Aerospace Engineering Commons^™

Impact Of Uncertainties On Structures Damage Tolerance Parameters, Breno De Bruns

Doctoral Dissertations and Master's Theses

This research aims to enhance the understanding and management of aerospace structural integrity. Traditional fracture control methods, such as damage tolerance analysis (DTA), assume deterministic factors, considering uncertainties inherent in material properties, inspections, and operational conditions only at the final stage by applying safety factors. This research seeks to incorporate these uncertainties throughout the analysis by integrating Monte Carlo simulation with Linear Elastic Fracture Mechanics (LEFM). The objective is to investigate how varying parameters affect crack growth prediction and the effectiveness of inspection strategies. The methodology involves systematically analyzing inspection intervals, considering factors like material properties, probability of detection (POD), …

Design For Additive Manufacturing: Simultaneous Optimization Of Structural Integrity And Minimal Support Structures, Naresh Ahuja

Doctoral Dissertations and Master's Theses

This dissertation addresses two core challenges limiting the widespread application of Topology Optimization (TO): the difficulty in fabricating its complex designs, especially for Additive Manufacturing (AM), and its significant computational costs. It develops a unified design framework that directly embeds AM constraints such as overhang angles and build direction into robust TO formulations. To enhance manufacturability, two distinct methodologies are proposed. Firstly, a Solid Isotropic Material with Penalization (SIMP) framework introduces a three-stage robust optimization algorithm. Secondly, the Geometric Projection Topology Optimization (GPTO) method inherently integrates overhang constraints by controlling individual geometric components and their inclined angles relative to a …

Research Into Technological Features In The Curring Process Of Multilayer Polymer Composite Parts, Umidbek Dilshod Ugli Kosimov, Jonibek Kobilovich Tokhirov, Andrey Dmitrievich Novikov

Technical science and innovation

This paper examines the main technologies and mechanisms used in the curing process of multilayer thick-walled parts of unmanned aerial vehicles (UAVs) made of polymer composite materials (PCM) based on epoxy resin. The study provides a detailed analysis of the technological features of the curing process, its kinetics, and the influence of heat transfer mechanisms on the final quality of molded components. It is emphasized that due to the low thermal conductivity of PCM, temperature inhomogeneity may occur during curing, leading to defects, internal stresses, and deterioration of the mechanical properties of the product. Therefore, ensuring uniform temperature distribution throughout …

Analyzing The Interfacial Properties Of Natural Fiber Composites, Rahul Kumar Arram

Doctoral Dissertations and Master's Theses

In response to growing environmental concerns and the urgent demand for sustainable development, the composite materials industry is increasingly challenged to balance high performance with environmental responsibility. Conventional composites, typically composed of synthetic fibers and petroleum-based resins, offer outstanding mechanical properties but are associated with significant ecological drawbacks due to their non-biodegradable nature and energy-intensive production. This has led to increased interest in the development of sustainable composites that minimize environmental impact without compromising functionality. This study presents the development of eco-friendly composites reinforced with natural bast fibers—specifically ramie and jute—through a comprehensive program of materials processing and characterization. To …

Towards Accountability: A Primer On The Space Debris Problem And An Overview Of The Legal Issues Surrounding It, William Schonberg

Civil, Architectural and Environmental Engineering Faculty Research & Creative Works

Since 1957, the near-Earth population of trackable space objects has grown in number to over 36,000. Of these 36,000+ trackable objects now in low Earth orbit, just a few thousand are working spacecraft. The rest are Earth-orbiting objects which are no longer operational and are considered to be space junk. Because this junk can no longer receive maneuvering commands from its Earth-based owners, the survivability of other spacecraft traveling through or operating in Earth orbit can be jeopardized by the impacts of any number of pieces of this space junk, whose origins can usually be traced back to defunct satellites. …

Mno2 Nanoscale Interface Modification, Alexander C. Skoppe

Doctoral Dissertations and Master's Theses

Interface modification of carbon fibers has been shown to improve the mechanical performance of composites. In addition, interface modification of carbon fiber composites can impart multifunctionality into the resulting composite. This work will explore ZnO and MnO2 as interface modifications for use on carbon fibers. When exposed to high temperatures, carbon fibers undergo fiber degradation, leading to the need for low-temperature hydrothermal processes. This work will develop and characterize a nanoscale ZnO and MnO2 interface modification for use on carbon fibers. These nanomodifications will be developed with low-temperature processes, minimizing the fiber degradation that the fibers undergo. Fourier transform infrared …

