Aerospace Engineering Commons^™

Characterizing Strain Accumulation, Residual Stress, And Microstructure Of Additive Manufactured Materials, Hannah K. Woods, Todd A. Book, Catalina Parada, Michael D. Sangid

The Summer Undergraduate Research Fellowship (SURF) Symposium

Additive Manufacturing (AM) is a rapidly evolving fabrication technology beneficial for its cost-saving potential to produce complex, low-volume shapes. However, AM materials are currently limited to nonstructural applications due to variability in their structural integrity, particularly their fatigue lives. IN718, Ti64, and Al10MgSi specimens manufactured by Direct Metal Laser Sintering (DMLS) were characterized based on variation of post-processing techniques and build direction. To understand the impact of each variable, surface roughness, hardness, residual stresses, microstructure, and strain accumulation in response to Low Cycle Fatigue (LCF) were studied. The use of Electron Backscatter Diffraction (EBSD) provided grain orientation and grain size …

Effect Of Time Delay Between Etching And Adhesive Bonding (“Outlife” Time) On Lap-Shear Strength Of Aluminum Alloys Using Environmentally-Friendly P2 Etch, Josh Barkhimer, Matthew Erich, Gokul Nair

Materials Engineering

Raytheon Company currently uses a Forest Products Laboratory (FPL) paste etchant for preparing aluminum surfaces for adhesive bonding, and FPL is a source of hazardous hexavalent chromium. The goal of this study was to evaluate a less-toxic P2 paste etchant as a possible replacement. Coupons of 2024-T3, 6061-T6, and 7075-T6 grades of aluminum alloy were solvent-degreased, abrasively cleaned, and etched at room temperature using P2 paste following a strict protocol adopted from Raytheon. Coupons were then left exposed to air for assigned time intervals (or “outlife” times) of 0, 1, 4, 8, 16, and 63 or 72 hours. The aluminum …

Characterization Of Laser Deposited Ti-6al-4v To Nb Gradient Alloys, Clincy Cheung

Materials Engineering

An alloy was fabricated with Ti-6Al-4V and Nb powder using laser deposition (LD) to form a compositional gradient. The gradient was deposited, starting with Ti-6Al-4V powder, onto a forged Ti-6Al-4V substrate in an Argon environment. Niobium (Nb) composition increased by 4-at.% with each layer deposited until the composition reached 100-at.% Nb. This process yielded steep thermal gradients and affected the microstructure and mechanical properties across the compositional gradient. To observe the microstructural changes in the alloy, an etched gradient was viewed with optical microscopy at 1000x, where the grain structure was observed to be an acicular α phase at 100-at.% …

Delamination Of C/Pekk I-Beam Using Virtual Crack Closure Technique And Cohesive Zone Method, Greeshma Ramakrishna

Open Access Theses

A damage study is conducted on a carbon epoxy/PEKK (poly-ether-ketone-ketone) thermoplastic composite I-Beam, with a pre crack of 100 mm modeled between the top flange and the filler (butt joint between filler and web). This project is in collaboration with Fokker Aerostructures, Netherlands and is part of the Thermoplastic Primary Aircraft Structure innovation program (TAPAS). The C/PEKK I-Beam is modeled after a section of the Gulfstream G650 aircraft's centre beam, which was previously a carbon fiber/epoxy hat-stiffened skin construction. The objective of the thesis is to identify if the crack propagates in the I-Beam within the load range that act …

Computational Fluid Dynamics Simulation Of Intracranial Aneurysms - Comparing Size And Shape, Zifeng Yang, Hongtao Yu, George P. Huang, Ryan Schwieterman, Bryan Ludwig

Mechanical and Materials Engineering Faculty Publications

Objective: To study the hemodynamics of an anatomic internal carotid artery aneurysm derived from a patient-specific model and then manipulate into two phantom morphologies: one growing uniformly by size and the other changing shape unevenly. Methods: The computational model of the saccular, internal carotid artery, aneurysm was constructed from 3D rotational, digitally subtracted, catheter angiography images. Computational fluid dynamics simulations were performed under pulsatile cardiac flow conditions. Velocity vectors, streamlines, pressure, and wall shear stress (WSS) and its variance distributions were quantitatively visualized. Results: The maximum pressure and WSS from the time-averaged distribution on the inside saccular surface of the …

A Multi-Scale Based Model For Composite Materials With Embedded Pzt Filaments For Energy Harvesting, A.E. El-Etriby, M.E. Abdel-Meguid, K.M. Shalan, Tarek Hatem, Yehia Bahei-El-Din

