Structures and Materials Commons^™

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 …

Smart Process Planning For Automated Fiber Placement, Matthew J. Godbold

All Dissertations

Automated Fiber Placement (AFP) is a preeminent manufacturing technology for producing high-performance composite structures, offering precise material placement, reduced waste, and the potential for highly optimized lightweight designs. While AFP has been widely adopted in aerospace applications, its broader use across industries such as automotive, wind energy, maritime, and sporting goods remains limited. A key barrier to wider adoption is the traditional separation of design, manufacturing, and inspection processes, which drives up cost and results in inefficiencies, sub-optimal designs, and limited feedback between lifecycle stages. In current practice, manufacturing is treated as an isolated process, disconnected from early-stage design decisions …

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 …

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 …

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 …

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 …

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 …

Detecting And Repairing Conflicting Constraints In Co-Trained Physics-Informed Neural Networks For Composite Curing Processes, Cooper J. Evans

Dissertations, Master's Theses and Master's Reports

Composite materials have become a critical component of modern manufacturing, especially in the automotive and aerospace industries. The curing process for these composites has been modeled using a variety of partial differential equations representing the heat transfer and composite curing kinetics. Optimizing the applied temperature profile is critical for maximizing the efficiency and capacity of composite part manufacturers. Constraints must be placed on the inputs and outputs of the model, including but not limited to, the applied temperature profile, part temperature, and final degree of cure. Conflicting sets of constraints are easy to unknowingly impose due to the highly coupled …

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

Theses and Dissertations--Mechanical and Aerospace Engineering

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

System-Level Assessment Of Non-Ideal Phase Change Material Behavior In Low Earth Orbit Spacecraft Thermal Control Models, Nathan S. Bruursema

Dissertations, Master's Theses and Master's Reports

Phase change materials (PCMs) are of interest in spacecraft thermal control because their latent heat capacity can provide passive thermal buffering during transient or cyclic heat loads. PCM behavior is often treated using idealized assumptions such as repeatable phase transition temperatures, consistent thermal accessibility across cycles, and full latent recovery. However, practical PCM behavior may be affected by non-ideal phenomena such as supercooling, interfacial resistance, and degradation of internal transport accessibility. This thesis examines the system-level relevance of these effects for low Earth orbit (LEO) spacecraft thermal control and identifies the operating conditions under which non-ideal PCM behavior becomes design-relevant. …

Design New Stage For Vacuum Pin On Disk, Miranda Boyd

Williams Honors College, Honors Research Projects

For my senior design project, I am redesigning the moving stage for the vacuum pin-on-disk test used in the Akron Engineering Tribology Lab. This system is used to evaluate bearings and lubricants for aerospace applications under controlled vacuum conditions. The current stage design limits flexibility when adjusting for different testing parameters, so my goal is to develop a new movable stage that allows for varying weights and loads to be applied accurately and safely. The redesigned stage will improve test efficiency, adaptability, and precision, ensuring the system can accommodate a wider range of experimental conditions and materials while maintaining compatibility …

Breaking The Vapor Barrier And Scale: Revolutionizing Steel Quenching With Ultrasound Technology, Anthony O. Santos

Williams Honors College, Honors Research Projects

The quenching process is a fundamental heat treatment used to enhance material properties by heating steel to its austenitizing temperature and rapidly cooling it to form high-strength martensite. However, this process is often hindered by two surface barriers: the Leidenfrost effect (vapor blanket) and oxide scale. These cooling limitations restrict the use of steel in high-performance aerospace applications due to inconsistent material properties and unpredictable engineering properties. This research investigates the use of fully submersible, 50-watt 40 kHz ultrasound technology to improve cooling rates in a Jominy test [4]. Through numerical simulations and experimental validation, the study demonstrates that acoustic …

Large Telescope Mount For Long Exposure Photos, Payne M. Landis, Anna J. Gray

Williams Honors College, Honors Research Projects

When viewing the stars through a telescope, it is common that the object you are viewing drifts out of view. Many amateur astronomers seek to capture long exposure images of the stars, planets, and galaxies with commercially available sky tracking telescope mounts. The complication is that these telescope mounts are both incredibly expensive and have low weight limits. These issues limit accessibility to these products based on the telescope. For each person, telescope parameters determine the amount of light and magnification that can be viewed, which then determines exposures time for adequate photo results. The options on the market for …

Optimization Of Post-Processing Methods For Additively Manufactured Metals, Julia R. Carano

Williams Honors College, Honors Research Projects

Ultrasonic Nanocrystal Surface Modification (UNSM) is a process used to change the surface hardness of flat-faced materials. It is a machining process using a high-powered laser and a blunt-tipped tool at high speeds which aims to improve the uniformity of the surface on most metals. By heating and pressing the surface of the workpiece, the grains of the material become less rounded and more cohesive on a microscopic level. This, ideally, results in a workpiece with improved material properties. The changes were previously observed through hardness testing.

