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A Mold Mating Surface Temperature Monitoring System For Injection Molding Using Infrared Thermography And Mahalanobis Distance, Yoshio Fukushima, Makoto Fukushima, Sho Shibuya, Keigo Kudo, Yuta Abe

ASEAN Journal on Science and Technology for Development

In plastic injection molding, minimizing defects is crucial for sustainable and stable manufacturing because resin behavior and molding conditions fluctuate due to variations in material lots, seasonal shifts, and factory environmental factors such as temperature and humidity. Among various process parameters, mold temperature　- specifically the mold mating surface temperature immediately after part ejection-　 plays a critical role in mitigating these variations and maintaining consistent product quality. However, embedding conventional sensors into the mating surface is structurally difficult. While non-contact infrared thermography is an effective alternative, shiny metallic mold surfaces suffer from low emissivity, leading to inaccurate readings. Furthermore, high-end …

Nonlinear Control Of A Ciws-Style 2-Dof Turret, Ryan Baur, Ethan Wang, Nilay Kant

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper develops and compares multiple control strategies for a two-degree-of-freedom CIWS (Close-In Weapon System)-style turret tracking rapidly maneuvering airborne targets. A simplified nonlinear manipulator model with realistic actuator torque limits is used as the plant. Five controllers are implemented: a baseline PID (Proportional-Integral-Derivative) controller, a feedforward PID, a Kalman-filter-assisted PID, and two feedback-linearized designs using PID and LQR (Linear-Quadratic-Regulator)-based surrogate dynamics. Controller performance is evaluated on increasingly aggressive three-dimensional target trajectories under varying sensor noise. Results show that PID-family controllers achieve competitive tracking accuracy while remaining torque-efficient and largely unsaturated. Feedback-linearized controllers improve tracking accuracy only when sufficient actuator …

Mission-Focused Multidisciplinary Design Optimization Of Tilt-Rotor Evtol Propulsion System, Tyler Critchfield, Andrew Ning

Faculty Publications

Tilt-rotor propulsion system design requires a multidisciplinary approach to tackle important challenges and competing tradeoffs between disciplines. In this paper, we model rotor aerodynamics, blade structures, vehicle drag, electric propulsion, and tonal/broadband acoustics for a tilt-rotor, electric vertical takeoff and landing aircraft using low-to-mid fidelity tools. We use gradient-based design optimization with automatic differentiation and parameter sensitivity analyses to explore the design space and complex tradeoffs of tilt-rotor distributed electric propulsion systems, exploring effects of variations in payload/empty weight, battery specific energy, and blade tip speed. This framework models multiple operating points with a mission-focused objective to account for the …

Design For Extrusion-Based Additive Manufacturing: Generation Of Guidelines For Ceramics With Comparison To Thermoplastics, Hollis Hervey Waites

Masters Theses

"Design for Additive Manufacturing (DfAM) has made much progress for polymer material extrusion processes (MEX-P), like Fused Deposition Modeling (FDM), but very little progress for ceramic MEX processes (MEX-C) like Direct Ink Writing (DIW). This thesis leverages MEX-P design guidelines to create an initial set of design guidelines for DIW. FDM and DIW processes and material properties are compared, and the effect of these factors on the differences in rules is discussed. Five design guidelines are identified as applying to all MEX. For three of these, an exact limit for DIW of alumina is studied: minimum corner radius in the …

Castrip Process Technology: Non-Grain Oriented (Ngo) Si Steels Extension And Carbide-Free Bainitic (Cfb) For Flat Products, Naram Naidu Meesala

Masters Theses

"This research explores the development of advanced steel grades manufactured through Castrip® twin-roll thin strip casting technology, with particular attention to non-grain-oriented electrical Si-Steels (NGOES) and carbide-free bainitic (CFB) steels. The Castrip® process offers a near-net-shape route for producing thin steel strips, which greatly decreases the number of processing stages, lowers energy demand, and reduces carbon dioxide emissions when compared with traditional steel production methods.

