Engineering Commons^™

Fabrication Of Alumina Membranes From Uv Resin– Alumina Particle Slurries, Dominique Henry Porcincula

Master's Theses

Ceramics membranes are made in a wide variety of different techniques using a wide variety of different materials. However, many of the common techniques utilize a slurry of ceramic particles, additives, and either organic solvent or water that is shaped into a membrane, left to dry, and then sintered together. Drying is a time consuming process, often requiring several hours for the liquid medium to evaporate. Defect formation caused by development of partial pressures across the drying membrane, including cracks and warpage, also typically occurs during the drying process. To address this, slurries of ceramic particles made with a low …

Failure Analysis Of Variably Sized 4340 Steel Mandrels Utilized In The Production Of Seamless Superalloy Rings Through The Vertical Ring Rolling Process, Mikhail Alexeyevich Vasilyev, Joshua Brady Venz

Materials Engineering

Vertical ring rolling is a forging process which forms seamless metal rings through applying a large force at elevated temperatures onto component materials stabilized by cylindrical mandrels. Carlton Forge Works, a company which produces rings of superalloy materials such as INCO718 and 718Plus, is experiencing a consistent failure of mandrels due to extreme conditions. An analysis of the lifetime (bulk material, heat treatment, and use) was performed, which aided in the identification of process variables tied to mandrel failure. Experiments were formed surrounding three variables of the mandrel heat treatment: Austenitization temperature, quenching temperature, and tempering conditions, with the goal …

Investigation Into Oxygen Diffusion As It Relates To Alpha Case Formation In Ti-6al-4v Based On Different Forging Thermal Cycles, Tyler J. Meador, Jon Leduc, Francesca Hope

Materials Engineering

An investigation into the growth kinetics of alpha case in Ti-6Al-4V in the presence of oxygen was conducted for different forging thermal cycles. This was done to determine whether the alpha case should be removed after each thermal cycle or as the final step after forging. The thermal cycles consisted of four hours at 1750 °F. Samples were subjected to this treatment one, two, three, and four times along with a continuous sixteen hour hold. Four cycle and Hold samples were subjected to an additional thermal cycle above the beta transus at 1925 °F. These then went through a final …

Improving The Tensile Mechanical Properties Of Direct Energy Deposited (Ded) Inconel 718 Aircraft Components Using A Standard Heat Treatment, Spencer Vincent Flynn

Materials Engineering

This project aimed to improve the mechanical properties of as-printed additively manufactured Inconel 718 samples using a heat treatment usually used for cast and wrought Inconel 718. The mechanical properties sought to be optimized were yield strength, ultimate tensile strength, elongation, and reduction in area. The property goals were to match or exceed those of cast and heat treated Inconel 718. Wire-fed electron beam direct energy deposition (DED) was used to manufacture the samples, which were then heat treated using the AMS 5663 standard in an inert atmosphere. The samples were then tested in tension to obtain data on their …

Effect Of Environmental And Ultraviolet Degradation On The Albedo Of Polyethylene Sheet Materials For Improved Energy Harvesting By Bifacial Photovoltaic Power Plants, William A. Jang, Roxy H. Jackson-Gain

Materials Engineering

Solar energy farms typically utilize monofacial photovoltaic (mPV) cells in their arrays to capture direct sunlight to produce renewable energy. However, the efficiency of these farms can be increased by 2 – 6% through the implementation of bifacial photovoltaic cells (bPV). These bPV cells function by capturing incident ultraviolet (UV) light energy that is reflected off the surface to increase its overall energy production. The amount of UV energy that is reflected is dependent on the albedo value of surface, which is a measure of energy reflectance. In this study, samples of unreinforced polyethylene (PE), scrim-reinforced polyethylene (SR-PE), and woven …

Covalent Adaptable Networks For Wood Coatings, Jachin Boaz Clarke

Materials Engineering

Wood swells and shrinks causing problems with seasonal humidity. Applying thick coatings of reactive finishes based on cross-linked polyurethane, epoxy, or polyesters can slow moisture-vapor exchange. However, the use of thick coatings leads to cracking and crazing sooner than thin finishes. This research proposes the addition of 3.3 mol % triazabicyclodecene, a conventionally used covalent adaptable network catalyst, in a commercially available polyester-based wood coating. The self-healing of the wood coating is tested using DMA stress relaxation and compression molding. The result from DMA renders inconclusive and compression molding indicates the novel wood coating oxidizes at elevated temperatures. The wood …

