Aerospace Engineering Commons^™

Crushing Behavior Of Crash Boxes With Hybrid Honeycomb–Auxetic Fillers: Effects Of Architecture, Geometry, And Material Behaviors, A. Yudhanto, A. Jusuf, L. D. Lumanauw, M. Falyanzhuri, A. Afdhal

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additively manufactured (AM) fillers provide new opportunities to tailor the crushing response and energy absorption of thin-walled metallic crash boxes. This study presents a combined experimental–numerical investigation of hexagonal AA6063-T4 crash boxes filled with architected structures, i.e., honeycomb, auxetic-reentrant, and hybrid honeycomb–auxetic topology. The hybrid configuration, which integrates cells with positive and negative Poisson's ratios, triggers coordinated mechanisms (that enhance folding behavior and collapse control) unattainable via single topology. Quasi-static axial compression tests were conducted to characterize force–displacement curves, deformation mechanisms, energy absorption (EA), and specific energy absorption (SEA). Finite element models developed in the explicit solver LS-DYNA were employed …

Payload Selection To Correlate Shielding Performance With Molecular Structure And Elemental Composition For Rosisat: The Radiation Orbital Shielding Investigation Satellite, Chase Patterson, Jacob L. Blanton, Kylie Nager

Beyond: Undergraduate Research Journal

Exposure to space weather in the Low Earth Orbit (LEO) environment poses significant challenges to both the integrity and longevity of orbital hardware, as well as the health of astronauts, driving the necessity for improved means of radiation shielding for future missions. With a 1U CubeSat formfactor, ROSISat is a planned LEO mission that aims to characterize the radiation shielding capabilities of seven candidate materials: ultra-high molecular weight polyethylene, boron nitride, carbon nanotubes, boron nitride nanotubes with polyethylene fibers, carbon fiber reinforced composite, and aerographene, as well as two control materials: aluminum 6061 and ep33. By comparing the shielding performance …

Optimization Of Co₂ Removal In Carbon Dioxide Removal Assembly (Cdra) Using Nonlinear Equilibrium Modeling And Zeolite-Based Adsorption Simulation, Frányerson R. López Ochoa

Discovery Day - Daytona Beach

This study follows a quantitative, non-experimental, existing-data design to examine the optimization of carbon dioxide removal in spacecraft’s Carbon Dioxide Removal Assembly (CDRA) through the integration of nonlinear isotherm modeling and process-level cycle simulation. Existing carbon dioxide adsorption equilibrium data from multiple zeolite sorbents, including Grace Davison Grade (544 13X, 522 5A, and 514 4A), Honeywell UOP (APG-III, LiLSX VSA-10), and BASF 13X, is analyzed to determine which adsorption models best represent carbon dioxide loading behavior and how these models can be used to reduce energy consumption in spacecraft regeneration processes. The study fitted eight nonlinear isotherm models – Langmuir, …

Enhancing Fibre–Matrix Interface Properties In Cfrps Using Cohesive Zone Modelling, Arjun Myadam, Alexander Skoppe

Discovery Day - Daytona Beach

Carbon fibre reinforced polymers (CFRPs) are extensively used in aerospace, automotive, and structural applications owing to their high specific strength, stiffness, and design flexibility. The mechanical performance of these composites is critically governed by the fibre–matrix interface, which controls stress transfer and directly influences damage initiation, crack propagation, and fracture behaviour. The interface strength is quantified through the interfacial shear strength (IFSS) and fracture energy, both serving as key indicators of composite integrity. Nanoscale fibre surface modifications are widely employed to enhance interfacial bonding and can also impart multifunctionality, such as capacitive properties, magnetic behaviour, and piezoelectricity. For instance, nanoscale …

N31 Multi-Sensor Data Fusion For Enhanced Cislunar Space Domain Awareness Using Radar And Optical Observations, Lucas Bottero