In the NGOES part of the study, several industrial Fe–Si steel compositions were cold rolled to final thicknesses ranging from 0.35 mm to 0.15 mm. These materials were then exposed to short-duration continuous annealing at …

Critical Parameters Controlling Oxide Scale Formation And Hydro-Descaling Efficiency During Steelmaking, Tochukwu Princewill Ojiako

Doctoral Dissertations

In modern steelmaking, cast slabs are exposed to high-temperature oxidizing environments during secondary cooling, reheating, and hot rolling, resulting in the formation of multilayer oxide scales on the steel surface. These scales interact with mold-flux residues originating from the casting process (CC). The morphology, chemistry, and adhesion of oxide scale strongly influence its removability during high-pressure hydraulic descaling and ultimately determine the surface quality of hot-rolled products. However, the mechanistic relationship between oxide scale evolution, scale-steel interfacial structure, and hydraulic descaling performance remains poorly understood.

This dissertation investigates oxide scale formation, modification, and removal in low-carbon thin-slab steels produced by …

Fabrication And Characterization Of A High Strength Novel Aluminum Alloy For Implementation With Directed Energy Deposition, Rachel Boillat-Newport

Doctoral Dissertations

"Additive manufacturing (AM) is of significant interest due to the ability to fabricate 3D components layer-by-layer. Compared with traditional manufacturing methods, AM allows for the direct fabrication of complex, intricate parts without the need for extensive machining, reducing manufacturing time and tooling costs and minimizing material waste. Aluminum alloys are highly desired for implementation via AM due to their high strength-to-weight ratios; however, there are several challenges that complicate the situation and hinder the use of aluminum alloys. One of the most challenging issues is that the desired high-strength alloys are not compatible with AM processing methods. A method to …

Manufacturing And Performance Evaluation Of Carbon/Epoxy Laminated Composites Cured Using Single- And Six-Magnetron Microwave Applications, Nayan Pundhir

Doctoral Dissertations

Microwave curing is fast, energy-efficient, and a viable alternative to conventional thermal curing processes. It has been widely adopted for processing carbon fiber-reinforced polymer (CFRP) composites because the high electrical conductivity of carbon fibers enables strong microwave coupling, leading to rapid volumetric heating and reduced energy consumption. The aim of this study is to investigate the use of microwave curing for manufacturing CFRP composites. IM7/Cycom 5320-1 unidirectional prepreg was utilized to fabricate laminated composites in two thickness ranges: 16-layer laminates (2.5 mm thickness) and 64-layer laminates (9.2 mm thickness). Two lay-up configurations were examined: symmetric cross-ply and quasi-isotropic. Different curing …

Simulation And Characterization Of Fuel Cell System Incorporated Internet Of Things, Ahmad N. Alhjouj

Mechanical Engineering Theses

Small air-cooled proton exchange membrane fuel cell (PEMFC) systems are increasingly relevant for portable and distributed applications, yet practical modeling and monitoring methods remain limited: high-fidelity physics-based models are too costly for real-time use, while purely data-driven models discard physical interpretability. This thesis develops an experimentally grounded gray-box framework for the characterization, reduced-order modeling, and IoT-enabled monitoring of a small hydrogen PEMFC system. A low-order nonlinear state-space model couples an electrochemical voltage layer to a lumped thermal layer, with parameters identified in stages using self-adaptive differential evolution. Identifiability analysis shows that static loss parameters are well constrained, while dynamic parameters …

Computational Study Of Rotating Detonation Combustors, Aditya Balasubramaniam

Mechanical and Aerospace Engineering Theses

Rotating detonation combustors (RDCs) are pressure-gain combustion devices that sustain one or more continuously rotating detonation waves, offering potential thermodynamic and performance advantages over conventional deflagration-based systems. Their behavior depends strongly on combustor geometry and operating conditions. Understanding these effects is therefore essential for the design and optimization of practical RDCs. Accordingly, this thesis numerically investigates annular RDCs with two primary objectives: (1) to evaluate the effects of propellant mass flux and (2) to assess the influence of annular width on detonation-wave dynamics and combustor performance.

