Structures and Materials Commons^™

A Systematic Study Into The Design And Utilization Of Burn Wire As A Means Of Tensioning And Releasing Spacecraft Mechanisms Through Applied Joule Heating, Chandler Dye

Mechanical Engineering Undergraduate Honors Theses

The joule heating characteristics of Nichrome burn wires, often used as a thermal cutting device in mechanisms designed to fasten and release CubeSat deployables, are examined in the following thesis. Wires ranging from 0.125 inches to 2 inches long, and diameters of 30 Ga and 40 Ga, are investigated through analytical calculations and thermal simulations based on heat transfer due to joule heating, and through physical circuitry-based experiments. The temperature data is used to generate heating curves to predict the time it takes for Nichrome wires to fail under varying testing parameters. This research aims to catalog a series of …

Characterizing Air Plasma Sprayed Aluminum Oxide Coatings For The Protection Of Structures In Lunar Environments, Perla Latorre Suarez

Electronic Theses and Dissertations, 2020-

Wear-resistant ceramic and ceramic composite coatings are significant to provide durability and support long-duration missions to the moon's surface for rovers, landers, robotic systems, habitats, and many other components. On the Lunar surface, structural components are continuously exposed to lunar dust projectiles that can cause protective coating delamination around the affected area, of protective coatings and this may not be physically visible. Ceramic coatings, composed of alumina, present excellent resistance to different types of wear due to their high strength and hardness as well as the ability to protect structural components from regolith impacts, wear, and abrasive damage. Air Plasma …

Kentucky Re-Entry Universal Payload System (Krups): Hypersonic Re-Entry Flight, John Daniel Schmidt

Theses and Dissertations--Mechanical Engineering

The Kentucky Re-entry Universal Payload System (KRUPS) is a small capsule designed as a technology testbed for re-entry experiments. For its first incarnation, KRUPS has been designed to test Thermal Protection Systems (TPS) and instruments in re-entry flights. Because of the unique environment a vehicle undergoes during re-entry, there is a high-demand for experimental data from re-entry experiments. KRUPS has been developed at the University of Kentucky (UK) over the past seven years to meet this demand. After completing sub-orbital campaigns, the first KRUPS hypersonic re-entry mission was attempted. The mission involved building three 11-inch diameter capsules each outfitted with …

Lupa: An Excursion Vehicle For The Moons Of Mars, Shannon Kavanagh, Bo Lewis, Alex Odinamba, Joshua Mulhern

Senior Design Project For Engineers

Our team has designed a spacecraft and mission for exploring the moons of Mars. The Lithological and Ultraviolet Photometry Assessment (LUPA) excursion vehicle is capable of crew habitation, autonomous rendezvous, and in-vacuum sample collection all in support of a parallel Mars surface mission to be carried out in the year 2040. Our project's key focus areas revolve around orbital mechanics, space vehicle propulsion analysis, scientific exploration, and the management of various interconnected spacecraft subsystems.

The Kentucky Re-Entry Universal Payload System (Krups): Orbital Flight, James Tyler Nichols

Theses and Dissertations--Mechanical Engineering

Due to the uniqueness of atmospheric entry environments, ground facilities cannot accurately replicate re-entry conditions. Consequently, scientists primarily rely on numerical models to predict these conditions and inform Thermal Protection System (TPS) designs. These models often lack flight validation, which is necessary for increasing their fidelity. Thus, there is a substantial need to obtain such data to advance modeling capabilities.

The Kentucky Re-entry Universal Payload System (KRUPS) is an adaptable test-bed for scientific experimentation with initial application to TPS. This vehicle was designed at the University of Kentucky to serve as an inexpensive means of obtaining validation data to enhance …

Structural Optimization Of Space Transit Vehicle Concept, Hercules, James Philip Rogers

Theses and Dissertations--Mechanical Engineering

STRUCTURAL OPTIMIZATION OF SPACE TRANSIT VEHICLE CONCEPT, HERCULES:

A COMPARATIVE STUDY OF STRUCTURAL OPTIONS

Hercules is a vehicle concept developed by NASA Langley's Vehicle Analysis Branch to satisfy the need for sustainable transit between Earth, the moon, and Mars. Hercules features unprecedented abort capabilities and mission flexibility to aid in NASA's Mars campaign. By utilizing modern software to perform structural analysis and optimization for a large selection of stiffened panel concepts, beam concepts, and materials trends in the structural optimization emerge. These trends will be invaluable for the design of future spacecraft needed to fulfill similar roles.

