Engineering topics
Publications and source records attributed to Seffens, Robert J..
Informatics-driven approaches, such as machine learning and sequential experimental design, have shown the potential to drastically impact next-generation materials discovery and design.
The transition to hydrogen as a clean and efficient energy carrier is impeded by challenges in the compatibility of hydrogen with materials used within hydrogen infrastructure. Elastomers, crucial in sealing components, often exhibit premature failures in high-pressure hydrogen environments due to excessive swelling. This study employs an innovative in-situ view cell system to assess the swelling behavior of hydrogenated nitrile butadiene rubber (HNBR) under various hydrogen conditions. The system, designed to withstand pressures up to 96.5 MPa, incorporates Digital Image Correlation (DIC) for strain measurements and volume estimation. Results reveal non-linear volume increases during depressurization, challenging conventional assumptions. Furthermore, investigations into peak hydrogen pressures and pressure-holding scenarios during decompression highlight complex swelling trends. The introduction of a novel computer vision (CV) method enhances precision in volume estimation, overcoming DIC limitations. The study provides insights into mitigating elastomer swelling, crucial for developing robust materials to support future hydrogen-driven energy systems.
In this study, we investigate the toughness and resistance to tear of thin-wall high-pressure die-cast (HPDC) aluminum alloys in two different orientations following the implementation of friction stir processing (FSP). The FSP technique was applied to two different HPDC Al-Si alloys: the recyclable-grade, high iron, A380 alloy and the premium-quality, low iron, Aural-5 alloy. Our findings reveal significant tear resistance and strength enhancements for both alloys after FSP modification. Specifically, FSPed A380 alloy requires 126% higher energy to tear, and it has 49% higher tear strength than the HPDC counterpart. Similarly, the tear energy and tear strength of the Aural-5 alloy witness enhancements of 69% and 21%, respectively. In conclusion, these results highlight the potential of FSP as a viable method for augmenting the mechanical properties of HPDC aluminum alloys, thereby opening up new avenues for their utilization in diverse engineering applications for crack obstruction.
Unlike existing literature that primarily concentrates on either the plasma treatment of adherends alone or solely on adhesive surfaces, this work leverages plasma modification of both adhesive in tape form and adherend surfaces to largely enhance the interfacial bonding between a thermoset-based adhesive tape and carbon-fiber-reinforced thermoplastic polymer (CFRTP) for structural bonding applications. Here, by conducting single lap shear tests on adhesively-bonded AA6061-CFRPPA (carbon-fiber-reinforced polyphthalamide) dissimilar joints, it is shown that the plasma treatment of adherends alone can increase the lap shear strength (LSS) of the joints by approximately 200% compared to non-treated counterparts. An additional plasma treatment of adhesive tape surfaces leads to even higher LSS improvement, reaching up to 315%, due to the formation of a denser crosslinked network of covalent bonds and a reduced area fraction of interfacial voids at the CFRPPA/adhesive interface. The highest plasma-enhanced LSS of the metal-CFRTP dissimilar joints rivals that of metal-metal joints, which is typically stronger than the joints associated with fiber-reinforced polymers. This study is important for achieving strong CFRTP-related structural components bonded using adhesive tape, providing better compatibility with plasma treatment and other joining methods like riveting compared to adhesive paste or liquid.
Safe design of adhesive joining in multi-materials in engineered structures requires the accumulation of numerous experimental data on the failure behavior of various adhesively-bonded material combinations under different loading conditions. The deep understanding of mechanical performance, fracturing morphologies, and main damage mechanisms is also quintessential for accelerating the development of proper physics-based and multi-scale models for assisting the design. Towards this goal, this work presents a comprehensive characterization of the failure behavior of adhesively-bonded metal–metal, metal–CFRP, and CFRP–CFRP material combinations under global shear deformation via single lap shear testing. Thanks to a synergistic combination of measurement methods by using Digital Imaging Correlation (DIC) and 3D optical profilometry, adhesive features on the adherend after failure were quantified and the main progressive damage mechanisms were identified. The characterization performed in this work provides quantitative data that contributes to a better understanding of shear failure in adhesive bonding across different bi-material combinations. Finally, the obtained results have practical implications, including the potential to enhance adhesive bonding design, identify failure causes in adhesive joints, and develop or validate computational models capable of capturing the observed behavior in various adhesively-bonded materials under global shear deformation.