A finite-volume framework is used to solve the compressible reactive Euler equations with hydrogen–air …

Electron Beam Irradiation Effects On Bulk Metals: A Comparative Study Of Polycrystalline Versus Single-Crystalline Structures, A. A. Elmustafa, N. A. Sultana, A. H. Al-Allaq, M. Ojha, Y. S. Mohammed, J. Vennekate, H. Baumgart

Mechanical & Aerospace Engineering Faculty Publications

This study investigates the effects of electron beam (e-beam) irradiation on the mechanical and structural properties of eight bulk metallic samples, comprising both polycrystalline (PC) and single-crystalline (SC) forms of Ni, Cr, V, and Ti. These metals were evaluated as potential candidates for beam exit windows in high-power (MW-class) particle accelerators. The primary objective is to identify metals capable of withstanding the conditions of high-power/MW-class e-beam accelerators and serve effectively as exit windows. Selection criteria were based on each metal’s intrinsic properties, power dissipation capability, and irradiation-induced changes in mechanical behavior, including hardness, elastic modulus, and defect density. Comprehensive characterization …

Field-Assisted Post-Processing Of Cold-Sprayed Pure Copper, Alan Hensley

Theses and Dissertations--Mechanical and Aerospace Engineering

The properties of materials processed through cold spray, and many other AM processes, are non-uniform and unpredictable. In most cases, post-processing is required to achieve desired properties and better uniformity. In cold spray, the typical method is an annealing heat treatment (AHT), which can improve bond strength, reduce porosity, and restore ductility, among other effects. AHT alone, however, is unable to completely remedy any of the unfavorable properties. In addition, long treatments at high temperatures are often needed for satisfactory results. This increases energy consumption and extends production times for products made by the process. For these reasons, numerous investigations …

Multiphysics Transport In Porous Thermal Protection Systems: Experimental Characterization Of Gas Permeability And Radiative Properties, Yejajul Hakim

Theses and Dissertations--Mechanical and Aerospace Engineering

Porous thermal protection systems (TPS) used in hypersonic vehicles exhibit coupled gas and radiative transport across multiple regimes and length scales. Accurate performance prediction requires reliable characterization of permeability, slip-flow behavior, and radiative transport properties, particularly for low-permeability and charred materials where existing data are limited. This dissertation presents experimental methods for characterizing multiphysics transport in porous TPS materials. A modular flow system was developed to measure permeability and slip behavior in both virgin and charred materials under relevant environments. A transient pressure decay method enables accurate permeability estimation in low-permeability regimes and provides insight into effective pore structure. Results …

Reciprocity-Based Transfer Function Techniques For Acoustic Source Reconstruction, Spring Isolator Characterization And Structural Damping Assessment, David Pum Thian Lal Paite Neihguk

Theses and Dissertations--Mechanical and Aerospace Engineering

Reciprocity implies that a system responds identically when the source and receiver positions are interchanged. This dissertation applies this principle to address three practical challenges in noise and vibration characterization, where conventional approaches are limited by inaccessible interfaces, constrained excitation conditions, or metrics that do not fully capture vibroacoustic behavior.

The first study develops and validates an inverse method to characterize ducted acoustic sources using acoustic free velocity. Acoustic reciprocity is applied to simplify transfer function measurements. The method is extended to large cross-section ducts, where the source is reconstructed as a collection of point sources along a plane. Validation …

Process-Guided Learning Via Data-Driven Modeling And Controller Synthesis, Benton Clark

Theses and Dissertations--Mechanical and Aerospace Engineering

This work introduces process-guided learning, a framework in which process characteristics and learning algorithms are combined in the modeling process of engineering applications with the aim of uniting traditional and data-driven modeling and control techniques. Traditional engineering methods using simplified analytic models fail to capture the increasing complexities of engineering problems with sufficient accuracy to achieve modern requirements. More advanced modeling and control techniques using high-fidelity models often produce a computational burden that is infeasible for real-time solutions. Data-driven modeling offers a simple and flexible algorithm for producing real-time capable, high-fidelity models, but naive implementations lack the physical constraints of …

Embeddable Optical Fiber Sensor For Simultaneous Strain And Temperature Monitoring, Amardeep Kaur, Sudharshan Anandan, Steve Eugene Watkins, Yinan Zhang, Kumbla Chandrashekhara, Hai Xiao

