The removal of support material from metal 3D printed objects is a laborious necessity for the post-processing of powder bed fusion printing (PBF). Supports are typically mechanically removed by machining techniques. Sacrificial supports are necessary in PBF printing to relieve thermal stresses and support overhanging parts often resulting in the inclusion of supports in regions of the part that are not easily accessed by mechanical removal methods. Recent innovations in PBF support removal include dissolvable metal supports through an electrochemical etching process. Dissolvable PBF supports have the potential to significantly reduce the costs and time associated with traditional support removal. However, the speed and effectiveness of this approach is inhibited by numerous factors such as support geometry and metal powder entrapment within supports. To fully realize this innovative approach, it is necessary to model and understand the design parameters necessary to optimize support structures applicable to an electrochemical etching process. The objective of this study was to evaluate the impact of block additive manufacturing support parameters on key process outcomes of the dissolution of 316 stainless steel support structures. The parameters investigated included hatch spacing and perforation, and the outcomes of interests included time required for completion, surface roughness, and effectiveness of the etching process. Electrical current was also evaluated as an indicator of process completion. Analysis of the electrical current throughout the etching process showed that the dissolution is diffusion limited to varying degrees, and is dependent on support structure parameters. Activation and passivation behavior was observed during current leveling, and appeared to be more pronounced in non-perforated samples with less dense hatch spacing. The correlation between electrical current and completion of the etching process was unclear, as the support structures became mechanically removable well before the current leveled. The etching process was shown to improve surface finish on unsupported surfaces, but support was shown to negatively impact surface finish. Tighter hatch spacing was shown to correlate to larger variation in surface finish, due to ridges left behind by the support structures. In future studies, it is recommended current be more closely correlated to process completion and more roughness data be collected to identify a trend between hatch spacing and surface roughness.

This report investigates the mass-transfer kinetics of gas diffusion through an asymmetrical hollow-fiber membrane developed for the membrane biofilm reactor (MBfR) when it is used to microbiologically convert syngas (a mixture of H2, CO2, and CO) to organic products. The asymmetric Matrimid® membrane had superior diffusion fluxes compared to commercially available symmetric, three-layer composite and polypropylene single-layer membranes. The Matrimid® asymmetric membrane had a H2 gas-gas diffusion flux between 960- and 1600-fold greater than that of the composite membrane and between 32,000- and 46,800-fold greater than that of the single-layer membrane. Gas-gas diffusion experiments across the Matrimid® membrane also demonstrated plasticization behavior for pure CO2 and H2 gas feeds. In particular, a 10 psia increase in inlet pressure resulted in a 12-fold increase in permeance for H2 and a 16-fold increase for CO2. Plasticization was minimal for symmetric composite and single-layer membranes. Thus, diffusion fluxes were much higher for the asymmetric membrane than for the symmetric composite and single-layer membranes, and this supports the promise of the asymmetric membrane as a high-efficiency means to deliver syngas to biofilms able to convert the syngas to organic products. Gas-liquid diffusion was much slower than gas-gas diffusion, and this supports the benefit of using the MBfR approach over fermentation reactors that rely on sparging syngas.

The mechanisms of extracellular respiration in Geobacter sulfurreducens, commonly considered to be a model organism for anode respiration, are yet to be completely understood. The interplay between electron and proton transport especially could be a key to gaining further insights. One way to investigate the mechanisms of extracellular respiration under varying environmental conditions is by analyzing the electrochemical response of the biofilm with respect to pH, buffer concentrations, and acetate concentrations. I seek to increase the understanding of the electrochemical response of the G. sulfurreducens biofilm through electrochemical impedance spectroscopy (EIS) and cyclic voltammetry (CV) techniques in concert with chronoamperometry. I used Geobacter sulfurreducens PCA biofilms in single-chamber electrochemical cells (approximately 100 mL volume) with a small gold working electrode (3.14 mm2). I observed limitations in the initial methods used for media replacement. I tracked changes in the CV data, such as EKA (midpoint potential), as a function of pH and buffer concentration. The media replacement method developed demonstrates success in pH experiments that will be transferrable to other environmental conditions to study electron transport. The experiments revealed that the clarity of data collected is dependent on the quality of the biofilm. A high quality biofilm is characterized by a high current density and normal growth behavior. The general trends seen in these experiments are that as pH increases the potential decreases, and as buffer concentration increases the potential decreases and pH increases. Acetate-free conditions in the reactor were unable to be achieved as characterized by non-zero current densities in the acetate-free experiments.