The structural optimization …

Development Of High-Density Propulsion System Technologies For Interplanetary Small Satellites And Cubesats, Morgan Andrew Roddy

Graduate Theses and Dissertations

The goal of this research was to support the development of a novel propulsion system for small satellites (<180 kg) and CubeSats. This was pursued by conducting a collection of studies that were designed to provide engineering data that would be critical in designing a functional prototype. The novel propulsion system was conceived by the author to provide best-in-class performance for the small satellite and CubeSat families of spacecraft. This context presents specific design requirements that the presented technology attempts to satisfy. The most critical among these is high density; the propellant was designed to be stored with high density and the thruster was designed to be as compact as possible. The propulsion system is composed of two primary elements, a propellant generator and a thruster. The propellant generator works by sublimating a solid crystal into vapor and then using this vapor to etch a dense metal. The resulting gaseous byproducts of this reaction are the propellant. This dissertation used xenon difluoride (XeF2) vapor to etch tungsten (W) which react to form xenon gas (Xe) and tungsten hexafluoride (WF6). This approach gave a theoretical propellant storage density 5.40 g/cm3; and 5.17 g/cm3 was demonstrated. The sublimation dynamics of the XeF2 were studied as a function of surface area and temperature and it was found to be suitable for the intended application due to its high effluence rate; that is, it sublimates fast enough to be useful. The sublimation rates are on the order of 10’s of µg/s. The etch rate of XeF2 on W was also studied and found to be suitably fast to provide useful amounts of reactants for use as a propellant, again on the order of 1’s of µg/s. The thruster is an electrostatic radio frequency (RF) ion thruster design and is manufactured with Low Temperature Co-Fired Ceramic (LTCC) materials system and manufacturing technology. Manufacturing samples of the thruster were built at the University of Arkansas in July 2015 and tested at NASA’s Marshall Space Flight Center in May 2018. Testing validated the viability of the LTCC thruster and provided valuable information on how to improve the thruster’s design.

Design, Validation, And Verification Of The Cal Poly Educational Cubesat Kit Structure, Nicholas B. Snyder

Master's Theses

In this thesis, the development of a structure for use in an educational CubeSat kit is explored. The potential uses of this kit include augmenting existing curricula with aspects of hands on learning, developing new ways of training students on proper space systems engineering practices, and overall contributing to academic capacity building at Cal Poly and its collaborators. The design improves on existing CubeSat kit structures by increasing accessibility to internal components by implementing a modular backplane system, as well as adding the ability to be environmentally tested. Manufacturing of the structure is completed with both additive (Fused Deposition Modeling …

Miniaturized Ultraviolet Imager Phase Iii, Bradley D. Albright, Nicolas A. Armenta, Colin W. Harrop

Mechanical Engineering

This document details the work to date, June 9, 2020, done by the Cal Poly Mechanical Engineering senior project team, Miniaturized Ultraviolet Imager: Phase III (MUVI III), sponsored by the University of California, Berkeley – Space Sciences Laboratory (UCB SSL). MUVI III is the third senior project team of an ongoing design, MUVI: the prototype of a 2U sized CubeSat intended to capture aurora images in the ionosphere. The first team, MUVI I, finished development of the UV imager. The second team, MUVI II, designed the mirror mounting and deployable door mechanisms. The goal of MUVI phase III is to …

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 …

Performance Enhancement And Characterization Of An Electromagnetic Railgun, Paul M. Gilles

Master's Theses

Collision with orbital debris poses a serious threat to spacecraft and astronauts. Hypervelocity impacts resulting from collisions mean that objects with a mass less than 1g can cause mission-ending damage to spacecraft. A means of shielding spacecraft against collisions is necessary. A means of testing candidate shielding methods for their efficacy in mitigating hypervelocity impacts is therefore also necessary. Cal Poly’s Electromagnetic Railgun was designed with the goal of creating a laboratory system capable of simulating hypervelocity (≥ 3 km/s) impacts. Due to several factors, the system was not previously capable of high-velocity (≥ 1 km/s) tests. A deficient projectile …

The Effects Of Atomic Oxygen On Patch Antenna Performance And Lifetime, Max J. Barta

