Improving And Expanding The Capabilities Of The Poly-Picosatellite Orbital Deployer, David Pignatelli

Master's Theses

The Poly-Picosatellite Orbital Deployer (P-POD) has undergone a series of revisions over the years. The latest revision, described in this Master’s Thesis, incorporates new capabilities like EMI shielding, an inert gas purge system, and an electrical interface to the CubeSats after they are integrated into the P-POD. Additionally, some mass reduction modifications are made to the P-POD, while its overall strength is increased. The P-POD inert gas purge system successfully flew, on a previous revision P-POD. The P-POD components are analyzed to a set of dynamic loads for qualification, and successfully undergoes random vibration qualification testing. The P-POD encounters some …

Effects Of Low Velocity Impact On The Flexural Strength Of Composite Sandwich Structures, Jeffrey Scott Carter

Master's Theses

The use of composite sandwich structures is rapidly increasing in the aerospace industry because of their increased strength-to-weight and stiffness-to-weight characteristics. The effects of low velocity impacts on these structures, however, are the main weakness that hinders further use of them in the industry because the damages from these loadings can often be catastrophic. Impact behavior of composite materials in general is a crucial consideration for a designer but can be difficult to describe theoretically. Because of this, experimental analysis is typically used to attempt to describe the behavior of composite sandwiches under impact loads. Experimental testing can still be …

Foss Big Data Storage Solution, Gary L. Jaffe

STAR Program Research Presentations

Utilizing the AERO Institute as an IT test bed or “sandbox”, a small-agile development team will design, build, and test a data management storage system to support post processing of archived and in-flight data collected with the Piccolo flight control system and Compact Fiber Optic Sensing System (C-FOSS). Both systems are integrated on the APV3 aircraft, a small remote-operated vehicle. Due to the amount of data collected from C-FOSS, a system will be designed to sort and organize large data sets. An open-source database will be explored as a viable solution to manage large data loads and provide multi-cluster system …

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 …

A Study On The Vibrational Performance Characteristics Of An E22 Isolator After Outgassing And Bake-Out, Alma Melendez

Master's Theses

The launch environment experiences many vibration, shock, and acoustic loads. A great concern is the high random vibration levels that can damage components and spacecraft structures, which can cause a mission failure. An effective method of reducing high frequency energy is using isolators. Overall, the need for vibration isolation has been increasing because there has been an increase in the use of mechanisms in which vibrations are prevalent. In addition, there has not been extensive research on the effects of isolators that are outgassed and cured. Therefore, it is important to investigate and understand the vibrational effects on isolators. It …

Analysis Of Environmentally Friendly Marking Ink For Military Equipment And Electronics, Liang Li

Master's Theses

Recent advancements in corrosion-resistance coating technology has reduce the use of environmentally harmful compounds such as Hexavalent Chromium by replacing Hexavalent Chromium in primers and topcoat. However, marking inks were neglected in the process. Products such as Enthone 50 series are still widely used, which contain compounds such as lead, hexavalent chromium, bisphenol A (BPA), Cadmium Sulfide, and more. Excluding catalyst compositions in Enthone, the chemicals in the ink alone contained three reproductive toxicant and numerous carcinogens. Therefore, it was essential to search and validate the performance of potential marking ink that would meet the standards in military applications.

Eleven …

Study The Effects Of Core Orientation And Different Face Thicknesses On Mechanical Behavior Of Honeycomb Sandwich Structures Under Three Point Bending, Joshua M. Lister

Master's Theses

This study will present the Experimental, numerical and analytical characterizations of composite sandwich structures needed to optimize structure design. In this study, the effects of varying honeycomb core ribbon orientation and varying face sheet thickness’s have on the flexural behavior of honeycomb sandwich structures was investigated. Honeycomb sandwich panels were constructed using Hexcel 6367 A250-5H carbon fiber face sheets and Hexcel Nomex HRH-10-1/8-5 honeycomb cores. The mechanical properties of the constituent materials were discovered experimentally using ASTM standards and theoretical models using honeycomb mechanics and classical beam and plate theory are described. A failure mode map for loading under three …

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. …

The Effects Of Fabrication Methods And Cure Cycle On The Mechanical Properties Of Carbon Fiber Laminate In Tensile And 3-Point Bend Testing, Adriano Agostino