Alternative ion exchange membranes for implementation in a peroxide production microbial electrochemical cel (PP-MEC) are explored through membrane stability tests with NaCl electrolyte and stabilizer EDTA at varying operational pHs. PP-MEC performance parameters \u2014 H2O2 concentration, current density, coulombic efficiency and power input required \u2014 are optimized over a 7 month continuous operation period based on their response to changes in HRT, EDTA concentration, air flow rate and electrolyte. I found that EDTA was compatible for use with the membranes. I also determined that AMI membranes were preferable to CMI and FAA because it was consistently stable and maintained its structural integrity. Still, I suggest testing more membranes because the AMI degraded in continuous operation. The PP-MEC produced up to 0.38 wt% H2O2, enough to perform water treatment through the Fenton process and significantly greater than the 0.13 wt% batch PP-MEC tests by previous researchers. It ran at > 0.20 W-hr/g H2O2 power input, ~ three orders of magnitude less than what is required for the anthraquinone process. I recommend high HRT and EDTA concentration while running the PP- MEC to increase H2O2 concentration, but low HRT and low EDTA concentration to decrease power input required. I recommend NaCl electrolyte but suggest testing new electrolytes that may control pH without degrading H2O2. I determined that air flow rate has no effect on PP-MEC operation. These recommendations should optimize PP-MEC operation based on its application.

Microbial fuel cells (MFCs) facilitate the conversion of organic matter to electrical current to make the total energy in black water treatment neutral or positive and produce hydrogen peroxide to assist the reuse of gray water. This research focuses on wastewater treatment at the U.S. military forward operating bases (FOBs). FOBs experience significant challenges with their wastewater treatment due to their isolation and dangers in transporting waste water and fresh water to and from the bases. Even though it is theoretically favorable to produce power in a MFC while treating black water, producing H2O2 is more useful and practical because it is a powerful cleaning agent that can reduce odor, disinfect, and aid in the treatment of gray water. Various acid forms of buffers were tested in the anode and cathode chamber to determine if the pH would lower in the cathode chamber while maintaining H2O2 efficiency, as well as to determine ion diffusion from the anode to the cathode via the membrane. For the catholyte experiments, phosphate and bicarbonate were tested as buffers while sodium chloride was the control. These experiments determined that the two buffers did not lower the pH. It was seen that the phosphate buffer reduced the H2O2 efficiency significantly while still staying at a high pH, while the bicarbonate buffer had the same efficiency as the NaCl control. For the anolyte experiments, it was shown that there was no diffusion of the buffers or MFC media across the membrane that would cause a decrease in the H2O2 production efficiency.

In microbial fuel cells (MFCs) the biocathode is developed as a potential alternative to chemical cathodic catalysts, which are deemed as expensive and unsustainable for applications. These cells utilize different types of microorganisms as catalysts to promote biodegradation of organic matter while simultaneously converting energy released in metabolic reactions into electrical energy. Most current research have focused more on the anodic microbes, including the current generating bacteria species, anodic microbial community composition, and the mechanisms of the extracellular electron transfer. Compared to the anode, research on the microbes of the biocathode of the MFCs are very limited and are heavily focused on the role of the bacteria in the system. Thus, further understand of the mechanism of the microbial community in the biocathode will create new engineering applications for sustainable energy. Previous research conducted by Strycharz-Glaven et al. presented an electrochemical analysis of a Marinobacter-dominated biocathode communitygrown on biocathodes in sediment/seawater-based MFCs. Chronoamperometry results indicated that current densities up to -0.04 A/m2 were produced for the biocathode. Cyclic voltammetry responses indicated a midpoint potential at 0.196 V ± 0.01 V. However, the reactor design for these experiments showed that no oxygen is supplied to the electrochemical system. By incorporating an air diffusion membrane to the cathode of the reactor, chronoamperometry results have produced current density in the system up to -0.15 A/m2. Cyclic voltammetry results have also displayed a midpoint potential of 0.25 V ± 0.01 V under scan rates of 0.2 mV/s. Thus, this electrochemical setup has increased the current output of the system.

Heliobacterium modesticaldum (H. modesticaldum) is an anaerobic photoheterotroph that can produce molecular hydrogen (H2) when it is fixing dinitrogen (N2). In addition, electrons can be injected into this organism via an electrode and redox mediator in a light-dependent fashion, as shown recently by the Redding and Jones research groups. These factors make H. modesticaldum an ideal organism for use in a microbial photoelectrosynthesis cell, in which electricity can be used to power specific metabolic processes that produce a desired compound (e.g. H2). However, the injection of electrons into this organism is not optimal, which may limit the H2 production rate. There is a gene (HM1_0653) in the genome encoding a multi-heme cytochrome c that is similar to the proteins known to be used for exit of electrons in the well- known electrode-respiring bacteria (e.g. Geobacteria). RNA-sequencing in the Redding lab has shown that the HM1_0653 gene is very poorly expressed in H. modesticaldum. Boosting expression of this cytochrome could lead to faster electron transfer into the cells and thereby more H2 production via photoelectrosynthesis. In order to gain a deeper understanding of this protein, it was expressed in E.coli by two different versions: (1) the entire gene and (2) a truncated gene with an additional hexahistidine tag (truncHM1_0653). Both cultures had a pink color, indicating the biosynthesis of cytochrome. It was discovered that the HM1_0653 protein was likely released into the medium and shows the most promise for ease of purification of HM1_0653. Furthermore, we explored protein expression in H. modesticaldum using the current transformation system in the Redding Lab, but the combination of gene toxicity and copy number of the vector resulted in cloning difficulties in E.coli. An alternative vector may prove more successful.

