Structures and Materials Commons^™

Large Telescope Mount For Long Exposure Photos, Payne M. Landis, Anna J. Gray

Williams Honors College, Honors Research Projects

When viewing the stars through a telescope, it is common that the object you are viewing drifts out of view. Many amateur astronomers seek to capture long exposure images of the stars, planets, and galaxies with commercially available sky tracking telescope mounts. The complication is that these telescope mounts are both incredibly expensive and have low weight limits. These issues limit accessibility to these products based on the telescope. For each person, telescope parameters determine the amount of light and magnification that can be viewed, which then determines exposures time for adequate photo results. The options on the market for …

Optimization Of Post-Processing Methods For Additively Manufactured Metals, Julia R. Carano

Williams Honors College, Honors Research Projects

Ultrasonic Nanocrystal Surface Modification (UNSM) is a process used to change the surface hardness of flat-faced materials. It is a machining process using a high-powered laser and a blunt-tipped tool at high speeds which aims to improve the uniformity of the surface on most metals. By heating and pressing the surface of the workpiece, the grains of the material become less rounded and more cohesive on a microscopic level. This, ideally, results in a workpiece with improved material properties. The changes were previously observed through hardness testing.

Thermal Radiation Effects On Particles From Plasma Arc Radiation, Reece Davis, Joseph Mcgee

Williams Honors College, Honors Research Projects

Understanding the radiation heating and transport of both microparticles and nanoparticles is a phenomenon that is critical for both space and Earth sciences. In space, these particles are heated by plasma arcs within ionized space clouds or solar flares and can be present the path of deep space missions and orbital satellites. While on Earth, processes such as forest fires, nuclear fusion, and microchip manufacturing include the plasma arc heating of particles. These particles lay within the Mie Scattering Regime and Rayleigh Scattering Regime and emit radiation differently based on their diameter. New mathematical and computational modeling has been conducted …

Predictive Structural Modeling In Ansys And Destructive Testing For Composite Structures, Dylan Matthews, Grant Abraham, Andrew Raineri

Williams Honors College, Honors Research Projects

Composite structures are central to the performance and reliability of Zips Racing’s Formula SAE vehicles, yet the team currently relies on historical data and partially unvalidated assumptions when selecting carbon fiber layups. This project aims to establish a quantitative, experimentally validated framework for designing composite components through the integration of simulation modeling, physical fabrication, and destructive mechanical testing. Analytical laminate theory models developed in MATLAB and laminate simulations created in Ansys ACP will be used to predict stiffness, strength, and failure characteristics for a range of candidate layups. These predictions will be validated through controlled testing of fabricated composite coupons …

Automated Soil Resetting System For Extraterrestrial Regolith Simulation, Parker W. Brennan, Anthony C. Daniels

Williams Honors College, Honors Research Projects

This project focuses on designing an automated soil resetting system for extraterrestrial regolith simulation. The system will prepare a regolith simulant testbed to a desired, repeatable density, enabling reliable wheel–terrain testing for planetary rover research. Manual soil preparation currently exposes testers to hazardous particulates and produces inconsistent results.

The proposed system will integrate mechanical and control elements to reset the soil bed safely and efficiently. A combination of raking and vibrational methods will be explored, with feedback sensors and automation to achieve target density control. The research will proceed through literature review, benchtop experimentation, prototype design, and full-scale testing over …

Fused Filament Fabrication Additive Manufacturing Of 17-4 Ph Stainless Steel: Process–Structure–Property Relationships In Magnetic Materials, Maanav Patel

Theses and Dissertations

Additive manufacturing (AM) enables the fabrication of complex metallic components through layer-by-layer processing directly from digital models. Among AM techniques, material extrusion–based processes such as fused filament fabrication (FFF) provide an accessible method for producing metal parts using filament feedstocks composed of metal powders and polymer binders. When applied to precipitation-hardening stainless steels such as 17-4 PH, the processing route and heat treatments can influence the resulting microstructure and functional properties. This work investigates the magnetic behavior of 17-4 PH stainless steel fabricated using FFF and evaluates how heat treatment conditions influence measured magnetic properties. Samples were produced and analyzed …

Vibration-Based Control Of Nonlinear Dynamic Systems, Ossyris N. Bury

Honors Undergraduate Theses

This thesis investigates vibration-based stability as a mechanism for achieving self-stabilizing nonlinear dynamic motion in engineered systems. Inspired by biological hovering flight, in which periodic wing motion can passively enhance stability, the study explores how controlled oscillations can be used to stabilize otherwise unstable mechanical configurations. The research centers on a simplified dynamic model based on the Kapitza pendulum, an inverted pendulum with a vertically oscillating base, which serves as a foundation for understanding vibration-induced stabilization. Analytical modeling using Lagrangian mechanics is employed to derive the governing equations of motion and identify the excitation conditions required for stable inverted behavior. …

Structural Batteries For Aerospace Applications, Tariqullah Wardak

Honors Undergraduate Theses

There is increasing pressure on the aviation sector to lower carbon emissions and switch to entirely electric and hybrid propulsion systems. However, the feasibility of standard lithium-ion batteries for long-range aircraft is limited, as they add substantial weight and occupy significant volume. Structural batteries, which combine load-bearing capability with energy storage, offer a potential pathway to lighter and more efficient aerospace systems.