Centre for Advanced Materials

Ambient vibrations are major source of wasted energy, exploiting properly such vibration can be converted to valuable energy and harvested to power up devices, i.e. electronic devices. Accordingly, energy harvesting using smart structures with active piezoelectric ceramics has gained wide interest over the past few years as a method for converting such wasted energy. This paper provides numerical and experimental analysis of piezoelectric fiber based composites for energy harvesting applications proposing a multi-scale modeling approach coupled with experimental verification. The multi-scale approach suggested predicting the behavior of piezoelectric fiber-based composites use micromechanical model based on Transformation Field Analysis (TFA) to …

Shape Memory Behavior Of Single Crystal And Polycrystalline Ni-Rich Nitihf High Temperature Shape Memory Alloys, Sayed M. Saghaian

Theses and Dissertations--Mechanical and Aerospace Engineering

NiTiHf shape memory alloys have been receiving considerable attention for high temperature and high strength applications since they could have transformation temperatures above 100 °C, shape memory effect under high stress (above 500 MPa) and superelasticity at high temperatures. Moreover, their shape memory properties can be tailored by microstructural engineering. However, NiTiHf alloys have some drawbacks such as low ductility and high work hardening in stress induced martensite transformation region. In order to overcome these limitations, studies have been focused on microstructural engineering by aging, alloying and processing.

Shape memory properties and microstructure of four Ni-rich NiTiHf alloys (Ni50.3Ti29.7Hf20, Ni50.7Ti29.3Hf20, …

Hybrid Manufacturing Process Of SicF/Sic Composite Using Preceramic Polymer, Robert Raymond Meinders

Masters Theses

"Continuous fiber-reinforced silicon carbide (SiC_f/SiC) ceramic composites have been increasingly used due to their high temperature strength and graceful failure mechanisms. A disadvantage is the high cost and lengthy production processes that are required to develop these materials. Polymer infiltration and pyrolysis (PIP) is one of the most attractive fabrication processes for composites due to shape flexibility, mass production and relatively low cost; however, the quality of material obtained by this method has been considered insufficient due to the microstructure defects of the material obtained. This study investigated a hybrid of multiple polymer manufacturing processes to maximize quality …

Acoustic Emission Characteristics Of Damage Accumulation In Kevlar® 49 Composites, Eduardo Andrade

Open Access Theses & Dissertations

Acoustic emission (AE) data attained during tensile testing of epoxy impregnated Kevlar® 49 (K/Ep) composite strands were reduced and analyzed to monitor progressive damage accumulation during the approach to tensile failure. The K/Ep material tested in this study was chosen due to its similarity to the material-of-construction used in composite overwrapped pressure vessels (COPVs) used on the NASA Space Shuttle Orbiter. Insight into the progressive microstructural degradation of K/Ep strands was gained by monitoring AE event rate and energy. Source location based on energy attenuation and arrival time data was used to differentiate between significant AE attributable to microstructural damage …

Fatigue Damage Prognosis Of Internal Delamination In Composite Plates Under Cyclic Compression Loadings Using Affine Arithmetic As Uncertainty Propagation Tool, Audrey J-M Gbaguidi

Doctoral Dissertations and Master's Theses

Structural health monitoring (SHM) has become indispensable for reducing maintenance costs and increasing the in-service capacity of a structure. The increased use of lightweight composite materials in aircraft structures drastically increased the effects of fatigue induced damage on their critical structural components and thus the necessity to predict the remaining life of those components. Damage prognosis, one of the least investigated fields in SHM, uses the current damage state of the system to forecast its future performance by estimating the expected loading environments. A successful damage prediction model requires the integration of technologies in areas like measurements, materials science, mechanics …

Passive Phase Separation Of Microgravity Bubbly Flows Using Conduit Geometry, Ryan M. Jenson, Andrew Paul Wollman, Mark M. Weislogel, Lauren Sharp, Robert Green, Peter J. Canfield, Jörg Klatte, Michael E. Dreyer

Mechanical and Materials Engineering Faculty Publications and Presentations

The ability to separate liquid and gas phases in the absence of a gravitational acceleration has proven a challenge to engineers since the inception of space exploration. Due to our singular experience with terrestrial systems, artificial body forces are often imparted in multiphase fluid systems aboard spacecraft to reproduce the buoyancy effect. This approach tends to be inefficient, adding complexity, resources, and failure modes. Ever present in multiphase phenomena, the forces of surface tension can be exploited to aid passive phase separations where performance characteristics are determined solely by geometric design and system wettability. Said systems may be readily designed …

