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Accelerated Corrosion Test with Operation Simulation of All-Aluminum Microchannel Heat Exchangers
The HVAC&R industry is looking to transition from copper-aluminum heat exchangers to all-aluminum microchannel technology. The want for the transition stemmed from seeing the performance improvement of all-aluminum microchannel radiators in the automotive industry. Applications differ between the two industries; therefore, applying this technology for HVAC&R use must be validated. Research towards operating modes of an all-aluminum heat exchanger in a defined corrosive environment will provide the industry with a better understanding of heat exchanger design and heat exchanger material selection. The worth in this is preventing overdesign and producing more efficient heat exchangers. Furthermore, ASHRAE members and the corrosion community will find value in a defined corrosion system and corrosion test procedure. The information gained through past research has progressed assessment of material performance; however, the methods improperly simulate and expedite natural weathering. The most common method being used is the ASTM (American Society of Testing Materials) Sea Water Acetic Acid Test. The research discussed in this paper was focused on improving a standard corrosion system by implementing system modifications to simulate heat exchanger operation while performing a modified wet-dry cyclic test (e.g. ASTM G85 Annex 5). The goal is to produce results that are more representative of natural corrosion behavior and its forms. Current results were gathered from five of ten samples that underwent initial testing. Finally, possible improvements towards the chamber system and the test method, including the salt solution, are discussed.
Analytical Model for Lateral Deflection in Cold-formed Steel Framed Shear Walls with Steel Sheathing
An analytical model for lateral deflection in cold-formed steel shear walls sheathed with steel is developed in this research. The model is based on the four factors: fastener displacement, steel sheet deformation, and hold-down deformation, which are from the effective strip concept and a complexity factor, which accounts for the additional influential factors not considered in the previous three terms. The model uses design equations based on the actual material and mechanical properties of the shear wall. Furthermore, the model accounts for aggressive and conservative designers by predicting deflection at different shear strength degrees.
Analytical Model of Cold-formed Steel Framed Shear Wall with Steel Sheet and Wood-based Sheathing
The cold-formed steel framed shear walls with steel sheets and wood-based sheathing are both code approved lateral force resisting system in light-framed construction. In the United States, the current design approach for cold-formed steel shear walls is capacity-based and developed from full-scale tests. The available design provisions provide nominal shear strength for only limited wall configurations. This research focused on the development of analytical models of cold-formed steel framed shear walls with steel sheet and wood-based sheathing to predict the nominal shear strength of the walls at their ultimate capacity level. Effective strip model was developed to predict the nominal shear strength of cold-formed steel framed steel sheet shear walls. The proposed design approach is based on a tension field action of the sheathing, shear capacity of sheathing-to-framing fastener connections, fastener spacing, wall aspect ratio, and material properties. A total of 142 full scale test data was used to verify the proposed design method and the supporting design equations. The proposed design approach shows consistent agreement with the test results and the AISI published nominal strength values. Simplified nominal strength model was developed to predict the nominal shear strength of cold-formed steel framed wood-based panel shear walls. The nominal shear strength is determined based on the shear capacity of individual sheathing-to-framing connections, wall height, and locations of sheathing-to-framing fasteners. The proposed design approach shows a good agreement with 179 full scale shear wall test data. This analytical method requires some efforts in testing of sheathing-to-framing connections to determine their ultimate shear capacity. However, if appropriate sheathing-to-framing connection capacities are provided, the proposed design method provides designers with an analytical tool to determine the nominal strength of the shear walls without conducting full-scale tests.
Bearing Strength of Cold Formed Steel Bolted Connections in Trusses
The existing design provision in North American Specification for Cold- Formed Steel Structural Member (AISI S100) for the bearing strength of bolted connections were developed from tests on bolted connected sheets which were restrained by bolt nut and head with or without washers. However, in the cold-formed assemblies, particularly in trusses, the single bolt goes through both sides of the connected sections, making the connected sheets on each side unrestrained. the warping of the unrestrained sheet may reduce the bearing strength of the bolted connection. This research investigates the behavior and strength of bearing failure in bolted connections in cold-formed steel trusses. Tensile tests were conducted on trusses connections with various material thicknesses. It was found that the AISI S100 works well for thick connections but provides unconservative predictions for thin materials. Based on the experimental results, a modified bearing strength method is proposed for calculating the bearing strength of bolted truss connections. the proposed method can be used for any cold-formed steel connections with unrestrained sheet.
Characterization of Boron Nitride Thin Films on Silicon (100) Wafer.
Cubic boron nitride (cBN) thin films offer attractive mechanical and electrical properties. The synthesis of cBN films have been deposited using both physical and chemical vapor deposition methods, which generate internal residual, stresses that result in delamination of the film from substrates. Boron nitride films were deposited using electron beam evaporation without bias voltage and nitrogen bombardment (to reduce stresses) were characterize using FTIR, XRD, SEM, EDS, TEM, and AFM techniques. In addition, a pin-on-disk tribological test was used to measure coefficient of friction. Results indicated that samples deposited at 400°C contained higher cubic phase of BN compared to those films deposited at room temperature. A BN film containing cubic phase deposited at 400°C for 2 hours showed 0.1 friction coefficient.
Characterization of Iron Oxide Deposits Formed at Comanche Peak Steam Electric Station
The presence of deposits leading to corrosion of the steam generator (SG) systems is a major contributor to operation and maintenance cost of pressurized water reactor (PWR) plants. Formation and transport of corrosion products formed due to the presence of impurities, metallic oxides and cations in the secondary side of the SG units result in formation of deposits. This research deals with the characterization of deposit samples collected from the two SG units (unit 1 and unit 2) at Comanche Peak Steam Electric Station (CPSES). X-ray diffraction (XRD), Fourier transform infrared spectrophotometry (FTIR), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) techniques have been used for studying the compositional and structural properties of iron oxides formed in the secondary side of unit 1 and unit 2. Magnetite (Fe3O4) was found to be predominant in samples from unit 1 and maghemite (g-Fe2O3) was found to be the dominant phase in case of unit 2. An attempt has been made to customize FTIR technique for analyzing different iron oxide phases present in the deposits of PWR-SG systems.