Discovery Day - Daytona Beach

MULTI-SENSOR DATA FUSION FOR ENHANCED CISLUNAR SPACE DOMAIN AWARENESS USING RADAR AND OPTICAL OBSERVATIONS   As operations extend into cislunar space, maintaining Space Domain Awareness (SDA) becomes increasingly challenging due to the vast distances, sparse infrastructure, and complex gravitational dynamics between Earth and the Moon. Radar and optical sensors are the primary modalities used for space surveillance, each with its strengths and limitations. Radar offers continuous observation capabilities regardless of lighting conditions but is limited by power and range at cislunar distances. Optical sensors provide high angular precision but depend on favorable illumination and line-of-sight geometry. However, there has been limited …

Vibration And Thermal-Vacuum Feasibility For Micro Carbon Fiber Filled Nylon Filament Lunar Applications, Andrew Murphy, Shannon O'Sullivan, Daniel Lopez

Discovery Day - Daytona Beach

The proposed work seeks to improve the fundamental understanding of the properties concerning 3-D printing filaments that have potential to be used for lunar applications. The associated properties in focus for the proposed study, vibration and thermal-vacuum-resistance, are fundamental aspects of spaceflight and are critical to mission success for objectives associated with the environmental factors in space. The successful outcome of the proposed work will answer questions relating to the feasibility of micro carbon fiber filled nylon 3-D printing filaments such as Markforged’s Onyx® for application for projects in the Space Technologies Laboratory, including for the development of structures relating …

Policy Brief: Satellite Resiliency Against Nuclear Detonation In Space, Brianna Johnshon, Samantha Harper, Tyler Thompson

Discovery Day - Daytona Beach

The deployment of nuclear weapons in space poses an arms challenge that is both critically important and inherently ambiguous. Although Article IV of the 1967 Outer Space Treaty (OST) explicitly prohibits placing nuclear weapons or other weapons of mass destruction in orbit (UNOOSA, 1966), recent developments suggest that this prohibition is not absolute. In 2024, the U.S. and Japan brought concerns regarding WMD in space to the UN Security Council, calling on states to work to prevent an arms race in space and agree not to place nuclear weapons and WMD in orbit (United Nations Security Council, 2024). However, this …

Project Nightshade: Carrier-Based Multirole Navy Strike Fighter Aircraft, Matthew Kaplan, Alex Gardner, Adam Wanner, Sara Gonzalez, Joseph Deleo, Canyon Swaffar

Discovery Day - Daytona Beach

Project Nightshade: Detail Design for a Carrier-Based Multirole Strike Fighter This project focuses on the structural detail design of the wing box for a carrier-based multirole strike fighter, emphasizing strength, stiffness, and fatigue resistance under maneuver and carrier landing loads. The objective is to develop a structurally efficient configuration capable of supporting critical loading conditions while maintaining realistic weight and structural integrity. Classical aerospace structural analysis methods were used to size primary load-carrying components including spar caps, shear webs, and skin panels. Maneuver and gust load cases were applied to determine internal shear forces and bending moments, enabling calculation of …

Zfq-50 "Radiance", Craig Slovensky, Michael Rath Iii, Kyan Spaete, Long P. Nguyen, Woo Hyun Lee, Roman Czerniejewski

Discovery Day - Daytona Beach

This project presents the preliminary design of the ZFQ-50 "Radiance", a Collaborative Unmanned Vehicle (CUV) built around the VerdeGo VH-5 blended turbofan intended for military defense applications. This design presents a novel aircraft coupled with a powerplant that blends traditional combustion thrust with electrical power output, an new and evolving capability within the aerospace industry. This aircraft was sized considering multiple constraint parameters, configuration trade studies, CFD analysis, and mission requirements including carrier assisted take-off and landing, an effective operational range, and a loiter period with 40 kW of continuous power output from the powerplant. The selected configuration allows for …

Project Chimaera: Development Of A Tessellated Tetrahedral Truss Structure For Adaptive Multi-Regime Morphing Wing Technology, Evan Meyer, Eric Rodarte, Maximo Failla, Joshua Shuster, Jackson G. Schuler

