Engineering Commons^™

Automatic Hole Saw Testing For Mk Morse, Jason Watson, Justin Zapotoczny

Williams Honors College, Honors Research Projects

M.K. Morse has a hole saw tester they use for their hole saw product line. The tester currently requires constant operator attention for a process that could be automated. The goal of this project is to create a new hole saw tester that can run without the need for an operator's complete attention and give reliable data for the hole saws.

Study On Motion Prediction Analysis Of Large Vessels Entering Kaohsiung Port Second Harbor, Li-Heng Cheng, Hsing-Yu Wang

Journal of Marine Science and Technology–Taiwan

Pilotage is a primary service offered by ports, ensuring the safe passage of entering and exiting vessels. This study applied motion prediction analysis to large vessels navigating the constrained waterways of Kaohsiung Port’s second harbor. To address the needs of pilots and port operators, a simplified planar motion equation was developed that incorporated speed over ground and rate of turn (ROT) as primary variables. The model relied on inputs of limited navigational data, enabling pilots to predict changes in heading and position over time and determine the conditions for safe harbor entry. Vessel paths and turning angles were analyzed to …

Scratching Behavior Of Copper-Niobium Nanolaminates, Matthew C. Peterson

Graduate Research Theses & Dissertations

Metal nanolaminates are known in material science for their unique mechanical properties and high strength due to their interface behavior. Cu/Nb nanolaminates specifically are studied for their uses in electronics due to their good conductivity and superior tensile strength compared to copper conductors, as well as their radiation resistance in radioactive environments. Currently, most molecular dynamics (MD) simulations of Cu/Nb simulations are axially loaded. This work attempts to characterize the scratching behavior of Cu/Nb nanolaminates with varying indenter size, temperature, speed, and layer thickness. The coefficient of friction (CoF), friction force, normal force, and material removal were then compared. A …

Materials Reliability In Direct-To-Chip Cooling: A Systematic Study Of Aluminum Corrosion In Next-Generation Data Center Coolants, Fnu Harish Gangadhara

Mechanical and Aerospace Engineering Theses - Archive

Data centers are rapidly scaling to support artificial intelligence, cloud platforms, and other high-performance workloads, driving a sharp increase in chip and rack power densities that are now approaching, and in some cases surpassing, 50–100 kW per rack. In response, direct-to-chip liquid cooling has become a key enabling technology for managing these extreme thermal loads, yet the durability of materials in contact with the coolant remains a major reliability concern over system lifetimes. Copper has traditionally been used for cold plates and cooling-loop components, but its relatively high cost, mass, and supply-chain uncertainty are motivating a shift toward aluminum as …

Development Of A Design Tool For Tow-Steered Composite Structures With Machine Learning-Assisted Modeling, Bangde Liu

Industrial, Manufacturing, and Systems Engineering Dissertations - Archive

Fiber-reinforced composites (FRCs) are widely used in aerospace, automotive, and other engineering applications due to their lightweight characteristics and superior mechanical properties. Traditional FRCs employ a fixed fiber orientation in each layer, and while different layup sequences can tailor performance, the mechanical properties remain spatially uniform. Tow-steered composites, which enable fibers to follow curvilinear paths, offer the potential for spatially varying stiffness and strength, improving structural performance.

This dissertation addresses key challenges in modeling and designing tow-steered composite structures, including the lack of commercial design tools, the high computational cost of design optimization, and the need to efficiently evaluate manufacturing …

Assessing Porosity Limit In Freeze-Cast Sintered Lithium Titanate (Li₄Ti₅O₁₂) Materials, Rohan Parai, Dipankar Ghosh

Mechanical & Aerospace Engineering Faculty Publications

This study aims to assess the lower limit of porosity that can be achieved in freeze-cast sintered lithium titanate (LTO) materials while maintaining the characteristic pore directionality. LTO materials were fabricated with solid loading varying in the range of 30–37 vol.%. Sucrose and cationic dispersant were used to vary viscosity and total solute concentration in the aqueous LTO suspensions. Two series of suspension compositions were selected for freeze-casting. In one series, aqueous suspensions were prepared by mixing deionized (DI) water, sucrose, and LTO powder, while in the other series, aqueous suspensions were prepared by mixing DI water, sucrose, cationic dispersant …

Morphing Shape Metastructures Using The Hybrid Position Feedback Control And Bistable Structural Elements, Mehmet Simsek, Thomas E. Alberts, Onur Bilgen