Surface Characterization Of Low-Density Polyethylene Mulch, Risha Shah

Materials Engineering

Plastic pollution in aquatic systems has traditionally been highlighted in past and current research due to the increase in plastic production every year. Unfortunately, quantitative and qualitative data regarding plastic pollution on land systems such as agricultural mulch is limited. Agricultural mulch breaks down into macroplastics and then degrades into microplastics. The microplastics investigated in this study are all secondary microplastics: microplastics that form due to weathering of larger fragments of plastic. Weathering can occur due to a variety of factors; however, UV radiation and mechanical weathering have been the factors of focus on most current research in microplastic formulation. …

Interlaminar Tensile Properties Of Unidirectional And Woven Carbon Fiber Reinforced Toughened Epoxy Laminates, Eric Timothy Casey, Sean Mckalip Thompson

Materials Engineering

This project aims to develop a dataset on interlaminar tensile strength comparing unidirectional and woven thermoset matrix carbon fiber composites keeping ply count, matrix material, and fiber diameter constant. The interlaminar tensile strength is an important property relating to the delamination failure mode. Interlaminar tensile strength is determined using the ASTM D6415 testing standard. This test is a modified four-point bend test using a 90° curved beam test specimen. Laminates were produced by laying up pre-impregnated carbon fiber sheets onto a curved beam tooling. The unidirectional laminate was produced with 20 plies in a [0,0,90,0,0]₄ layup pattern. The woven …

Design, Modeling, And Testing Of A Novel Inductor For Electric Vehicles: Iron Nitride Soft Magnetic Composites, Sydney F. Fultz-Waters, Jacob Krynock

Materials Engineering

New technology for electric vehicles (EVs) must meet the requirements of higher energy usage, lower costs, and more sustainable source materials. One promising material for EV power system components is iron nitride (IN) soft magnetic composites (SMCs) because of their competitive magnetic properties and high abundance of the source materials. As part of an ongoing program at Sandia National Laboratories, this project focused on using computer modeling to optimize the prototyping process for an iron nitride SMC toroidal inductor to reach a target inductance of 600 μH. Four inductors with different combinations of wiring (26 AWG and 20 AWG) and …

3d Printed Aircraft, Matthew Nagy, Charles D'Amico, Alexis Salgado Medina

Mechanical Engineering

This project is to design, build, and test a 3D-printable aircraft. The goal is to create a final design that will be able to fly for the longest duration possible, around 20 seconds. To determine the correct preliminary design and manufacturing process for a 3D printed RC aircraft, an analysis of multiple design options and manufacturing materials was performed. This allowed for a variety of choices for aircraft type, airfoil design, structure, among other topics to be narrowed down to the most promising option. It has been found that the aircraft will follow a design similar to industry motor-gliders, with …

Exploring The Potential Of Pavegen’S Kinetic Energy Generating Floor For Sustainable Energy Solutions: A Proposal For Cal Poly Slo, Brandon J. Cuneo

Construction Management

This paper proposes the installation of Pavegen's kinetic energy generating floors at Cal Poly’s campus as a sustainable energy solution. Pavegen has developed a pioneering technology that converts footsteps into clean and renewable energy. The versatility of these floors is demonstrated through successful implementations in various settings, such as transportation hubs and public spaces, generating power from foot traffic. Collaborations with Schneider Electric, installation at Dupont Circle, and integration at Heathrow Airport showcase the potential for sustainable urban infrastructure. This paper outlines research conducted on Pavegen and similar solutions, including communication with company representatives and examining proposed installation locations at …

Experimental Characterization And Computer Vision-Assisted Detection Of Pitting Corrosion On Stainless Steel Structural Members, Riley J. Muehler

Master's Theses

Pitting corrosion is a prevalent form of corrosive damage that can weaken, damage, and initiate failure in corrosion-resistant metallic materials. For instance, 304 stainless steel is commonly utilized in various structures (e.g., miter gates, heat exchangers, and storage tanks), but is prone to failure through pitting corrosion and stress corrosion cracking under mechanical loading, regardless of its high corrosion resistance. In this study, to better understand the pitting corrosion damage development, controlled corrosion experiments were conducted to generate pits on 304 stainless steel specimens with and without mechanical loading. The pit development over time was characterized using a high-resolution laser …