Master's Theses

The space environment is a volatile and challenging place for satellites to survive in. For Low Earth Orbiting (LEO) satellites, atomic oxygen (AO) is a constant corrosive effect that degrades the outer surface of satellites over long durations. Atomic oxygen exists in the atmosphere between 180 and 675 km and has a relatively high energy at 4.5 eV, which allows AO to break molecular bonds in materials on the surfaces of spacecraft. As the number and complexity of CubeSat missions increase, there is an increased risk that AO degradation on commercial off the shelf parts (COTS), such as antenna, could …

Redesign Of Cubesat For Beam Charging, Kuba Preis

Industrial and Manufacturing Engineering

This paper is intended to be a study in the applications of the design freedom granted by additive manufacture in the design of a 1U CubeSat frame. The main loads experienced by a CubeSat are structural (during launch) and thermal (solar radiation). Beam charging is an emerging technology which involves charging a CubeSat using a laser beam. In this paper, a CubeSat frame was redesigned to account for the structural loads induced during launch and the thermal loads induced when beam charging. The thermal, weight, design, and structural requirements for a new CubeSat design were derived. The 1U CubeSat frame …

System Architecture Design And Development For A Reusable Lunar Lander, Chad Batten, Camille E. Bergin, Aaron Crigger, Darryl Harris, Gillian Suzanne Mcglothin

Chancellor’s Honors Program Projects

No abstract provided.

Ultraviolet Imager Application For A Cube Satellite, Jason Grillo, Troy Hajjar, Brady Hill

Mechanical Engineering

This document serves as the final design review (FDR) report for the 2018 Cal Poly CubeSat Ultraviolet Imager senior project, sponsored by UC Berkeley Space Sciences Laboratories (SSL). SSL wants to monitor the ionosphere above Earth to gain a better understanding of its properties and particle interactions. Far Ultraviolet (FUV) imaging is a good way to obtain high quality images of the ionosphere and the Earth's auroras, and advancement in optic technologies have made cube satellites (CubeSats) an ideal vessel for a FUV imager, as they are relatively low-cost, lightweight, and can be repeatedly deployed. These CubeSat FUV imagers could …

Modification Of A Ground Based Atomic Oxygen Simulation Apparatus To Accommodate Three Dimensional Specimens, Charles Ward

Master's Theses

The space environment presents various challenges when designing systems and selecting materials for applications beyond Earth’s atmosphere. For mission success, these challenges must be considered. One of the detrimental aspects of the space en- vironment is Atomic Oxygen, AO. Only present in harmful quantities in Lower Earth Orbit, LEO, AO causes significant damage to materials by breaking molecular bonds. California Polytechnic State University’s, Cal Poly’s, space environments laboratory features an apparatus capable of simulating this environment. Very thin or short samples were tested to observe the mass loss due to erosion of the sample material. Recent modifications to the system …

A Novel Magnetorheological Fluid Damper For A Small Spacecraft With Flexible Appendages, Robert Waelchli

Doctoral Dissertations and Master's Theses

Small satellites have become increasingly popular over the past thirty years, particularly since the adoption of the common CubeSat architecture early this century. Because of their restricted volume and electrical budgets however, there are practical limits to the missions that small satellites may adopt. One potential near-term solution to the problem of limited electrical power may be the adoption of larger, flexible solar arrays. However, spacecraft with flexible appendages have historically presented attitude control challenges relating to platform stability given the dynamic response of the flexible components to applied torques. These challenges may be particularly disruptive to a small spacecraft …

Thermal-Fatigue And Thermo-Mechanical Equivalence For Transverse Cracking Evolution In Laminated Composites, Javier Cabrera Barbero

Graduate Theses, Dissertations, and Problem Reports

Carbon fiber reinforced plastics (CFRP) are potential materials for many aerospace and aeronautical applications due to their high specif strength/weight and a low coeffcient of thermal expansion (CTE) resulting in a high long-term stability. Among candidate structures, the re-entry reusable launch vehicles (RLV), the fuel oxidant storage and transportation at cryogenic temperature, space satellites, and aircraft structure (frame, wings, etc...) can be highlighted. However, CFRP are prone to internal damage as a result of high residual stresses and thermal fatigue loading. In this study, micro-cracking damage evolution in laminated composites subjected to monotonic cooling and thermal cyclic loads is developed …

Design Of Shape-Conforming Nosecone For Optimal Fluid Flow From Transonic To Supersonic Range, Anna Tombazzi

Williams Honors College, Honors Research Projects

Modern flight vehicles, such as rockets, missiles, and airplanes, experience a force caused by forebody wave drag during the flight. This drag force is induced when the frontal point of each vehicle breaks the pressure wave during flight. Efforts to reduce this wave drag force to improve flight efficiency include modifying the nosecone profile of the flight vehicles to lower the drag force.