Mechanical & Aerospace Engineering Faculty Publications

This research introduces a new multi-degree-of-freedom metastructure concept utilizing a hybrid position feedback controller. An arbitrary number of bistable segments, or structural elements, are connected serially or in parallel to form a distributed bistable structure, or a so-called metastructure. The hybrid controller, an unstable-then-stable second-order single-degree-of-freedom system, leverages the resonant mode of a bistable system to destabilize it and dynamically induce snap-through between equilibria. The metastructure inherits multiple bistable positions, maintaining equilibrium shapes without consuming power and enabling many equilibrium configurations. Two geometric configurations are proposed and analyzed using a modified hybrid feedback control approach, which rejects forces from neighboring …

Aeg Improved Football Helmet Liner, Matthew Dyson, John Clore, Brady Slates, Nathan Walker

Williams Honors College, Honors Research Projects

The National Football League (NFL) is a leading professional American football organization experiencing rapid growth in popularity. However, the high-contact nature of the sport frequently results in player injuries, with head trauma and concussions being major concerns. This project aims to mitigate these risks by developing an advanced helmet liner designed to reduce the impact of direct collisions and torsional shear forces. In order to do this, we will utilize an impact testing machine with a modified helmet mount. By enhancing the liner's effectiveness, the proposed design seeks to improve player safety without compromising performance. The study focuses on innovative …

Investigation Of Arm Stiffness Modulation During Overground Physical Human-Human Interaction, Henry Tien

Masters Theses

The vision of advancing robots capable of direct physical engagement with humans begins with an understanding of how humans interact with each other. Even rudimentary interactive tasks, such as shaking hands, provides tremendous challenges for modern robotics and current research into the biomechanics of such interactions is limited. Thus, further analysis of physical Human-Human Interaction (pHHI) will bolster efforts to enhance collaborative robot capabilities. To this end, a custom Force Perturbation Handle (FPH) was developed, including the requisite mechanical, electrical, and software systems, to investigate the unique role of arm stiffness modulation in haptic communication between humans. The novel device …

Aerodynamic Design Workflow Optimization For Fsae: Advanced Cfd And Hpc Automation, Kyle Maynor

Masters Theses

This research identifies and resolves inefficiencies in the Computational Fluid Dynamics (CFD) workflow of the Missouri S&T Racing Formula SAE Team’s aerodynamic development. Key bottlenecks were found in simulation runtime, laborious simulation preparation, an overly manual simulation submission process, and unchecked mesh quality. A fully reimagined workflow was implemented with simulation parameters to adjust vehicle attitudes. From this, an automated design sweep could be executed to generate aero maps of the developing vehicle using the Design Manager Project. A Python-based submission app handles the terminal interfacing and macro editing that significantly slowed the job submission process before. Using a university …

Design Of A Spacecraft Power System Experiment, Jay Bakulkumar Kamdar

Masters Theses

This research delves into the design, implementation, and analysis of a controlled experimental framework for photovoltaic cell characterization and its application in spacecraft power systems. Such a system was simulated and validated by benchmarking characteristics of a photovoltaic module and implementing them in a system design simulation yielding performance data for comparative analysis. A hardware setup was developed to perform IV characterization tests under steady state thermal conditions. Experiments conducted across various thermal regulation profiles helped quantify the effects of temperature on the photovoltaic performance parameters. Active cooling reduced the steady state cell temperature by 17.9% and improved the cell …

Pla-Based Bone Tissue Engineering Scaffolds Incorporating Hydroxyapatite And Bioactive Glass Using Digital Light Processing, Engin Gepek, Fateme Fayyazbakhsh, Lev Suliandziga, Vadym Mochalin, Osman Iyibilgin, Yue-Wern Huang, Ming C. Leu

Chemistry Faculty Research & Creative Works

Bone tissue engineering (BTE) aims to repair bone defects using biocompatible materials with tailored geometries and pore structures, providing appropriate mechanical support and control over biodegradation kinetics to promote bone growth. In this study, we utilized digital light processing (DLP) 3D printing to fabricate scaffolds with varying pore sizes using polymer–ceramic slurries composed of polylactic acid (PLA) as the main polymer matrix, incorporated with hydroxyapatite (HA) and bioactive borate glass (BBG) at various ratios. We studied the effect of composition on rheological behavior, printability, mechanical properties, bioactivity, degradation rate, and biocompatibility. While HA increased viscosity and reduced printing accuracy, it …

Mechanical And Thermal Characterization Of Additively Manufactured Carbon/Nylon 12 And Carbon/Peek Composites, Matik Heskin, Bradley Deuser, Thomas P. Schuman, K. Chandrashekhara, John Bayldon, Jeff Degrange, Steven Patterson, Neiko Levenhagen