Thermal Radiation Effects On Particles From Plasma Arc Radiation, Reece Davis, Joseph Mcgee

Williams Honors College, Honors Research Projects

Understanding the radiation heating and transport of both microparticles and nanoparticles is a phenomenon that is critical for both space and Earth sciences. In space, these particles are heated by plasma arcs within ionized space clouds or solar flares and can be present the path of deep space missions and orbital satellites. While on Earth, processes such as forest fires, nuclear fusion, and microchip manufacturing include the plasma arc heating of particles. These particles lay within the Mie Scattering Regime and Rayleigh Scattering Regime and emit radiation differently based on their diameter. New mathematical and computational modeling has been conducted …

Automated Soil Resetting System For Extraterrestrial Regolith Simulation, Parker W. Brennan, Anthony C. Daniels

Williams Honors College, Honors Research Projects

This project focuses on designing an automated soil resetting system for extraterrestrial regolith simulation. The system will prepare a regolith simulant testbed to a desired, repeatable density, enabling reliable wheel–terrain testing for planetary rover research. Manual soil preparation currently exposes testers to hazardous particulates and produces inconsistent results.

The proposed system will integrate mechanical and control elements to reset the soil bed safely and efficiently. A combination of raking and vibrational methods will be explored, with feedback sensors and automation to achieve target density control. The research will proceed through literature review, benchtop experimentation, prototype design, and full-scale testing over …

Fused Filament Fabrication Additive Manufacturing Of 17-4 Ph Stainless Steel: Process–Structure–Property Relationships In Magnetic Materials, Maanav Patel

Theses and Dissertations

Additive manufacturing (AM) enables the fabrication of complex metallic components through layer-by-layer processing directly from digital models. Among AM techniques, material extrusion–based processes such as fused filament fabrication (FFF) provide an accessible method for producing metal parts using filament feedstocks composed of metal powders and polymer binders. When applied to precipitation-hardening stainless steels such as 17-4 PH, the processing route and heat treatments can influence the resulting microstructure and functional properties. This work investigates the magnetic behavior of 17-4 PH stainless steel fabricated using FFF and evaluates how heat treatment conditions influence measured magnetic properties. Samples were produced and analyzed …

Material Degradation And Analysis Of N-Doped Graphene/Mof Nanocatalysts For Orr In Electrochemical Energy Systems, Niladri Talukder

Dissertations

The development of advanced electrochemical energy conversion and storage systems is crucial for achieving sustainable energy security. As alternatives to precious metal-based catalysts in electrochemical systems, especially for the oxygen reduction reaction (ORR), Nitrogen-doped Graphene with Metal-organic Frameworks (N-G/MOF) nanocatalysts have shown exceptional promise in recent years. This research advances the understanding of N-G/MOF nanocatalysts by systematically examining their structural features, degradation traits, correlated performance losses, and other aspects related to catalytic activities.

First, nitrogen-doped graphene (N-G) nanocatalysts were thoroughly investigated, resolving their physical properties, the influence of synthesis parameters, molecular-level material structures, and chemical and electronic structural details of …

Extraction Of Aluminum From Lunar Regolith Through Molten Salt Electrolysis, Jacob N. Ortega, Todd P. Sander, Jeffrey D. Smith, Fateme Rezaei, David J. Bayless, William Schonberg, Daniel S. Stutts, Frank D. Han

Materials Science and Engineering Faculty Research & Creative Works

This paper presents the methodology, development, and results of an end-to-end regolith-to-metal concept for producing aluminum in-situ on the lunar surface, namely, the Lunar In-Situ Aluminum Production through Molten Salt Electrolysis (LISAP-MSE) method. Using electrolytic reduction, aluminum oxide (i.e., alumina) can be reduced into aluminum and oxygen via electrolysis in a molten salt bath. A steady supply of hydrogen chloride could allow this in-situ resource utilization (ISRU) method to supply several necessary materials consumed in the electrolytic reduction step of the process to produce bulk aluminum metal, oxygen, water, and silica from anorthite abundant in lunar highland regions. In this …

Improving Fatigue Strength And Life Of Single Crystal Cmsx-4, Jochen Peter Fuhr, Lloyd Hackel, Nicolau I. Morar, Noah Holtham, Keivan Davami, Montu Sharma, Rajkumar Roy

15th International Conference on Shot Peening

The deep penetration of laser peening (LP) and retention of residual stress at high temperature by LP is significant in improving fatigue life and strength of superalloys exposed to high temperature and corrosion. Single crystal CMSX-4, was evaluated for stress relaxation and both fatigue life and fatigue strength of material that was LP-treated compared to non-LP and shot-peened (SP) specimens. LP was done with multiple layers using a 20 J/pulse laser where the laser high energy enabled using a 5 mm spot size on the metal surface. Stress measurements by the slitting technique showed the plastic penetration depth exceeded SP …

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 …

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, …

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 …

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. …

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 …

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 …

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 …

Linking Molecular Structure Evolution To Mechanical Degradation During Environmental Aging In Conventional And Recyclable Epoxy Systems, Ben T. Jewell

Dissertations, Master's Theses and Master's Reports

The long-term performance of polymeric materials in extreme environments is governed by complex chemical and physical aging processes that alter their molecular structure and mechanical integrity. Conventional thermoset epoxies, while widely used in structural applications, are particularly susceptible to oxidative degradation at elevated temperatures, leading to embrittlement and loss of structural integrity. In the first part of this work, diffusion-limited oxidation (DLO) in a bulk structural epoxy was systematically investigated to establish the link between heterogeneous microstructural evolution and macroscopic mechanical degradation. High-temperature oxidation experiments were conducted in a controlled environmental chamber, and the resulting chemical, thermal, and mechanical changes …