A scanning reference electrode technique (SRET) apparatus has been designed and commissioned to investigate the corrosion of friction stir spot welds (FSSW) made in AZ31 magnesium alloys. The operational parameters of the apparatus have been calibrated to give good spatial resolution. By combining the SRET data with material flow data and immersion test data it was found that the FSSW process caused the formation of distinct noble and active regimes within the weld area. The noble region was aligned with the stir zone (SZ) and was caused by a dynamically recrystallized grain structure which is void of dislocations / twins, and β Mg17Al12. Localized corrosion attack was observed in both SRET and immersion testing along the thermo-mechanically affected zone (TMAZ). The same effect was consistently observed with a flat versus concave shoulder tool, and dwell times of 1s and 4s.

The oxidation behavior of model binary and ternary alloys in supercritical water (SCW) was examined. Binary alloys contained 9 or 14 at% Cr. Ternary alloys had 1.5 at% of one of the following elements: Si, Al, V, Mn or Ti. Samples with different surface finishes were exposed to SCW for up to 500 hours. The oxidized samples were characterized using gravimetry, SEM, HRTEM and EDX. After exposure, a uniform double layer oxide with outwardly grown magnetite inwardly grown Fe-Cr mixed oxide was detected on most of samples. Alloys contains 14 at% Cr or/and 1.5 at% Si showed a mixed oxidation mode, where relatively thick double layer oxides coexisted with thin protective oxide. The coverage with the thin oxide increased with the increase of deformation and/or Cr and/or Si content. A 20 nm thick Si-enriched layer was detected at such alloy/oxide interfaces. This behavior is very similar to “third element effect”.

Environmental and economic factors demand radical advances in solar cell technologies. Organic and polymer photovoltaics emerged in the 1990's that have led to low cost per unit area, enabled in significant part by the convenient manufacturing of roll-to-roll-processible solution-cast semiconductors. Colloidal quantum dot solar cells dramatically increase the potential for solar conversion efficiency relative to organics by enabling optimal matching of a photovoltaic device's bandgap to the sun's spectrum. Infrared-absorbing colloidal quantum dot solar cells were first reported in 2005. At the outset of this study in 2007, they had been advanced to the point of achieving 1.8% solar power conversion efficiency. These devices degraded completely within a few hours’ air exposure. The origin of the extremely poor device stability was unknown and unstudied. The efficiency of these devices was speculated to be limited by poor carrier transport and passivation within the quantum dot solid, and by the limitations of the Schottky device architecture. This study sought to tackle three principal challenges facing colloidal quantum dot photovoltaics: stability; understanding; and performance. In the first part of this work, we report the first air-stable infrared colloidal quantum dot photovoltaics. Our devices have a solar power conversion efficiency of 2.1%. These devices, unencapsulated and operating in an air atmosphere, retain 90% of their original performance following 3 days’ continuous solar harvesting. The remarkable improvement in device stability originated from two new insights. First, we showed that inserting a thin LiF layer between PbS film and Al electrode blocks detrimental interfacial reactions. Second, we proposed and validated a model that explains why quantum dots having cation-rich surfaces afford dramatically improved air stability within the quantum dot solid. The success of the cation-enrichment strategy led us to a new concept: what if - rather than rely on organic ligands, as all prior quantum dot photovoltaics work had done - one could instead terminate the surface of quantum dots exclusively using inorganic materials? We termed our new materials strategy ionic passivation. The goal of the approach was to bring our nanoparticles into the closest possible contact while still maintaining quantum confinement; and at the same time achieving a maximum of passivation of the nanoparticles' surfaces. We showcase our ionic passivation strategy by building a photovoltaic device that achieves 5.8% solar power conversion efficiency. This is the highest-ever solar power conversion efficiency reported in a colloidal quantum dot device. More generally, our ionic passivation strategy breaks the past tradeoff between transport and passivation in quantum dot solids. The advance is relevant to electroluminescent and photodetection devices as well as to the record-performing photovoltaic devices reported herein.