Discovery Day - Daytona Beach

Project Chimaera: Physical Assembly of tessellated tetrahedral wing for Multi-Regime Flight. Modern Aircrafts lose aerodynamic efficiency because they are primarily made utilizing fixed wings which are designed for a single optimal flight condition. This forces an aircraft’s performance to become compromised across various speed maneuvers and flight regimes. Project Chimaera addresses this limitation through the development of a morphing wing capable of dynamically changing its geometry extensively during flight to allow an aircraft to travel between subsonic, supersonic, and hypersonic speeds. Whereas traditional wings rely on wing flaps and other flight controls; Project Chimaera addresses the limitation of flight controls …

Modeling The Effect Of Damping On Mechanical Vibrations In An Aircraft Wing, Daniel Ingleton, Ethan Burrell, Noah Evans

Discovery Day - Daytona Beach

Aircraft wings experience vibrations during flight due to aerodynamic forces, turbulence, engine effects, and the flexibility of the structure itself. If these vibrations are not properly controlled, they can affect the wing’s performance, structural life, and overall aircraft safety. This research project focuses on modeling how damping reduces mechanical vibrations in an airplane wing. To make the problem manageable, the wing will be represented as a simplified cantilever beam. The project will examine how damping, stiffness, and mass influence the wing’s vibration response over time. Using mathematical equations of motion and simulation tools such as MATLAB or ANSYS, the study …

Simulation-Based Analysis Of Aeroelastic Flutter Using A 2-Dof Mass–Spring–Damper Model, Jamie Shore, Jose Murphy, Emily Brown, Leia Vargas Ii, Carl Pellegrino

Discovery Day - Daytona Beach

This research project focuses on utilizing a mass-spring dampening system to analyze wing flutter. Given that wing flutter is an instability caused by elastic and inertial forces, these create increasing oscillations that lead to structural failure. Our group will create a simulator developed in MATLAB to analyze data on how different variables such as angle of attack, aspect ratio and wind speed influence the flutter. The simulation will help us to determine how flutter is affected by mass, structural stiffness, and the damping coefficient on several materials. These materials include aluminum 6061, birch wood, steel 36, and tungsten. The goal …

Global Time-Resolved Measurements Of Inlet/Isolator Unstart Induced By Mass Injection, Andrew N. Bustard, Benjamin L. Bemis, Aaron Marques, Matthew J. Zahr, Thomas J. Juliano

Publications

The inner surface pressure of an axisymmetric inlet/isolator model was measured using anodized-aluminum pressure-sensitive paint (PSP) viewing through cast acrylic. Temperaturesensitive paint was utilized to correct for the PSP’s temperature sensitivity. The model was tested under Mach 5.7 flow at 𝑹𝒆 = 7.1 ×106 /m under conventional noise conditions. Transverse jet injection with jet-to-inlet mass-flow ratios up to 0.8 was used to induce unstart in the inlet/isolator. Background-oriented schlieren visualization of the inlet shocks was collected simultaneously with the PSP to determine when the inlet unstarted. Computational fluid dynamics results were used to determine off-wall flow structures and quantify approach …

Tailoring Crushing Responses Of Hexagonal Crash Box Filled With Additively Manufactured Lattice Structures By Assessing The Influence Of Material Parameters, L. D. Lumanauw, A. Jusuf, M. H. Jarwadi, L. Gunawan, T. Sebaey, A. Yudhanto

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Hexagonal crash boxes offer superior crashworthiness compared to other cross-sectional geometries, and their performance can be further enhanced by integrating additively manufactured lattice fillers. This study investigates the quasi-static crushing behavior of hexagonal crash boxes filled with hexagonal close-packed (HCP) lattice structures fabricated via stereolithography (SLA). Finite element models developed in ABAQUS/Explicit, validated against quasi-static compression experiments, show discrepancies below 5%, indicating that polymeric lattice fillers provide modest performance gains, achieving a crushing force efficiency (CFE) of 20%–25%. Replacing polymeric lattices with metallic fillers, namely 316L stainless steel and Ti–6Al–4V titanium alloy, substantially increases energy absorption, with Ti–6Al–4V delivering the …