Digital Image Correlation Of Heterogeneous Deformations In Polycrystalline Material With Electron Backscatter Diffraction, Javier Esquivel

Open Access Theses

This work establishes the ability to conduct digital image correlation (DIC) investigations at varying length scales. DIC allows for a computational method of strain field measurements using multiple images to track random speckle patterns on material surfaces. The use of a powder silicon oxide speckle allows for high optical magnification correlation using conventional load frames. Self-assembling gold nanoparticles provide sub-micron resolution speckle patterns to study microstructure influences on deformation using scanning electron microscopy. The complex microstructure in aerospace grade aluminum and nickel-based superalloys, give rise to varied deformation fields, which can be studied using electron backscatter diffraction. Specimen preparation techniques, …

Mode I Fatigue Delamination Onset Of Carbon Fibre Reinforced Polymer With Novel Post-Cure Throughthickness Reinforcement, Christopher John Kourloufas

Open Access Theses

A novel trough thickness reinforcement (TTR) technique, proposed by Kravchenko et al., has been tested under mode I fatigue loading conditions in order to investigate characterisation of the onset of delamination growth in unidirectional 8552/IM7. The experimental results, following standard test method ASTM D6115-13, indicate that the mode I fatigue delamination onset behaviour can be altered by the inclusion of TTR both ahead and behind the crack tip. Tests have been conducted at a wide range of maximum displacement values, corresponding to percentages of the critical fracture toughness value determined for the maternal, GIC . The results were found …

Fiber Length And Orientation In Long Carbon Fiber Thermoplastic Composites, Imad Hanhan, Connor Sullivan, Bhisham Sharma, Michael Sangid

The Summer Undergraduate Research Fellowship (SURF) Symposium

Carbon fiber composites have become popular in aerospace applications because of their lightweight yet strong material properties. The injection molding process can be used to produce discontinuous fiber composites using less time and resources than traditional methods, thereby broadening carbon fiber composites’ applications in different industries. Utilization of longer fibers offers more load carrying capability and superior strength properties for injected molded composites. Since the fiber length and the orientation distribution in Long Fiber Thermoplastics (LFTs) directly affects LFT composites’ material properties, there is a need to study the microstructure of LFTs and characterize fiber length and orientation distributions. Therefore, …

Simulation Of Bio-Inspired Porous Battery Electrodes, Raju Gupta, R. Edwin Garcia, Rui Tu

The Summer Undergraduate Research Fellowship (SURF) Symposium

Advancement of technology has led to the increase in use of electronic devices. However, longer life of the rechargeable battery used in electronic devices is one of the biggest issue and demand in the world of electronic devices at present. Battery's performance is affected by the orientation, arrangement, shape and size, and porosity of the materials out of which battery electrodes are made. The goal of this project is to develop a set of numerical libraries that allow developing material micro structures that will allow increasing the performance of rechargeable batteries. We focused on the development of an algorithm that …

Dynamic Response Of Textile Material Under Transverse Impact, Yuchen Zheng, Matthew C. Hudspeth, Weinong W. Chen

The Summer Undergraduate Research Fellowship (SURF) Symposium

Textile materials, such as Dyneema and Kevlar, are the major raw materials for state of the art military or personal security armor vests. However, in impact experiments, actual observed penetration speed is much lower than theoretically predicted penetration speed. Each armor vest is composed of high performance yarns which are woven together to form fabrics, which when stacked together form a vest. Understanding penetration behavior of yarns is essential to evaluate the performance of fabric, which will be useful for the design of better vests. The project is composed of three parts: static experiments, dynamic yarn experiments and dynamic fabric …

Overview Of Instruments For Investigating Dust Interactions On Small Solar System Bodies By Landers And Rovers, Ryan L. Kobrick, Jeffrey A. Hoffman, Kenneth W. Street Jr., Douglas L. Rickman

Publications

Small Solar System bodies such as asteroids, comets and Mars' moons Phobos and Deimos have relatively unknown regolith environments. It is hypothesized that dust preserved in the regolith on the surfaces will have similar mechanical properties to lunar dust because of similar formation processes from micrometeoric bombardment, low relative gravity for slow settling times, and virtually no weathering because there is no atmosphere.