Self-Regulated Thermal Management With Shape-Memory Alloy Torsional Tubes, Paula Sanjuan Espejo

Doctoral Dissertations and Master's Theses

The need for dynamic thermal management that adapts to varying system needs and requirements is a growing topic of interest in different engineering disciplines, most prominently aerospace and electronics. This demand for improved thermal management systems comes from the general increase of system efficiencies leading to an increase in component energy density. Shape-memory alloy actuators, which respond with a mechanical shape recovery to variations in temperature, can be used as self-regulated thermal management actuators that are able to respond to environmental thermal changes autonomously. In this dissertation, modeling and experimental analysis of a two-way shape-memory effect trained SMA torsional tube …

Embeddable Multi-Material Wireless Micro-Sensors Utilizing Additive Manufacturing And Enhanced Microstructure, Nicholas Reed

Doctoral Dissertations and Master's Theses

The development of embeddable, multi-material wireless microsensors offers transformative potential for structural health monitoring (SHM) in aerospace applications. This work integrates additive manufacturing (AM) techniques with advanced microstructural design to produce flexible, high-resolution sensors that can be directly embedded into polymer substrates. By utilizing the vat photopolymerization process, customized embedded sensors are seamlessly integrated into polymer AM structures. These sensors are then continuously refined, targeting increases in performance, both internal and external. Microstructural enhancements are explored to modify the rheological properties of the fabricated embedded sensing channels and enhance the adhesive bonding between the embedded sensor and the AM structure. …

Reusing Materials In The Aerospace Industry, Lama Alanazi, Burtegeljin Gombosuren, Byhalia Jewett

Beyond: Undergraduate Research Journal

This research explores the material recycling methods used by the aerospace industry, particularly in comparison to the reusability of aerospace materials and with the objective to find uses for recycled materials from aircraft. Through an analysis of various other material mitigation methods, it is apparent that the physical degradation of materials after they go through recycling processes and the cost of recycling are the most prominent issues holding the aerospace industry back from being able to recycle aircraft up to 100%. From a comparison of physical characteristics of materials after reprocessing, several materials were found to meet industry standards, while …

Investigation Into Silicone-Silicate Conversion Due To Atomic Oxygen In The Low Earth Orbit Environment, Justin T. Self

Master's Theses

Silicones have been widely used over the years in spacecraft for a variety of functions, but atomic oxygen (AO) exposure in Low Earth Orbit causes a silicate (SiO₂) surface layer to rapidly develop on the silicone which results in a permanent change in its thermal and optical properties. Although this silicone to silicate conversion is known to occur, statistical predictions of layer formation as a function of time on orbit are not found in literature. This thesis utilized optical and scanning electron microscopy, Fourier-Transform Infrared Spectroscopy, diffuse reflectance spectroscopy, and nonlinear regression statistical techniques after RF plasma asher …

In-Situ Defect Detection In Selective Laser Melting Using Convolutional Neural Networks, Ethan Gaigalas

Master's Theses

This thesis develops and trains a convolutional neural network (CNN) to classify defects in metal parts produced by selective laser melting (SLM) using acoustic emission (AE) data. The model successfully identified porosity and standard build layers with high accuracy but consistently struggled to classify lack of fusion (LOF) defects, regardless of input type, normalization, or class count. These results suggest that while AE signals contain distinguishable features for certain defect types, LOF signals may be too subtle or inconsistent for reliable detection. The study addresses the ongoing challenge of in-situ quality monitoring in metal additive manufacturing, where defects like cracks, …

Effect Of Thermal History On The Fracture And Fatigue Behaviors Of Semi-Crystalline Polymers Prepared Via Material Extrusion Additive Manufacturing, Ava M. Lea, Khaled Matalgah, Arief Yudhanto, Trevor J. Fleck

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Material extrusion (MEX) additive manufacturing (AM) is transforming the design and production of complex structures, providing reliable on-demand components. However, the effect of thermal history on the resultant microstructure and damage tolerance of MEX-AM materials is not fully understood. This research investigates the critical role of interfacial thermal history, which is dependent on processing conditions, in determining the fracture and fatigue behaviors of semi-crystalline polymers, as exemplified by polyamide-6 (PA-6). Utilizing infrared thermography, the thermal history, and its dependence on nozzle temperature of extruded PA-6, was investigated. Quasi-static and cyclic tests of compact tension specimens were used to evaluate fracture …

Model-Based Design Of Compressed Lithium-Metal Pouch Cell Battery Modules For Evtol Applications, Scott J. Stirling

Master's Theses

Batteries with higher specific energy and power are essential for extending the range and performance of electric vertical takeoff and landing aircraft (eVTOLs). Anode-free lithium-metal pouch cells offer strong potential at the cell-level but require high compressive pressures to enhance cycle life and discharge performance. These pressures necessitate heavier structural components, reducing packaging efficiency at the module level.

