Structures and Materials Commons^™

Fabrication & Mechanical Properties Of Hastelloy-X Matrix Ceramic Composite, Sultan Stewart

Doctoral Dissertations and Master's Theses

In the aerospace industry, there is a desire for increased thermal and mechanical properties of sealing materials. In this thesis, porous Hastelloy-X alloy scaffolds with 80% porosity, currently used for fabricating seals in turbine applications, were used as the base material. The microstructure of the porous Hastelloy-X scaffolds was infiltrated using a room temperature curing silicate colloid (trade name -Dichtol HTWG Hydro #2506) and a novel zirconia based colloid to fabricate the metal matrix composites. Various fabrication processes, some using vacuum and pressure to assist the flow were utilized to infiltrate the scaffolds. The green composites were then cured at …

The Effect Of Part Curvature On The Formation Of Residual Stresses In Carbon Fiber Prepreg Laminates, Bradley Rogan

Doctoral Dissertations and Master's Theses

The formation of residual stresses during the processing of composite parts can lead to undesired defects such as delamination which can reduce the overall strength of a completed component. Furthermore, the addition of curvature to the part geometry tends to result in wrinkle formation which leads to stress concentrations developing throughout the curing process in the areas near these wrinkles. In this work, Digital Image Correlation (DIC) will be used to monitor the development of stresses throughout the cure cycle of carbon fiber prepreg in several different lay-ups and across tool plates with varying curvatures to determine what effect the …

Flexible Mold For Microstructures Replication, Zefu Ren, Dae Won Kim

Student Works

Space debris has been a growing concern in space exploration sector. To combat this issue, biomimicry is utilized to create a gecko’s feet microstructure that will be attached to a gripper or robotic arm. This will enable capture of debris through the use of dry adhesive microstructure. However, the production of such microstructures is expensive which hinders their implementation. The objective of this research is to develop an advanced fabrication process to mass produce gecko’s feet microstructure with soft polymer mold. The possibility of using different coating methods with coating materials will be justified. The process of fabricating mold and …

Shape Optimization Of A Sandwich Composite Plate With Low-Velocity Impact Loading And Effect Of Finite Difference Sensitivity Analysis, Utsav Shah

Doctoral Dissertations and Master's Theses

The structural design of spacesuits is essential in an advancing future of both Lunar and Martian space exploration. A typical spacesuit is made of sandwich composite material and designed to withstand various pressure and loading conditions while also considering the safety and comfort of the astronauts. One of the critical load cases in spacesuit design is a low-velocity impact (LVI) which may occur due to tool drop and other similar scenarios. The objectives of this work were (a) to create a finite element (FE) model of a component of a spacesuit, (b) validation of the FE model through experiments, (c) …

Design, Analysis And Experimental Evaluation Of 3d Printed Variable Stiffness Structures, Rossana R. Fernandes

Doctoral Dissertations and Master's Theses

The rapid progress of additive manufacturing (AM) introduces new opportunities but also new challenges for design and optimization to ensure manufacturability, testability and accurate representation/prediction of the models. The present dissertation builds a bridge between design, optimization, AM, testing and simulation of advanced optimized variable-stiffness structures. The first part offers an insight on the mechanical, viscoelastic and failure characteristics of AM continuous fiber composites. This understanding was used in the second part to investigate the feasibility of different topology and fiber-orientation optimization methods and the manufacturability of the resulting models. The study also assesses the effects of the manufacturing constraints …

Additively Manufactured Dielectric Elastomer Actuators: Development And Performance Enhancement, Stanislav Sikulskyi

Doctoral Dissertations and Master's Theses

The recently emerging and actively growing areas of soft robotics and morphing structures promise endless opportunities in a wide range of engineering fields, including biomedical, industrial, and aerospace. Soft actuators and sensors are essential components of any soft robot or morphing structure. Among the utilized materials, dielectric elastomers (DEs) are intrinsically compliant, high energy density polymers with fast and reversible electromechanical response. Additionally, the electrically driven work principle allows DEs to be distributed in a desired fashion and function locally with minimum interference. Thus, a great effort is being made towards utilizing additive manufacturing (AM) technologies to fully realize the …