Precious Plastics - Plastic Brick Machine Fabrication, Timothy Ukaobasi Kanu, Evi Paraskevi Troulis

Architectural Engineering

The goal of this research is to determine the structural parameters of the recycled plastic polypropylene when molded into bricks resembling CMU blocks. To accomplish this, three mechanisms had to be assembled: the shredder, the injector, and the 1x1 mold. A tensile and compression test were to be performed on the plastic brick, and the values would be used to compare the tensile and compressive strength of PP plastic bricks, as well as their modulus of elasticity and stress vs. Strain performance. These values would be analyzed to determine whether it would be feasible to build an entire plastic wall. …

Building Structures From Mycelium, Noah M. Brown

Physics

The purpose of this project was to develop a method for creating bricks from mycelium and agricultural waste. The bulk of the research happened in two parts, the first part being a period in which different substrates, strains, and methods were used build the bricks. This research took place in San Luis Obispo and was aided by a group of students in PSC392 under Dr. Pete Schwartz in early 2022. After developing a method for constructing these bricks, the research was moved to St. Thomas, Jamaica, in collaboration with an ecovillage called The Source Farm from July to September. The …

Fabrication Of Thin-Film Composite, Reverse-Osmosis Membranes With Polyethylenimine Modifications For Enhancing Membrane Fouling Resistance, Stephanie N. Hamilton

Master's Theses

Increasing water reuse opportunities for communities has become increasingly important as access to clean water is becoming more scarce. Reverse Osmosis (RO) is an advanced treatment technology used in water recycling wastewater for potable reuse applications. RO is a promising technology; however, the membranes have limitations including their high energy demand and their susceptibility to membrane fouling. The main objective of this study was to develop a reproducible method for the fabrication of RO membranes with enhanced flux and reduced susceptibility to fouling. Literature contains numerous publications on fabrication of thin film composite (TFC) RO membranes with high performance. However, …

Developing Positive Thermal Coefficient (Ptc) Heaters For Solar Electric Cooking, Katarina Ivana Brekalo, Andrew Shepherd

Physics

Positive Thermal Coefficients, PTCs, are materials that abruptly change in resistance in response to changes in temperature. The purpose of this experiment is to explore the viability of using the switching type ceramic PTC thermistor as a replacement for current resistive heaters. These types of PTCs have a nonlinear change in resistance with increases in temperature. This device will be used as a temperature-controlling heating element intended to power an Insulated Solar Electric Cooker (ISEC). The ISEC is designed to cook meals throughout the day for impacted communities as an alternative cooking method that doesn’t require biofuel as an energy …

Processing And Characterization Of Silicon Nitride For Rapid And Low-Level Detection Of Water Pathogens, Arielle H. Buchanan, Logan A. Chai

Materials Engineering

Water sanitation is a serious issue affecting the lives of many, and methods for assessing water cleanliness have been a major research interest for decades. Rapid and accurate water pathogen detection methods that can be performed in field applications have been a growing research focus, especially in low-income countries most affected by poor water quality. Silicon nitride was explored as a material for colorimetric water-pathogen sensing due to the large body of knowledge around its processing, and its isoelectric point. A bioassay of chlorophenol red-β-Dgalactopyranoside (CPRG) and β-galactosidase (β-gal) enzymes with Escherichia coli (E. coli) bacteria was used to examine …

In Situ Marine Biodegradation Of Poly(Lactic) Acid And Thermoplastic Starch Blends, Brittany Denicholas

Materials Engineering

Marine life has been suffering from macro- and microplastics since the inception of petroleum-based plastic. Bio-based biodegradable polymers such as PLA and TPS can help mitigate the damage done by petroleum plastics. Blending PLA and TPS can reduce the cost while preventing a significant effect on the material properties. PLA/TPS blend compositions such as 90/10, 80/20, 70/30 could be candidates for a solution. The PLA/TPS blends have been submerged in a marine environment at the Cal Poly Pier in Avila Beach for 8 weeks. Three sample sets containing three of each blend composition were collected every week and tested in …

Effect Of Oxygen Equivalence On The Strength And Toughness Of Ti-6al-4v Forgings, Kira Baylor, Clarissa Drouillard