To evaluate this tradeoff, a full-factorial enumeration model was developed to explore viable module designs within a constrained packaging volume. The model scales subsystem masses, enforces design rules and material limits, and accounts for large (~20%) cell thickness changes during cycling.

Results …

Optimizing Concrete Strength: How Nanomaterials And Ai Redefine Mix Design, Dan Huang, Guangshuai Han, Ziyang Tang

Physics and Engineering Science

Nanomaterials and supplementary cementitious materials (SCMs) are typically used together in efforts to enhance the performance of concrete and mitigate the environmental impact of concrete construction. However, the complex interactions between nanomaterials, SCMs, and cement make concrete mix design a challenging, iterative, and labor-intensive process, often relying on trial-and-error experimentation. Machine learning (ML) offers an opportunity to better understand the influence of input parameters and to accelerate the optimization of mix designs through data-driven insights. This study proposes an open-source and easy-to-access framework, Canopy, to support the concrete research community in optimizing mix design. Using a dataset collected from the …

Re-Analysis Of The Anthropogenic Effect Of The Covid-19 Global Lockdown On Night-Time Lunar Surface Temperatures, W. Schonberg, S. Haque

Civil, Architectural and Environmental Engineering Faculty Research & Creative Works

A study by Durga Prasad and Ambily observed an anomalous decrease in the lunar surface temperatures during the period April–May 2020, which they then attributed to the anthropogenic effects of the COVID-19 global lockdown effect. We have re-examined their data and while the anomalous decrease in the lunar surface temperature during April–May 2020 appears in our analysis as well, so does another significant dip in early 2018. Furthermore, the decline to the minimum observed during April–May 2020 is seen to begin in 2019, that is, quite some time before the COVID-19 event that led to the global lockdown and the …

Characterizing Heating And Resistance Properties Of Nichrome Burn Wire To Be Used In Cubesat Actuation, Noah Moix

Mechanical Engineering Undergraduate Honors Theses

This thesis investigates the use of Nichrome 60 wire as a burn wire mechanism, commonly utilized in CubeSats and other aerospace engineering applications requiring precise, single-use release systems. The experiment focused on characterizing the thermal and resistive behavior of Nichrome 60 wire under Joule heating conditions. Four wire configurations were tested: 34-gauge and 36-gauge wires, each at lengths of 1 inch and 2 inches. Each configuration was subjected to a constant current until thermal failure occurred. During testing, real-time measurements of electrical resistance and wire temperature were recorded. This data was used to generate resistance vs. temperature profiles for each …

Mixed-Mode Fracture Analysis Of Additively Manufactured Periodic Orthotropic Functionally Graded Microcellular Materials, Behnam Shahbazian

Theses and Dissertations

The quest for safety, efficiency, and innovation in aerospace engineering demands a relentless focus on understanding how materials and structures behave under extreme and complicated loading conditions. Among the many challenges faced by engineers in this field, predicting and preventing structural failure stands out as both a fundamental necessity and a complex problem. Fracture mechanics, the science of how materials fail under stress, is a cornerstone of this effort. Whether it is the fuselage of an aircraft enduring cyclic loading or the lightweight components of a spacecraft resisting impact, the ability to accurately predict fracture behavior directly influences the reliability …

Exploring Metal Additive Manufacturing In Martian Atmospheric Environments, Zane Mebruer

Mechanical Engineering Undergraduate Honors Theses

On-surface manufacturing is key to the success of a planetary colonization, especially that of Mars. However, traditional subtractive manufacturing processes are equipment, energy, and material intensive, meaning novel additive manufacturing (AM) processes must be pursued for this end. Selective laser melting, one of the most effective and versatile AM methods, would be incredibly beneficial to a Martian mission but requires an artificial argon atmosphere to create effective parts. The purpose of this study was to examine if carbon dioxide, the gas that makes up over 95% of Mars’ surface atmosphere, would be a sufficient substitute for argon in SLM fabrication. …

Thermal Characterization Of 3d Printing Materials For Increasing Insulation Potential And Practicality, Jackson H. Minnick