Aerospace Engineering

This project was completed at the California Polytechnic State University, San Luis Obispo Aerospace Engineering Structures and Composites Lab during Spring Quarter 2013. The purpose of this project was to research and to gain insight into the effects of fabrication methods and of modifying cure cycles for Newport NB-301 12l 2x2 Twill Weave Carbon Fiber material properties. The two fabrication methods used were autoclave and heat press (compression molding) methods. Each fabrication method used two cure cycles, a recommended cure cycle of 275°F for 1 hour and a modified cure cycle of 250°F for 1.5 hours. The exact product data …

Study Of Natural Composite Materials Square Beam Under Three Point Bending Test, Casey Wu

Aerospace Engineering

The purpose of this report is to summarize the findings on three point bending tests to try to find the optimum geometrical shape and layup configuration of a square beam composed of natural composites. The final project was entered into the SAMPE 2013 bridge building competition to compete internationally against other universities in the natural square beam category. The main focus of the bridge project is to compose it entirely of natural occurring fibers and other natural materials to create a “green” beam. The beams in the competition are tested under 3 point bending tests and will be scored based …

Design, Fabrication, And Testing Of An Emr Based Orbital Debris Impact Testing Platform, Jeffrey J. Maniglia Jr.

Master's Theses

This paper describes the changes made from Cal Poly’s initial railgun system, the Mk. 1 railgun, to the Mk. 1.1 system, as well as the design, fabrication, and testing of a newer and larger Mk. 2 railgun system. The Mk. 1.1 system is developed as a more efficient alteration of the original Mk. 1 system, but is found to be defective due to hardware deficiencies and failure, as well as unforeseen efficiency losses. A Mk. 2 system is developed and built around donated hardware from the Naval Postgraduate School. The Mk. 2 system strove to implement an efficient, augmented, electromagnetic …

Analysis And Mitigation Of The Cubesat Dynamic Environment, Steve M. Furger

Master's Theses

A vibration model was developed for CubeSats inside the Poly-Picosatellite Orbital Deployer (P-POD). CubeSats are fixed in the Z axis of deployers, and therefore resonate with deployer peaks. CubeSats generally start fixed in the X and Y axes, and then settle into an isolated position. CubeSats do not resonate with deployers after settling into an isolated position. Experimental data shows that the P-POD amplifies vibration loads when CubeSats are fixed in the deployer, and vibration loads are reduced when the CubeSats settle into an isolated position. A concept for a future deployer was proposed that isolates CubeSats from the deployer …

Design Of A Specimen Fixture For Impact Resistance Testing In An Instron Dynatup 8250 Drop Weight Impact Tester, Daniel Alejandro Barath

Aerospace Engineering

The purpose of this report is to outline the path and methods used to design a specimen fixture for the testing and analysis of fiber reinforced composites subjected to impact loading. This design is done in support of the California Polytechnic State University in San Luis Obispo Structures and Composites Laboratory. The design request was made at the request of Dr. Eltahry Elghandour to support the graduate students Kodi A. Rider and Y. Vanessa Wood in their master’s degree thesis projects.

The design request involved the design of a specimen fixture compatible with the existing impact apparatus located in the …

Investigation Of Astm E 238 Bearing Pin Properties For Various Aerospace Alloys, Trevor J. Lee

Master's Theses

Aircraft are often designed with numbers determined by testing in a lab, rather than by repeatedly building prototypes. These lab tests conform to testing specifications so that the numbers can be compared between manufacturers, suppliers, and lab technicians. One such specification is ASTM specification E238 – 84(08), and it is used to determine important properties of a bearing pin joint like hinges, bolt holes, and rivet joints. The properties determined from this fastener-through-plate method are bearing strength, bearing yield strength, and bearing stiffness.

