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Nondestructive Evaluation And Structural Health Monitoring Of Manufacturing Flaws And Operational Damage In Composite Structures, Robin James

Theses and Dissertations

Advanced composite materials have begun to be used extensively in the manufacturing of aerospace structures. Composite aerospace structures can develop complex types of damages during the manufacturing stages and operational lifetime. This creates an indispensable demand for appropriate nondestructive evaluation (NDE) and structural health monitoring (SHM) methods that are tailored to specific types of damage. This dissertation addresses innovative methods for NDE and SHM of manufacturing flaws and operational damage in composite structures.

For the NDE of manufacturing flaws in carbon fiber reinforced polymer (CFRP) composites, an eddy current testing (ECT) NDE method has been developed by conducting multiphysics modeling …

Instrumentation And Experimentation Development For Robotic Systems, Tristan Kyzer

Theses and Dissertations

Localization of robotic systems is a necessity for control of robotic systems and often requires the use of costly sensors and equipment onboard the robot or installed within a facility. GPS or GNSS sensors are effective for localizing robots in GPSaccessible environments, but do not work as well in dense urban areas or inside fully enclosed buildings, such as factories or warehouses. Sensors such as LiDAR can be costly and require substantial experience and knowledge to utilize as well as potential changes to infrastructure for use. Computer vision-based localization systems offer potential as a localization solution for various applications. A …

Preferential Vaporization Potential Of Crude Oils And Its Impact On Flame Flashback Behaviors, Ayuob Al Wahaibi

Theses and Dissertations

As combined cycle gas turbines for power generation operating on light distillate fuels provide a sufficient energy, there is a global trend in using heavy liquids (e.g. HFO, crude oils) for direct-firing in gas turbine. However, using these heavy fuels imposes many challenges due to their wide range of physical/chemical properties, which control near-limit combustion behaviors, such lean blow-out and flashback. In addition, the ignition propensity of these heavy fuels is not reported in crude assays, and utilizing a simple, with small sample, and quick methodology to characterize the ignition propensity is important in determining the fuel quality.

In this …

Experimental Investigation Of Single And Two-Phase Heat Transfer Performance In Microchannels With Surface Modifications And Multiple Inlet Restrictors, Saad Kadham Oudah

Theses and Dissertations

Due to shrinking component sizes and faster switching speeds, the volumetric heat generation rates and surface heat flux in many advanced power electronic devices have increased exponentially, creating an urgent need for efficient cooling technologies. It has become particularly challenging to maintain an optimal temperature at the device level. Among advanced cooling techniques, single-phase and two-phase microchannel heat sinks show considerable promise in removing a significant amount of heat from a small surface area. Considered one of the most efficient heat dissipaters, the two-phase microchannel heat sink can handle very high heat flux at a small footprint and requires relatively …

Separate Effects Tests For Studying Thermal Gradient Driven Cracking In Uo2 Pellets Undergoing Resistive Heating, Sobhan Patnaik

Theses and Dissertations

A variety of normal operation and accident scenarios can generate thermal stresses large enough to cause cracking in light-water reactor (LWR) fuel pellets. Cracking of fuel pellets can lead to reduced heat removal, larger centerline temperatures, and localized stress in cladding, all of which impact fuel performance. It is important to understand the temperature profile on the pellet before and after cracking to improve cracking models in fuel performance codes such as BISON. However, in reactor observation and measurement of cracking is very challenging owing to the harsh environment and design of fuel rods.

Recently, a state-of-the-art experimental pellet cracking …

Experimental Investigation Of Spray Cooling Integrated With A Modified Vapor Compression Refrigeration System Using Several Refrigerants, Nabeel Mukhlif Abdulrazzaq

Theses and Dissertations

Spray cooling has gained increasing interest over the last three decades due to its high thermal performance as a direct cooling technique. Researchers are investigating spray cooling in thermal management systems for electronic applications, particularly focusing on the use of dielectric fluids including FC-72, FC-87, ammonia, and refrigerants such as R113 and R134a. Their studies indicate that the usage of dielectric fluids as a working fluid in spray cooling systems is promising and has significant thermal performance enhancement, which is suitable for a wide range of electronic applications. However, several deficiencies have been identified with the working fluids studied thus …