Mechanical Engineering Undergraduate Honors Theses

This study served as an exploration into the possible existence of a correlation between the infill lattice structure of a 3D printed wall section and the thermal performance of that sample as characterized by thermal conductivity measured in units of Watts per meter Kelvin. With the continual increase in the practicality, fidelity, and applicable fields of additive manufacturing, namely FDM 3D printing, research on specific print characteristics and their effects on the material and thermal characteristics of the part in question is steadily becoming more commonplace. Although the thermal conductivity of 3D printed wall sections as a function of infill …

Experimental And Theoretical Fracture Analysis Of Rift Manufactured Carbon Fiber-Vinyl Ester Lamina, Daniel Joseph Longo

Theses and Dissertations

This thesis investigates the fracture behavior of unidirectional carbon fiber-vinyl ester (CFVE) laminates manufactured using the Resin Infusion with Flexible Tooling (RIFT) process, a cost-effective alternative to autoclave-based fabrication methods. Composite materials like CFVE are increasingly adopted in high-performance applications due to their high strength-to-weight ratio and corrosion resistance; however, their anisotropic nature presents challenges in predicting crack initiation and propagation. To address this, a comprehensive approach combining experimental testing, finite element modeling (FEM), and classical fracture mechanics was employed. Orthotropic mechanical properties were first determined through tensile and shear tests, providing critical properties for FEM simulations. A series of …

Experimental And Theoretical Fracture Analysis Of Additively Manufactured Orthotropic V-Notches, Venkata Siva Sainath Bavapuram

Theses and Dissertations

This study presents a comprehensive investigation into the fracture behavior of additively manufactured orthotropic V-notched components made of Acrylonitrile Butadiene Styrene (ABS) material. The research integrates both theoretical and finite element approaches to evaluate stress intensity factors (SIFs) in Modes-I and II, which are fundamental in characterizing stress field distributions around notches under applied loading conditions. Unlike isotropic materials, where stress fields depend only on geometry of the component, the anisotropic nature of 3D-printed ABS introduces a dependency on material properties that necessitate different approaches to include anisotropy of the material.

Tensile specimens are 3D-printed with specific material orientations to …

G.W.A.I.H.I.R. Guided Wing Aircraft For Intelligent Hybrid Insertion And Recovery, Abdirahman Ahmed Shirwa, Zach Richards, Derek Harwood, Alex Duncan

Senior Design Project For Engineers

The paper outlines the conceptual and preliminary design of a hybrid vertical takeoff and landing (VTOL) heavy lift unmanned aerial vehicle (UAV) for autonomous cargo transport missions. The primary design objective was to create an aircraft capable of carrying a 15 kg payload over a range of 33 km, achieving a top cruise speed of 45 km/h and maintaining an endurance capacity of at least 90 minutes.

A comprehensive literature review informed key design decision, including airfoil selection, structural material, propulsion system configuration, and control. Key requirements were established early in the design process, such as payload capacity, energy efficiency, …

40 - Design, Fabrication, And Installation Of Morphing Control Surfaces For Small-Scale Uas, Kyle Purser

Undergraduate Research Symposium

Morphing control surface technology, inspired by organic structures and compliant mechanisms, offers significant potential for enhancing the aerodynamic efficiency and performance of unmanned aerial systems (UAS). Despite these benefits, its adoption has been hindered by complexities in design, manufacturing, and installation, particularly when compared to traditional flap systems. This research explores the design, fabrication, and integration of morphing control surfaces for small-scale UAS using additive manufacturing techniques. To reduce costs and streamline the design process, fused deposition modeling (FDM) additive manufacturing was employed for component fabrication. An off-the-shelf Horizon Sport Cub S2 served as the testing platform, modified with a …

Engineering Anisotropic Porosity In Green Parts From Binder Jet 3d Printing, Reshma Chandrashekhar Kubsad

Doctoral Dissertations and Master's Theses

Binder Jet Additive Manufacturing (BJAM) is a promising metal additive manufacturing technique that enables the fabrication of complex geometries without the need for support structures. However, the inherent porosity in green parts, remains a challenge in achieving desired mechanical properties and performance. Instead of treating porosity as a limitation, this thesis explores engineering of anisotropic porosity engineering, where controlled variations in porosity in the green parts can be used to enhance functionality and efficiency in specific applications. The objective of this research is to investigate and analyze the key print parameters that influence green part density. By systematically varying layer …

Modeling The Dynamics Of Flexible Aerospace Vehicles Using The Theory Of Functional Connections, Carlo Lombardi