Adhering to the methods outlined in ASTM E238, a study was performed, looking at the effects that …

The Effect Of Sensor Mass, Sensor Location, And Delamination Location Of Different Composite Structures Under Dynamic Loading, Albert Darien Liu

Master's Theses

This study investigated the effect of sensor mass, sensor location, and delamination location of different composite structures under dynamic loading. The study pertains to research of the use of accelerometers and dynamic response as a cost-effective and reliable method of structural health monitoring in composite structures. The composite structures in this research included carbon fiber plates, carbon fiber-foam sandwich panels, and carbon-fiber honeycomb sandwich panels. The composite structures were manufactured with the use of a Tetrahedron MTP-8 heat press. All work was conducted in the Cal Poly Aerospace Structures/Composites Laboratory. Initial delaminations were placed at several locations along the specimen, …

Effects Of Seawater On The Mechanical Behavior Of Composite Sandwich Panels Under Monotonic Shear Loading, Thomas Robert Woo

Master's Theses

Abstract

Salt water environments are very harsh on materials that are used within them. Many issues are caused by either corrosion and/or internal degradation to the materials themselves. Composites are better suited for this environment due to their high strength to weight ratios and their corrosion resistance, but very little is known about the fracture mechanics of composites. The goal of this study is to gain a better understanding for the behavior of a composite boat hull under a shear loading, similar to the force water applies on the hull as the boat moves through the water; then attempt to …

Manufacturing Processes In An All-Aluminum Airframe, Stewart Mcdougall

Aerospace Engineering

One often overlooked aspect to building an aircraft is the manufacturing process used to put it into production. This may be a major contributor to acquisition cost and requires a large amount of money to implement. Once all the tooling has been purchased, one of the greatest costs is labor. The experience of building an all-aluminum aircraft shows that the production process is one which may be done in many different ways. Minimizing the assembly time is important for aircraft manufacturers and one of the best ways to do that is on the assembly line itself. Specific practices in the …

Optimizing The Mechanical Characteristics Of Bamboo To Improve The Flexural Behavior For Biocomposite Structural Application, Jay Lopez

Master's Theses

Global awareness and preservation have spurred increasing interest in utilizing environmentally friendly materials for high-performance structural applications. Biocomposites pose an appealing solution to this issue and are characterized by their sustainable lifecycles, biodegradable qualities, light weight, remarkable strength, and exceptional stiffness. Many of these structural qualities are found in applications that exhibit flexural loading conditions, and this study focuses on improving the bending performance of engineered biocomposite structures. The current application of biocomposites is increasing rapidly, so this expanding research explores other natural constituent materials for biocomposite structures under flexural loading.

The renewable material investigated in this study was experimentally …

Mechanical Optimization And Buckling Analysis Of Bio-Composites, Cameron D. Chan

Master's Theses

Today’s environmental concerns have led a renewed search in industry to find new sustainable materials to replace non-renewable resources. President Barack Obama also quoted in the recent 2012 Presidential Debate “that there is a need to build the energy sources of the future and invest in solar, wind, and bio-fuels.” Bio-composites are believed to be the future and the new substitute for non-renewable resources. Bio-composites are similar to composites in that they are made up of two constituent materials; however the main difference is that bio-composites are made from natural fibers and a biopolymer matrix. This research investigates the buckling …

Performance Effects Of Damage Arrestment Devices On Sandwich Composite Beams Under Monotonic Loading, Yvette Vanessa Wood

Aerospace Engineering

Face-core delamination has become a subject matter in the Aerospace industry, as it can lead to early failure. In this study, sandwich composite beams are tested initially with no delamination to obtain the ultimate strength. A second case of delamination in the center of the beam in initialized to verify a decrease in ultimate strength. This experiment investigates the performance effects of the addition of Damage Arrestment Devices (DADs), in composite sandwich beams. The performance criterion is measured by strength in flexural loading test. The objective of this project is to verify an increase in the strength and performance with …

Two-Stage, High-Altitude Rocket With Internal Skeleton Design Entered In Advance Category Of 7th Esra Irec, Samuel S. Bowman, Kevin J. Byrne, Allen Capatina, Aliki S. Loper-Leddy, Joshua A. Van Schoyck

Aerospace Engineering

A high-altitude, two-stage rocket was designed, built, and entered in the advanced category of the 7^th Annual Experimental Sounding Rocket Association (ESRA) Intercollegiate Rocketry Engineering Competition (IREC). The rocket, called AJAKS, featured an internal skeleton made of carbon fiber rods, and a combination of plywood, carbon, and aluminum bulkheads. Loads were driven through the internal structure, with an outer skin tube providing an aerodynamic surface. A unique separation device was developed to ensure proper stage separation. The competition required the rocket to carry a 10-lb payload, which was chosen by the team to consist of an IMU and data …

A Resistance Based Structural Health Monitoring System For Composite Structure Applications, Dennis N. Boettcher

Master's Theses

This research effort explored the possibility of using interwoven conductive and nonconductive fibers in a composite laminate for structural health monitoring (SHM). Traditional SHM systems utilize fiber optics, piezoelectrics, or detect defects by nondestructive test methods by use of sonar graphs or x-rays. However, these approaches are often expensive, time consuming and complicated.