Anaerobic digestion (AD), a common process in wastewater treatment plants, is traditionally assessed with Biochemical Methane Potential (BMP) tests. Hydrolysis is considered its rate-limiting step. During my research, I assessed the impact of pretreatment on BMPs and microbial electrochemical cells (MECs). In the first set of experiments, BMP tests were performed using alkaline and thermal pretreated waste activated sludge (WAS), a control group, and a negative control group as samples and AD sludge (ADS) as inoculum. The data obtained suggested that BMPs do not necessarily require ADS, since samples without inoculum produced 5-20% more CH4. However, ADS appears to reduce the initial methanogenesis lag in BMPs, as no pH inhibition and immediate CH4 production were observed. Consumption rate constants, which are related to hydrolysis, were calculated using three methods based on CH4 production, SSCOD concentration, and the sum of both, called the lumped parameter. All the values observed were within literature values, yet each provide a different picture of what is happening in the system. For the second set of experiments, the current production of 3 H-type MECs were compared to the CH4 production of BMPs to assess WAS solids' biodegradability and consumption rates relative to the pretreatment methods employed for their substrate. BMPs fed with pretreated and control WAS solids were performed at 0.42 and 1.42 WAS-to-ADS ratios. An initial CH4 production lag of about 12 days was observed in the BMP assays, but MECs immediately began producing current. When compared in terms of COD, MECs produced more current than the BMPs produced CH4, indicating that the MEC may be capable of consuming different types of substrate and potentially overestimating CH4 production in anaerobic digesters. I also observed 2 to 3 different consumption events in MECs versus 3 for BMP assays, but these had similar magnitudes, durations, and starting times in the control and thermal pretreated WAS-fed assays and not in alkaline assays. This might indicate that MECs identified the differences of alkaline pretreatment, but not between control WAS and thermal pretreated WAS. Furthermore, HPLC results suggest at least one hydrolysis event, as valerate, butyrate, and traces of acetate are observed in the reactors' effluents. Moreover, a possible inhibition of valerate-fixing microbial communities due to pretreatment and the impossibility of valerate consumption by ARB might explain its presence in the reactors' effluents.

The effect of ammonium on microbial fermentation was investigated to improve the efficiency of microbial electrochemical cells (MXC). Electron balances of anaerobic microbial cultures with varying ammonium concentrations (reported as g N-NH4+/L) were used to study the distribution of electrons from different fermentable substrates to acetate, propionate, and methane. Results showed that with a high ammonium concentration (between 2.25 to 3g N-NH4+/L) fewer electrons routed to methane during the fermentation of 300 me-eq./L of electron donors .The majority of electrons (~ 60-80%) in the serum bottles experiments were routed to acetate and propionate for all fermentable substrates with high ammonium concentration. While methane cannot be utilized by anode respiring bacteria (ARBs) to produce current, both acetate and propionate can, which could lead to higher Coulombic efficiencies in MXCs. Experiments in microbial electrolysis cells (MECs) with glucose, lactate, and ethanol were performed. MEC experiments showed low percentage of electrons to current (between 10-30 %), potentially due to low anode surface area (~ 3cm2) used during these experiments. Nevertheless, the fermentation process observed in the MECs was similar to serum bottles results which showed significant diversion of electrons to acetate and propionate (~ 80%) for a control concentration of 0.5 g N-NH4+/L .

Trichloroethene (TCE) and hexavalent chromium [Cr(VI)] are toxic and carcinogenic contaminants found in drinking water resources across the United States. A series of Bench-scale treatability studies were conducted to evaluate the effectiveness of a consortium of facultative and strictly anaerobic bacteria, KB-1®, to remove TCE and Cr(VI) from a contaminated aquifer in San Diego. These series of treatability studies were also performed to prepare data and mature packed sediment columns for the deployment of the In Situ Microcosm Array (ISMA), a diagnostic device for determining optimal treatments for a contaminated aquifer, at this particular site. First, a control panel for the ISMA’s Injection Module (IM) was created in order to deliver nutrients to the columns. Then, a column treatability study was performed in order to produce columns with an established KB-1® consortium, so that all TCE in the column influent was converted to ethene by the time it had exited the column. Finally, a batch bottle treatability study was performed to determine KB-1®’s effectiveness at remediating both TCE and Cr(VI) from the San Diego ground-water samples. The results from the column study found that KB-1® was able to reduce TCE in mineral media. However, in the presence of site ground-water for the batch bottle study, KB-1® was only able to reduce Cr(VI) and no TCE dechlorination was observed. This result suggests that the dechlorinating culture cannot survive prolonged exposure to Cr(VI). Therefore, future work may involve repeating the batch bottle study with Cr(VI) removed from the groundwater prior to inoculation to determine if KB-1® is then able to dechlorinate TCE.