A Comparative Evaluation Of Experimentally Validated Finite Element Modeling Strategies To Simulate Compression-After-Impact Behavior Of Multidirectional Cfrp Laminates With Barely Visible Impact Damage, Niildiip Chandraa, Vinh Tung Le, Arief Yudhanto, Abhendra K. Singh, Douglas E. Smith

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Abstract The finite element-based approaches to predict compression-after-impact (CAI) performance of carbon fiber reinforced polymer (CFRP) subject to a low-velocity impact rely on assumptions about compressive failure mechanisms within the barely visible impact damage (BVID). Comprehensive evaluations of finite element (FE) models concerning accuracy, efficiency, and validity with respect to experimental tests are limited. This study explores several finite element-based approaches developed in ABAQUS Explicit to predict the residual strength and related compressive failure mechanisms of multidirectional CFRP laminates. Drop-weight impact experiments followed by CAI tests employing 3D Digital Image Correlation (DIC) were used to validate our FE models by …

Direct Ink Writing Of Functional Fiber/Granular Composites, Zhuoyuan Yang

Doctoral Dissertations and Master's Theses

Direct ink writing provides a versatile manufacturing route for fabricating functional fiber and granular composites with controlled architecture, tunable interfaces, and customized material distributions. Fiber reinforced composites offer high stiffness, strength, fatigue resistance, and functional anisotropy, while granular composites provide scalable access to particle based structures with high material efficiency and broad resource compatibility. However, the additive manufacturing of these composite systems remains challenging. For fiber based composites, precise control of fiber placement, matrix impregnation, interfacial bonding, and freestanding deposition is difficult to achieve during printing. For granular composites, stable particle flow, controllable packing, binder infiltration, and shape retention are …

Cohesive Zone Modelling Of Fiber–Matrix Interface In Composite Materials, Arjun Myadam

Doctoral Dissertations and Master's Theses

Carbon Fiber reinforced polymers (CFRPs) are widely used in aerospace, automotive, and structural applications due to their high specific strength, stiffness, and design flexibility. Their mechanical performance is critically governed by the fiber–matrix interface which controls stress transfer and directly influences damage initiation, crack propagation, and fracture behaviour. The interface properties are quantified through the Interfacial Shear Strength (IFSS) and fracture energy, both serving as key indicators of composite integrity. Effective interfacial bonding is therefore essential to the composite’s strength. Nanoscale fiber surface modifications provide a promising approach to enhance interfacial bonding and can also impart multifunctionality. These multifunctionalities can …

Advancing Sensing And Structural Health Monitoring Of Non-Conventional Space Structures, Scott Bender

Doctoral Dissertations and Master's Theses

Future lunar and deep-space missions will require new structural concepts that reduce mass while maintaining reliability. Two technologies that have received significant attention are inflatable habitats and additively manufactured structures; however, challenges remain in their characterization, validation, and long-term monitoring. This dissertation investigates methods to improve the testing and sensing of these non-conventional aerospace structures through the use of advanced photogrammetry and embedded distributed fiber-optic sensors. A color-filtering digital image correlation technique was developed to isolate orthogonal strain directions in woven inflatable structures, providing improved characterization of biaxially loaded softgoods. In addition, methods were developed to embed distributed fiber-optic sensors …

Mars Rover Wheels And Drive, Presley S. Sacavitch, Ryan W. Trevena, Dylan A. Mack, Daniel Hudak

Mechanical Engineering

Cal Poly’s Poly1Rover team, advised by Professor Rich Murray, aims to deploy four student-designed mini-Mars rovers, each equipped with a sample-tube retrieval claw, before 2030. However, the wheels of Poly1Rover’s current 6th generation rover are not ready for deployment to Mars, as they do not utilize space-grade materials, are not optimized for manufacturability, and lack sufficient spoke compliance to absorb landing and high-impact loads. This project will be developed by a team of Mechanical Engineering students at California Polytechnic State University, San Luis Obispo (Cal Poly): Daniel Hudak, Dylan Mack, Presley Sacavitch, and Ryan Trevena. Next Intent is providing funding …