Chemistry Faculty Research & Creative Works

This study explores additive manufacturing of carbon fiber-reinforced thermoplastic composites using the Composite-Based Additive Manufacturing (CBAM) process. Carbon/Nylon 12 and Carbon/PEEK composites were fabricated and evaluated through mechanical (compression, tensile, flexural, and impact) and thermal (DSC and TGA) tests. Carbon/PEEK exhibited superior mechanical performance, with 97.5% higher tensile strength, 79.8% higher elastic modulus, and 59.6% higher flexural strength compared to Carbon/Nylon 12. Thermal testing showed that Carbon/PEEK had higher thermal stability, beginning degradation at 350 °C versus 298 °C for Carbon/Nylon. These results indicate that CBAM-fabricated Carbon/PEEK composites are suitable for applications requiring high strength and temperature resistance.

An Adaptive Sampling Strategy On Optimal Takeoff Trajectory Prediction Of Electric Drones, Dheeraj Paramkusham, Samuel Sisk, Jiachen Wang, Shuan Tai Yeh, Xiaosong Du, Nathan Roberts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Electric vertical takeoff and landing (eVTOL) aircraft transforms future transportation systems by alleviating transportation congestion on the ground. This eVTOL technique possesses unique features, including reduced noise, low pollutant emissions, efficient operating costs, and flexible maneuverability. Meanwhile, battery consumption poses critical challenges to flight task duration. Thus, optimal takeoff trajectory design is essential due to immense power demands during eVTOL takeoffs. Conventional design optimization, however, iteratively evaluates high fidelity simulation models, making the design process computationally intensive. In this work, we implement a machine learning-enabled inverse mapping optimization concept, i .e., directly predicting optimal design based on design requirements (including …

Study On Field Emission Characteristics Of Carbon Nanotube Arrays Patterned Via Laser Welding Of Dissimilar Materials, Hung Yin Tsai, Yi Hung Chen, Kuan Ching Wang, Paul W. Leu, Ming C. Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper describes a new method of growing carbon nanotube (CNT) arrays using laser welding of a catalyst metal onto the surface of a quartz substrate, followed by CNT growth through the chemical vapor deposition (CVD) process. A major advantage of this method is its ability to pattern the catalyst before growing the CNTs, thus allowing for the formation of CNTs at specific locations. The laser pre-treatment method minimized structural damage to CNTs in comparison to the laser post-processing method, achieving a lower ID/IG value of 0.72 in Raman spectroscopy analysis. Using hexagonally patterned CNT arrays on quartz, we achieve …

Correction: Advancing Cislunar Space Domain Awareness Through Robust Optimization Framework For Optical Sensors-Based Autonomous Satellite Systems (American Institute Of Aeronautics And Astronautics Inc, Aiaa), Smriti Nandan Paul, Siwei Fan, Igor Panfil

Mechanical and Aerospace Engineering Faculty Research & Creative Works

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High-Order Dynamic Mode Decomposition For Multidimensional Harmonic Retrieval, Yanming Zhang, Steven Gao, Lijun Jiang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Estimating channel parameters such as azimuth, elevation, Doppler shift, and delay is a key challenge in wireless communication, often formulated as a multidimensional harmonic retrieval (MHR) problem. To address this, we propose a high-order dynamic mode decomposition (HODMD) framework for robust frequency estimation from high-dimensional signals in noisy environments. The HODMD approach combines high-order singular value decomposition (HOSVD) to decompose tensor data into a core tensor and mode matrices, with dynamic mode decomposition (DMD) to extract frequencies from the imaginary parts of the DMD eigenvalues. Simulation examples validate the effectiveness of the proposed method, demonstrating its efficiency in solving MHR …

Performance Evaluation And Multiphysics Process Modeling Of Carbon Fiber Reinforced Thermoset Composites Using Microwave And Autoclave, Nayan Pundhir, Patrick Schwartzkopf, K. Chandrashekhara, Logan Wilcox, Kristen M. Donnell, Jim Lua, Rui Li

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In this study, IM7/Cycom 5320-1 unidirectional prepreg has been utilized to manufacture 16-layer laminated composites: a symmetric cross-ply ([0°/90°]4s) and a quasi-isotropic ([45°/90°/−45°/0°]2s) configuration. Microwave and autoclave curing processes have been employed to manufacture the laminated composites. The manufactured composite cure was assessed using differential scanning calorimetry (DSC). The quality and porosity of the microwave-cured parts were juxtaposed to those of autoclave-cured parts through optical microscopy and micro-computed tomography (micro-CT) scanning. Mechanical characterization of the microwave-cured panels was conducted using uniaxial tensile and flexural tests, with results juxtaposed to autoclave-cured samples. Experimental characterization revealed that the microwave-cured parts exhibited nearly …