The primary objective of this research was to apply a resistance based method of structural health monitoring to a composite structure to determine structural integrity and presence of defects.

The conductive properties of fiber such as carbon, copper, or constantan - a copper-nickel alloy - can be …

The Effect Of A Low-Velocity Impact On The Flexural Strength And Dynamic Response Of Composite Sandwiches With Damage Arrestment Devices, Kodi A. Rider

Master's Theses

Impact strength is one of the most important structural properties for a designer to consider, but is often the most difficult to quantify or measure. A constant concern in the field of composites is the effect of foreign object impact damage because it is often undetectable by visual inspection. An impact can create interlaminar damage that often results in severe reductions in strength and instability of the structure. The main objective of this study is to determine the effectiveness of a damage arrestment device (DAD) on the mechanical behavior of composite sandwiches, following a low-velocity impact. A 7.56-lb_f crosshead …

Effect Of Multifunctional Material On The Mechanical Behavior Of Composite Structure Using Finite Element Analysis, Nicholas A. Romonoski

Aerospace Engineering

No abstract provided.

Development Of A Pyrotechnic Shock Simulation Apparatus For Spacecraft Applications, Joseph Binder, Matthew Mccarty, Chris Rasmussen

Aerospace Engineering

This report details the research, design, construction, and testing of a pyrotechnic shock simulation apparatus for spacecraft applications. The apparatus was developed to be used in the Space Environments Lab at California Polytechnic State University. It will be used for testing spacecraft components with dimensions up to 24”x12”x12” as well as CubeSats. Additionally, it may be used as an instructional or demonstrational tool in the Aerospace Department’s space environments course. The apparatus functions by way of mechanical impact of an approximately 20 lb stainless steel swinging hammer. Tests were performed to verify the simulator’s functionality. Suggestions for improvement and further …

Thermal Vacuum Integration For Cal Poly's Space Environments Laboratory, Chelsea Barackman, Steven Jackowski

Aerospace Engineering

The purpose of the senior project is to construct a thermal vacuum by utilizing a preexisting vacuum chamber in the Space Environments Lab, and a donated Advanced Thermal Sciences (ATS) chiller. While a thermal vacuum is already available on campus, building one for the Space Environments Lab would grant undergraduates access to the equipment, allowing a much better understanding of testing methods and procedures in use by the aerospace industry. This paper explains the design and analysis of the thermal vacuum (T-VAC) project as well as the operation and procedures required for the ATS chiller and fill/drain tank. The thermal …

A Study On Organic Epoxy And Hemp Composite Plates With An Emphasis On Mechanical And Finite Element Analysis, Alma Melendez

Aerospace Engineering

Several vibration and tensile tests were conducted for four natural fiber hemp composites in order to observe its behavior and acquire the material properties of hemp. Two plates were made on the Cal Poly press table, while the other two plates were made on the Cal Poly vacuum table. All four plates are made of 100% hemp under three different types of weave. The first plate is called CTPT-12, has a thickness of 0.053 inches, and was made on the press table. The second plate is called CTL4 with a thickness of 0.152 inches and made on the press table. …

The Study Of Natural Composite I-Beam In A Three Point Bending Test, Abdel Shabbar

Aerospace Engineering

The objective of this experiment is to conduct a series of unidirectional tensile test on several samples of natural occurring plant fibers. Among the materials tested, hemp has proven to be the most promising candidate as the base material in creating an all-natural composite I-Beam. This I-Beam will be entered into the annual SAMPE 2012 competition to compete against other schools and universities nationwide. These I-Beams will undergo a three point bending test, and must withstand the greatest load whilst remaining in the parameters set by SAMPE. This I-Beam will go on to take third place internationally. In addition, the …

Flaperon Assembly Manual For Pegastol Aftermarket Wings, Eric Alan Gray

Aerospace Engineering

No abstract provided.