Effect Of Galvanic Corrosion On Crack Propagation Of Cold Expanded Holes In Aa2024-T3, Ken Shishino

Doctoral Dissertations and Master's Theses

A search for the balance between weight reduction and durability of a structure has always been a popular topic within the aerospace industry. Among numerous researches to improve a structure’s fatigue life, processes on mechanically fastened joints have been a topic of focus as it is naturally a discontinuity in the material leading to a local stress concentration under loading. Cold expansion is a well-known technique with a wide range of applications in both new and repaired structures. The benefits include the extension of fatigue life and a delay in crack growth without addition of weight. However, localized galvanic corrosion …

Investigation Of Bio-Inspired Pin Geometries For Heat Transfer Applications, Anish Prasad

Doctoral Dissertations and Master's Theses

Array of circular cylindrical pins or tubes are one of the most widely used type of convection cooling systems, profoundly used in the internal cooling of gas turbine blades. They promote heat transfer due to flow acceleration, secondary flows and wake shedding, at the expense of large pressure loss and unsteadiness in the flow. The need to reduce pressure loss and maintain the heat transfer rates are a much needed requirement for a variety of industries to improve the cooling efficiency. One such prominent line of research is conducted on optimizing the design of the circular cylindrical pins to increase …

Analysis Of After Impact Characteristics And Structural Optimization Of Cfrp Composite Plate, Zhennan He

Doctoral Dissertations and Master's Theses

Low-velocity impact (LVI) on composites may cause Barely Visible Impact Damage (BVID), which is one of the most common damage types and may result in a decrease in strength of the composite. The objectives of this research were (a) to identify the characteristics of a carbon/epoxy composite plate after low-velocity impact, (b) to create a validated model to simulate the impact process and progressive failure, and (c) to perform sizing and shape optimization of the laminate for improving the damage resistance of the plate. As a part of this thesis, composite plates were fabricated using carbon fiber reinforced polymer (CFRP) …

Parametric Analysis Of Particle Spreading With Discrete Element Method, Yuxuan Wu

Doctoral Dissertations and Master's Theses

The spreading of metallic powder on the printing platform is vital in most additive manufacturing methods, including direct laser sintering. Several processing parameters such as particle size, inter-particle friction, blade speed, and blade gap size affect the spreading process and, therefore, the final product quality. The objective of this study is to parametrically analyze the particle flow behavior and the effect of the aforementioned parameters on the spreading process using the discrete element method (DEM). To effectively address the vast parameter space within computational constraints, novel parameter sweep algorithms based on low discrepancy sequence (LDS) are utilized in conjunction with …

Experimental Analysis Of Heat Generation In Carbon, Mounisha Ganesan

Doctoral Dissertations and Master's Theses

The purpose of this research is to study a novel non-covalent functionalization technique of single-walled carbon nanotubes (SWCNTs) and to examine the feasibility of using carbon nanotube films as thin film heaters. We developed a unique methodology to synthesize a well dispersed, environmentally friendly solution of CNTs that could be easily spin coated as well as spray coated on different substrates based on the application. Using the produced solutions, thin films of SWCNTs were fabricated on a glass substrate. Two sets of experiments were conducted to study the influence of polyaromatic moiety and the pH on the electro thermal characteristics …

Effect Of Cold Work Expansion On The Fatigue Life Of Pre-Cracked Al 2024-T3, Christopher Leirer

Doctoral Dissertations and Master's Theses

No abstract provided.

Piezoresistive Hybrid Nanocomposites For Strain And Damage Sensing: Experimental And Numerical Analysis, Audrey Jean-Miche Gbaguidi

Doctoral Dissertations and Master's Theses

Carbon nanomaterials such as carbon nanotubes (CNTs) and graphite nanoplatelets (GNPs) demonstrate remarkable electrical and mechanical properties, which suggest promising structural and functional applications as fillers for polymer nanocomposites.