Design And Testing Of An Intrusive Arm For Supersonic Flow Sampling, Caleb Roberts, Davide Viganò

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Intrusive probes are critical tools in supersonic wind tunnel testing, enabling direct measurement of flow properties such as pressure and heat flux. To support these measurements, a single-axis intrusive arm was designed and implemented in the Missouri S&T Supersonic Wind Tunnel. The system is designed to maintains precise probe positioning, while withstanding the aerodynamic loads, and preserving a dynamic seal between the test section and ambient environment. Its modular design accommodates a range of probe types for various research applications. This paper presents the design methodology, including structural, mechanical, and aerodynamic considerations, and details the integration process. System performance was …

Deep Reinforcement Learning-Based Optimal Takeoff Trajectory Design Of An Evtol Drone, Nathan M. Roberts, Bingling Huang, Xiaosong Du

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The continuing development of electric vertical take-off and landing (eVTOL) aircraft presents promising opportunities to alleviate transportation congestion. However, designing and executing takeoff trajectories that optimally balance energy usage, passenger comfort, and aircraft constraints remains challenging. Conventional design optimization provides a solution for pre-defined flight conditions and environments but is not ideal in real-world applications. In contrast, deep reinforcement learning (DRL) implements optimal policy making real-time decisions with no assumption of mathematical models. Seeing the lack of literature on DRL-based takeoff trajectory design of eVTOL aircraft, we implement and conduct DRL-based optimal takeoff trajectory designs for the Airbus³ Vahana …

Industry 5.0, Human–Machine Interface, And Smart Manufacturing In Additive Manufacturing—A Recent Trend, Atiqur Rahman, Md Hazrat Ali, Muhammad Arif Mahmood, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The emergence and importance of Industry 5.0 are transforming production by integrating smart technology with human creativity and intelligence, especially in advanced additive manufacturing. This critical review precisely analyzes the function of human–machine interfaces (HMIs) in enhancing additive processes, emphasizing their incorporation into smart manufacturing systems and hybrid manufacturing methods, including material extrusion (MEX), laser powder bed fusion (LPBF), and directed energy deposition (DED). It also evaluates artificial intelligence (AI), the Internet of Things (IoT), and cybersecurity, which enhance HMIs in process monitoring, operation, and system adaptability. This study aims to provide a critical analysis and future research direction on …

Optimizing Uav Swarm Deployment For Efficient Communication Signal Strength Alignment In Disaster Scenarios, Mina Khalilzadeh Fathi, Chaoying Pei

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In disaster scenarios, establishing reliable communication infrastructure is critical, and unmanned aerial vehicle (UAV) swarms offer a promising solution as temporary base stations. This study models communication demand in disaster-affected areas by applying Gaussian kernels to building data, forming a spatial demand distribution. Signal strength is estimated using the normalized inverse Free Space Path Loss (FSPL) to account for realistic attenuation. To guide UAV placement, we extract high-demand regions from the demand distribution using a gradient-based thresholding method. Based on this information, we develop a greedy algorithm to iteratively position UAVs for optimal coverage in areas with the greatest communication …

Few-Shot Learning-Enhanced Tiered Path Planning For Mars Rover Navigation, Ziyi Wang, Di Yu, Mina Khalilzadeh Fathi, Chaoying Pei

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Path planning for Mars rovers presents significant challenges due to the diverse terrain, ranging from easily navigable areas to hazardous zones. Traditional methods typically classify terrain simply as passable or impassable, failing to account for the nuances of more moderately challenging areas. In this paper, we introduce a tiered terrain-aware path planning strategy, employing few-shot learning to classify and segment Martian terrain into levels of difficulty. The few-shot learning model, trained on Earth, is sent to the rover, enabling real-time processing of images from satellites or helicopters. The flexibility of few-shot learning, which requires minimal data and training time, enables …

From Spark To Wildfire: Predicting Wildfire Origins And The Efficacy Of “Fire Safe” Cigarettes In California Grasslands, Trevor Blackwell Haltermann

Cal Poly Humboldt theses and projects

As wildfires in North America increase in size and frequency, the societal impacts become greater as well. With greater risk and high fire suppression costs it is pertinent to improve fire investigation methods and limit the potential for human caused ignitions. Two distinct studies were carried out to assess the accuracy of fire pattern indicators and the efficacy of “fire safe” cigarette technology in lowland grass fuel types in California. The first study utilized 24 experimental small-scale fires within a wind tunnel to examine the accuracy of microscale fire pattern indicators and the factors that influence the accuracy of predictions …

