Structures and Materials Commons^™

Thermal Modeling Of Additive Manufacturing Using Graph Theory: Validation With Directed Energy Deposition, Jordan Severson

Mechanical (and Materials) Engineering -- Dissertations, Theses, and Student Research

Metal additive manufacturing (AM/3D printing) offers unparalleled advantages over conventional manufacturing, including greater design freedom and a lower lead time. However, the use of AM parts in safety-critical industries, such as aerospace and biomedical, is limited by the tendency of the process to create flaws that can lead to sudden failure during use. The root cause of flaw formation in metal AM parts, such as porosity and deformation, is linked to the temperature inside the part during the process, called the thermal history. The thermal history is a function of the process parameters and part design.

Consequently, the first step …

Experimental Study On Compression And Shear Strength Of Cfrp, Joseph Gentile, Ethan Garber

Discovery Day - Prescott

The increasing use of carbon fiber-reinforced polymer (CFRP) in the aerospace industry requires a better understanding of its damage properties. Many modern aircraft under high loads are utilizing this material for their primary structures due to its high strength to weight ratio. However, CFRPs are sensitive to out-of-plane loading such as low-velocity impact and indentation. These damages can reduce the compressive strength significantly without leaving a visible mark on the surface, which is known as Barely Visible Impact Damage (BVID). The behavior and residual strength of CFRPs after impact damage under compressive loading are still not fully understood. Studies of …

Sae Aero West Heavy Lift Competition Team - Eaglenautics, Anthony Pirone, Evan Stuart, Jessica Millard, Nathaniel Scott

Discovery Day - Prescott

ERAU’s SAE Aero Design West Competition team encourages students of all majors who have an interest in the design of heavy-lift cargo and passenger aircraft to design, build, and fly a large RC aircraft to meet a new set of regulations each competition year. Since the team, Eaglenautics, was founded in 2017 it has successfully been to competition once in April 2019 in California. The team’s aircraft flew 4 out of 5 flight rounds, passed all technical inspections, and is now on display in ERAU’s Aero-Fab in the AXFAB. The 2020 competition requirements are unique in that the cargo’s weight-to-volume …

The Effect Of Oxygen On Properties Of Zirconium Metal, Jie Zhao

Doctoral Dissertations

The influence of oxygen on the thermophysical properties of zirconium has been investigated using MSL-EML (Material Science Laboratory Electromagnetic Levitator) on ISS (International Space Station) in collaboration with NASA (National Aeronautics and Space Administration), ESA (European Space Agency), and DLR (German Aerospace Center). Zirconium samples with different oxygen concentrations was subjected to multiple melt cycles during which the thermophysical properties, such as density, viscosity and surface tension, have been measured at various undercooled and superheated temperatures. Also, there are melt cycles for verifying the solidification mechanism. Similar samples were found to show anomalous nucleation of the solid for certain ranges …

Development And Testing Of Novel Antimicrobial Materials For Additive Manufacturing With Application In Space, Michael Thompson, Jorge Zuniga, Christopher Copeland, Roberto Saavedra, Claudia Cortes Reyes, Andres Acuña Velásquez, Daniel Martínez Pereira, Claudio Soto

UNO Student Research and Creative Activity Fair

PURPOSE: The purpose of the study was twofold: (i) develop and test the antimicrobial properties of a polylactic acid- and a polyurethane-based filament, and (ii) use these filaments to manufacture a socket-based prosthesis to verify printability and longevity of the antimicrobial properties. It was hypothesized that the formulation of a novel biocidal copper-based nanocomposite with a biocompatible 3D printing polymer/copolymer can be used for the development of antimicrobial medical devices to mitigate microbial risks during long space flight missions [1, 2, 3].

METHODS: Polylactic Acid-based Filament Development-The development of a polylactic acid-based filament involved several processes, such as fermentation …

Structural Dynamic And Inherent Damping Characterization Of Additively Manufactured Airfoil Components, Andrew W. Goldin

Theses and Dissertations

The push for low cost and higher performance/efficient turbine engines have introduced a new demand for novel technologies to improve robustness to vibrations resulting in High Cycle Fatigue (HCF). There have been many proposed solutions to this, some passive and some active. With the advent of Additive Manufacturing (AM), new damping techniques can now be incorporated directly into the design and manufacture process to suppress the vibrations that create HCF. In this study, this novel unfused pocket damping technology is applied to a blade structure and the resulting damping effectiveness is quantified. The application of this technology to complex geometries …

Laser Shock Peening Pressure Impulse Determination Via Empirical Data-Matching With Optimization Software, Colin C. Engebretsen