Cold-Formed Steel Bolted Connections Using Oversized and Slotted Holes without Washers
In cold-formed steel (CFS) construction, bolted connections without washers for either oversized or slotted holes may significantly expedite the installation process and lower the cost. However, the North American Specification (AISI S100, 2007) for the Design of Cold-Formed Steel Structural Members requires washers to be installed in bolted connections with oversized or slotted holes. A research project (Phase 1) sponsored by American Iron and Steel Institute (AISI) was recently completed at the University of North Texas (UNT) that investigated the performance and strength of bolted CFS connections with oversized and slotted holes without using washers. The research presented in this thesis is the Phase 2 project in which the bolted CFS connections were studied in a broader respect in terms of the failure mechanism, the material thickness, and the hole configurations. Single shear and double shear connections without washers using oversized holes, oversized combined with standard or slotted holes were experimentally examined. Combined with Phase 1 results, the Phase 2 gives a comprehensive evaluation of the behavior and strength of bolted CFS connections with oversized and slotted holes without using washers. Revisions to the existing AISI North American Specification requirements for bolted connections are proposed to account for the reduction in the connection strength caused by the oversized and slotted hole configurations without washers. Specific LRFD and LSD resistance factors and ASD safety factors for different hole configurations in terms of the new proposed methods were presented.
Cold-Formed Steel Bolted Connections without Washers on Oversized and Slotted Holes
The use of the cold-formed steel sheet bolted connections without washers is so significant; however, the North American Specifications for the Design of Cold Formed Steel Structural Members, NASPEC, doesn't provide provisions for such connections. The bearing failure of sheet and the shear failure of sheet were considered in this study. For the sheet shear strength, it was found that the NASPEC (2007) design provisions can be used for oversized holes in both single and double shear configurations and for the double shear connections on short slotted holes. For the sheet bearing strength, a new design method was proposed to be used for low and high ductile steel sheets. The method was compared with the NASPEC and the University of Waterloo approach. Washers were still required for single shear connections on short slotted holes. Besides, connections using ASTM A325 bolts yielded higher bearing strength than connections using ASTM A307 bolts.
Cold-formed Steel Framed Shear Wall Sheathed with Corrugated Sheet Steel
Incombustibility is one important advantage of the sheet steel sheathed shear wall over wood panel sheathed shear wall. Compared to shear wall sheathed with plywood and OSB panel, shear wall sheathed with flat sheet steel behaved lower shear strength. Although shear wall sheathed with corrugated sheet steel exhibited high nominal strength and high stiffness, the shear wall usually behaved lower ductility resulting from brittle failure at the connection between the sheathing to frames. This research is aimed at developing modifications on the corrugated sheathing to improve the ductility of the shear wall as well as derive practical response modification factor by establishing correct relationship between ductility factor ? and response modification factor R. Totally 21 monotonic and cyclic full-scale shear wall tests were conducted during the winter break in 2012 by the author in NUCONSTEEL Materials Testing Laboratory in the University of North Texas. The research investigated nineteen 8 ft. × 4 ft. shear walls with 68 mil frames and 27 mil corrugation sheet steel in 11 configurations and two more shear walls sheathed with 6/17-in.OSB and 15/32-in. plywood respectively for comparison. The shear walls, which were in some special cutting arrangement patterns, performed better under lateral load conditions according to the behavior of ductility and shear strength and could be used as lateral system in construction.
Cold-Formed Steel Member Connections Using BAC Screw Fasteners
In this project, the main research objective is intend to seek criteria for evaluating the capacity of BAC screw fasteners with mixed configuration of waterproof seal washer, sealer tape and different pre-drill holes to determine shear and tension strength values for the screws used in cold-formed steel connections. The thesis presents the design methods and test program conducted to investigate the behavior and strength of the screw connections in shear and tension test. Test results were compared with AISI design provisions to determine if new design equations will be developed for those screws used in BAC cooling tower applications. LRFD resistance factors and ASD safety factors were investigated to the proposed design equations.
Comparative Analysis and Implementation of High Data Rate Wireless Sensor Network Simulation Frameworks
This thesis focuses on developing a high data rate wireless sensor network framework that could be integrated with hardware prototypes to monitor structural health of buildings. In order to better understand the wireless sensor network architecture and its consideration in structural health monitoring, a detailed literature review on wireless sensor networks has been carried out. Through research, it was found that there are numerous simulation software packages available for wireless sensor network simulation. One suitable software was selected for modelling the framework. Research showed that Matlab/Simulink was the most suitable environment, and as a result, a wireless sensor network framework was designed in Matlab/Simulink. Further, the thesis illustrates modeling of a simple accelerometer sensor, such as those used in wireless sensor networks in Matlab/Simulink using a mathematical description. Finally, the framework operation is demonstrated with 10 nodes, and data integrity is analyzed with cyclic redundancy check and transmission error rate calculations.
A Computer-Based Process Control System for a Target Station in a LINAC Facility
An event-driven, sequential, process control system was designed for International Isotopes, Inc., to automate and remotely control a target station at the company's linear accelerator facility. The designed system consisted of two major sections: a software program (virtual instrument), which was developed by LabVIEW, and a hardware interface (FieldPoint Modular Distributed I/O System by National Instrument), which had to be a pre-developed system that did not require customization. The designed virtual instrument was tested on a simulation model that mimed the target station. The result was a valid design.
Computer Virus Spread Containment Using Feedback Control.