This thesis explores a rigorous approach to model the behaviour of an electrochemical cell. A simple planar electrochemical cell consisting of stainless steel electrodes separated by a sulfuric acid electrolyte layer is modeled from first principles. The model is a dynamic model and is valid under constant temperature conditions. The dynamic model is based on the Poisson-Nernst-Planck electrodiffusion theory and physical attributes such as the impact of nonlinear polarization, the stoichiometric reactions of the electrolyte and changes to the transport coefficients are investigated in stages. The system of partial differential equations has been solved using a finite element software package. The simulation results are compared with experimental results and discrepancies are discussed. The results suggest that the existing theory is not adequate in explaining the physics in the immediate vicinity of the electrode/electrolyte interface even though the general experimental and simulation results are in qualitative agreement with each other.

Doctor of Philosophy / Physics / Christopher M. Sorensen / We demonstrated that gram quantities of pristine graphene nanosheets (GNs) can be produced via detonation of a hydrocarbon. This one-step and catalyst-free method is eco-friendly and economical for the production of GNs. The hydrocarbons detonated were C₂H₂, C₂H₄, C₃H₈ and CH₄ in the presence of O₂. The carbon products obtained from the detonation were analyzed by XRD, TEM, XPS and Raman spectroscopy. Depending upon the ratio of O₂ to C₂H₂, the GNs of size up to ~ 250 nm, SSA up to ~ 200 m²/g and yield up to 70% with 2-3 layers' stack have been obtained so far. N₂O was determined as a good alternative to O₂ as an oxidizer to produce GNs by detonating C₂H₂ with it. A two-color pyrometer was designed and calibrated to measure the temperature of the detonation of hydrocarbons. The measured detonation temperatures were in between 2700 K and 4300 K. Along with the high detonation temperature, the composition of precursor hydrocarbon was observed to be crucial as well to determine its suitability to detonate with oxidizer to produce GNs. The hydrocarbons C₂H₂ and C₂H₄ were determined as the suitable precursors to produce GNs whereas detonation of C₃H₈ yields mere amorphous carbon soot and CH₄ gives no solid carbon while detonated with O₂. It has been proposed that the hydrocarbons with C/H≥0.5 are suitable for GNs production by detonation method. Highly oxidized graphene nanosheets (OGNs) were produced by solution-based oxidation of GNs prepared via a controlled detonation of acetylene at O₂/C₂H₂=0.8. The produced OGNs were about 250 nm in size and hydrophilic in nature. The C/O ratio was dramatically reduced from 49:1 in the pristine GNs to about 1:1 in OGNs, as determined by X-ray photoelectron spectroscopy. This C/O in OGNs is the least ever found in all oxidized graphitic materials that have been reported. Thus, the OGNs produced from the detonated GNs with such high degree of oxidation herein yields a novel and promising material for future applications.

Doctor of Philosophy / Department of Grain Science and Industry / X. Susan Sun / Biobased polymers derived from renewable resources are increasingly important due to acute concerns about the environmental issues and limited petroleum resources. Poly(lactic acid) (PLA) is such a polymer that has shown great potential to produce biodegradable plastics. However, low glass transition temperature (Tg), low thermal stability, slow biodegradation rate, and high cost limit its broad applications. This dissertation seeks to overcome these limitations by reinforcing PLA with inorganic nanoparticles and low-cost agricultural residues. We first synthesized PLA nanocomposites by in situ melt polycondensation of L-lactic acid and surface-hydroxylized nanoparticles (MgO nanocrystals and TiO2 nanowires) and investigated the structure-property relationships. PLA grafted nanoparticles (PLA-g-MgO, PLA-g-TiO2) were isolated from the bulk nanocomposites via repeated dispersion/centrifugation processes. The covalent grafting of PLA chains onto nanoparticle surface was confirmed by Fourier transform infrared spectroscopy and thermalgravimetric analysis (TGA). Transmission electron microscopy and differential scanning calorimetry (DSC) results also sustained the presence of the third phase. Morphological images showed uniform dispersion of nanoparticles in the PLA matrix and demonstrated a strong interfacial interaction between them. Calculation based on TGA revealed that more than 42.5% PLA was successfully grafted into PLA-g-MgO and more than 30% was grafted into PLA-g-TiO2. Those grafted PLA chains exhibited significantly increased thermal stability. The Tg of PLA-g-TiO2 was improved by 7 °C compared with that of pure PLA. We also reinforced PLA with low-value agricultural residues, including wood flour (WF), soy flour (SF), and distillers dried grains with solubles (DDGS) by thermal blending. Tensile measurements and morphological images indicated that methylene diphenyl diisocyanate (MDI) was an effective coupling agent for PLA/WF and PLA/DDGS systems. MDI compatibilized PLA/WF and PLA/DDGS composites showed comparable tensile strength and elongation at break as pure PLA, with obviously increased Young’s modulus. Increased crystallinity was observed for PLA composites with SF and DDGS. Such PLA composites have similar or superior properties compared with pure PLA, especially at a lower cost and higher biodegradation rate than pure PLA. The results from this study are promising. These novel PLA thermoplastic composites with enhanced properties have potential for many applications, such as packaging materials, textiles, appliance components, autoparts, and medical implants.