This project revolved around creating a design to make the transformation of nosecone shapes from a ¾ Parabolic profile to a ½ Power Series profile possible, mid-flight. Using a novel nosecone assembly, shape memory alloys (SMAs) and …

Analyses Of Densely Crosslinked Phenolic Systems Using Low Field Nmr, Jigneshkumar Patel

Doctoral Dissertations

A uniform dispersion of reactants is necessary to achieve a complete reaction involving multi-components, especially for the crosslinking of rigid high-performance materials. In these reactions, miscibility is crucial for curing efficiency. This miscibility is typically enhanced by adding a third component, a plasticizer. For the reaction of the highly crystalline crosslinking agent hexamethylenetetramine (HMTA) with a strongly hydrogen-bonded phenol formaldehyde resin, furfural has been traditionally used as the plasticizer. However, the reason for its effectiveness is not clear. In this doctoral thesis work, miscibility and crosslinking efficiency of plasticizers in phenolic curing reactions are studied by thermal analysis and spectroscopic …

Structural Behavior Of Inflatable, Reinforced, Braided, Tubular Members, Joshua Clapp

Electronic Theses and Dissertations

The Hypersonic Inflatable Aerodynamic Decelerator (HIAD) system being developed by the National Aeronautics and Space Administration (NASA) is an inflatable structure composed of multiple, concentric, pressurized tori, load straps, and a thermal protection system. The HIAD overcomes limitations inherent with the use of rigid decelerators since the deployed diameter is much larger than the packed size, which makes it an enabling technology for new opportunities in space exploration. The HIAD is designed to decelerate and protect spacecraft during atmospheric re-entry. The objective of this research was to improve understanding of structural behavior of HIAD components through material testing, structural testing …

Structural Micrometeoroid And Radiation Shielding For Interplanetary Spacecraft, Jared Allen Ruekberg

Master's Theses

This paper focused on two significant space forces that can affect the success of a spacecraft: the radiation and micrometeoroid environments. Both are looked at in the context of the region of space between Earth and Mars. The goal was create reference environments, to provide context to results of environmental modeling, and to provide recommendations to assist in early design decisions of interplanetary spacecraft. The radiation section of this report used NASA's OLTARIS program to generate data for analysis. The area of focus was on the radiation effects for crewed missions, therefore effective dose equivalent was the metric used to …

Improving And Expanding The Capabilities Of The Poly-Picosatellite Orbital Deployer, David Pignatelli

Master's Theses

The Poly-Picosatellite Orbital Deployer (P-POD) has undergone a series of revisions over the years. The latest revision, described in this Master’s Thesis, incorporates new capabilities like EMI shielding, an inert gas purge system, and an electrical interface to the CubeSats after they are integrated into the P-POD. Additionally, some mass reduction modifications are made to the P-POD, while its overall strength is increased. The P-POD inert gas purge system successfully flew, on a previous revision P-POD. The P-POD components are analyzed to a set of dynamic loads for qualification, and successfully undergoes random vibration qualification testing. The P-POD encounters some …

A Design Pathfinder With Material Correlation Points For Inflatable Systems, Jared T. Fulcher

Theses and Dissertations--Mechanical Engineering

The incorporation of inflatable structures into aerospace systems can produce significant advantages in stowed volume to mechanical effectiveness and overall weight. Many applications of these ultra-lightweight systems are designed to precisely control internal or external surfaces, or both, to achieve desired performance. The modeling of these structures becomes complex due to the material nonlinearities inherent to the majority of construction materials used in inflatable structures. Furthermore, accurately modeling the response and behavior of the interfacing boundaries that are common to many inflatable systems will lead to better understanding of the entire class of structures. The research presented involved using nonlinear …