In this research, a security architecture based on the feedback control theory has been proposed. The first loop has been designed, developed and tested. The architecture proposes a feedback model with many controllers located at different stages of network. The controller at each stage gives feedback to the one at higher level and a decision about network security is taken. The first loop implemented in this thesis detects one important anomaly of virus attack, rate of outgoing connection. Though there are other anomalies of a virus attack, rate of outgoing connection is an important one to contain the spread. Based on the feedback model, this symptom is fed back and a state model using queuing theory is developed to delay the connections and slow down the rate of outgoing connections. Upon implementation of this model, whenever an infected machine tries to make connections at a speed not considered safe, the controller kicks in and sends those connections to a delay queue. Because of delaying connections, rate of outgoing connections decrease. Also because of delaying, many connections timeout and get dropped, reducing the spread. PID controller is implemented to decide the number of connections going to safe or suspected queue. Multiple controllers can be implemented to control the parameters like delay and timeout. Control theory analysis is performed on the system to test for stability, controllability, observability. Sensitivity analysis is done to find out the sensitivity of the controller to the delay parameter. The first loop implemented gives feedback to the architecture proposed about symptoms of an attack at the node level. A controller needs to be developed to receive information from different controllers and decision about quarantining needs to be made. This research gives the basic information needed for the controller about what is going on at individual nodes of …
Construction Management Methods and Techniques in Army Tactical Shelter
This thesis presents a research effort aimed at developing using construction methods and techniques in army tactical shelter. The beginning step focuses on developing and identifying different activities and work breakdown structure applicable in shelter prototype. The next step focuses on identifying resource allocation. This include allocate resources based on the delivered project as per alternative one and for the second alternative as optimization, resource allocation modified and tried to level and minimize resource peak. In addition, the cost calculated for the whole project as well as for each WBS and activities which consider as alternative one and in the second alternative, cost mitigation applied according to available resources and adjusting predecessors and successors of each activity. In conclusion, two alternatives compared, available outcome presents, and future work suggested for the project team to continue this effort.
Control and Automation of a Heat Shrink Tubing Process
Heat shrink tubing is used to insulate wire conductors, protect wires, and to create cable entry seals in wire harnessing industries. Performing this sensitive process manually is time consuming, the results are strongly dependent on the operator’s expertise, and the process presents safety concerns. Alternatively, automating the process minimizes the operators’ direct interaction, decreases the production cost over the long term, and improves quantitative and qualitative production indicators dramatically. This thesis introduces the automation of a heat shrink tubing prototype machine that benefits the wire harnessing industry. The prototype consists of an instrumented heat chamber on a linear positioning system, and is fitted with two heat guns. The chamber design allows for the directing of hot air from the heat guns onto the wire harness uniformly through radially-distributed channels. The linear positioning system is designed to move the heat chamber along the wire harness as the proper shrinkage temperature level is reached. Heat exposure time as a major factor in the heat shrink tubing process can be governed by controlling the linear speed of the heat chamber. A control unit manages the actuator position continuously by measuring the chamber’s speed and temperature. A model-based design approach is followed to design and test the controller, and MATLAB/Simulink is used as the simulation environment. A programmable logic controller is selected as the controller implementation platform. The control unit performance is examined and its responses follow the simulation results with adequate accuracy.
Corrosion Protection of Low Carbon Steel By Cation Substituted Magnetite
Surfaces of low carbon steel sheet were modified by exposure to highly caustic aqueous solutions containing either chromium or aluminum cations. Corrosion resistances of such surfaces were compared with that of steel surfaces exposed to plain caustic aqueous solution. In all cases a highly uniform, black coating having a spinel structure similar to magnetite (Fe3O4) was obtained. The coated steel surfaces were characterized using X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and Fourier transform infrared spectrophotometry (FTIR). Polarization resistances (Rp) of modified steel surfaces were measured and compared with that of bare steel surfaces. Results indicate that chromium (Fe2+ Fe3+x Cr3+1-x) or aluminum (Fe2+ Fe3+x Al3+1-x) substituted spinel phases formed on steel surfaces showed higher Rp values compared to only magnetite (Fe2+ 2Fe3+O4) phase formed in the absence of either chromium or aluminum cations. Average Rp values for steel surfaces with chromium containing spinel phase were much higher (21.8 k?) as compared to 1.7 k? for bare steel surfaces. Steel surfaces with aluminum containing spinel phase and steels with plain magnetite coated samples showed average Rp values of 3.3 k? and 2.5 k? respectively. XPS and EDS analysis confirmed presence of cations of chromium and aluminum in Fe3O4 in cation substituted samples. FTIR results showed all coating phases were of spinel form with major absorption bands centered at either 570 cm-1 or 600 cm-1 assigned to Fe3O4 and ?-Fe2O3 respectively.
Cost Savings Realized Through Proper Sizing of an Excessive Instrument Air System.
The purpose of this research was to determine if installing a smaller air compressor could reduce the electrical usage of a large semiconductor manufacturing plant. A 200 horsepower Atlas Copco compressor was installed with the existing 500 horsepower Ingersoll-Rand compressors. Testing was conducted during the regular manufacturing process at MEMC Southwest in Sherman, Texas. Analysis of the data found that installing the new compressor could reduce electrical consumption. The study also found there are specific operational setpoints that allow the compressor to operate more efficiently.
A Data Acquisition System Experiment for Gas Temperature and Pressure Measurements on a Liquid-Nitrogen-Powered Vehicle
A data acquisition system was set up to measure gas temperatures and pressures at various points on a liquid-nitrogen-powered vehicle. The experiment was attempted to develop a data acquisition method for applications on engines that use liquid air as the fuel. Two thermocouples and a pressure transducer were connected using data acquisition instruments interfaced to a laptop computer to acquire data.
The Design and Development of Lightweight Composite Wall, Roof, and Floor Panels for Rigid Wall Shelter
This thesis presents a research effort aimed at developing a stronger, lighter, and more economic shelter using rigid wall panels. Reported herein is insulation research, wall and roof panel design and testing, floor section modeling and strength calculations, and cost and weight calculations. Beginning stages focus on developing solid wall and roof panels using cold-formed steel corrugated sheathing and members, as well as polyurethane spray foam for insulation. This research includes calculating uniform load density, to determine the overall strength of the panel. The next stage focuses on the flexural strength of the wall and roof panels, as well as finalizing the floor design for the shelter. This includes determining maximum flexural strength required to meet the standards set by the project goal. Direct strength method determined the correct thickness of members to use based on the dimension selected for the design. All Phases incorporated different connection methods, with varied stud spacing, to determine the safest design for the new shelters. Previous research has shown that cold-formed steel corrugated sheathing performs better than thicker flat sheathing of various construction materials, with screw and spot weld connections. Full scale shear wall tests on this type of shear wall system have been conducted, and it was found that the corrugated sheathing had rigid board behavior before it failed in shear buckling in sheathing and sometimes simultaneously in screw connection failures. Another aspect of the research is on the insulation of the wall panels. Research was conducted on many different insulation options for the mobile facilities. Specifically, insulation made of lightweight material, is non-combustible, added rigidity to the structure, and has high thermal properties. Closed cell polyurethane spray foam was selected for full-scale testing in this research. Closed cell polyurethane adds extra rigidity, is lighter than common honeycomb insulation, and has a higher …
Design and Validation of an Automated Multiunit Composting System.