Enhanced Flow Boiling And Bubble Dynamics With Hfe7100 & Di Water In Interconnected Microchannels, Jiaxuan Ma

Theses and Dissertations

Flow boiling in microchannels using dielectric fluids is one of the most desirable cooling solutions for high power electronics. Primary two-flow patterns, including bubbly flow, slug flow, and annular flow, have been well established in microchannels. However, it is challenging to promote flow boiling performance, particularly critical heat flux (CHF), due to their unfavorable thermophysical properties. Considering these situations, flow boiling in parallel and isolated microchannels have been extensively studied. In this dissertation, a novel concept that has five parallel microchannels (W=200 µm, H=250 µm, L=10 mm) are interconnected by micro-slots (20 µm wide and 250 µm deep) starting from …

Nano-Engineered High-Performance Copper-Water Heat Pipes, Ahmed A. Abdulshaheed

Theses and Dissertations

Recently, heat pipes have gained an exceptional reputation as passive systems. They have become an attractive choice for many engineering applications due to their simple design, high rate of heat transfer, low weight, and low cost of maintenance [1]. A Heat pipe consists of a vacuumed shell filled partially with a compatible working fluid. Three main sections comprise a heat pipe: evaporator, adiabatic, and condenser section. The heat pipe utilizes the principle of evaporation and condensation for operations, i.e., the phase change of working fluid. Heat pipe allows high heat rates to transfer over considerable lengths with minimum temperature differences …

Anisotropic Wave Behavior In Isotropic Material With Orthogonal Surface Perturbation, Khaleda Akter

Theses and Dissertations

Elastic wave propagation in anisotropic media is of great interest in various branches of engineering and applied sciences. In this study, an anisotropic wave propagation behavior in isotropic material with orthogonal surface perturbation is presented. The conventional method of estimating dispersion equations for isotropic material is to apply Helmholtz decomposition on the potential functions for Rayleigh-Lamb wave and Shear Horizontal (SH) waves. However, the presence of isotropic material with orthogonal surface perturbations in two coordinate directions significantly affect the wave propagation behavior due to its direction dependency, and hence, the Helmholtz decomposition of the potential functions cannot be applied to …

Prediction Of Residual Stress And Distortion In Laser Powder Bed Fusion Additive Manufacturing, Bhanuprakash Sairam Kosaraju

Theses and Dissertations

Additive Manufacturing (AM) has its proven advantages to unlock the design space and manufacturing capabilities for complex geometries with lightweights. Distortion is one of the most common defects that occur in Laser Powder Bed Fusion Additive Manufacturing (LPBFAM), which is caused by the significant residual stress during the printing process. This can lead to numerous process iterations to achieve the requisite form and fit tolerances.

In this study, Finite Element (FE) model that utilizes the element birth approach was developed to predict the residual stress and distortion in the LPBFAM process. The methodology leverages a simplified approach where the detailed …

Grafting Based Thermoplastic-Thermoset Bonding For Aerospace Structures, Saurabh Vaidya

Theses and Dissertations

The use of carbon fiber composites is rapidly increasing in the aerospace industry. Fiber reinforced plastic composites can primarily be classified as thermoplastic and thermoset, both offer unique advantages over one another. Thermosets cure at relatively low temperature and in general, are lower priced than thermoplastic composites. However, the cost of autoclave for the curing of thermosets is a major drawback. On the other hand, thermoplastics are showing higher damage tolerance. They can be re-melted and re-consolidated and have the potential to be re-used / recycled. The repair of TP composites is not developed yet. Therefore, both the types attract …

Multimodal Robotic Health In Future Factories Through Iiot, Data Analytics, And Virtual Commissioning, Clint Saidy

Theses and Dissertations

The manufacturing sector is continuously reinventing itself by embracing opportunities offered by the industrial internet of things and big data, among other advances. Modern manufacturing platforms are defined by the quest for ever increasing automation along all aspects of the production cycle. Furthermore, in the next decades, research and industry are expected to develop a large variety of autonomous robots for a large variety of tasks and environments enabling future factories. This continuing pressure towards automation dictates that emergent technologies are leveraged in a manner that suits this purpose. These challenges can be addressed through the advanced methods such as …

