more. However, the high cost of silver makes these less effective for disposable and low-cost applications.

This work aimed to develop a particle-free formulation for a nickel reactive ink capable of metallizing highly pure nickel at temperatures under 100 °C to facilitate printing on substrates like paper or plastic. Nickel offers a significantly cheaper alternative to silver at slightly reduced bulk conductivity.

To meet these aims, three archetypes of inks were formulated. First were a set of glycerol-based inks temperature ink containing nickel acetate, hydrazine, and ammonia in a mixture of water and glycerol. This ink reduced between 115 – 200 °C to produce slightly oxidized deposits of nickel with carbon content around 10 wt %.

The high temperature was addressed in a second series, which replaced glycerol with lower boiling glycols and added sodium hydroxide as a strong base to enhance thermodynamics and kinetics of reduction. These inks reduced between 60 and 100 °C but sodium salts contaminated the final deposits.

In a third set of inks, sodium hydroxide was replaced with tetramethylammonium hydroxide (TMAH), a strong organic base, to address contamination. These inks also reduced between 60 and 100 °C. Pipetting or printing onto gold coated substrates produce metallic flakes coated in a clear, thick residue. EDS measured carbon and oxygen content up to 70 wt % of deposits. The residue was hypothesized to be a non-volatile byproduct of TMAH and acetate.

Recommendations are provided to address the residue. Ultimately the formulated reactive inks did not meet design targets. However, this thesis sets the framework to design an optimal nickel reactive ink in future work.
ContributorsDebruin, Dylan Jerome (Author) / Torres, Cesar (Thesis advisor) / Rykaczewski, Konrad (Thesis advisor) / Hildreth, Owen (Committee member) / Arizona State University (Publisher)
Created2019
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Description
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
Polymer fibers have broad applications in wearable electronics, bulletproof vests, batteries, fuel cells, filters, electrodes, conductive wires, and biomedical materials. Polymer fibers display light density and flexibility but are mostly weak and compliant. The ceramic, metallic, and carbon nanoparticles have been frequently included in polymers for fabricating continuous, durable, and

Polymer fibers have broad applications in wearable electronics, bulletproof vests, batteries, fuel cells, filters, electrodes, conductive wires, and biomedical materials. Polymer fibers display light density and flexibility but are mostly weak and compliant. The ceramic, metallic, and carbon nanoparticles have been frequently included in polymers for fabricating continuous, durable, and functional composite fibers. Nanoparticles display large specific areas, low defect density and can transfer their superior properties to polymer matrices. The main focus of this thesis is to design, fabricate and characterize the polymer
anocarbon composite fibers with unique microstructures and improved mechanical/thermal performance. The dispersions and morphologies of graphene nanoplatelets (GNPs), the interactions with polyvinyl alcohol (PVA) molecules and their influences on fiber properties are studied. The fibers were fabricated using a dry-jet wet spinning method with engineered spinneret design. Three different structured fibers were fabricated, namely, one-phase polymer fiber (1-phase), two-phase core-shell composite fiber (2-phase), and three-phase co-axial composite fiber (3-phase). These polymer or composite fibers were processed at three stages with drawing temperatures of 100˚C, 150˚C, and 200˚C. Different techniques including the mechanical tester, wide-angle X-Ray diffraction (WAXD), scanning electron microscope (SEM), thermogravimetric analysis (TGA), and differential scanning calorimeter (DSC) have been used to characterize the fiber microstructures and properties.
ContributorsVerma, Rahul (Author) / Song, Kenan (Thesis advisor) / Jiang, Hanqing (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2018
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Description
Additive Manufacturing and 3D printing are becoming important technologies in the manufacturing sector. The benefits of this technology include complex part geometry, short lead-times, low waste, and simple user interface. However, the technology does not come without its drawbacks: mainly the removal of support structures from the component. Traditional techniques