The piezoresistive behavior of these nanocomposites makes them ideal for sensing applications. Besides, hybrid nanocomposites with multiple fillers like carbon nanotubes (CNTs) and graphite nanoplatelets (GNPs) are known to exhibit improved electrical and mechanical performance when compared to mono-filler composites.

To comprehensively understand the mechanisms of electrical percolation, conductivity, and piezoresistivity in hybrid nanocomposites, the author develops a two-dimensional (2D) and a three-dimensional (3D) computational Monte Carlo percolation network models for …

Topology Optimization And Analysis Of Thermal And Mechanical Metamaterials, Lee Alacoque

Doctoral Dissertations and Master's Theses

To take advantage of multi-material additive manufacturing technology using mixtures of metal alloys, a topology optimization framework is developed to synthesize high-strength spatially periodic metamaterials possessing unique thermoelastic properties. A thermal and mechanical stress analysis formulation based on homogenization theory is developed and is used in a regional scaled aggregation stress constraint method, and a method of worst-case stress minimization is also included to efficiently address load uncertainty. It is shown that the two stress-based techniques lead to thermal expansion properties that are highly sensitive to small changes in material distribution and composition. To resolve this issue, a uniform manufacturing …

Filament Winding Composite Airframes For Sounding Rockets, Eric Ford

Student Works

This study’s objective was to determine the feasibility of manufacturing carbon fiber cylinders using an X-Winder filament winder for a structural airframe in sounding rockets. Multiple carbon fiber tubes were manufactured using the X-Winder and tested. The results of this testing successfully demonstrated that tubes manufactured with the X-Winder are capable of performing as an airframe for small sounding rockets. Five tube samples were destructively tested in compression, and the average maximum compressive strength of the tubes was 9,854 lbf. One of the tubes was used as the airframe in a small sounding rocket which flew to 4,042 feet above …

Analysis Of Local Convection Heat Transfer Rates Of Supercritical Carbon Dioxide In Tubes, Yang Chao

Doctoral Dissertations and Master's Theses

Numerical investigation on thermodynamic characteristics of pure supercritical carbon dioxide (𝑆𝐶𝑂2) and mixtures of Helium and 𝑆𝐶𝑂2 in horizontal straight tubes with diameter of 6mm under cooling and heating conditions is carried out by using SST 𝑘 − 𝜔 turbulence model. The computations are conducted at operating pressure of 8MPa with various operating conditions. Simulations are conducted by using the latest poly-hexcore mesh method in ANSYS FLUENT 19.2 and tetrahedral mesh method in CFX 19.2, results and solving time are compared. The effect of heat flux, mass flux, inlet temperature and buoyancy on heat transfer performance are studied, pressure drop …

Viscoplastic Study Of 3d Printed Carbon Fiber Composites, Alexander M. Seifans

Doctoral Dissertations and Master's Theses

The research presented here involves an attempt to model the viscoplastic response of 3D printed carbon fiber composites made using the Mark Two 3D printer by Markforged. The ability to manufacture composites through the use of 3D printers is relatively new and contains gaps in the various mechanical properties of the material, of interest is the viscoplastic response.

Due to the fabrication method, the properties of the composites cannot be assumed to be similar to that of conventionally made composites as the fused deposition in printing alters the material properties. In order to understand the effects of the printed fiber …

Shape Optimization Of Microfiber Composite Energy Harvesters, Suyash Lahoti

Doctoral Dissertations and Master's Theses

A model of energy harvesting beam with a piezoelectric material, microfiber composite (MFC), in a unimorph configuration was setup in Matlab using the governing equations of motions of a coupled electromechanical system. The equations of motion were derived using Hamilton’s variational principles and constitutive relations of a piezoelectric material. The mathematical model developed in Matlab was validated with an experiment and frequency response functions. The validated model was used to perform shape optimization so as to obtain the shape of the beam and the patch that harvests the largest voltage. The shape variables were length of the beam (LB), length …