Influence Of Grain Size And Widmanstätten Colonies On Variability Of Tensile Properties Of Forged Ti-6al-4v, Blake T. Gaspar

Master's Theses

When testing forgings for specifications, it was found that some parts did not meet the requirements for mechanical properties. This triggered an investigation into two of the parts from the lot that did not meet specification. The ultimate reason for failure was due to lower than necessary yield strength and ultimate tensile strength values, as well as unwanted variability between regions of the part. Therefore, samples of the regions were tensile tested to determine the differences that existed in yield strength, ultimate tensile strength, and elongation. After tensile testing, quantitative metallography and fractography were conducted to identify aspects of the …

An Investigation Into The Properties And Fabrication Methods Of Thermoplastic Composites, Ann E. Livingston-Peters

Master's Theses

As applications for thermoplastic composites increase, the understanding of their properties become more important. Fabrication methods for thermoplastic composites continually improve to match designs specifications. These advanced thermoplastics have begun to show an improvement in mechanical properties over those found in thermoset composites commonly used in industry. Polyaryletherketones (PEK) have high service temperatures, good mechanical properties, and improved processing capabilities compared to thermoplastics used in the past making them important to the aerospace industry. The wide range of types of PEK make them suitable for a variety of applications, but selection of specific chemistries, processing parameters, and composite stack-ups determine …

Blast Energy Mitigation In Porous Rocks, Brittany Corinne Essink

Open Access Theses

Geo-materials are commonly used and sought after for blast mitigation applications due to their wide availability and low cost compared to industry trademarked materials. Characterization of these natural geo-materials such as volcanic rocks is of paramount importance in determining their blast mitigation capabilities. While there is a large amount of information available for materials such as concrete or sand blasts, information on the properties of volcanic rocks is far more scarce. This lack of data is due to the wide range of existing natural volcanic rocks and the variation in the minerals and pore structures of the rocks.

In this …

Post-Fracture Capacity Of Railroad Flat Car Bridges, Teresa L. Washeleski

Purdue Road School

Railroad flatcars (RRFCs) are a convenient option to replace existing deteriorating bridge structures on low-volume roads. They are typically used as the bridge superstructure by placing two or more flatcars side-by-side to achieve the desired bridge width. Utilizing RRFCs as a bridge allows for rapid construction and greater cost savings compared to traditional practices. These benefits make them an attractive solution for rural communities in Indiana, as well as other states.

Uncertainty remains about the response under higher loads than could be easily achieved in the field and the level of redundancy of railroad flatcar bridges. Using RRFCs as bridges …

Post-Failure Capacity Of Built-Up Steel Members, Matthew H. Hebdon

Purdue Road School

Mechanically fastened built-up steel members have long been known to possess internal member redundancy and, as a result, multiple load paths which can be exploited to increase their functional life. Internal redundancy provides the ability to resist total member failure in the event of a fracture of an individual component. However, there is little experimental data in the literature regarding post-fracture capacity in terms of strength and subsequent fatigue life. The experimental study currently underway will provide needed information on parameters that affect the ability of built- up members to arrest a fracture as well as the available remaining fatigue …

Precipitation, Orientation And Composition Effects On The Shape Memory Properties Of High Strength Nitihfpd Alloys, Emre Acar

Theses and Dissertations--Mechanical and Aerospace Engineering

NiTiHf high temperature shape memory alloys are attractive due to their high operating temperatures (>100 ^oC) and acceptable transformation strain compared to NiTi. However, NiTiHf has limitations due to their lack of ductility and low strength, resulting in poor shape memory properties. In this study, Pd has been added to NiTiHf alloys in an attempt to improve their shape memory behavior. A combined approach of quaternary alloying and precipitation strengthening was used.

The characterization of a Ni_45.3Ti_29.7Hf₂₀Pd₅ (at. %) polycrystalline alloy was performed in compression after selected aging treatments. Transmission electron …

Investigation Into The Effects Of Wire Mesh On Tensile And Impact Properties Of Fiber Metal Laminates, Shivani A. Rudradat

Doctoral Dissertations and Master's Theses

An investigational study was conducted into the tensile and impact behavior of Fiber Metal Laminates by combining 5052 aluminum mesh or2024-T3 aluminum sheets,2.47 N (8.9 oz) or 6.67 N (24 az) ShieldStand^® S fiberglass, and Hysol EA 9313 epoxy. Testing was performed under the guidelines of ASTM D3039-00 utilizing an lnstron 8802 Servohydraulic Materials Testing Instrument for tensile tests and ASTM D3763-06 utilizing an Inston 9250 HV Dynatup Impulse Impact Testing System for impact tests. Samples were strained at arate of 2 mrn/min for tensile tests and impacted with enetgies of 10 to 40 J in l0 J increments …