Theses and Dissertations

Laser shock peening (LSP) is a form of work hardening by means of laser induced pressure impulse. LSP imparts compressive residual stresses which can improve fatigue life of metallic alloys for structural use. The finite element modeling (FEM) of LSP is typically done by applying an assumed pressure impulse, as useful experimental measurement of this pressure impulse has not been adequately accomplished. This shortfall in the field is a current limitation to the accuracy of FE modeling, and was addressed in the current work. A novel method was tested to determine the pressure impulse shape in time and space by …

Characterization Of Directed Energy Deposition Additively Manufactured Grcop-42 Alloy, Scott Landes

Electronic Theses and Dissertations

GRCop is an alloy family constructed of copper, chromium, and niobium and was developed by NASA for high heat flux applications. The first of its kind, GRCop-84, was specifically designed for the environments seen by channel cooled main combustion chamber liners. To further increase thermal conductivity while maintaining material strength characteristics, the percentage of alloying elements were cut in half and GRCop- 42 was developed. In recent years, NASA has successfully additively manufactured GRCop with comparable material characteristics to wrought GRCop using a Laser Powder Bed Fusion (L-PBF) process. Benefits of this process include fabrication of intricate cooling channels as …

Redesign And Analysis For Landing Gear Components, Daniel Clarke

Williams Honors College, Honors Research Projects

A project for Collins Aerospace, the company I co-op at, where I will redesign several components of a landing gear for a military program. Any structural/stress analysis will also be performed. The goal is to reduce weight while maintaining strength and structural integrity.

Rocket Motor Nozzle, Corey Hillegass

Williams Honors College, Honors Research Projects

For this honors research and senior design project, the authors will research, analyze, and manufacture a rocket motor nozzle for the Akronauts rocket design team. This research and design project will improve how the rocket design team will decide and manufacture nozzles going forward. The impact of this improvement allows the rocket design team to take steps toward being self-sustaining by manufacturing student designed parts as opposed to commercially bought parts. This will not only be successful in increasing student impact on future designs, but also provides a technical challenge for the authors and will present as an impressive feat …

Multiscale Modeling Of Carbon Fibers/Graphene Nanoplatelets/Epoxy Hybrid Composites For Aerospace Applications, Hashim Al Mahmud

Dissertations, Master's Theses and Master's Reports

Significant research effort has been dedicated for decades to improve the mechanical properties of aerospace polymer-based composite materials. Lightweight epoxy-based composite materials have increasingly replaced the comparatively heavy and expensive metal alloys used in aeronautical and aerospace structural components. In particular, carbon fibers (CF)/graphene nanoplatelets (GNP)/epoxy hybrid composites can be used for this purpose owing to their high specific stiffness and strength. Therefore, this work has been completed to design, predict, and optimize the effective mechanical properties of CF/GNP/epoxy composite materials at different length scales using a multiscale modeling approach. The work-flow of modeling involves a first step of using …

Evaluating The Effectiveness Of Aerospace Materials, Vehicle Shape And Astronaut Position At Lowering The Whole Body Effective Dose Equivalent In Deep Space, Daniel K. Bond

Theses and Dissertations

As future crewed, deep space missions are being planned, it is important to assess how spacecraft design can be used to minimize radiation exposure. Collectively with shielding material, vehicle shape and astronaut position must be used to protect astronauts from the two primary sources of space radiation: Galactic Cosmic Rays (GCR) and Solar Particle Events (SPE). GCRs, which are composed of low intensity, highly energetic, and fully ionized stable and meta-stable isotopes, are considered a chronic source of radiation risk to the astronauts. SPEs, which originate from solar coronal mass ejections, are composed mostly of high intensity protons that can …

Carbon Fiber Composite Recycling, Wolfe Dennis

All Undergraduate Projects

During construction of Boeing’s aircrafts, carbon fiber reinforced composites are used as the primary material for the wings of the aircraft. Excess material during the manufacturing process is trimmed and discarded as waste. Although there is no viable process thus far, these trimmings have the potential to be recycled and reclaimed to be used in various other manufactured products. The trimmings of carbon fiber composite are approximately 10-12 layers of material bonded together. This project focuses on delaminating the trimmings into individual layers so that the carbon can be pyrolyzed from the bonding resin. In order to separate the layers …

Open-Ended Capstone Project: Designing And Manufacturing Of A Low-Cost Carbon Fiber Reinforced Composite Suborbital Rocket Payload Housing Using A 3d Printed Core, Garam Kim, Sergey Dubikovsky, Peng Hao Wang, Ronald Sterkenburg