Doctoral Dissertations and Master's Theses

Modeling and control of flexible vehicles is a topic of high interest in the aerospace field and a key challenge lies in finding accurate mathematical representations of the flexible dynamics of continuous elastic structures that allow simple integration into estimation and control algorithms. The answer was found in approximating the dynamics of these systems with sets of coupled Ordinary Differential Equations (ODE) for which a well-established estimation and control theory is available. Each of the techniques employed to achieve this goal is characterized by its own strengths and limitations. Hence, the main objective of this research is to develop the …

Mechanical Response Of Triply Periodic Minimal Surface Gyroid Structures Under Combined Loading, Jay B. Patel

Theses and Dissertations

This work explored combined tensile and torsional loads applied to additively manufactured Inconel 718 specimens employing Triply Periodic Minimal Surface (TPMS) structures. The gyroid TPMS unit cell was selected with two variations of cylindrical cell maps, a rectangular cell map, and a spherical cell map. All four variants were tested in an axial-torsion test frame at room temperature using equal parts of vertical and angular displacement control until failure. The combined loading in these tests utilized tension and torsion. The data from the tests were compared to finite element analysis (FEA) models to visualize when yielding was predicted. Finally, the …

Thermal Stability Analysis Of Aqueous Ionic Amines For Sustainable Co2 Capture, Li Hua Zang, Keegan Everitt, Kevin West, Brooks D. Rabideau, Breanna Dobyns, James Davis

Shelby Hall Graduate Research Forum Posters

In closed air cabin atmospheres such as those of spacecraft, CO₂ accumulation jeopardizes crew respiratory function and may gradually affect sensitive equipment, making effective air revitalization critical. Traditional CO₂ capture methods like monoethanolamine (MEA) efficiently capture CO₂ but suffer from high volatility, leading to solvent loss and unpleasant odor, as well as corrosion and degradation, requiring frequent replacement. These flaws demand eco-friendly, durable alternatives. This study addresses these limitations by exploring a series of aqueous ionic amines (AIAs), salts similar to MEA in CO₂ capture efficiency but with improved thermal stability—crucial for preventing degradation under high regeneration temperatures and prolonged …

Mars Sample Return Earth Entry System Uncertainty Analysis, Michael D. Squire, Victor Cabrera, Eric Christiansen, Alan Jenkin, Kevin Hoffman, Quincy Mckown, Peter Parker, Glenn Peterson, Bruno Victorino Sarli, William P. Schonberg, Katie Steward, Brian Tulaba, Joel Williamsen

Civil, Architectural and Environmental Engineering Faculty Research & Creative Works

Spacecraft designers and operators use micrometeoroid and orbital debris (MMOD) risk assessments to predict the probability that an MMOD particle impact will cause a critical failure to their systems. An important aspect of MMOD risk and associated requirements is the treatment of uncertainty, often difficult to quantify, or even estimate, for many elements of MMOD risk. This paper describes recent efforts to estimate uncertainties in inputs to the MMOD risk assessment process for a portion of the planned Mars Sample Return (MSR) campaign. The uncertainty bounds developed were used to examine their effect on overall mission MMOD risk.

Analyzing Micrometeoroid And Orbital Debris Shield Performance For Sample Return Spacecraft, William P. Schonberg, Michael Squire

Civil, Architectural and Environmental Engineering Faculty Research & Creative Works

Sample-return missions typically seek to collect and return samples from extraterrestrial locations to Earth for analysis. The return of samples from certain locations in the solar system represents a potential hazard to Earth's biosphere from foreign microorganisms. One way this could occur would be a break-up of the returning capsule during entry (which would disperse the samples through the air) due to undetected damage to the capsule thermal protection system (TPS). As a result, missions that plan to return payloads from some destinations are likely to have certain design requirements for the TPS surrounding their returning capsules, which may include …

Graphene-Polymer Nanocomposite For Electromagnetic Interference Shielding, Ravi Venkata Surya Sai Mogilisetti

Mechanical and Aerospace Engineering Theses - Archive

Polymers have widespread usage in most industries, such as aerospace, automotive, telecommunications, and medicine, mainly because they have a positive lightweight nature and excellent mechanical properties. One significant advantage of polymeric materials is their ability to combine nano-fillers, greatly enhancing their mechanical, electrical, and thermal properties. In the category of polymer matrices, polypropylene (PP) is notable for its low cost, ease of processing, and balanced mechanical properties. However, its relatively lower modulus and strength limit their applications in high-performance engineering. This research explores the addition of graphene into polypropylene to improve its mechanical properties and establish a conductive network for …