Acoustic And Ultrasonic Beam Focusing Through Aberrative And Attenuative Layers, Hossain Ahmed

Theses and Dissertations

Ultrasonic nondestructive evaluation (NDE) is a well-established technique to assess material properties and material state in noninvasive way. However, conventional NDE technologies are limited by the thick top coatings over the structure and, therefore, require time consuming removal and replacement of the coatings to perform the inspection. In biological application, although ultrasonic NDE is a safer method in compared to other radioactive non-invasive techniques, aberration of acoustic beams is more common as it encounters multiple tissue layers of complex geometry with nonhomogeneous properties. These limit the use of ultrasonic NDE in engineering and biological applications. To alleviate this problem, recently …

Local Eigenvalue Modification Procedure For Real-Time Model Updating Of Structures Experiencing High-Rate Dynamic Events, Claire Rae Drnek

Theses and Dissertations

Estimating the state of structures that experience high-rate dynamics requires real-time model updating capabilities. In this work, high-rate dynamic events are characterized by 1) large uncertainties in the external loads, 2) high levels of non-stationarities and heavy disturbances, and 3) unmodeled dynamics generated from changes in system configurations. To achieve real-time model updating, an algorithm must circumvent any pre-calculations and be able to update the structure’s state on the timescale of 2 ms or less. This can be accomplished in one of two ways: either by creating a simplified model of a complex structure or by simplifying the calculations needed …

Artificial Intelligence Approaches For Structural Health Monitoring Of Aerospace Structures, Kimberly A. Cardillo

Theses and Dissertations

Structural health monitoring (SHM) and non-destructive evaluation (NDE) have been a significant research topic to help with damage detection in aerospace structures. SHM and NDE techniques are based on extracting damage sensitive features to determine the criticality of damage and lifetime of a structure. Acoustic emission (AE) signal detection is an important technique in SHM and NDE especially for fatigue crack growth. AE signals for thin aerospace structures consist of ultrasonic guided Lamb waves that propagate through the structure. This thesis focuses on AE signal repeatability, load at which AE signals occur, feature extraction, artificial intelligence and electro-mechanical impedance of …

Autonomous Drone-Based Sensor Package Deployment To The Underside Of Structures, Sabrina Rose Carroll

Theses and Dissertations

The objective of this project is to design, develop and experimentally test an Unmanned Aircraft System (UAS, commonly known as a drone) for the deployment of sensor packages to the underside of structures. This work begins with an in-depth review of existing automation techniques for various drone applications focusing on applications requiring interaction with the environment. Further reviewed is the impact of structures above the UAS during flight on the behavior of the aircraft.

Considering these topics, the development of a custom drone is presented to address the difficulties of delivering a package to the underside of a structure. Starting …

Lamb Wave Nondestructive Evaluation And Imaging On Plate-Like Structures, Zhaoyun Ma

Theses and Dissertations

Structure components are designed with a certain service life and damage may occur, or they may come with manufacture defects. Such damage and defects may lead to structural failure if not detected in time. To ensure the structural safety and prevent catastrophic failure, effective inspection is critical for in-time maintenance. Nondestructive evaluation (NDE) and structural health monitoring (SHM) have been widely applied for damage inspection and evaluation in various industries due to their noninvasive nature. Lamb wave based NDE/SHM has become the most popular ultrasonic methods that has been proved effective in different engineering applications that can be used to …

Development Of A Cfd Model For The Drying Of Aluminum-Clad Spent Nuclear Fuel, Nathaniel Cooper

Theses and Dissertations

The United States Department of Energy (DOE) currently manages approxi- mately 2500 metric tons of heavy metal (MTHM) of spent nuclear fuel (SNF), pri- marily from naval sources and domestic research reactors, and has agreements in place to accept 10,000 MTHM of aluminum-clad SNF from foreign reactors by 2029. However, due to the closure and the Yucca Mountain site and difficulties in the vitrification process, the majority of this fuel is expected to be placed in intermediate dry storage.