Ethylene propylene diene (EPDM) rubber has gained increasing interest for use in hydrogen infrastructure due to its excellent sealing performance and low temperature properties. However, severe structural damage has been observed in EPDM O-rings after exposure to high-pressure hydrogen. The origination and propagation mechanisms of this damage are poorly understood. Here, to address this knowledge gap, multi-scale imaging leveraging X-ray micro-computed tomography (micro-CT), helium ion microscopy (HeIM), and transmission electron microscopy (TEM) were used in this work to study a series of sulfur-cured ethylene propylene diene (EPDM) rubber materials with varying additives that were exposed to different hydrogen environments. Micro-CT captured the substantial structural damage due to hydrogen exposure; it revealed an association between zinc oxide (ZnO) particles and damage initiation. Further studies by TEM and scanning TEM with energy dispersive X-ray spectroscopy (EDS) were focused on these particles at the micro-to nano-scale range. TEM indicated that hydrogen causes void formation at the interface between ZnO and the rubber matrix. HeIM enabled imaging of surface morphology of the material at high resolution pre- and post-hydrogen exposure while providing information on chemical composition and that cannot be captured by either micro-CT or TEM.
Here, this work proposes an approach to improve the interfacial bonding between carbon-fiber-reinforced thermoplastic polymers (CFRTP) and thermoset adhesive by using the surface modification with the combination of air plasma, thermal, and step-over effects. Thanks to the proper heating which causes the exposure of carbon fibers on the CFRTP surface, both polymer matrix and these exposed carbon fibers can have improved bonding with adhesive due to air plasma treatment. By conducting the Double Cantilever Beam (DCB) tests performed on adhesively-bonded AA5052/CFRP-PA66 dissimilar joints, it was shown in this work that the average Mode I specific fracture energy can be improved up to about 180% compared to non-treated counterparts. The foregoing improvement can be further increased by considering the step-over distance of the surface treatment, which triggers the tortuous damage path in the failure process of adhesively-bonded structures. By manipulating this treatment parameter, often overlooked in the literature, and other parameters (i.e., treatment speed, nozzle tip-to-surface distance, etc.) investigated in this study, the average Mode I specific fracture energy of adhesively-bonded AA5052/CFRP-PA66 dissimilar joints can be improved reaching up to about 410% compared to non-treatment counterparts.
Understanding the adhesive and interfacial fracture is important for developing and achieving better adhesive jointing in bi-materials, the location which becomes less vulnerable in engineered structure components. Still, to characterize the fracturing behavior of various adhesively-bonded materials, it was shown in this work that the Mode I fracture energies estimated from conventional methods (e.g., work-of-fracture, (modified) compliance calibration method, (modified) beam theory, etc.) can be strongly affected by adherent thickness, adhesive bond length, and material type. Consequently, this hindered the proper understanding of fracturing in adhesive jointing of bi-materials since the estimated fracture energies can exhibit unreasonable difference among various material combinations, thus leading to the confusion in the literature due to the unfair comparison on these non-objective results estimated by leveraging conventional methods on the specimens with different geometries. This work compared size effect method with conventional methods on the calculation of the Mode I fracture energies of metal-metal, metal-CFRP, and CFRP-CFRP material combinations via Double Cantilever Beam (DCB) tests. The results showed that the estimated fracture energies of various material combinations are not dependent on the specimen geometries. This aspect allowed the fair comparison particularly on the interfacial fracturing between metal/adhesive and CFRP/adhesive, and the difference was further explained and correlated with the damage morphology on the material surface after failure identified through three-dimensional profilometer.