International Journal of Aviation, Aeronautics, and Aerospace

Composite materials are utilized in many industries today due to its high performance and lightweight. However, the part manufacturing process of traditional composites is complicated and often involves high cost. The molds used for composite manufacturing are usually one of the contributors to the high part manufacturing cost. The authors demonstrated in this paper a manufacturing process for a carbon fiber reinforced composite rocket payload housing using an additively manufactured polylactic acid (PLA) payload housing core. The paper also demonstrates the designing and manufacturing of a functional product, which was used in a real-life application, achieved by college undergraduate students. …

Influence Of Size Effects On Surface Generation During Finish Machining And Surface Integrity In Ti-6al-4v, Ian S. Brown

Theses and Dissertations--Mechanical Engineering

Finish machining is an essential manufacturing process that is used to enhance the mechanical characteristics of critical components. The deformation that occurs at the tool and workpiece interface in finish machining significantly affects a host of component properties, commonly referred to as “surface integrity” properties. Surface roughness is a machining deformation-affected characteristic that is of high relevance in contemporary manufacturing. However, over recent decades it has been made clear that the material properties of the deformed surface layers are relevant to component performance as well. Predicting the overall surface quality of a machined component is of great relevance to the …

Carbon Oxidation At The Atomic Level: A Computational Study On Oxidative Graphene Etching And Pitting Of Graphitic Carbon Surfaces, Simon Schmitt

Theses and Dissertations--Mechanical Engineering

In order to understand the oxidation of solid carbon materials by oxygen-containing gases, carbon oxidation has to be studied on the atomic level where the surface reactions occur. Graphene and graphite are etched by oxygen to form characteristic pits that are scattered across the material surface, and pitting in turn leads to microstructural changes that determine the macroscopic oxidation behavior. While this is a well-documented phenomenon, it is heretofore poorly understood due to the notorious difficulty of experiments and a lack of comprehensive computational studies. The main objective of the present work is the development of a computational framework from …

Peridynamic Approaches For Damage Prediction In Carbon Fiber And Carbon Nanotube Yarn Reinforced Polymer Composites, Forrest E. Baber

Theses and Dissertations

Aerospace structures are increasingly utilizing advanced composites because of their high specific modulus and specific strength. While the introduction of these material systems can dramatically decrease weight, they pose unique certification challenges, often requiring extensive experimental testing in each stage of the design cycle. The expensive and time-consuming nature of experimental testing necessitates the advancement of simulation methodologies to both aid in the certification process and assist in the exploration of the microstructure design space.

Peridynamic (PD) theory, originating from Sandia National Lab’s in the early 2000’s, is a nonlocal continuum-based method that reformulates the equation of motion into an …

Design Of Banner Tow Mechanism For Bush Plane, Kyle Ciarrone, Ivan Martin, Rishabh Gadi, Tyler Brandt

Williams Honors College, Honors Research Projects

The 2019-2020 AIAA DBF objective was to design, build, and test a banner-towing bush plane that carries wooden passengers and luggage. Senior members on the team undertook the creation of the banner tow mechanism subsystem as their senior design project on behalf of the design team due to the challenge of its mechanical design and the aerodynamic considerations regarding its placement and enclosure aboard the aircraft. The competition as well as access to campus resources were canceled due to COVID-19, so full testing and integration of the mechanism was not achieved. However, the engineering design process was experienced from the …

Experimental Evaluation Of Strength Degradation Temperature For Carbon Epoxy Filament Wound Composite, Jai Krishna Mishra, Surya Prakash Rao Ch Dr, Subhash Chandra Bose P Dr, Kishore Nath N Dr, Rama Rao Golla Mr

International Journal of Aviation, Aeronautics, and Aerospace

Polymeric composites have been widely used in various structural and thermal aerospace applications. Polymeric composites having high strength and high modulus reinforcement are ideally suited for lot of critical aerospace applications as structure is designed with high specific strength and high specific modulus. In case of launch vehicles/ missile one such application is design and manufacturing of solid rocket motor casing with polymeric composites as it give high performance and reduces inert weight of propulsion system. The high specific strength and high specific modulus of composite materials makes it ideal choice for designing the composite rocket motor case (CRMC). These …

Aeroelasticity Of Composite Plate Wings Using Hsdt And Higher-Order Fem, Justin A. Haught

Graduate Theses, Dissertations, and Problem Reports

The aeroelasticity of composite wings is becoming an increasingly researched topic in aircraft design, as designers continue to replace aluminum alloy components with those made of composite materials because of their favorable strength-to-weight ratio, fatigue characteristics, and corrosion resistance. Additionally, the bending-torsion coupling exhibited by composite laminates readily allow for the aeroelastic optimization of an aerodynamic structure through the process of aeroelastic tailoring. Wings made of composites materials, however, are more vulnerable to shear deformation.

The objective of the present research is to study the divergence and flutter characteristics of composite plate wings using a higher-order shear deformation theory (HSDT) …