Additive Manufacturing and 3D printing are becoming important technologies in the manufacturing sector. The benefits of this technology include complex part geometry, short lead-times, low waste, and simple user interface. However, the technology does not come without its drawbacks: mainly the removal of support structures from the component. Traditional techniques that involve sawing and cutting can be expensive and take a long time, increasing the overall price of 3D printed metal components. This paper discusses two approaches taken for dissolvable support structures in 3D printed stainless steel (17-4 PH). For the first time in powder bed fusion components, with the help of Christopher Lefky and Dr. Owen Hildreth, dissolvable support capabilities are achieved in metal prints. The first approach, direct dissolution, involves direct corrosion of the entire part, leading to support removal. This approach is not self-terminating, and leads to changes in final component geometry. The second approach involves a post-build sensitization step, which physically alters the microstructure and chemical stability of the first 100-200 microns of the metal. The component is then etched at an electric potential that will readily corrode this sensitized surface, but not the underlying base metal. An electrolytic solution of HNO3/KCl/HCl paired with an anodic bias was used for the direct dissolution approach, resulting in a loss of about 120 microns of material from the components surface. For the self-limiting approach, surface sensitization was achieve through a post build annealing step (800 C for 6 hours, air cooled) with exposure to a sodium hexacynoferrate slurry. When the slurry decomposes in the furnace, carbon atoms diffuse into the surface and precipitate a chromium-carbide, which reduces the chemical stability of the stainless steel. Etching is demonstrated in an anodic bias of HNO3/KCl. To determine proper etching potentials, open circuit potential and cyclic voltammetry experiments were run to create Potentiodynamic Polarization Curves. Further testing of the self-terminating approach was performed on a 316 stainless steel interlocking ring structure with a complex geometry. In this case, 32.5 hours of etching at anodic potentials replaced days of mechanical sawing and cutting.
ContributorsZucker, Brian Nicholas (Co-author) / Lefky, Christopher (Co-author) / Hildreth, Owen (Co-author, Thesis director) / Hsu, Keng (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
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Description
A scheme has been developed for finding the gas and temperature profiles in an environmental transmission electron microscope (ETEM), using COMSOL Multiphysics and the finite element method (FEM). This model should permit better correlation between catalyst structure and activity, by providing a more accurate understanding of gas composition than the

A scheme has been developed for finding the gas and temperature profiles in an environmental transmission electron microscope (ETEM), using COMSOL Multiphysics and the finite element method (FEM). This model should permit better correlation between catalyst structure and activity, by providing a more accurate understanding of gas composition than the assumption of homogeneity typically used. While more data is needed to complete the model, current progress has identified several details about the system and its ideal modeling approach.
It is found that at the low pressures and flowrates of catalysis in ETEM, natural and forced convection are negligible forms of heat transfer. Up to 250 °C, radiation is also negligible. Gas conduction, being enhanced at low pressures, dominates.
Similarly, mass transport is dominated by diffusion, which is most accurately described by the Maxwell-Stefan model. Bulk fluid flow is highly laminar, and in fact borders the line between continuum and molecular flow. The no-slip boundary condition does not apply here, and both viscous slip and thermal creep must be considered. In the porous catalyst pellet considered in this work, Knudsen diffusion dominates, with bulk flow being best described by the Darcy-Brinkman equation.
With these physics modelled, it appears as though the gas homogeneity assumption is not completely accurate, breaking down in the porous pellet where reactions occur. While these results are not yet quantitative, this trend is likely to remain in future model iterations. It is not yet clear how significant this deviation is, though methods are proposed to minimize it if necessary.
Some model-experiment mismatch has been found which must be further explored. Experimental data shows a pressure dependence on the furnace temperature at constant power, a trend as-yet unresolvable by the model. It is proposed that this relates to the breakdown of the assumption of fluid continuity at low pressures and small dimensions, though no compelling mathematical formulation has been found. This issue may have significant ramifications on ETEM and ETEM experiment design.
ContributorsLangdon, Jayse Tanner (Author) / Crozier, Peter (Thesis director) / Hildreth, Owen (Committee member) / Chemical Engineering Program (Contributor) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2017-05
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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 thermal stresses and support overhanging parts often resulting in the

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.
ContributorsAbranovic, Brandon (Author) / Hildreth, Owen (Thesis director) / Torres, Cesar (Committee member) / Chemical Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05