This thesis covers the design of an automated multiunit composting system (AMUCS) that was constructed to meet the experimental apparatus requirements of the ASTM D5338 standard. The design of the AMUCS is discussed in full detail and validated with two experiments. The first experiment was used to validate the operation of the AMUCS with a 15 day experiment. During this experiment visual observations were made to visually observe degradation. Thermal properties and stability tests were performed to quantify the effects of degradation on the polymer samples, and the carbon metabolized from the degradation of samples was measured. The second experiment used the AMUCS to determine the effect of synthetic clay nanofiller on the aerobic biodegradability behavior of poly (3-hydroxybutyrate-co-3-hydroxyvalerate).
Design Method for Cold-Formed Steel Shear Wall Sheathed with Polymer Composite Panel
In order to predict the strength of shear wall with cold-formed steel framing members, analytical models were reviewed. Multiple analytical models were studied, as well as twenty-one connection tests were performed. The connection tests consist of 50-ksi cold-formed steel framing track, different fastening configurations, and different sheathing thicknesses (1/8" and 1/2"). No.12 screw resulted in the highest peak load of all fastening configurations, while the rivet connection had the lowest peak load. In addition, failure modes were observed after conducting the connection tests including shear in fastening, screw pullout, and bearing in the sheathing. However, only the rivet and No.10 screw fastening configurations were used in the prediction analysis of the shear wall by the elastic model. Six shear wall tests were conducted on both panels (1/2"and 1/8" thickness). After doing the comparison between the experimental and the elastic model, the percentage difference for the 1/8" and the 1/2" polymer composite panels (3''along the edge and 6''along the chord stud), was very small. It was 6.2% for the 1/8" and 2.96% for the 1/2" panels. This means the analytical model can predict the shear wall peak load. However, the percentage difference was slightly higher being 7.4% for the 1/2" polymer composite panels with 6" along the perimeter with the 12" at the chord stud. After comparing the experimental values to the predicted value of shear walls, it was concluded that this model is the most appropriate analytical method for predicting the shear wall capacity framed with cold-formed steel sheathed with polymer composite panels. Many of these configurations were used in a prototype shelter that was constructed and built at the structural testing laboratory at the University of North Texas.
Design Method of Cold-Formed Steel Framed Shear Wall Sheathed by Structural Concrete Panel
The objective of this research is developing a new method of design for cold-formed steel framed shear wall sheathed by ¾" thick USG structural panel concrete subfloor using a predictive analytical model and comparing the results obtained from the model with those achieved from real testing to verify the analytical model and predicted lateral load-carrying capacity resulted from that. Moreover, investigating the impact of various screw spacings on shear wall design parameter such as ultimate strength, yield strength, elastic stiffness, ductility ratio and amount of energy dissipation is another purpose of this research.
Design, Modeling, and Experiment of a Piezoelectric Pressure Sensor based on a Thickness-Shear Mode Crystal Resonator
This thesis presents the design, modeling, and experiment of a novel pressure sensor using a dual-mode AT-cut quartz crystal resonator with beat frequency analysis based temperature compensation technique. The proposed sensor can measure pressure and temperature simultaneously by a single AT-cut quartz resonator. Apart from AT-cut quartz crystal, a newly developed Langasite (LGS) crystal resonator is also considered in the proposed pressure sensor design, since LGS can operate in a higher temperature environment than AT-cut quartz crystal. The pressure sensor is designed using CAD (computer aided design) software and CAE software - COMSOL Multiphysics. Finite element analysis (FEA) of the pressure sensor is performed to analyze the stress- strain of the sensor's mechanical structure. A 3D printing prototype of the sensor is fabricated and the proposed sensing principle is verified using a force-frequency analysis apparatus. Next to the 3D printing model verification, the pressure sensor with stainless steel housing has been fabricated with inbuilt crystal oscillator circuit. The oscillator circuit is used to excite the piezo crystal resonator at its fundamental vibrational mode and give the frequency as an output signal. Based on the FEA and experimental results, it has been concluded that the maximum pressure that the sensor can measure is 45 (psi). The pressure test results performed on the stainless steel product shows a highly linear relationship between the input (pressure) and the output (frequency).
Design of a Machine Condition Monitoring System with Bluetooth Low Energy
This thesis discusses the design considerations for a machine conditioning sensor utilizing Bluetooth low energy (BLE).
Design of a Monitoring System for a Plasma Cleaning Machine
Plasma cleaning is the most effective dry process to remove surface contaminates from a SAW (Surface Acoustical Wave) device. Consistent gas pressures, flows, and good electrical connections between the chamber shelves are necessary for the process to function predictably. In addition, operation of the monitoring system must be transparent to the plasma cleaning unit. This thesis describes a simple solution to the complex problem of monitoring a plasma cleaning system. The monitoring system uses the LabVIEW® G programming language and hardware, both products of National Instruments, Inc.®, to monitor critical parameters necessary to achieve a consistent process when cleaning these devices.
Design of Power Amplifier Test Signals with a User-Defined Multisine
Cellular radio communication involves wireless transmission and reception of signals at radio frequencies (RF). Base stations house equipment critical to the transmission and reception of signals. Power amplifier (PA) is a crucial element in base station assembly. PAs are expensive, take up space and dissipate heat. Of all the elements in the base station, it is difficult to design and operate a power amplifier. New designs of power amplifiers are constantly tested. One of the most important components required to perform this test successfully is a circuit simulator model of an entire communication system that generates a standard test signal. Standard test signals 524,288 data points in length require 1080 hours to complete one test of a PA model. In order to reduce the time taken to complete one test, a 'simulated test signal,' was generated. The objective of this study is to develop an algorithm to generate this 'simulated' test signal such that its characteristics match that of the 'standard' test signal.