Before being placed in interim storage, all assemblies must be subjected to a drying process, either by forced gas recirculation (FGR) …

Steady-State And Transient Study Of Flow Boiling In Microchannels With Microgrooves/Micronozzles, Congcong Ren

Theses and Dissertations

Microchannel flow boiling is one of the most desired cooling solutions for high power electronics. Owing to the high latent heat of vaporization, high heat fluxes can be achieved through phase-change heat transfer. However, the enhancements of (critical heat flux) CHF and heat transfer coefficient (HTC) are usually inhibited by the transitional flow patterns, which highly influence the liquid rewetting. In the past two decades, many techniques have been explored to enhance the liquid rewetting in microscale.

In this dissertation, four parallel micro-grooves fabricated on the bottom of five microchannels (W=200 μm, H=250 μm, L=10 mm) were designed to promote …

Ultrasonic Nondestructive Evaluation Using Non-Contact Air-Coupled Lamb Waves, Wenfeng Xiao

Theses and Dissertations

Ultrasonic Lamb waves have been proved as an effective nondestructive evaluation (NDE) method due to their ability to propagate a long distance with less energy loss as well as their sensitivity to various defects on the surface or inside the structure. However, there are still challenges towards using them as a rapid inspection method for complex structural geometries, various damage types, and harsh environments, such as efficiency in Lamb wave actuation and sensing, understanding of the complicated multi-modal Lamb wave propagation, and robust detection algorithms for damage quantification and evaluation. To address these challenges, this dissertation focuses on developing a …

Exploration And Evaluation Of Novel Cathode Materials For Intermediate-To-Low Temperature Solid Oxide Fuel Cells, Chunyang Yang

Theses and Dissertations

Solid oxide fuel cells (SOFCs) have attracted considerable attentions due to its high conversion efficiency, fuel flexibility, and clean nature. However, the high cost and poor long-term stability induced by the high operating temperature (> 800 °C) of the conventional SOFCs hinder the further application. Therefore, lowering operating temperature to intermediate temperature range (IT, 650-800 °C) or even low temperature range (LT, 400-650 °C) is of practical importance for realizing SOFCs’ full commercial potential. Nevertheless, due to the large activation energy associated with oxygen reduction reaction (ORR), cathode polarization resistance becomes the dominate loss limiting SOFCs performance as operating temperature …

Enhancing Single And Two-Phase Heat Transfer Of Microgap Heat Sinks Using Nano-Structure Coatings, Yueyang Zhao

Theses and Dissertations

Due to the shrinking size and increasing power of electronics, the heat flux generated by electronic devices has greatly increased and imposed challenges to thermal management technologies. Numerous cooling technologies have been developed to cool high-power electronics. Among them, flow boiling in microchannels or a microgap has been one of the most efficient ways to remove high heat flux, which requires less coolant compared with single-phase cooling techniques. However, the flow boiling instability is the one of the most challenging issues, which lead to the premature critical heat flux (CHF) conditions and deteriorate heat transfer rate. The capillary force generated …

Guided-Wave Shm And Nde Of Composite Structures: Modeling And Experiments, Hanfei Mei

Theses and Dissertations

The extensive use of composites in aerospace structures has posed new challenges for implementing effective structural health monitoring (SHM) and nondestructive evaluation (NDE) techniques due to the general anisotropic behavior and complex damage scenarios in composites. This dissertation addresses the SHM and NDE of composites using ultrasonic guided waves, with an emphasis on theoretical modeling and experimental validation of guided-wave propagation and interaction with damage in composites. A semi-analytical finite element (SAFE) approach is presented to calculate guided-wave dispersion curves in composites. The theoretical framework is formulated using the finite element method (FEM) to describe the material variation along the …

Fundamental Understanding Of Plasma Discharge Formation In Liquid And Multiphase Configurations Through Multiphysics Modeling, Ali Charchi Aghdam

Theses and Dissertations

During the last two decades, non-thermal plasma discharges in and in contact with liquids have received significant attention due to their wide range of applications including chemical analysis, medical, water treatment, fuel processing, etc. Despite the tremendous interest and advances attained in the experimental studies, modeling efforts providing a comprehensive understanding of the underlying physicochemical processes are limited. There is still no unified theory on plasma formation in dense medium and various theories have been proposed such as the presence of bubbles and tunneling which are topics of debate. In the first part of this study, a mathematical model is …