Doctor of Philosophy / Department of Chemical Engineering / James H. Edgar / The sublimation recondensation crystal growth of aluminum nitride, titanium nitride, and yttrium nitride were explored experimentally and theoretically. Single crystals of these nitrides are potentially suitable as substrates for AlGaInN epitaxial layers, which are employed in ultraviolet optoelectronics including UV light-emitting diodes and laser diodes, and high power high frequency electronic device applications. A thermodynamic analysis was applied to the sublimation crystal growth of aluminum nitride to predict impurities transport (oxygen, carbon, and hydrogen) and to study the aspects of impurities incorporation for different growth conditions. A source purification procedure was established to minimize the impurity concentration and avoid degradation of the crystal’s properties. More than 98% of the oxygen, 99.9% of hydrogen and 90% of carbon originally in the source was removed. The AlN crystal growth process was explored in two ways: self-seeded growth with spontaneous nucleation directly on the crucible lid or foil, and seeded growth on SiC and AlN. The oxygen concentration was 2 ~ 4 x 1018cm-3, as measured by secondary ion mass spectroscopy in the crystals produced by self-seeded growth. Crystals grown from AlN seeds have visible grain size expansion. The initial AlN growth on SiC at a low temperature range (1400°C ~1600°C) was examined to understand the factors controlling nucleation. Crystals were obtained from c-plane on-axis and off-axis, Si-face and C-face, as well as m-plane SiC seeds. In all cases, crystal growth was fastest perpendicular to the c-axis. The growth rate dependence on temperature and pressure was determined for TiN and YN crystals, and their activation energies were 775.8±29.8kJ/mol and 467.1±21.7kJ/mol respectively. The orientation relationship of TiN (001) || W (001) with TiN [100] || W [110], a 45o angle between TiN [100] and W [100], was seen for TiN crystals deposited on both (001) textured tungsten and randomly orientated tungsten. Xray diffraction confirmed that the YN crystals were rock-salt structure, with a lattice constant of 4.88Å. Cubic yttria was detected in YN sample from the oxidation upon its exposed to air for limited time by XRD, while non-cubic yttria was detected in YN sample for exposures more than one hour by Raman spectra.

Master of Science / Department of Mechanical and Nuclear Engineering / Kevin Lease / Carbon fiber reinforced composites (CFRP’s) are a mainstay in many industries, including the aerospace industry. When composite components are damaged on an aircraft, they are typically repaired with a composite patch that is placed over the damaged material and cured into the existing composite material. This curing process involves knowledge of the curing time necessary to sufficiently cure the patch. The inexact nature of curing composites on aircraft causes a significant waste of time and material when patches are unnecessarily redone. Knowing how differences in cure cycle affect the strength of the final material could reduce this waste. That is the focus of this research. In this research, the interfacial shear strength (IFSS) of carbon fiber/epoxy composites was investigated to determine how changes in cure cycle affect the overall material strength. IFSS is a measure of the strength of the bond between the two materials. To measure this, the microbond method was used. In this method, a drop of epoxy is applied to a single carbon fiber. The specimen is cured and the droplet is sheared from the fiber. The force required to debond the droplet is recorded and the data is analyzed. The IFSS of AS4/Epon828, T650/Epon828, and T650/Cycom 5320-1 composites were evaluated. For the former two material systems, a cure cycle with two steps was chosen based on research from others and then was systematically varied. The final cure time was changed to determine how that parameter affected the IFSS. It was found that as the final cure time increased, so did the IFSS and level of cure achieved by the composite to a point. Once the composite reached its fully cured state, increasing the final cure time did not noticeably increase the IFSS. For the latter material system (T650/Cycom 5320-1), the two cure cycles recommended by the manufacturer were tested. These had different initial cure steps and identical final cure steps. Although both cure cycles caused high IFSS, the cycle with the higher initial temperature, but shorter initial cure time achieved a higher level of cure than that with a longer time, but shorter temperature.