Multidimensional Modeling Of Pyrolysis Gas Transport Inside Orthotropic Charring Ablators, Haoyue Weng

Theses and Dissertations--Mechanical Engineering

During hypersonic atmospheric entry, spacecraft are exposed to enormous aerodynamic heat. To prevent the payload from overheating, charring ablative materials are favored to be applied as the heat shield at the exposing surface of the vehicle. Accurate modeling not only prevents mission failures, but also helps reduce cost. Existing models were mostly limited to one-dimensional and discrepancies were shown against measured experiments and flight-data. To help improve the models and analyze the charring ablation problems, a multidimensional material response module is developed, based on a finite volume method framework. The developed computer program is verified through a series of test-cases, …

Design, Fabrication, And Testing Of An Emr Based Orbital Debris Impact Testing Platform, Jeffrey J. Maniglia Jr.

Master's Theses

This paper describes the changes made from Cal Poly’s initial railgun system, the Mk. 1 railgun, to the Mk. 1.1 system, as well as the design, fabrication, and testing of a newer and larger Mk. 2 railgun system. The Mk. 1.1 system is developed as a more efficient alteration of the original Mk. 1 system, but is found to be defective due to hardware deficiencies and failure, as well as unforeseen efficiency losses. A Mk. 2 system is developed and built around donated hardware from the Naval Postgraduate School. The Mk. 2 system strove to implement an efficient, augmented, electromagnetic …

Development Of A Pyrotechnic Shock Simulation Apparatus For Spacecraft Applications, Joseph Binder, Matthew Mccarty, Chris Rasmussen

Aerospace Engineering

This report details the research, design, construction, and testing of a pyrotechnic shock simulation apparatus for spacecraft applications. The apparatus was developed to be used in the Space Environments Lab at California Polytechnic State University. It will be used for testing spacecraft components with dimensions up to 24”x12”x12” as well as CubeSats. Additionally, it may be used as an instructional or demonstrational tool in the Aerospace Department’s space environments course. The apparatus functions by way of mechanical impact of an approximately 20 lb stainless steel swinging hammer. Tests were performed to verify the simulator’s functionality. Suggestions for improvement and further …

Thermal Vacuum Integration For Cal Poly's Space Environments Laboratory, Chelsea Barackman, Steven Jackowski

Aerospace Engineering

The purpose of the senior project is to construct a thermal vacuum by utilizing a preexisting vacuum chamber in the Space Environments Lab, and a donated Advanced Thermal Sciences (ATS) chiller. While a thermal vacuum is already available on campus, building one for the Space Environments Lab would grant undergraduates access to the equipment, allowing a much better understanding of testing methods and procedures in use by the aerospace industry. This paper explains the design and analysis of the thermal vacuum (T-VAC) project as well as the operation and procedures required for the ATS chiller and fill/drain tank. The thermal …

Design, Manufacturing And Testing Of An Environmentally-Green Bipropellant Thruster, Alex Bendoyro, Gabriel Sanchez, Erin Stearns, Phillip Takahashi

Aerospace Engineering

This project reviews the design, manufacturing and experimentation process of a green bi-propellant thruster designed to output 5 lbf. The goals were to successfully design, manufacture and test a thruster, while discovering the complications that arise through out the complete design process of a green thruster. The thruster was successfully designed using ideal rocket equations and the design was successfully confirmed using CFD and FEA. Manufacturing of the thruster was fully planned and revealed mild flaws in thruster design. For example some features were not manufacturable to the exact measurements desired. Testing of the engine gave results inconsistent with expected …

Design, Fabrication, And Testing Of An Electromagnetic Rail Gun For The Repeated Testing And Simulation Of Orbital Debris Impacts, Jeff Maniglia, Jordan Smiroldo, Alex Westfall, Guy Zohar

Aerospace Engineering

An Electromagnetic Railgun (EMRG) was designed, built, and tested, capable of firing a projectile a 1 gram projectile at 650 m/s muzzle velocity. The EMRG utilizes an injector, a high voltage power supply, a capacitor bank, inductors and rails. The injector fires 2300 psig Nitrogen gas into the system to provide an initial velocity. The high voltage power supply charges the capacitor bank. The capacitor bank discharges the electric potential built up through the projectile while inside the rails in order to create the EMRG’s force. The inductors are used to pulse form the capacitor bank in order to get …