Materials Engineering

Tensile testing and fracture toughness testing were conducted to establish a numerical relationship between interstitial content and performance in forged Ti-6Al-4V. The value of oxygen equivalence was used to represent the interstitial content by combining the weight percent of oxygen, carbon, and nitrogen. The correlation between oxygen equivalence and mechanical properties can be used to accurately predict the performance of forged parts. Samples of forged parts with varying levels of interstitial content were subjected to a recrystallization anneal at 75 F below the beta transus temperature to decrease microstructure variability across parts with a second anneal at 1300 F to …

Citric Or Acetic Acid Effects On The Crosslinking Of Pvoh, Samuel Carr, Erika Szaldobagyi

Materials Engineering

Transportation and shipping processes are the most dangerous times for food due to harsh handling and frequent temperature changes. Plain corrugated boxes cannot withstand the damp environment caused by melting ice that is used to keep foods cold and fresh. To minimize damage, a protective polymer film coating can be applied. These coatings can be unsafe when used with food and will lead to excess waste by limiting the recyclability of the boxes. The purpose of this project was to produce nontoxic crosslinked PVOH films to determine suitability for a cost effective, biodegradable, and repulpable corrugated box coating. Polyvinyl alcohol …

Stabilization Of Palm Wood Using Water-Based Impregnation, David A. Barnes

Materials Engineering

Impregnation is a technique for stabilizing wood that involves saturating the material in a liquid and allowing it to cure before use. Stabilization methods such as this are employed for a variety of reasons; chiefly, the low dimensional stability of wood and palm means that they are subject to several failure modes that arise from changing environmental conditions, such as cracking, warping, and bending. Samples of Borassus flabellifer, black palm, provided by DuraPalm were impregnated with solvent-based and water-based stabilizers, and untreated wood samples used as a control group. Kop-Coat WoodYouth® Plus was used as a solvent-based stabilizer, and impregnation …

Determining The Efficacy Of A Silica And Bacterial Cellulose Composite Model System, Hannah Martin, Daisy Kamp

Materials Engineering

Bacterial cellulose (BC) is a sustainable alternative to petroleum-based polymer films for synthetic leather applications. Synthesized by a symbiotic culture of bacteria and yeast, BC is a three-dimensional structure composed of cellulose microfibrils. However, pure BC lacks certain desirable properties such as high tensile strength. Previous studies have shown that loading BC with nanoparticles to form nanocomposites has improved BC’s mechanical properties. However, this was not studied as a function of particle size. This study focuses on using silica/BC nanocomposites to model the impact that particle size and silica soaking concentrations have on the uptake efficiency of these particles into …

Effects Of Release Materials And Temperature Ramp Rates On The Surface Finish Of Carbon-Fiber Composite Components, Sudeep Louis, Thucmy Dang, Ethan Schlocker

Materials Engineering

Toray Advanced Composites is interested in improving their carbon fiber reinforced polymers (CFRP) manufacturing process by enhancing their control on the amount of surface roughness for varied customer preference. Surface roughness of CFRP is important in post-production processes including coating, priming, and painting. This project seeks to determine the effects of three release materials and two temperature ramp rates on the surface finish of CFRP. The release materials used were Tooltech, FEP, and Frekote 770-NC. The two initial temperature ramp rates were 1°F/min and 2°F/min. Surface roughness was measured using a profilometer and analyzed using Ra values. Ra is an …

Analysis Of Novel Corrosion Resistant Maraging Steels For Use In Additive Manufacturing, Bradley Michael Samuel, James Knowlton Smith

Materials Engineering

Stainless maraging steel has been proven to be an industry standard material for plastic injection molds. Its high hardness and corrosion resistance extend the lifetime of the tool. This alloy system is also well-suited to additive manufacturing, which can be utilized to form internal cooling channels, further increasing tool life. Using Rapid Alloy Development (RAD) Oerilkon METCO is developing a new composition of stainless maraging tool steel that has high hardness/strength, is corrosion resistant, and has additive-capable melting and solidification properties. This study tests the hardness and corrosion resistance of the new RAD alloys against the current market competitor Corrax …

Investigation Of The Effects Of Cladding Layers On Longitudinal And Transverse Mechanical Properties In Composite Laminates, Rachel Potratz, Tiffany Foo, Joseph Kamlet