Mode I Fracture Toughness Of Eight-Harness-Satin Carbon Cloth Weaves For Co-Cured And Post-Bonded Laminates, Josh E. Smith

Master's Theses

Mode I interlaminar fracture of 3k 8-Harness-Satin Carbon cloth, with identical fill and weft yarns, pre-impregnated with Newport 307 resin was investigated through the DCB test (ASTM D5528). Crack propagations along both the fill and weft yarns were considered for both post-bonded (co-bonded) and co-cured laminates. A patent-pending delamination insertion method was compared to the standard Teflon film option to assess its applicability to mode I fracture testing. The Modified Beam Theory, Compliance Calibration method, and Modified Compliance Calibration method were used for comparative purposes for these investigations and to evaluate the validity of the proposed Equivalent Stiffness (EQS) method. …

Validation Of Long-Fiber Thermoplastic Composite Models, Christian A. Vuong, Megan Kinney, Michael Sangid

The Summer Undergraduate Research Fellowship (SURF) Symposium

With increased pressure to reduce energy consumption, long-fiber reinforced thermoplastic composites (LFTs) are of interest to aerospace and automotive industries due to their light weight in combination with other desirable mechanical properties and ease of manufacturing to replace common materials such as aluminum and magnesium. However, the performance of LFTs is highly dependent on microstructural variables such as fiber length and orientation, which are heavily influenced by the manufacturing process. Accurately predicting these factors would allow for more rapid advances in LFTs by reducing the experiments needed for certification and decreasing expenses. While models that serve this purpose exist, the …

The Comparison Of Composite Aircraft Field Repair Method (Cafrm) With Traditional Aircraft Repair Technologies, Peng Hao Wang

Open Access Dissertations

In the aviation industry, manufacturers made the transition from aluminum to composite materials for the majority of their primary structures over the last few decades. While the design and manufacturing techniques have consistently evolved, field repair methods were consistently overlooked. In this study, specimens fabricated using some of the common repair methods such as the autoclave repair method, and Double Vacuum Debulk (DVD) repair method were tested against the Composite Aircraft Field Repair Method (CAFRM) proposed by the researcher. Specimens were tested with microscopy, acid digestion, short beam shear, and mode I fracture tests. The researcher was able to determine …

Solution To Certain Problems In The Failure Of Composite Structures, Jonathan Goodsell

Open Access Dissertations

The present work contains the solution of two problems in composite structures. In the first, an approximate elasticity solution for prediction of the displacement, stress and strain fields within the m-layer, symmetric and balanced angle-ply composite laminate of finite-width subjected anticlastic bending deformation is developed. The solution is shown to recover classical laminated plate theory predictions at interior regions of the laminate and thereby illustrates the boundary layer character of this interlaminar phenomenon. The results exhibit the anticipated response in congruence with the solutions for uniform axial extension and uniform temperature change, where divergence of the interlaminar shearing stress is …

Applicability Of Continuum Fracture Mechanics In Atomistic Systems, Shao-Huan Cheng

Open Access Dissertations

By quantitating the amplitude of the unbounded stress, the continuum fracture mechanics defines the stress intensity factor K to characterize the stress and displacement fields in the vicinity of the crack tip, thereby developing the relation between the stress singularity and surface energy (energy release rate G). This G-K relation, assigning physical meaning to the stress intensity factor, makes these two fracture parameters widely used in predicting the onset of crack propagation. However, due to the discrete nature of the atomistic structures without stress singularity, there might be discrepancy between the failure prediction and the reality of nanostructured materials. Defining …

Fatigue Testing And Data Analysis Of Welded Steel Cruciform Joints, Alina Shrestha

LSU New Orleans Theses and Dissertations

In this study, ABS Publication 115, “Guidance on Fatigue Assessment of Offshore Structures” is briefly reviewed. Emphasis is on the S-N curves based fatigue assessment approach of non-tubular joints, and both size and environment effects are also considered. Further, fatigue tests are performed to study the fatigue strength of load-carrying and non-load-carrying steel cruciform joints that represent typical joint types in marine structures. The experimental results are then compared against ABS fatigue assessment methods, based on nominal stress approach, which demonstrates a need for better fatigue evaluation parameter. A good fatigue parameter by definition should be consistent and should correlate …