Electrical and Computer Engineering Faculty Research & Creative Works

We present an embeddable hybrid optical fiber sensor based on a cascaded extrinsic Fabry–Pérot interferometer (EFPI) and intrinsic Fabry–Pérot interferometer (IFPI) for simultaneous strain and temperature monitoring in high-performance composite materials. The sensor is fabricated using femtosecond laser micromachining and is embedded within bismaleimide composite laminates manufactured via an out-of-autoclave process. Experimental results demonstrate linear and decoupled responses to strain and temperature, with the EFPI showing minimal temperature sensitivity (1.7 pm/°C) and the IFPI exhibiting high temperature sensitivity (16.1 pm/°C). Strain sensitivities for both components were consistent at 0.6pm/με in embedded conditions. The sensor maintained structural integrity and stable spectral …

Upconversion Photoluminescence In Wsse Alloy Monolayer Under Uniaxial Tensile Strain, Shrawan Roy, Jie Gao, Xiaodong Yang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The optical responses of monolayer transition metal dichalcogenides (1L-TMDs) can be tuned effectively by using mechanical strain. In this work, the tuning of upconversion photoluminescence (UPL) emission in 1L-WSSe alloy by applying uniaxial tensile strain is investigated. When the uniaxial tensile strain is changed from 0 % to 1.02 %, the peak position of UPL emission has a redshift of around 25.6 nm, and the UPL intensity goes up with an exponential function of the applied strain as the upconversion energy difference is varied from −197 meV to −131 meV. The sublinear power dependence for UPL emission in 1L-WSSe alloy …

Physics-Constrained Generative Adversarial Networks For Dimensionality Reduction In Optimization, Samuel Sisk, Xiaosong Du

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Electric vertical takeoff and landing (eVTOL) aircraft make a unique form of urban air mobility due to their low noise, zero emission, and precision control. To maximize efficiency, high-fidelity simulation-based multidisciplinary design optimization discovers the optimal balance among subsystems within an eVTOL. However, conventional multidisciplinary design optimization is computationally intensive due to excessive high-fidelity model evaluations. Moreover, complex nonlinear constraints deteriorate optimization efficiency and convergence. While surrogate models enable efficient design optimization, surrogate modeling suffers in large-scale applications and surrogate-based optimization still has to deal with nonlinear constraints. To address these challenges, the authors' previous work proposed physics-constrained generative adversarial …

Optimal Takeoff Trajectory Prediction Of Electric Drones Based On A Fully Automated Optimal Experimental Design Method, Jiachen Wang, Dheeraj Paramkusham, Xiaosong Du

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Electric vertical takeoff and landing (eVTOL) aircraft is attracting great interest as a viable solution to promote urban aerial mobility with promising flexibility as well as emission reductions. However, the low specific energy of the current battery is still a strong constraint on the range and endurance of eVTOL flights, especially considering the significant power demands during the takeoff process. Engineering design optimization permits promising solutions for the minimum takeoff energy consumption but can be computationally intensive due to iteratively evaluating simulation models. Surrogate-based design optimization is efficient but still relies on optimization iterations which prohibit real-time decision-making. To fill …

Multiphysics Modeling Of Melt Pool Dynamics And Powder Bed Stability In Lpbf Of Inconel 718 For A Circular Cavity, Nayan Pundhir, Oluwapelumi O. Adejumo, Kumbla Chandrashekhara, Joseph W. Newkirk, Heath Misak, Cesar Ortiz Rios

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser powder bed fusion (LPBF) is a metal additive manufacturing process in which a concentrated laser beam selectively melts successive powder layers to fabricate components. Final part quality is highly sensitive to process parameters such as hatch spacing, powder bed density, laser power, and scanning speed. In this study, a computational fluid dynamics model employing discrete element method has been developed in FLOW-3D to simulate LPBF of Inconel 718. The modeled powder bed incorporates particle size distribution data obtained from scanning electron microscopy and is evaluated for single-layer, single-track deposition over a circular cavity. The model captured melt pool dynamics …