Extended-Duration Satellite Testing Via Altitude-Controlled High-Altitude Balloon, Drew Early, Evan Champney, Nikki Allen, Riley Galatis, Lukas Hezel, Joseph Kloess, Andrew Donnell, Sam Whitlock, Kaden Queener

Von Braun Symposium Student Posters

Undergraduate runner-up, 2025 Von Braun Symposium Student Poster Contest

Molecular Dynamics-Based Two-Dimensional Simulation Of Powder Bed Additive Manufacturing Process For Unimodal And Bimodal Systems, Yeasir Mohammad Akib, Ehsan Marzbanrad, Farid Ahmed

Manufacturing & Industrial Engineering Faculty Publications

The trend of adapting powder bed fusion (PBF) for product manufacturing continues to grow as this process is highly capable of producing functional 3D components with micro-scale precision. The powder bed’s properties (e.g., powder packing, material properties, flowability, etc.) and thermal energy deposition heavily influence the build quality in the PBF process. The packing density in the powder bed dictates the bulk powder behavior and in-process performance and, therefore, significantly impacts the mechanical and physical properties of the printed components. Numerical modeling of the powder bed process helps to understand the powder spreading process and predict experimental outcomes. A two-dimensional …

Influence Of Alloy Composition On The Process Robustness Of Steels Consolidated Via Laser-Directed Energy Deposition, Jonathan Kelley

Masters Theses

"To ensure consistent quality of additively manufactured parts, it is advantageous to identify alloys which can meet performance criteria while being robust to process variations. Toward this end, this work investigated the effect of alloy composition on the robustness of steels consolidated via laser-directed energy deposition (L-DED). Ultra-high-strength low-alloy steel (UHSLA) and pure iron powders were mixed in-situ to produce 10 compositions containing 10-100% UHSLA by mass. JMatPro material simulations roughly predicted phases and mechanical properties. Two sets of experiments were used to evaluate the sensitivity of as-built hardness (all 10 compositions) and tensile properties (5 select compositions) to process …

Polymorphism And Mechanical Behavior In Hot-Pressed 3d-Printed Polyamide Composite: Effects Of Pressure And Temperature, John Barber, Patricia Revolinsky, Jimesh Bhagatji, Diego Pedrazzoli, Sergii Kravchenko, Oleksandr Kravchenko

Mechanical & Aerospace Engineering Faculty Publications

The aim of this work is to study the effect of high-temperature compaction (HTC) upon the polymorphism and the mechanical behavior of an additively manufactured (AM) carbon fiber-reinforced polyamide (PA6). Different pressure and temperature levels during HTC were tested to determine the overall effect on the mechanical behavior and material crystalline composition. Treated, carbon fiber-reinforced PA6 samples were analyzed using differential scanning calorimetry, X-ray diffraction, thermogravimetric analysis, scanning electron microscopy, and three-point bending testing. When considered with respect to as-printed samples, an HTC temperature of 190 °C combined with 80 psi pressure resulted in an increased flexural modulus and strength …

Optimizing Material Selection And Operational Conditions For Xhv Systems: Lessons From Aisi 1020 And 316l Comparative Studies, Aiman H. Al-Allaq, Md Abdullah Mamun, Matt Poelker, Abdelmageed Elmustafa

Mechanical & Aerospace Engineering Faculty Publications

In this study, AISI 1020 low-carbon steel was investigated as a cost-effective alternative to SS316L stainless steel for reaching extreme high vacuum (XHV) conditions. After being baked at 400°C, a vacuum chamber made of low-carbon steel material exhibited an outgassing rate approximately 2000 times smaller than a similar chamber made of stainless steel. Its activation energy for hydrogen diffusion (27 kJ/mol) is less than half that of stainless steel (60.3 kJ/mol), indicating more efficient hydrogen removal during bakeout. MolFlow+ simulations supported the experimental data and demonstrated the importance of system geometry optimization and minimizing stainless steel content for achieving optimal …

Fault Tree Analysis For Robust Design, Jonathan Degroff, Gene Jean-Win Hou

Mechanical & Aerospace Engineering Faculty Publications

The objective of this research is to incorporate system failure into a robust design formation and solution process. The system failure referred to here will be built using fault tree analysis (FTA), which will take all lower-level failure events into consideration. Two examples are investigated here. One will directly treat the probabilities of the basis events as design variables, The other will be formulated in five different models: deterministic design optimization, the reliability index-based, the “and” gate-based, the “or” gate-based and the “inhibit” gate-based robust design. Their corresponding optimization solutions will be compared with each other. The post-optimality analysis of …