Studies Of Oval Tube And Fin Heat Exchangers, Phillip Nielsen

Undergraduate Student Works

Heating Ventilation and air-conditioning (HVAC) is a system which changes the temperature of the surroundings for the purposes of cooling or heating. This system requires energy to maintain a temperature difference from the outside temperature. Optimizing the flow over the evaporator coils is one way to increase the cooling efficiency. This will reduce the power required to have a sustainable system. Optimizing the flow to increase the energy transfer between the fins and the incoming air could result in a greater Coefficient of Performance (COP). This will be achieved by changing the geometry of the tubes for greater interaction with …

Experimental Study On Compression And Shear Strength Of Cfrp, Joseph Gentile, Ethan Garber

Discovery Day - Prescott

The increasing use of carbon fiber-reinforced polymer (CFRP) in the aerospace industry requires a better understanding of its damage properties. Many modern aircraft under high loads are utilizing this material for their primary structures due to its high strength to weight ratio. However, CFRPs are sensitive to out-of-plane loading such as low-velocity impact and indentation. These damages can reduce the compressive strength significantly without leaving a visible mark on the surface, which is known as Barely Visible Impact Damage (BVID). The behavior and residual strength of CFRPs after impact damage under compressive loading are still not fully understood. Studies of …

Sae Aero West Heavy Lift Competition Team - Eaglenautics, Anthony Pirone, Evan Stuart, Jessica Millard, Nathaniel Scott

Discovery Day - Prescott

ERAU’s SAE Aero Design West Competition team encourages students of all majors who have an interest in the design of heavy-lift cargo and passenger aircraft to design, build, and fly a large RC aircraft to meet a new set of regulations each competition year. Since the team, Eaglenautics, was founded in 2017 it has successfully been to competition once in April 2019 in California. The team’s aircraft flew 4 out of 5 flight rounds, passed all technical inspections, and is now on display in ERAU’s Aero-Fab in the AXFAB. The 2020 competition requirements are unique in that the cargo’s weight-to-volume …

Experimental Evaluation Of Strength Degradation Temperature For Carbon Epoxy Filament Wound Composite, Jai Krishna Mishra, Surya Prakash Rao Ch Dr, Subhash Chandra Bose P Dr, Kishore Nath N Dr, Rama Rao Golla Mr

International Journal of Aviation, Aeronautics, and Aerospace

Polymeric composites have been widely used in various structural and thermal aerospace applications. Polymeric composites having high strength and high modulus reinforcement are ideally suited for lot of critical aerospace applications as structure is designed with high specific strength and high specific modulus. In case of launch vehicles/ missile one such application is design and manufacturing of solid rocket motor casing with polymeric composites as it give high performance and reduces inert weight of propulsion system. The high specific strength and high specific modulus of composite materials makes it ideal choice for designing the composite rocket motor case (CRMC). These …

Open-Ended Capstone Project: Designing And Manufacturing Of A Low-Cost Carbon Fiber Reinforced Composite Suborbital Rocket Payload Housing Using A 3d Printed Core, Garam Kim, Sergey Dubikovsky, Peng Hao Wang, Ronald Sterkenburg

International Journal of Aviation, Aeronautics, and Aerospace

Composite materials are utilized in many industries today due to its high performance and lightweight. However, the part manufacturing process of traditional composites is complicated and often involves high cost. The molds used for composite manufacturing are usually one of the contributors to the high part manufacturing cost. The authors demonstrated in this paper a manufacturing process for a carbon fiber reinforced composite rocket payload housing using an additively manufactured polylactic acid (PLA) payload housing core. The paper also demonstrates the designing and manufacturing of a functional product, which was used in a real-life application, achieved by college undergraduate students. …

In-Situ Measurement Of Resin Shrinkage For Aerospace Components, Samarth Motagi

Doctoral Dissertations and Master's Theses

Resin shrinkage due to chemical changes and thermal gradients plays an important role in the residual stress evolution during composite manufacturing. In this thesis, we develop a new in-situ experimental approach for measuring resin shrinkage during curing with the help of digital image correlation (DIC) instrumented on a specially designed autoclave with borosilicate viewports. The images of the resin sample are captured at regular intervals with the help of DIC to measure the displacement and strains during the curing process. We utilize this method for a comparative analysis of resin shrinkage in two common aerospace epoxies, Epoxy 105 and EPON …