Determination of the Shelf Life of Aluminum Electrolytic Capacitors.
The aluminum electrolytic capacitor is used extensively in the electric utility industry. A factor limiting the storage of spare capacitors is the integrity of the aluminum oxide dielectric, which over time breaks down contributing to a shelf life currently estimated at one nuclear power electric generating station to be approximately five years. This project examined the electrical characteristics of naturally aged capacitors of several different styles to determine if design parameters were still within limits. Additionally, the effectiveness of a technique known as “Reforming” was examined to determine its impact on those characteristics.
Development and Test of High-Temperature Piezoelectric Wafer Active Sensors for Structural Health Monitoring
High-temperature piezoelectric wafer active sensors (HT-PWAS) have been developed for structure health monitoring at hazard environments for decades. Different candidates have previously been tested under 270 °C and a new piezoelectric material langasite (LGS) was chosen here for a pilot study up to 700 °C. A preliminary study was performed to develop a high temperature sensor that utilizes langasite material. The Electromechanical impedance (E/M) method was chosen to detect the piezoelectric property. Experiments that verify the basic piezoelectric property of LGS at high temperature environments were carried out. Further validations were conducted by testing structures with attached LGS sensors at elevated temperature. Additionally, a detection system simulating the working process of LGS monitoring system was developed with PZT material at room temperature. This thesis, for the first time, (to the best of author’s knowledge) presents that langasite is ideal for making piezoelectric wafer active sensors for high temperature structure health monitoring applications.
Development of a Coaxiality Indicator
The geometric dimensioning and tolerancing concept of coaxiality is often required by design engineers for balance of rotating parts and precision mating parts. In current practice, it is difficult for manufacturers to measure coaxiality quickly and inexpensively. This study examines feasibility of a manually-operated, mechanical device combined with formulae to indicate coaxiality of a test specimen. The author designs, fabricates, and tests the system for measuring coaxiality of holes machined in a steel test piece. Gage Repeatability and Reproducibility (gage R&R) and univariate analysis of variance is performed in accordance with Measurement System Analysis published by AIAG. Results indicate significant design flaws exist in the current configuration of the device; observed values vary greatly with operator technique. Suggestions for device improvements conclude the research.
Development of a Hybrid Molecular Ultraviolet Photodetector based on Guanosine Derivatives
Modern studies on charge transfer reaction and conductivity measurements of DNA have shown that the electrical behavior of DNA ranges from that of an insulator to that of a wide bandgap semiconductor. Based on this property of DNA, a metal-semiconductor-metal photodetector is fabricated using a self-assembled layer of deoxyguanosine derivative (DNA base) deposited between gold electrodes. The electrodes are lithographically designed on a GaN substrate separated by a distance L (50nm < L < 100nm). This work examines the electrical and optical properties of such wide-bandgap semiconductor based biomaterial systems for their potential application as photodetectors in the UV region wherein most of the biological agents emit. The objective of this study was to develop a biomolecular electronic device and design an experimental setup for electrical and optical characterization of a novel hybrid molecular optoelectronic material system. AFM results proved the usage of Ga-Polar substrate in conjugation with DG molecules to be used as a potential electronic based sensor. A two-terminal nanoscale biomolectronic diode has been fabricated showing efficient rectification ratio. A nanoscale integrated ultraviolet photodetector (of dimensions less than 100 nm) has been fabricated with a cut-off wavelength at ~ 320 nm.
Development of a Simplified Fracture Toughness Tool for Polymers
This thesis presents research toward the development of a simple inexpensive fracture toughness tool for polymeric materials. Experiments were conducted to test the specimen configuration and the fracture toughness tool against an established ASTM standard for polymer fracture toughness, D5045, and a commonly used four-point bend method. The materials used in this study were polycarbonate and high density polyethylene. Reductions in both the production time and the variability resulting from the preparation of the specimens were addressed through the use of specially designed fixtures. The effects from the razor cut depths used in the chevron notch were compared to the fracture toughness values obtained in order to determine the effect upon the validity of the fracture toughness.
Direct Immersion Cooling Via Nucleate Boiling of HFE-7100 Dielectric Liquid on Hydrophobic and Hydrophilic Surfaces
This study experimentally investigated the effect of hydrophobic and hydrophilic surfaces characteristics on nucleate boiling heat transfer performance for the application of direct immersion cooling of electronics. A dielectric liquid, HFE – 7100 was used as the working fluid in the saturated boiling tests. Twelve types of 1-cm2 copper heater samples, simulating high heat flux components, featured reference smooth copper surface, fully and patterned hydrophobic surface and fully and patterned hydrophilic surfaces. Hydrophobic samples were prepared by applying a thin Teflon coating following photolithography techniques, while the hydrophilic TiO2 thin films were made through a two step approach involving layer by layer self assembly and liquid phase deposition processes. Patterned surfaces had circular dots with sizes between 40 – 250 μm. Based on additional data, both hydrophobic and hydrophilic surfaces improved nucleate boiling performance that is evaluated in terms of boiling incipience, heat transfer coefficient and critical heat flux (CHF) level. The best results, considering the smooth copper surface as the reference, were achieved by the surfaces that have a mixture of hydrophobic/hydrophilic coatings, providing: (a) early transition to boiling regime and with eliminated temperature overshoot phenomena at boiling incipience, (b) up to 58.5% higher heat transfer coefficients, and (c) up to 47.4% higher CHF levels. The studied enhanced surfaces therefore demonstrated a practical surface modification method for heat transfer enhancement in immersion cooling applications.
Direct Strength Method for Web Crippling of Cold-formed Steel C-sections
Web crippling is a form of localized buckling that occurs at points of transverse concentrated loading or supports of thin-walled structural members. The theoretical computation of web crippling strength is quite complex as it involves a large number of factors such as initial imperfections, local yielding at load application and instability of web. The existing design provision in North American specification for cold-formed steel C-sections (AISI S100, 2007) to calculate the web-crippling strength is based on the experimental investigation. The objective of this research is to extend the direct strength method to the web crippling strength of cold-formed steel C-sections. ABAQUS is used as a main tool to apply finite element analysis and is used to do the elastic buckling analysis. The work was carried out on C-sections under interior two flange (ITF) loading, end two flange (ETF) loading cases. Total of 128 (58 ITF, 70 ETF) sections were analyzed. Sections with various heights (3.5 in.to 6 in.) and various lengths (21 in. to 36 in.) were considered. Data is collected from the tests conducted in laboratory and the data from the previous researches is used, to extend the direct strength method to cold formed steel sections. Proposing a new design for both the loading cases and calculation of the resistance factors under (AISI S100, 2007) standards is done.