Effects Of Atomic Oxygen Exposure On Stressed Drag Sail Materials For Low Earth Orbit Applications, Nazanin Sadeghian Dezaki

Master's Theses

As low Earth orbit (LEO) has become an increasingly valuable region for satellite operations, it has grown increasingly congested. The Federal Communications Commission (FCC) deorbit regulations require satellites to be deorbited within 5 years of launch, and drag sails represent a practical means of meeting this requirement. An important consideration for drag sail design is the effect of atomic oxygen (AO) on sail materials. To address the gap in the literature regarding the behavior of stressed drag sail materials under AO exposure, a new test plate was manufactured for the California Polytechnic State University minimum atmospheric experimentation (MAX) AO chamber. …

Hamster: Hybrid-Actuated Mobile Spherical Terrain Exploration Rover, Winnie Gao

Master's Theses

The expansion of space exploration to increasingly challenging planetary environments requires mobility systems capable of extreme traversal capabilities and operational reliability. This thesis presents the design, development, and testing of a low-cost Hybrid-Actuated Mobile Spherical Terrain Exploration Rover (HAMSTER) intended for use on a planetary surface exploration mission. HAMSTER uses a pendulum-based actuation method for steering and an actuated internal shaft to propel the vehicle forward. The internal structure includes a two-tiered central case composed of the navigation control module, accelerometer, motor controller, primary DC motor, battery, voltage regulators, Raspberry Pi, pendulum servo motor, and drive shafts. Additive manufacturing through …

Improving The Reliability And Performance Of A Supersonic Indraft Tube Wind Tunnel, Christian J. Kaml

Master's Theses

Access to supersonic testing is increasing in demand, and wind tunnels remain one of the safest and most cost-effective methods for gathering high-speed flow data. Despite being more economical than alternative options, supersonic wind tunnel facilities often require substantial investment to construct, operate, and maintain.

The novel indraft tube tunnel architecture was conceived as a high-speed flow testbed that incorporates features of both Ludwieg tubes and indraft wind tunnels to maintain costs low enough to be accessible even to small universities. This design was first developed and tested in 2018 at California Polytechnic State University, featuring a cost per test …

Sentience, Sheetal Agrawal

Masters Theses

The increasing urgency for sustainable and adaptive systems has driven research toward embedding intelligence directly into materials rather than relying solely on external sensing and control systems. This thesis explores how smart material1 embedded systems can be designed to recognize and respond to environmental signatures, defined as measurable patterns such as temperature fluctuations and mechanical forces. Central to this investigation is the integration of shape memory alloys, particularly Nitinol, with geometry-based actuation mechanisms that amplify material behavior into functional system responses.

The central argument is that designing with smart materials is a design problem, not primarily a materials science problem …

Trussworthy - A Lunar Module Truss System, Anthony Wehrli, Sebnem Kalayci, Tyler Williams, Sofia Lopez-Linares Perez, Connor Mcdonagh, Presley Robb

Undergraduate Research and Scholarship Symposium

TrussWorthy is a modular truss-based construction platform designed to support the gradual development of sustainable infrastructure on the lunar surface. Aligned with NASA’s Moon to Mars objectives, the system emphasizes in-situ resource utilization (ISRU) by transforming lunar regolith into structural components through sintering and additive manufacturing. By reducing dependence on Earth-supplied materials, TrussWorthy aims to lower launch costs while enabling scalable, long-term construction capabilities. The design integrates autonomous excavation, 3D printing, and robotic assembly, building on technologies expected from upcoming Artemis and Commercial Lunar Payload Services missions. Engineered to withstand extreme thermal cycling, vacuum conditions, and reduced lunar gravity, the …

Lunar Regolith Sintered Brick Apparatus, Andrew Fasano, Noah Parayil, Darius Felix Karra

