Reaction synthesis is a processing technique where the thermal activation energy needed to form a compound is provided by the exothermic heat of formation of the thermodynamically stable product. This type of synthesis has been used to form a variety of ceramics, intermetallics, and in-situ composites. In this work, the effects of changing the stoichiometry of the titanium aluminide matrix, and the effects of extrinsic reaction variables on the behavior of the reaction were studied and compared to theoretical predictions. It was shown that changing the stoichiometry of the titanium aluminide did have an effect on the measured heat of reaction; however this did not match the prediction. Changing the extrinsic variables of titanium and aluminum particle sizes also showed a significant effect on the behavior of the reaction. / Master of Science

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The in-situ synthesis of piezoelectric-reinforced metal matrix composites has been attempted with a variety of target matrix and reinforcement materials using reaction synthesis and high energy ball milling. Zinc oxide (ZnO) and barium titanate (BaTiO₃) have been successfully synthesized within copper and iron matrices in a range of volume percentages using reaction synthesis. The microstructures of these composites have been analyzed and found to partially consist of an interpenetrating microstructure. After considering experimental findings and thermodynamic issues involved with synthesis, ideal reaction system parameters have been identified that promote the creation of a composite with ideal microstructure and formulated composition. Reactive high energy ball milling has been used to create copper matrix composites reinforced with zinc oxide and copper matrix composites reinforced with lead titanate (PbTiO₃). The microstructures and compositions of each volume percentage formulation of the composite powders have been analyzed. In this work, several promising piezoelectric-reinforced metal matrix composite systems have been identified as having potential to be synthesized in an in-situ manner. / Master of Science

The ever-growing Internet of Things is promoting more data acquisition, data exchange and fewer human interactions, engendering a higher demand for sensors and therefore power. While in most cases it is possible to directly connect these sensors to the power grid, it will not always be feasible with emerging technologies, especially in remote areas where human access is limited. Moisture-Electric Energy Transformation (MEET) devices are components that use moisture as a “fuel” to generate electrical power. Upon contact with moisture, a potential difference results from a diffusion mechanism, allowing charge to be stored locally in capacitors or rechargeable batteries to be utilized for useful work. The focus of the present work was to investigate the potential of Cold Gas Dynamic Spray (CGDS) as an additive manufacturing (AM) process for the fabrication of MEET devices. Following a layer-by-layer approach, MEET devices were successfully built by CGDS, by combining aluminum (electrode material) and an in-situ composite of polyether ether ketone (PEEK) and alumina (diffusion medium). The main challenges of this work were the determination of the spray parameters of PEEK and the investigation of the MEET capability of the manufactured devices. On the other hand, the main contributions of this work were the demonstration of the viability of CGDS in the deposition of PEEK/Al2O3 on aluminum 6061-T6 substrates, as well as the potential of PEEK as a MEET-capable material. The diffusion mechanisms that govern power generation were also hypothesized, explained and summarized. Initial tests of a MEET device of 66 mm x 34 mm indicate an uninterrupted power generation cycle of over 30 hours, and a maximum output voltage of 268 mV with a 6.8 MΩ load. The output power and power per unit area of the device were computed to be 10.63 nW and 4.736 µW/m2 respectively. The output current and current density were evaluated to 39.53 nA and 17.62 µA/m2.