Structures and Materials Commons^™

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 …

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

Master's Theses

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

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

Master's Theses

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

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, …

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 …

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 …

Performance Of Multi-Composite Materials With Corrugated And Cell Geometries Under Low-Velocity Impact, Lukas S. Kolbl

Master's Theses

Composite structures have demonstrated great potential to improve mechanical performance in various applications, including ballistics protection. This study demonstrates that the integration of geometrically optimized composites into core-face sheet assemblies provide great impact resistance. The research investigated the performance of two composite manufacturing methods under low-velocity impact through residual strength and damage comparisons. Corrugated core composites were produced with traditional manufacturing methods, namely compression molding, using twelve stacking sequences. These stacking sequences were chosen to represent four laminate groups, where a unique fiber orientation scheme was employed across three laminate thicknesses (6, 8, and 12 layers). In contrast, honeycomb and …

Sizing Wind Tunnel Heater For High Enthalpy Conditions, Justin M. Slavick

Master's Theses

This paper determines the feasibility of adding a heater to an existing blowdown supersonic wind tunnel to unlock new high-enthalpy test applications, considering cost and power requirements at a variety of different states. This process includes both modeling the current range of test section properties in Cal Poly's blowdown wind tunnel and determining the new range of properties that a heat exchanger could induce. These results are verified with a computational fluid dynamics study. Additionally, sublimation and ablation properties of materials are explored to create appropriate models to study atmospheric re-entry once the heat exchanger is implemented.

It is found …

The Effect Of Atomic Oxygen On Additively Manufactured Materials, Ryan Grogan

Master's Theses

Additive manufacturing (AM) is a rapidly developing manufacturing method utilized in fields such as the aerospace industry. In-space AM is a technology of interest for the future of spaceflight, including on-orbit manufacturing. However, AM materials are subject to defects that may impact their performance in space-based applications. How these defects change the material’s reaction to the space environment, specifically atomic oxygen (AO), has only recently been explored. AO is a highly corrosive, dominant constituent in low Earth orbit that causes continuous erosion of spacecraft surfaces. The effect of AO on various AM materials is investigated in this thesis. Stainless steel, …

Composite Solid Rocket Motor Case Optimization With Matlab Genetic Algorithm, Aleksandr Breit

Master's Theses

This study utilizes MATLAB genetic algorithm (GA) to perform optimization on a solid rocket motor (SRM) chamber structure. The (SRM) structure is modelled as a cylindrical composite laminate where unidirectional fiber orientations are the primary design variable in the optimization problem formulation. Additional design variables such as chamber length, diameter, and internal pressure are altered along with the ply angles to minimize the safety margin towards a near-zero value and encourage efficient layup design. Classical lamination theory with Tsai-Wu failure criterion are used to calculate ply-level safety margins. A thickness minimization scheme is employed to reduce the ply count from …

Effects Of Atomic Oxygen On Outgassing Of Silicone Materials, Samuel Westrick

Master's Theses

An important consideration for spacecraft material selection is the space environment that the spacecraft will be operating in. Two features of the space environment that drive material selection are material outgassing and the presence of atomic oxygen in low Earth orbit (LEO). Materials that are considered for use in space are tested to be able to understand how they’ll outgas on orbit and how they’ll respond to interactions with atomic oxygen. However, testing to understand how atomic oxygen interaction with a material will affect how the material will outgas is rare and not standardized. This thesis used a vacuum chamber …

Structural Loads And Preliminary Structural Design For A World Speed Record-Breaking Turbo-Prop Racing Airplane, Matthew G. Slymen

Master's Theses

The Cal Poly SLO Turbo-Prop Racer project aims to design a world speed record-breaking aircraft, capable of flying more than 550 miles per hour on a 3-kilometer closed course. To further this endeavor, this thesis presents the calculations of load distributions across the aircraft’s wing and tail and preliminary structural estimates of primary structural components for verification of the loads calculations and for use in a future finite element model. The aircraft’s fundamental design characteristics effect on the structure of the aircraft, namely the unique Y-tail design, are first examined. Then, loads are calculated in accordance with the regulation dictated …