Senior Design Project For Engineers

This project describes the preliminary design and analysis of the Semi-Autonomous Lunar Regolith Sintered Brick Apparatus that will assist in developing permanent infrastructure on the Moon. An issue with permanent lunar operations is the transportation of materials to the Moon. To address this, the designed device uses lunar regolith as the source material for producing bricks. This design considers the constraints set for operation with the Griffin lunar lander: maximum payload mass of 200 kg, power consumption below 5 kW, and limited payload dimensions. The design uses a combination of a laser sintering motion system, a regolith layering subsystem, a …

Stabilized Cargo Relay Aircraft For Precision Payload Yielding, Dato A. Tabidze, Michael Conely, Ben Courtney

Senior Design Project For Engineers

As military missions become more complicated, warfighters need more capable drones to use across diverse scenarios. The same also applies to civilian applications, like infrastructure inspection, package delivery, and disaster response. Current multirotor drones, also known as unmanned aircraft systems (UAS), provide simplicity, affordability, and ease of operation; however, their primary limitation is their low payload-to-weight ratio, which typically falls at 1:1 or less. The DARPA Lift Challenge aims to shatter the heavy lift bottleneck, seeking novel drone designs that can carry payloads more than four times their weight, which would revolutionize the way we use drones across all sectors. …

Experimental Investigation Of Mode-Ii Interlaminar Fatigue Damage In Stitched And Unstitched End-Notched Flexure Carbon Fiber Composites, Madelyn Sloan Berry

Honors Theses

Composite materials are increasingly used in aerospace structures due to their high strength-to-weight ratio, but their susceptibility to interlaminar fatigue damage remains a critical concern, particularly under mode-II shear loading. This study investigates the fatigue behavior of stitched and unstitched quasi-isotropic carbon fiber composite specimens made of SAERTEX Class-75 non-crimp fabrics and Hexcel 1078-1 epoxy via vacuum assisted resin transfer molding. Global fatigue behavior was analyzed using displacement and crack length cycle relationships derived from compliance calibration methods (CCM), while local behavior was examined using digital image correlation (DIC). Unstitched specimens exhibited a single rapid crack growth associated with unstable …

Instrumentation And Control Of A Novel Device To Simulate A Hypersonic Environment, Andrew Marcello

Doctoral Dissertations and Master's Theses

The hypersonic flow regime poses several challenges regarding the design of hypersonic vehicles. Among them is the massive energy and economic expense associated with ground- testing evaluation of material responses within this extreme environment. In order to provide a low-cost, rapid option for preliminary material analysis within hypersonic applications, a novel device is under production to replicate this environment on the surface of these materials. This device has been designed to work in conjunction with Argonne National Laboratory (ANL) Advanced Photo Source (APS) synchrotron, to allow for in-situ characterization of ablation and oxidation on the sample surface.

To achieve this, …

Reinforcement Learning - Driven Satellite Attitude Recovery: Unknown Faults, Simulation-To-Processor In Loop, Chinmay Mirji, Saeed A Ahmadi

Student Research Symposium (SRS)

Conventional attitude control algorithms often degrade when faced with actuator faults, sensor noise, or system uncertainties. This work presents a reinforcement-learning (RL) framework for satellite attitude recovery under unknown failures, focusing on real-time deployment through a processor-in-the-loop (PIL) setup. A continuous-control DDPG agent is trained in a high-fidelity Python/Basilisk simulation environment, where domain randomization captures variations in inertia, external torque, and actuator limitations to promote robust policy learning.

Conceptual Exploration Of Film Cooling Techniques In Hydrogen Gas Turbines, Wen Wu

Student Research Symposium (SRS)

Film cooling is a key heat transfer technique that protects gas turbine blades from extreme temperatures, allowing higher turbine inlet temperatures and greater thermal efficiency. It works by ejecting a thin layer of cooler air from the compressor through small holes onto the hot surface, creating a protective film layer that lowers surface temperature and reduces thermal stress on blades. This process is vital in power generation and propulsion systems that operate near material limits. With growing emphasis on sustainability, film cooling has gained new importance in hydrogen-fueled gas turbines. Hydrogen combustion creates water vaper and low-density exhaust gases, which …