Materials Engineering

The addition of cladding layers to composite laminates is used in industry to improve bond adhesion and the ease of manufacturing. However, there is no public data on the effects of cladding layers on the mechanical properties of composite components. To directly observe how cladding layers affect mechanical properties, four laminates with zero, one, two, and three cladding layers of twill fabric were added symmetrically to a biased core. The mechanical testing performed was tensile, short beam strength, and compression testing in the longitudinal and transverse directions. The measured strengths were related to the longitudinal properties of the core, and …

Non-Destructive Material Analysis Of Metals And Composites Via Thermography, Jonathan R. Doubt, James L. Chapman

Materials Engineering

The Naval Surface Warfare Center, Port Hueneme Division, is interested in the development of non-destructive damage assessment of shipboard materials via drones at distance. Long Pulsed Thermography (LPT), a method of non-destructive evaluation, was investigated as a possible method for detecting damage in metals (5005h24 Al alloy and 1008 carbon steel) and composites (aramid fiber honeycomb sandwich structure) at distances from 0.5 m to 3.0 m. LPT was conducted using two 1000 W can lights to heat the samples, and a FLIR E8-XT thermal camera. The images were then analyzed using ImageJ software to determine if damage could be detected …

Evaluating The Effects Of Granulated Rubber And Glass Fibers In Polymer Concrete As A Structural Material For Wafer Grinding Machines, Kevin Gabriel Kuehn, Philip Randall Streeter

Materials Engineering

Polymer concrete is a composite material used to replace cast iron and steel in wafer grinding machines for vibration damping. During the grinding and lapping processes of manufacturing silicon wafers, excessive vibrations may cause subsurface damage which requires additional polishing and reduces yield. Nine compositions containing various levels of granulated rubber and glass fibers were manufactured. CRM WRF-10 granulated rubber was examined at 0%, 5%, and 10% and Corning Cem-Fil glass fibers were added at 0%, 0.5%, and 1% by weight. Smooth-On EpoxAcast 690 epoxy resin was held constant at 16% for each composition. Crushed granite aggregate from Martin Marietta, …

Soil Degradation Of A Plastic Blend Of Opuntia Ficusindica Juice, Animal Protein And Beeswax, Isabel A. Gamez, Daniel R. Kava

Materials Engineering

Since the introduction of single use plastics in the early 1900s, their usage has increased exponentially. Unfortunately, due to this exponential increase there are negative environmental implications of their production, which requires further consideration. Currently, there are various waste disposal practices for SUPs, including landfilling, incineration, and recycling. Recent data revealed that only 14 % of plastic waste was recycled, with 40% of plastic waste being landfilled, while the rest of the plastic waste was incinerated or released to the environment at 14 % and 32 %, respectively. A potential solution to the plastic waste issue is developing a polymer …

Dynamic Response Of Elastic Two-Story Steel Moment Frame Scaled Structure Equipped With Viscous Dampers, Garrett L. Barker, Alexander L. Poirier

Architectural Engineering

The authors of this report are Architectural Engineering undergraduate students at California Polytechnic State University, San Luis Obispo. Damping is a complex, experimentally derived value that is affected by many structural properties and has a profound effect on the dynamic response of structures. Deducing the inherent damping of a steel moment frame and affecting the damping ratio with viscous dampers are two topics explored in this paper. Dampers are commonly implemented in resilient structures that perform better in a design basis earthquake, reducing the seismic cost and downtime. Undergraduate coursework does not delve into the factors that affect damping and …

Model-Based Design Of An Optimal Lqg Regulator For A Piezoelectric Actuated Smart Structure Using A High-Precision Laser Interferometry Measurement System, Grant P. Gallagher

Master's Theses

Smart structure control systems commonly use piezoceramic sensors or accelerometers as vibration measurement devices. These measurement devices often produce noisy and/or low-precision signals, which makes it difficult to measure small-amplitude vibrations. Laser interferometry devices pose as an alternative high-precision position measurement method, capable of nanometer-scale resolution. The aim of this research is to utilize a model-based design approach to develop and implement a real-time Linear Quadratic Gaussian (LQG) regulator for a piezoelectric actuated smart structure using a high-precision laser interferometry measurement system to suppress the excitation of vibratory modes.

The analytical model of the smart structure is derived using the …