Atomized Oxidative Polymerization As A 3d Printing Platform For Binder-Free, Bulk Conductive Polymer Architectures, Tazdik Patwary Plateau, Hiep Pham, Jonghyun Park

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Translating the ultrahigh intrinsic conductivity of conjugated polymers into bulk 3D architectures remains a formidable challenge due to the fundamental dichotomy between rheological printability and electronic purity. Existing strategies necessitate a compromise: solution-processing requires insulating binders that degrade charge transport, while binder-free vapor-phase polymerization (VPP) is kinetically confined to surface-limited thin films by diffusion constraints. Here, we introduce atomized oxidative polymerization (AOP), a manufacturing paradigm that overcomes these kinetic barriers via active, layer-by-layer monomer atomization. This approach ensures stoichiometric reaction conditions throughout the printed volume, driving a structural transition toward highly conductive quinoid-dominant chains with enhanced π-π stacking. The resulting …

Performance Evaluation Of Thick Carbon Fiber-Reinforced Laminates Manufactured Using Six-Magnetron Microwave System, Nayan Pundhir, Sourav Bolar, Kumbla Chandrashekhara, Kristen Donnell, Jim Lua, Kalyan Shrestha, Rui Li

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Microwave curing is a fast, energy-efficient, and a viable alternative to conventional thermal curing processes. It has been widely adopted for processing carbon fiber-reinforced polymer composites because the high electrical conductivity of carbon fibers enables strong microwave coupling. In this study, IM7/Cycom 5320-1 unidirectional prepreg has been used to fabricate 64-layer laminated composites. Symmetric cross-ply ([0°/90°]16S) and a quasi-isotropic ([45°/90°/−45°/0°]8S) layup have been investigated. A custom-built six-magnetron microwave applicator and an autoclave were employed to manufacture the composite panels. Degree of cure of the manufactured laminates was evaluated via differential scanning calorimetry. Interfacial bonding and porosity of the microwave-cured laminates …

Anisotropic Second-Harmonic Ince-Gaussian Beam Generation Using Nbobr2 Holograms, Jayanta Deka, Xiaodong Yang, Jie Gao

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Ince-Gaussian (IG) modes are a complete and orthogonal set of solutions to the paraxial wave equation in elliptic coordinates representing a continuous transition between Hermite-Gaussian modes and Laguerre-Gaussian modes. Chip-scale platforms to generate IG beams have great significance for various applications, including optical trapping and micromanipulation of particles, optical communication, and quantum optics. On the other hand, materials with high optical anisotropy are crucial for building polarization-sensitive optical devices. In this context, niobium oxide dihalides are a new class of ferroelectric materials exhibiting strong, tailorable, and highly anisotropic second-harmonic generation responses. Here, we report the generation of highly anisotropic second-harmonic …

Supersonic Wind Tunnel Free Stream Turbulence Characterization Using 2-Point Focused Laser Differential Interferometry, Joseph Villarreal, Joshua Gary, Davide Vigano

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Non-intrusive laser-based diagnostics, such as Two-Point Focused Laser Differential Interfer-ometry (2-FLDI), play a crucial role in modern aerodynamic research by enabling simultaneous measurements of density and velocity in compressible flows. A 2-FLDI system has been developed and implemented for the Missouri S&T Supersonic Wind Tunnel to characterize free stream turbulence fluctuations and free stream convective velocity. Design choices that enabled the 2-FLDI to overcome low turbulence to measure free stream velocity are detailed. The free stream velocity measurements are validated against previous particle image velocimetry data, showing good agreement. Analysis of normalized velocities and density-based turbulence intensities found that the …

2-Point Focused Laser Differential Interferometry Measurements Of A Parallel Jet In Supersonic Flow, Joshua Gary, Joseph Villarreal, Davide Vigano

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Turbulence in compressible flows plays a central role in applications such as air-fuel mixing in supersonic combustors and is significantly more complex than incompressible turbulence due to the presence of fluctuating thermodynamic quantities. As such, models like the Strong Reynolds Analogy (SRA) are used to relate these quantities. However, SRA validity has been examined primarily in boundary-layer flows. In this work, a newly developed Two-Point Focused Laser Differential Interferometry (2-FLDI) system is implemented in a two-dimensional parallel supersonic jet. The diagnostic is described in detail, including optical alignment procedures, calibration methods, and data analysis techniques. Measurements acquired at multiple streamwise …