Drive Level Dependence of Advanced Piezoelectric Resonators
Resonators are one of the most important parts of electronic products. They provide a stable reference frequency to ensure the operation of these products. Recently, the electronic products have the trend of miniaturization, which rendered the size reduction of the resonators as well [1]. Better design of the resonators relies on a better understanding of the crystals' nonlinear behavior [2]. The nonlinearities affect the quality factor and acoustic behavior of MEMS (Micro-Electro-Mechanical-System) and nano-structured resonators and filters [3]. Among these nonlinear effects, Drivel Level Dependence (DLD), which describes the instability of the resonator frequency due to voltage level and/or power density, is an urgent problem for miniaturized resonators [2]. Langasite and GaPO4 are new promising piezoelectric material. Resonators made from these new materials have superior performance such as good frequency-temperature characteristics, and low acoustic loss [2]. In this thesis, experimental measurements of drive level dependence of langasite resonators with different configurations (plano-plano, single bevel, and double bevel) are reported. The drive level dependence of GaPO4 resonators are reported as well for the purpose of comparison. The results show that the resonator configuration affects the DLD of the langasite resonator. Experiments for DLD at elevated temperature are also performed, and it was found that the temperature also affects the DLD of the langasite resonator.
Dynamic Behaviors of Historical Wrought Iron Truss Bridges – a Field Testing Case Study
Civil infrastructure throughout the world serves as main arteries for commerce and transportation, commonly forming the backbone of many societies. Bridges have been and remain a crucial part of the success of these civil networks. However, the crucial elements have been built over centuries and have been subject to generations of use. Many current bridges have outlived their intended service life or have been retrofitted to carry additional loads over their original design. A large number of these historic bridges are still in everyday use and their condition needs to be monitored for public safety. Transportation infrastructure authorities have implemented various inspection and management programs throughout the world, mainly visual inspections. However, careful visual inspections can provide valuable information but it has limitations in that it provides no actual stress-strain information to determine structural soundness. Structural Health Monitoring (SHM) has been a growing area of research as officials need to asses and triage the aging infrastructure with methods that provide measurable response information to determine the health of the structure. A rapid improvement in technology has allowed researchers to start using new sensors and algorithms to understand the structural parameters of tested structures due to known and unknown loading scenarios. One of the most promising methods involves the use of wireless sensor nodes to measure structural responses to loads in real time. The structural responses can be processed to help understand the modal parameters, determine the health of the structure, and potentially identify damage. For example, modal parameters of structures are typically used when designing the lateral system of a structure. A better understanding of these parameters can lead to better and more efficient designs. Usually engineers rely on a finite element analysis to identify these parameters. By observing the actual parameters displayed during field testing, the theoretical FE models …
Effect of Amines as Corrosion Inhibitors for a Low Carbon Steel in Power Industry
Commonly used amines in power industry, including morpholine, DBU (1,8-diazabicyclo[5.4.0]undec-7-ene), and DMA (dimethylallylamine) were evaluated for their effect on AISI 1018 steel at 250oF. Samples were exposed to an autoclave containing amine added aqueous solution at pH of 9.5 for 1, 2, 4, 6, 8, and 12 hours. Morphology studies were carried using scanning electron microscope (SEM), phase analysis was done utilizing Fourier transform infrared spectroscopy (FTIR), and weight loss was performed to assess kinetics of oxidation. Control samples showed the highest metal dissolution rate. DBU showed the best performance in metal protection and SEM indicated the presence of a free-crack layer formed by fine particles in that set. FTIR showed that DBU apparently favored the formation of magnetite. It is believed that fine particles impede intrusion of aggressive ions into the metal surface by forming a barrier layer. FTIR demonstrated that DMA formed more oxyhydroxides, whereas morpholine presented magnetite to hematite transformation as early as 2 hours. SEM revealed that control and DMA produced acicular particles characteristic of oxyhydroxides while morpholine and DBU presented more equiaxed particles.
Effect of Engineered Surfaces on Valve Performance
Performance of air operated valves is a major maintenance concern in process industries. Anecdotal information indicates that reliability of some high maintenance valves has been improved by using an ion deposition process to achieve engineered surfaces on selected components. This project compared friction for various surface treatments of selected valve components. Results indicate valve performance may be slightly more consistent when an engineered surface is applied in the valve packing area; however surface treatment in this area does not appear to have a dominant affect on reducing valve friction. Results indicate a linear relation between stem friction and torque applied to packing flange nuts, and even after a valve is in service, controlled packing adjustments can be made without significantly changing valve stroke time.
Effect of Polyphosphoric Acid on Aging Characteristics of PG 64-22 Asphalt Binder
This research presents the results on an experimental investigation to identify the effect of polyphosphoric acid (PPA) on aging characteristics of an asphalt binder. Addition of PPA to asphalt binders is said to improve performance of flexible pavements. Asphalt binder PG 64-22 in modified and unmodified conditions was subjected to aging in the laboratory using a regular oven and also simulated short term aging using rolling thin film oven (RTFO) test. Aging experiments were conducted to analyze the extent of oxidation in terms of changes in molecular structure of the asphalt binder. These changes were appraised using Fourier transform infrared (FTIR) spectroscopy, dynamic shear rheometer (DSR), and epifluorescence microscopy tests. FTIR was used to determine the changes in major bands with addition of PPA. Stiffness and viscoelastic behaviors of asphalts were determined from the DSR test. The stiffness is measured by calculating the shear modulus, G* and the viscoelastic behavior is measured by calculating the phase angle, sin &#948;. Epifluorescence microscopy is a tool used to study properties of organic or inorganic substances. The morphological characteristics of PPA modified asphalt samples were observed through epifluorescence microscopy. Epifluorescence microscopy reveals the polymer phase distribution in the asphalt binders. Results of this investigation show PPA addition to asphalt binders improve G*/sin &#948; characteristics of asphalt binders. In addition, presence of PPA in polymer containing asphalt did not adversely affect aging of the binders.