Master of Science / Department of Chemistry / Jun Li / With the increasing consumption of energy and the depletion of fossil fuels, finding an alternative energy source is critical. Solar energy is one of the most promising energy sources and solar cells are the devices that convert solar radiation into electricity. Currently, the most widely used solar cell is based on p-n junction formed with crystalline silicon materials. While showing high efficiency, the high fabrication cost limits its broad applications. Dye sensitized solar cell (DSSC) is a promising low-cost alternative to the Si solar cell, but its efficiency is much lower. Improvements in materials and interfaces are needed to increase the DSSC efficiency while maintain the low cost. In this thesis, three projects were investigated to optimize the DSSC efficiency and reduce the cost. The first project is to optimize the TiO[subscript]2 barrier layers on Fluorine-doped Tin Dioxide (FTO) surface. Two preparation methods, i.e. TiCl[subscript]4 solution treatment and thermal oxidation of sputtered Ti metal films, were employed and systematically studied in order to minimize electron-hole recombination and electron backflow during photovoltaic processes of DSSCs. TiCl[subscript]4 solution treatment method was found to create a porous TiO[subscript]2 barrier layer. Ti sputtering method created a very compact TiO[subscript]2 blocking layer. Two methods showed different characteristics and may be used for different DSSC studies. The second project is to reduce the DSSC cost while maintaining the efficiency by replacing the expensive Pt counter electrode with a novel vertically aligned carbon nanofiber (VACNF) electrode. A large specific electrode surface area (~125 cm[superscript]2 over 1 cm[superscript]2 geometric area) was obtained by using VACNFs. The relatively high surface area, good electric conductivity and the large numbers of active graphitic edges existed in cone-like microstructure of VACNFs were employed to improve redox reaction rate of I[subscript]3[superscript]-/I[superscript]- mediators in the electrolyte. Faster electron transfer and good catalytic activities were obtained with such counter electrodes. The third project is to develop a metal organic chemical vapor deposition (MOCVD) method to coat TiO[subscript]2 shells on VACNF arrays as potential photoanodes in the DSSC system in order to improve the electron transfer. Fabrication processes were demonstrated and preliminary materials were characterized with scanning electron microscopy and transmission electron microscopy. MOCVD at 300 mTorr vapor pressure at 550° C for 120 min was found to be the optimal condition.

Master of Science / Department of Civil Engineering / Kyle A. Riding / Air void clustering around coarse aggregate in concrete has been identified as a potential source of low strengths in concrete mixes by several Departments of Transportation around the country. Research was carried out to (1) develop a quantitative measure of air void clustering around aggregates, (2) investigate whether air void clustering can be reproduced in a laboratory environment, (3) determine if air void clustering can blamed for lower compressive strengths in concrete mixes, (4) and identify potential factors that may cause clustering. Five types of coarse aggregate and five different air entraining agents were included in the laboratory study to see if aggregate type or chemical composition of air entraining agent directly relates to air void clustering. A total of 65 mixes were made, implementing the frequently used technique of retempering that has been previously associated with air void clustering around aggregates. Compressive strength specimens as well as samples for hardened void analysis were made. Compressive strength at 7 and 28 days was determined and the automated hardened void analysis (including a new method of clustering evaluation) was performed on all samples. It was found that it is possible to reproduce air void clustering in laboratory conditions. However, the results have shown that retempering does not always cause air void clustering. It was also observed that air void clustering is not responsible for a decrease in compressive strength of retempered concrete as neither aggregate type nor chemical composition of air entraining agent had a significant impact on severity of void clustering around coarse aggregate particles. It was also found that the total air content and an inhomogeneous microstructure and not air void clustering were responsible for lower strengths.