Kinetic And Multidimensional Transport Coupled Numerical Investigation Of Nox Formation During Syngas And Natural Gas Combustion, Sheikh Farhan Ahmed

Theses and Dissertations

The primary objective of this thesis work is focused on the chemical kinetic modeling of the formation of Oxides of Nitrogen (collectively termed as NOx), regarded as a major pollutant emitted by combustion devices, and the application of that model to simulate transport coupled multidimensional distribution of NOx in a reacting flow. The underlying motivation of this kinetic modeling is the noted discrepancies among the existing models, which become critical in selecting the correct model in advanced gas turbine and engine research. The first part of this work is the performance evaluation and comparison of the existing models. Based on …

The Manufacturing And Characterization Of Pseudo-Woven Carbon Fiber Composite Architectures For Enhanced Damage Tolerance, Cyrus Vakili Rad

Theses and Dissertations

Traditional unidirectional carbon fiber reinforced polymer matrix composites exhibit brittle failure, limited toughness, and poor damage tolerance often resulting in the overdesign of composite systems. This work focuses on the automated fiber placement (AFP) manufacturing and characterization of a new family of pseudo-woven (PW) laminate architectures aimed to enhance impact resistance and damage tolerance. The PW laminate architecture uses a specialized in situ AFP process implementing tow skips to produce its laminate architecture. This results in a heterogeneous architecture possessing spatially variable in-plane material properties unlike traditional laminated composites. This heterogeneity is associated with topological variations in the fiber orientations …

Design Of Bio-Inspired Multifrequency Acoustic Sensors And Metamaterial Energy Harvesting Smart Structures, Mohammadsadegh Saadatzi

Theses and Dissertations

Due to the limited availability and high depletion rates of nonrenewable sources of energy as well as environmental concerns, the scientific community has started to explore many alternative clean sources of energies. It is identified that civil, mechanical and Aerospace structures are always subjected to acoustic noises and vibration which could potentially be used as renewable source of energy. Roads and Industrial noise barriers are used inside industrial facilities alongside the walls, around construction pillars, nearby machinery and other equipment to separate quite work zones, protect walls, deliver extra safety and precautions while diminish sound and vibrational pressure. We hypothesized …

Damage Evaluation Of Rolling Element Bearings For Shipboard Machinery, Brenna Lyn Feirer

Theses and Dissertations

Rolling element bearings perform an essential role in most all rotating machinery. To prevent degradation to machine performance, unforeseen costs and unexpected system failure, bearing fault diagnosis and prognosis are used. Acoustic Emission (AE) introduces high sensitivity, early and rapid detection of cracking, and real time monitoring that can alarm once cracking is noticed.

The purpose of this research is to nondestructively monitor the crack growth in rolling element bearings in a marine environment and to determine the acoustic emission parameters which embody crack initiation and propagation. The intellectual merit lies in:

1. the signal alarm developed from an AE …

Effects Of Material Characteristics And Equipment Configuration On Profilometry Scanning Results For Error Mitigation In Automated Fiber Placement, Jacob Ondeck

Theses and Dissertations

The Automated Fiber Placement manufacturing process is a method for constructing layered composite parts. This is done by placing tapes of material on a tool using a compaction roller and heat to tackify the material [1]. This manufacturing process is not new, but latest equipment generations can still introduce randomly occurring defects, presenting often as tow twists, gaps, unintentional overlaps and even missing tows during the layup process. These defects deviate the manufactured structure from the as-designed structure, and have been proven to introduce stress concentration sources, which can ultimately undermine the performance of a structure [2]. To detect and …

Influence Of Dynamic Multiaxial Transverse Loading On Ultrahigh Molecular Weight Polyethylene Single Fiber Failure, Frank David Thomas

Theses and Dissertations

High performance fibers such as ultrahigh molecular weight polyethylene (UHMWPE) are often used for ballistic impact applications in the form of textile fabrics and composite laminates. In order to predict the ballistic performance of such materials, single-fiber experiments are performed to quantify the material behavior at smaller length scales, which can be applied to larger length scales as a result. Failure of UHMWPE is well understood as a function of simple tension at low and high strain rates, as well as under various multiaxial loading states. However, experimental characterization of single UHMWPE fibers under transverse loading at high strain rates …