This work investigates a carbon-fiber-based structural battery that utilizes carbon fiber as both a current-collecting, load-bearing electrode and a component of the composite structure. In contrast to lithium-ion chemistries, a zinc-based aqueous electrolyte is chosen for better environmental …

Material Degradation And Analysis Of N-Doped Graphene/Mof Nanocatalysts For Orr In Electrochemical Energy Systems, Niladri Talukder

Dissertations

The development of advanced electrochemical energy conversion and storage systems is crucial for achieving sustainable energy security. As alternatives to precious metal-based catalysts in electrochemical systems, especially for the oxygen reduction reaction (ORR), Nitrogen-doped Graphene with Metal-organic Frameworks (N-G/MOF) nanocatalysts have shown exceptional promise in recent years. This research advances the understanding of N-G/MOF nanocatalysts by systematically examining their structural features, degradation traits, correlated performance losses, and other aspects related to catalytic activities.

First, nitrogen-doped graphene (N-G) nanocatalysts were thoroughly investigated, resolving their physical properties, the influence of synthesis parameters, molecular-level material structures, and chemical and electronic structural details of …

In-Situ Investigations Of Calcium-Magnesium-Aluminosilicates (Cmas) Infiltration Effects On Thermal Barrier Coatings Under Extreme Environments Replicating Jet Engines, Zachary Stein

Doctoral Dissertations and Master's Theses

Calcium-magnesium-aluminosilicate (CMAS) particulates, such as sand or volcanic ash, are ingested by gas turbine jet engines during operation. When operating within high abundance regions, these particulates negatively interact and degrade the high temperature thermal barrier coatings (TBC) protecting underlying superalloy turbine blades vital to engine operation. These CMAS particulates melt within the engine and infiltrate into the ceramic coatings. In electron-beam physical vapor deposited (EB-PVD) TBCs, the CMAS within the intercolumnar gaps stiffens the coatings and causes thermomechanical induced high stress concentrations, risking crack formation. While molten, the CMAS thermochemically alters and destabilizes the coating, also risking coating failure. Premature, …

Simulation Of Rocket Response To Electromagnetic Environments Using Finite Element Modeling, Eden Powers

Fall Showcase for Research and Creative Inquiry

The purpose of this project is to develop a rocket model in FEMAP with NX-Nastran to simulate how a rocket might respond when exposed to external electromagnetic conditions. A simplified model of the SpaceX Starship will be constructed and analyzed to explore how various electromagnetic conditions interact with the rocket’s materials and geometry.

Internal Structural Design For Low-Cost Unmanned Fighter/Interceptor Aircraft, Andrew Zubyk

Discovery Day - Daytona Beach

Akriveia Aerospace is focused on the design of a high strength and efficient structure to accommodate the small size of Akriveia Aerospace’s Accipiter aircraft while ensuring the structure’s ability to sustain the required loadings. Emphasis is placed on wing spar, fuselage bulkhead, bulkhead-to-spar bracket, skin, and spar web sizing; as well as the fasteners used to join the structural components. The Accipiter was inspired based on historical and modern fighter/interceptor aircraft, such as the F-16 Fighting Falcon and F-35 Joint Strike Fighter. Preliminary sizing was conducted using conventional evaluation techniques; future aims involve validation using Finite Element Analysis. Due to …

Wing Structure Design The Ramp-200, Nicholas Hillburn

Discovery Day - Daytona Beach

This project focuses on the design of the wing structure to increase fatigue resistance and lessen the shear force across the skin of the wings, while maintaining the structure’s stability and soundness. The designed wing structure will be optimized to account for the proposed weight and endurance of the aircraft. The overall wing shape and size was defined using preliminary design methods and optimized for efficiency at Mach 0.9. The main structures were sized using calculations that were programmed into MATLAB and supported by hand calculations. Finite element analysis was used to verify sizing, and the structures were assessed using …

Wing Structure Design For Yf-27 Shrike Homeland Defense Interceptor, Maurya Jandyala

Discovery Day - Daytona Beach

This project focuses on designing the wing structure of an interceptor aircraft to withstand sustained supersonic flight and provide sufficient fuel storage for extended operations. The aircraft and structure were designed according to the AIAA Homeland Defense Interceptor request for proposal (RFP). Sizing of structural components was performed utilizing hand calculations and an idealized shear box approach focused on maximum aircraft limit loads. Based on these preliminary calculations, different wing structural components such as spars, ribs, stringers, and attachment points were designed using computer aided design (CAD) software. Finite element analysis was used to verify results and structural integrity of …

