Aerospace Engineering Commons^™

Development Of A Potassium Permanganate Catalyst-Infused Fuel Grain For Hydrogen Peroxide Hybrid Thruster Ignition Enhancement, Ryan J. Thibaudeau

All Graduate Theses and Dissertations, Fall 2023 to Present

This thesis describes and addresses the need for reliable ignition in small satellite hybrid propulsion systems using hydrogen peroxide. It describes process of creating custom 3D printed ABS plastic fuel grains with small amounts of catalysts. These catalysts lead to a more reliable and energy-efficient ignition of a hybrid rocked propulsion system using catalyst-infused ABS and high-test hydrogen peroxide (HTP). Hydrogen peroxide is a high-density oxidizer and therefore more volumetrically efficient for a small satellite using hybrid rocket technology when compared to gaseous oxygen (GOX). The traditional ignition methods of hybrid rocket propulsion systems using HTP are compared to and …

Multifunctional Additive Manufacturing And Multiphysics Numerical Investigations Of Carbon Fiber Structural Battery Composite Using A Drop-On-Demand Method With In-Situ Consolidation, Xiangyang Dong, Yuekun Chen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Lightweight Carbon Fiber Structural Battery Composite Has Great Potential in Increasing Structural Energy Storage Efficiency for Multifunctional Applications. However, It is Still Challenging to Design Carbon Fiber Multifunctional Composite Due to Lack of Proper Manufacturing Methods. in This Study, an Integrated Multifunctional Design and Fabrication Approach is Developed by Combining a Drop-On-Demand Additive Manufacturing Method with a Multiphysics Numerical Model to Guide the Development of the New Multifunctional Composite. through Deposition with In-Situ Consolidation, the Function and Thickness of Each Carbon Fiber Layer as Well as its Fiber Volume Fraction Are Accurately Controlled. Decreasing Layer Thickness Improves Flexural Properties. the …

Fusion Bonding Behavior Of 3d Printed Pa6/Cf Composites Via Post Fabrication Compaction, Gonzalo Fernandez Mediavilla

Mechanical & Aerospace Engineering Theses & Dissertations

Additive manufacturing (AM) is becoming a robust production technology for aerospace, healthcare, and construction industries among others. Fused Deposition Modelling (FDM) is one of the methods most used to 3D print products. FDM has limitation due to interlayer adhesion and restriction imposed by the printing direction. Specially with AM composites, as reinforced nylon PA6 with short fibers, parts show more strength along the direction of the filament due to the alignment of the carbon fibers, but weaker in other directions. The proposed method to solve this issue is to print parts separately and join them together by fusion bonding. PA6/CF …

Experimental And Numerical Studies Of Slurry-Based Coextrusion Deposition Of Continuous Carbon Fiber Micro-Batteries To Additively Manufacture 3d Structural Battery Composites, Aditya R. Thakur, Xiangyang Dong

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Carbon Fiber Structural Battery Composites Have Recently Attracted Growing Interests Due to their Potentials of Simultaneously Carrying Mechanical Loads and Storing Electrical Energy for Lightweight Application. in This Study, We Present a Slurry-Based Coextrusion Deposition Method to Additively Manufacture 3D Structural Battery Composites from Carbon Fiber Micro-Batteries. Cathode Slurry is Coextruded Together with Solid Polymer Electrolyte-Coated Carbon Fibers in a Single Deposition. a Network of Carbon Fiber Micro-Batteries is Achieved within the Fabricated Structural Battery Composites. Electrochemical Tests Show a Stable Charge-Discharge Performance Up to 100 Cycles. the Rheological Behavior of the Cathode Slurry is Found to Govern the Coextrusion …

Performance Evaluation Of Composite Sandwich Structures With Additively Manufactured Aluminum Honeycomb Cores With Increased Bonding Surface Area, M. Rangapuram, S. K. Dasari, Joseph William Newkirk, K. Chandrashekhara, H. Misak, P. R. Toivonen, D. Klenosky, T. Unruh, J. Sam

Materials Science and Engineering Faculty Research & Creative Works

Modern aerostructures, including wings and fuselages, increasingly feature sandwich structures due to their high-energy absorption, low weight, and high flexural stiffness. The face sheet of these sandwich structures are typically thin composite laminates with interior honeycombs made of Nomex or aluminum. Standard cores are structurally efficient, but their design cannot be varied throughout the structure. With additive manufacturing (AM) technology, these core geometries can be altered to meet the design requirements that are not met in standard honeycomb cores. This study used a modified aluminum honeycomb core, with increased surface area on the top and bottom, as the core material …

Experimental Approach For Development Of A Powder Spreading Metric In Additive Manufacturing, M. Hossein Sehhat, Austin T. Sutton, Zane Yates, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The Powder Spreading is a Vital Step of Powder-Based Additive Manufacturing (AM) Processes. the Quality of Spread Powder Can Considerably Influence the Properties of Fabricated Parts. Poorly Packed Powder Beds with High Surface Roughness Result in Printed Part Layers with Large Porosity and Low Dimensional Accuracy, Leading to Poor Mechanical Properties. Therefore, the Powder Spread ability and its Dependence on Process Parameters and Powder Characteristics Should Be Quantified to Improve the Efficiency of Powder-Based AM Methods. This Study Proposes a Novel Dimensionless Powder Spread Ability Metric that Can Be Commonly Used in Different Powder-Based AM Processes. the Quality of Spread …

Exploring Additive Manufacturing In A Space Environment - A Capstone Design Project Experience, Zain Zafar Khan, Zachary Alan Sobelman, Sharanabasaweshwara Asundi

Mechanical & Aerospace Engineering Faculty Publications

The employment of additive manufacturing in the non-standard environments like space, ships, or submarines has the potential to be an advanced utility not only in the pre-flight production of aerospace components and structures, but also for the onboard manufacturing of components and tools necessary for future space missions. For example, the ability to produce tools and structural components on the International Space Station can provide the space community the opportunity to make repairs and upgrades to the space station without wasting time and resources transporting such materials through additional missions. Additive manufacturing would allow for space missions to use on …

Development Of A Regeneratively Cooled Liquid Rocket Engine, Dillon Petty, Nicole Zimmerli

Williams Honors College, Honors Research Projects

An additively manufactured (AM) liquid rocket engine, consisting of an injector, combustion chamber, and nozzle, was designed and printed using state-of-the-art methods and materials. The parts were manufactured using laser powder bed fusion. Additive manufacturing allowed for complex geometries and features, such as printing manifolds onto the components with a reduced number of parts. Additive, regenerative cooling channels were designed into the chamber and nozzle to allow for long-duration steady-state operation.

The feed system for the engine was designed and built to allow for pressure-regulated and steady-state testing. Tanks for the fuel and oxidizer were designed and built for a …

Additively Manufactured Carbon Fiber- Reinforced Thermoplastic Composite Mold Plates For Injection Molding Process, C. Bivens, A. Wood, D. Ruble, M. Rangapuram, S. K. Dasari, K. Chandrashekhara, J. Degrange

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Polymer injection molding processes have been used to create high-volume parts quickly and efficiently. Injection molding uses mold plates that are traditionally made of very hard tool steels, such as P20 steel, which is extremely heavy and has very long lead times to build new molds. In this study, composite-based additive manufacturing (CBAM) was used to create mold plates using long-fiber carbon fiber and polyether ether ketone (PEEK). These mold plates were installed in an injection molding machine, and rectangular flat plates were produced using Lustran 348 acrylonitrile butadiene styrene (ABS). Tensile and flexural testing was performed on these parts …