Effects of a Surface Engineered Metallic Coating on Elastomeric Valve Stem Seal Leakage
Valve stem seal leakage is a major source of fugitive emissions, and controlling these emissions can result in added expense in leak detection and repair programs. Elastomeric O-rings can be used as valve stem seals, and O-ring manufacturers recommend lubrication of elastomeric seals to prevent damage and to assure proper sealing. In this research, a metallic coating was applied as a lubricant using a vacuum vapor deposition process to the surface of elastomeric valve stem seals. Valve stem leak measurements were taken to determine if the coated O-rings, alone or with the recommended lubrication, reduced valve stem seal leakage. This research determined that the metallic coating did not reduce valve stem leakage.
Effects of Minimum Quantity Lubrication in Drilling 1018 Steel.
A common goal for industrial manufacturers is to create a safer working environment and reduce production costs. One common method to achieve this goal is to drastically reduce cutting fluid use in machining. Recent advances in machining technologies have made it possible to perform machining with minimum-quantity lubrication (MQL). Drilling takes a key position in the realization of MQL machining. In this study the effects of using MQL in drilling AISI 1018 steel with HSS tools using a vegetable based lubricant were investigated. A full factorial experiment was conducted and regression models were generated for both surface finish and hole size. Lower surface roughness and higher tool life were observed in the lowest speed and feed rate combination.
Effects of Minimum Quantity Lubrication (Mql) on Tool Life in Drilling Aisi 1018 Steel
It has been reported that minimum quantity lubrication (MQL) provides better tool life compared to flood cooling under some drilling conditions. In this study, I evaluate the performance of uncoated HSS twist drill when machining AISI 1018 steel using a newly developed lubricant designed for MQL (EQO-Kut 718 by QualiChem Inc.). A randomized factorial design was used in the experiment. The results show that a tool life of 1110 holes with a corresponding flank wear of 0.058 mm was realized.
Effects of Processing Techniques on Mechanical Properties of Selected Polymers
The mechanical properties of a polymer represent the critical characteristics to be considered when determining the applications for it. The same polymer processed with different methods can exhibit different mechanical properties. The purpose of this study is to investigate the difference in mechanical properties of the selected polymers caused by different processing techniques and conditions. Three polymers were studied, including low density polyethylene (LDPE), polypropylene (PP), and NEXPRENE® 1287A. Samples were processed with injection molding and compression molding under different processing condition. Tensile and DMA tests were performed on these samples. The acquired data of strain at break from the tensile tests and storage modulus from the DMA were utilized to calculate brittleness. Calculated brittleness values were used to perform analysis of variance (ANOVA) to investigate the statistical significance of the processing technique and condition. It was found that different processing techniques affect the brittleness significantly. The processing technique is the major factor affecting brittleness of PP and NEXPRENE, and the processing temperature is the major factor affecting brittleness of LDPE.
Effects of Rebar Temperature and Water to Cement Ratio on Rebar-Concrete Bond Strength of Concrete Containing Fly Ash
This research presents the results on an experimental investigation to identify the effects of rebar temperature, fly ash and water to cement ratio on concrete porosity in continuously reinforced concrete pavements (CRCP). Samples were cast and analyzed using pullout tests. Water to cement ratio (w/c) and rebar temperature had a significant influence on the rebar-concrete bond strength. The 28-day shear strength measurements showed an increase in rebar-concrete bond strength as the water to cement ratio (w/c) was reduced from 0.50 to 0.40 for both fly ash containing and non fly ash control samples. There was a reduction in the peak pullout load as the rebar surface temperature increased from 77o F to 150o F for the cast samples. A heated rebar experiment was performed simulating a rebar exposed to hot summer days and the rebar cooling curves were plotted for the rebar temperatures of 180o F - 120o F. Fourier transform infrared spectroscopy was performed to show the moisture content of cement samples at the rebar-concrete interface. Mercury intrusion porosimetry test results on one batch of samples were used for pore size distribution analysis. An in-depth analysis of the morphological characteristics of the rebar-concrete interface and the observation of pores using the scanning electron microscope (SEM) was done.
Effects of Thickness and Indenter Tip Geometry in Nanoindentation of Nickel Films
Nanoindentation has become a widely used technique to measure the mechanical properties of materials. Due to its capability to deform materials in micro- and nano-scale, nanoindentation has found more applications in characterizing the deformation behavior and determining the mechanical properties of thin films and coatings. This research deals with the characterization of samples received from Center for Advanced Microstructures and Devices (CAMD) and Integran Technologies Inc., Toronto, Canada and the objective of this investigation was to utilize the experimental data obtained from nanoindentation to determine the deformation behavior, mechanical properties of thin films on substrates and bulk materials, and the effect of geometrically different indenters (Berkovich, cubecorner, and conical). X-ray diffraction (XRD), transmission electron microscope (TEM), scanning electron microscopy (SEM), and atomic force microscopy (AFM) analysis were performed on these materials to determine the crystal orientation, grain size of the material, and also to measure any substrate effects like pile-up or sin-in respectively. The results indicate that indentation size effect (ISE) strongly depends on shape of the indenter and less sensitive to penetration depth where as the hardness measurements depends on shape of indenter and depth of penetration. There is a negligible strain rate dependency of hardness at deeper depths and a significant increase in the hardness due to the decrease in grain size and results also indicate that there is no significant substrate effect on thin films for 10% and 20% of film thicknesses. Nanocrystalline material could not validate a dislocation based mechanisms deformation for indentation made by cubecorner and conical indenters in depths less than 1mm.
Electrical resistivity as a measure of change of state in substrates: Design, development and validation of a microprocessor-based system.