Hybrid Structural Composites With Energy Harvesting Capabilities, Simon Furnes

Doctoral Dissertations and Master's Theses

Hybrid materials have received significant interest due to the potential enhancements they provide over traditional materials such as sensing, actuating, energy scavenging, thermal management, and vibration damping. While traditional materials can be utilized for either one of these functions or loadbearing, the hybrid materials are superior as they allow combination of a wide array of functionalities whilst being suitable for load-bearing purposes.

The goal of this thesis is to elucidate the synergistic effects of hybridization of two piezoelectric materials; zinc oxide nanowires (ZnO NWs) and thin film of lead zirconium titanate (PZT) on the mechanical and energy harvesting of beams …

Thermal Bending, Buckling And Post-Buckling Analysis Of Unsymmetrically Laminated Composite Beams With The Effects Of Moisture And Geometric Imperfections, Claudia Barreno

Doctoral Dissertations and Master's Theses

This thesis is concerned with the analytical study of the thermal bending, buckling, and post-buckling of unsymmetrically laminated composite beams with imperfection under hygrothermal effects. Three different boundary conditions will be considered on this study. The non-linear governing partial differential equations are derived by taking into account the von-Karman geometrical nonlinearity for an imperfect unsymmetrical laminated composite beam. Classical beam theory (CBT) as well as first order shear deformation theory (FSDT) will be used. The effects of temperature, angle of orientation, moisture variations, imperfection, and geometrical parameters, will be evaluated and discussed. Two different laminated composite laminates will be considered: …

Hypervelocity Impact Analysis Of Hybrid Nanocomposite Sensors For Inflatable Space Structures, Yachna Gola

Doctoral Dissertations and Master's Theses

Future space exploration requires easy-to-transport, and easy-to-build and deploy space habitats. NASA and Bigelow Aerospace have collaborated so that human habitation can be made safe and easy with inflatable space habitats (Litteken, 2017). One of the biggest threats faced by these structures in outer space is impact damage by micrometeoroid orbital debris (MMOD) traveling at velocities as high as 15 km/s (Lemmens, Krag, Rosebrock, & Carnelli, 2013). This work presents fabrication and testing of hybrid nanocomposites with carbon nanotubes (CNT) and coarse graphene nanoplatelets (GNP) as fillers and flexible epoxy matrix, that are proposed to be used for sensing the …

Non-Linear Bending Analysis Of Functionally Graded Beams With Spring Constraints And Thermal Effects, Swetha Suresh

Doctoral Dissertations and Master's Theses

No abstract provided.

3d Textile Preforms And Composites For Aircraft Strcutures: A Review, Abbasali Saboktakin

International Journal of Aviation, Aeronautics, and Aerospace

Over the last decades, the development of 3D textile composites has been driven the structures developed to overcome disadvantages of 2D laminates such as the needs of reducing fabrication cost, increasing through-thickness mechanical properties, and improving impact damage tolerance. 3D woven, stitched, knitted and braided preforms have been used as composites reinforcement for these types of composites. In this paper, advantages and disadvantages of each of them have been comprehensively discussed. The fabric architects and their specification in particular stitched preforms and their deformation mode for aerospace applications have been reviewed. Exact insight into various types of damage in textile …

Fe Modeling Methodology For Load Analysis And Preliminary Sizing Of Aircraft Wing Structure, Jun Hwan Jang, Sang Ho Ahn

International Journal of Aviation, Aeronautics, and Aerospace

It is a critical part at the basic design phase of aircraft structural design to build a finite element model and it will have a direct impact on time and cost for airframe structure development. In addition, the objective of finite element model will be varied depending on each design review phase and the modelling methodology varied accordingly. In order to build an effective and economic finite element model, it is required to develop adequate level of modelling methodology based on each design phase and its objectives. Therefore, in this paper, the finite element modeling methodology was presented for internal …