A Full Polymer Piezoelectric Flextensional Energy Harvester, Nadia Ahbab, Sidra Naz, Bingqi Zhao, Tian-Bing Xu

Mechanical & Aerospace Engineering Faculty Publications

This study presents a full polymer piezoelectric flextensional energy harvester (FPPFEH) comprising a single-layer poly(vinylidene fluoride) (PVDF) film bonded to a 3D-printed polylactic acid (PLA) flextensional frame. For an arm inclination angle of θ=10°, the free-body model gives a theoretical geometric force-amplification factor of M_F=cot θ ≈ 5.67; this value represents an ideal upper bound and was not independently validated by local force or strain measurements. During assembly, the film was tensioned only to remove visible slack and maintain a flat configuration. No intentional pretension was applied, and any residual tension was not measured. Off-resonance force-controlled tests showed …

Comparison Of Fixed Tilt And Single Axis Tracking Solar Photovoltaics During Winter, Isobel R. Bowker

Dissertations, Master's Theses and Master's Reports

As solar projects are built in northern climates, it is necessary to understand how snow cover impacts power generation. While there are validated models that predict snow shedding for fixed tilt projects, there is not one for single axis tracking systems. This report aims to characterize the differences between fixed tilt and single axis tracking systems under the same snow conditions. Generation data was collected over four winter months for fixed tilt and tracking systems at Michigan Technological University. Models were created for both systems using weather information from the site, in which losses were set to zero to create …

Application Of Reactive Power Theory To Wave Energy Converters Under Multi-Frequency Excitation: Analysis And Experimentation, Mckenna R. Collins

Dissertations, Master's Theses and Master's Reports

There is abundant energy surging in the oceans across the globe. However, there have been technological challenges in extracting that energy for use. Wave energy converter (WEC) technology is being developed to find innovative ways to convert wave kinetic energy into electricity, but there are still efficiency obstacles that inhibit large-scale use. Focusing on heave-point absorber control theory, this thesis continues the work to improve the efficiency of WECs. This is done by leveraging a superposition of linear mass-spring-damper models to analyze a WEC under multi-frequency excitation and applying proportional-derivative gains to each linear model. However, to analyze this system, …

Coupled Shrinking Core And Bubble Dynamics Model For Enhancement Of Metal-Water Reactions With Acoustic Cavitation, Troy Metz

Dissertations, Master's Theses and Master's Reports

Hydrogen is a valuable fuel. Hydrogen can be produced in several ways including thermochemical cycles, electrolysis, and metal-water reactions. Thermochemical cycles typically use high temperatures, often with corrosive species. Electrolysis requires high purity water. Metal-water reactions do not have these drawbacks. Activators such as lithium and gallium are often used to enhance metal-water reactions. However, these activators add to the complexity of metal-water reactions and may not work for all metals. A novel method to improve metal-water reactions is cavitation. During bubble collapse, shock waves and microjets are produced that can cause surface erosion. The objective of this work is …

Long Short-Term Memory (Lstm) -Based Neural Network Model For Optimizing Composite Manufacturing Process Using Autoclave, Sourav Bolar, Steven Corns, Nayan Pundhir, Kumbla Chandrashekhara

Engineering Management and Systems Engineering Faculty Research & Creative Works

Producing high-quality fiber-reinforced composites requires precise temperature control during autoclave curing, as even small variations can lead to defects that compromise strength and reliability. At the same time, manufacturers aim to reduce energy use and shorten curing cycles without sacrificing material performance. To address these challenges, this study develops a data-driven Long Short-Term Memory (LSTM) neural network model capable of forecasting temperature evolution inside the autoclave throughout the curing cycle. The model is trained on time-series temperature data collected from multiple sensing locations, enabling it to learn the spatial and temporal trends that govern heat flow during curing. Data augmentation …