Smart structures are relevant and significant because of their relevance to phenomena such as hazard mitigation, structural health monitoring and energy saving. Electrical resistance could potentially serve as an indicator of structural well-being or damage in the structure. To this end, the development of a microprocessor-based automated resistance measurement system with customized GUI is desired. In this research, a nodal electrical resistance acquisition circuit (NERAC) system was designed. The system hardware interfaces to a laptop, which houses a customized GUI developed using DAQFactory software. Resistance/impedance was measured using DC/AC methods with four-point probes technique, on three substrates. Baseline reading before damage was noted and compared with the resistance measured after damage. The device was calibrated and validated on three different substrates. Resistance measurements were taken from PVDF samples, composite panels and smart concrete. Results conformed to previous work done on these substrates, validating the effective working of the NERAC device.
Energy Harvesting Wireless Piezoelectric Resonant Force Sensor
The piezoelectric energy harvester has become a new powering option for some low-power electronic devices such as MEMS (Micro Electrical Mechanical System) sensors. Piezoelectric materials can collect the ambient vibrations energy and convert it to electrical energy. This thesis is intended to demonstrate the behavior of a piezoelectric energy harvester system at elevated temperature from room temperature up to 82°C, and compares the system’s performance using different piezoelectric materials. The systems are structured with a Lead Magnesium Niobate-Lead Titanate (PMN-PT) single crystal patch bonded to an aluminum cantilever beam, Lead Indium Niobate-Lead Magnesium Niobate-Lead Titanate (PIN-PMN-PT) single crystal patch bonded to an aluminum cantilever beam and a bimorph cantilever beam which is made of Lead Zirconate Titanate (PZT). The results of this experimental study show the effects of the temperature on the operation frequency and output power of the piezoelectric energy harvesting system. The harvested electrical energy has been stored in storage circuits including a battery. Then, the stored energy has been used to power up the other part of the system, a wireless resonator force sensor, which uses frequency conversion techniques to convert the sensor’s ultrasonic signal to a microwave signal in order to transmit the signal wirelessly.
Evaluation of dynamic and static electrical characteristics for the DY8 and YI8 process gallium diodes in comparison to the DI8 process boron diodes.
A rectifier is an electrical device, comprising one or more semiconductor devices arranged for converting alternating current to direct current by blocking the negative or positive portion of the waveform. The purpose of this study would be to evaluate dynamic and static electrical characteristics of rectifier chips fabricated with (a) DY8 process and (b) YI8 process and compare them with the existing DI8 process rectifiers. These new rectifiers were tested to compare their performance to meet or exceed requirements of lower forward voltages, leakage currents, reverse recovery time, and greater sustainability at higher temperatures compared to diodes manufactured using boron as base (DI8 process diodes) for similar input variables.
Fabrication and Testing of Biomimetic Microstructures for Walkway Tribometers
The main objective of this work is to give contribution in both additive manufacturing (AM) and tribometry derived from the application and study of materials available with the use of biomimetic designs. Additional contributions are determining what effects treatments for flooring surfaces may have on the dynamic coefficient of friction and the effects of these products on common surfaces. The validity of the proposed methodology for a proof of concept was demonstrated by comparing measured dynamic coefficient of friction for designs using standardized equipment and comparing these values to plantar skin tested using an accepted and standardized testing method that has been extensively researched and validated. Initial biomimetic designs and characteristics unique to each design were researched and compared. Eleven designs were selected to be fabricated, tested, and compared to select the most desirable applications for further investigation. Research into potential treatments commercially available for use was done to determine the efficacy of these products. Prototype sensor designs were selected and fabricated using direct light processing (DLP) technology. Examination of the measured values was done through an analysis of the variances in the response variable and comparisons using Fisher and Tukey pairwise comparison method. Future work recommendations are provided for further development and improvement of the topics presented in this thesis.
Factors influencing horizontal cracking in continuously reinforced concrete pavements (CRCP).
This research presents the results on an experimental investigation to identify the significant factors influencing horizontal cracking in continuously reinforced concrete pavements (CRCP). An in-depth analysis of the microstructure, morphological characteristics of the interfacial transition zone (ITZ) and the observation of cracking using the environmental scanning electron microscope (ESEM) was done. Characterization of oxides using Fourier transform infrared spectroscopy (FTIR) and electron dispersive x-ray spectroscopy (EDS) was also performed. Water to cement ratio (w/c) and rebar temperature had a significant influence on the rebar-concrete bond strength. The 28-day shear strength measurements showed an increase in rebar-concrete bond strength as the water to cement ratio (w/c) was reduced from 0.50 to 0.40. There was a reduction in the peak pullout load as the temperature increased from 14oF to 252oF for the corroded and non-corroded rebar experiments. The corroded rebar pullout test results showed a 20-50 % reduction in bond strength compared to the non-corroded rebars. FTIR measurements indicated a presence of lepidocrocrite (γ -FeOOH) and maghemite (γ -Fe2O3) on the ITZ. ESEM images showed the existence of microcracks as early as three days after casting with the bridging of these cracks between coarse aggregate locations in the interfacial zone propagating through the mortar.
FEM of nanoindentation on micro- and nanocrystalline Ni: Analysis of factors affecting hardness and modulus values.
Nanoindentation is a widely used technique to measure the mechanical properties of films with thickness ranging from nanometers to micrometers. A much better understanding of the contact mechanics is obtained mostly through finite element modeling. The experiments were modeled using the software package Nano SP1 that is based on COSMOSM™ (Structural Research & Analysis Corp, www.cosmosm.com), a finite element code. The fundamental material properties affecting pile-up are the ratio of the effective modulus to yield stress Eeff/σ and the work hardening behavior. Two separate cases of work hardening rates were considered; one with no work hardening rate and other with a linear work hardening rate. Specifically, it is observed that pile up is large only when hf/hmax is close to one and degree of work hardening rate is small. It should also be noted that when hf/hmax < 0.7 very little pile-up is observed no matter what the work-hardening behavior of the material. When pile-up occurs the contact area is greater than that predicted by the experimental methods and both the hardness and modulus are overestimated. In this report the amount by which these properties are overestimated are studied and got to be around 22% approx. Bluntness of the tip often leads to the misinterpretation of the load-displacement data. Further analysis was done in order to find out the amount of deviation from the ideal tip due to tip bluntness. Radius of the tips were also calculated for cubecorner (41.35 nm) and conical indenter (986.05 nm).
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