Sal-E: Responsive Space Pathfinder Mission, Adrian Serniak, Kayla Wong

College of Engineering Summer Undergraduate Research Program

The main objective of the SAL-E mission is to grow the Cal Poly CubeSat Lab’s (PolySat) capabilities in rapid spacecraft design and testing, as well as to provide the current generation of students with the opportunity to design, test, integrate, and communicate with a satellite. This summer we will mainly be focusing on aspects of spacecraft test and integration, as we prepare for our satellite handoff in the Fall. Specifically, we will be conducting satellite assembly, Thermal Vacuum Chamber (TVAC) Testing, Vibrations Testing, and software validation and testing on the flight unit satellite. Students participating in this multidisciplinary SURP will …

Additively Manufactured Bioinspired Microstructures For Active Surface Modification, Zefu Ren

Doctoral Dissertations and Master's Theses

Advancements in additive manufacturing have facilitated the development of bioinspired microstructures, which hold promise for applications, such as liquid transport, self-cleaning, and anti-icing. However, the controllability of these microstructures remains an area requiring further exploration. This research explores the design, fabrication, and active control of 3D-printed bioinspired microstructures for dynamic wettability modulation. First, the anisotropic scales of butterfly wings were replicated through optimized two-photon polymerization printing strategies, achieving directional droplet motion controlled by structural geometry and arrangement. The reversed wetting trend compared with natural wings revealed key insights into the structure–performance relationship. Next, microstructures were integrated with dielectric elastomer actuators …

Extraction Of Aluminum From Lunar Regolith Through Molten Salt Electrolysis, Jacob N. Ortega, Todd P. Sander, Jeffrey D. Smith, Fateme Rezaei, David J. Bayless, William Schonberg, Daniel S. Stutts, Frank D. Han

Materials Science and Engineering Faculty Research & Creative Works

This paper presents the methodology, development, and results of an end-to-end regolith-to-metal concept for producing aluminum in-situ on the lunar surface, namely, the Lunar In-Situ Aluminum Production through Molten Salt Electrolysis (LISAP-MSE) method. Using electrolytic reduction, aluminum oxide (i.e., alumina) can be reduced into aluminum and oxygen via electrolysis in a molten salt bath. A steady supply of hydrogen chloride could allow this in-situ resource utilization (ISRU) method to supply several necessary materials consumed in the electrolytic reduction step of the process to produce bulk aluminum metal, oxygen, water, and silica from anorthite abundant in lunar highland regions. In this …

Improvement Of The Fatigue Behaviour Of Additive Manufatured Scalmalloy By Using Surface Improvement Processes, Francisco José Boby Alcaide, Irene Eras, José Manuel De Los Santos, Alejandro Munoz Castro, Antonio Perinan Butrón, Jorge Sogorb

15th International Conference on Shot Peening

The use of light metals such as Aluminum alloys has experienced a remarkable increase for the additive manufacturing (AM) industry, especially in aerospace.

AM Scalmalloy®. (an Al-Mg-Sc alloy) shows outstanding behavior with much higher mechanical performance with respect to other alloys for powder bed fusion laser-based (PBF-LB) process like AlSi10Mg or AlSi7Mg. Recent studies have mainly focused on static loading, with minor attention to cyclic loading despite its vital importance in many applications.

In this work, the fatigue performance of PBF-LB Scalmalloy was investigated considering the effects of surface treatments to identify the set of optimal post-processes. Shot peening with …

Methodologies And Applications Of Precision Shot Peening To Hole Or Slot Geometry, James C. Hoffman

15th International Conference on Shot Peening

Shot peening, a commonly used method of fatigue and surface enhancement, is a critical process in many of the components in the aerospace industry. When it comes to small holes and/or slot geometries in these components, the process can become a challenge when these features are smaller than a conventional size Almen strip. In these cases, a decision must be made about how to process this type of geometry. Oftentimes, the method to apply the shot peen process is already defined in a process specification or part print so we must adhere to that method. If a method is not …

Improving Fatigue Strength And Life Of Single Crystal Cmsx-4, Jochen Peter Fuhr, Lloyd Hackel, Nicolau I. Morar, Noah Holtham, Keivan Davami, Montu Sharma, Rajkumar Roy

15th International Conference on Shot Peening

The deep penetration of laser peening (LP) and retention of residual stress at high temperature by LP is significant in improving fatigue life and strength of superalloys exposed to high temperature and corrosion. Single crystal CMSX-4, was evaluated for stress relaxation and both fatigue life and fatigue strength of material that was LP-treated compared to non-LP and shot-peened (SP) specimens. LP was done with multiple layers using a 20 J/pulse laser where the laser high energy enabled using a 5 mm spot size on the metal surface. Stress measurements by the slitting technique showed the plastic penetration depth exceeded SP …