Aeroelastic Analysis Of Small-Scale Aircraft, Kent Roberts

Master's Theses

The structural design of flight vehicles is a balancing act between maximizing loading capability while minimizing weight. An engineer must consider not only the classical static structural yielding failure of a vehicle, but a variety of ways in which structural deformations can in turn, affect the loading conditions driving those deformations. Lift redistribution, divergence, and flutter are exactly such dynamic aeroelastic phenomena that must be properly characterized during the design of a vehicle; to do otherwise is to risk catastrophe. Relevant within the university context is the design of small-scale aircraft for student projects and of particular consideration, the DBF …

Prediction Of In-Plane Stiffnesses And Thermomechanical Stresses In Cylindrical Composite Cross-Sections, Bryson M. Chan

Master's Theses

Accurate mechanical analysis of composite structures is necessary for the prediction of laminate behavior. Cylindrical composite tubes are a mainstay in many structural applications. The fundamental design of circular composite cross-sections necessitates the development of a comprehensive composite lamination theory. A new analytical method is developed to characterize the behavior of thin-walled composite cylindrical tubes using a modified plate theory. A generated numerical solver can predict properties such as axial stiffness, bending stiffness, layer stresses, and layer strains in composite tubes subjected to combined mechanical loading and thermal effects. The model accounts for the curvature by transforming and translating the …

Comparing Radiation Shielding Potential Of Liquid Propellants To Water For Application In Space, John Czaplewski

Master's Theses

The radiation environment in space is a threat that engineers and astronauts need to mitigate as exploration into the solar system expands. Passive shielding involves placing as much material between critical components and the radiation environment as possible. However, with mass and size budgets, it is important to select efficient materials to provide shielding. Currently, NASA and other space agencies plan on using water as a shield against radiation since it is already necessary for human missions. Water has been tested thoroughly and has been proven to be effective. Liquid propellants are needed for every mission and also share similar …

Design, Validation, And Verification Of The Cal Poly Educational Cubesat Kit Structure, Nicholas B. Snyder

Master's Theses

In this thesis, the development of a structure for use in an educational CubeSat kit is explored. The potential uses of this kit include augmenting existing curricula with aspects of hands on learning, developing new ways of training students on proper space systems engineering practices, and overall contributing to academic capacity building at Cal Poly and its collaborators. The design improves on existing CubeSat kit structures by increasing accessibility to internal components by implementing a modular backplane system, as well as adding the ability to be environmentally tested. Manufacturing of the structure is completed with both additive (Fused Deposition Modeling …

Development Of An Analysis Tool And Weight Estimation Method For Aircraft Wing Structures, Kevin M. Barton

Master's Theses

The goal of this effort was to build an analysis tool for aircraft wings and incorporate it into a program that optimizes the wing structure for the lowest weight for the conceptual design phase. The analysis tool calculates the internal stresses in primary load carrying members using established analysis methods for semimonocoque beams. Via a Graphical User Interface (GUI) built in MATLAB, the user can define the structural layout and material properties of the load carrying members. The program requires a degenerate geometry model built with Vehicle Sketch Pad (OpenVSP) to define the outer mold line (OML) of the wing, …

Performance Enhancement And Characterization Of An Electromagnetic Railgun, Paul M. Gilles

Master's Theses

Collision with orbital debris poses a serious threat to spacecraft and astronauts. Hypervelocity impacts resulting from collisions mean that objects with a mass less than 1g can cause mission-ending damage to spacecraft. A means of shielding spacecraft against collisions is necessary. A means of testing candidate shielding methods for their efficacy in mitigating hypervelocity impacts is therefore also necessary. Cal Poly’s Electromagnetic Railgun was designed with the goal of creating a laboratory system capable of simulating hypervelocity (≥ 3 km/s) impacts. Due to several factors, the system was not previously capable of high-velocity (≥ 1 km/s) tests. A deficient projectile …

A Comparison Of Crushing Parameters Of Graphite Composite Thin-Walled Cylinders Cured In Low And High Pressures, Trenton John Matson

Master's Theses

Out-of-Autoclave (OoA) processes for manufacturing aerospace-grade parts needs to be better understood to further the development and success of industries that are manufacturing reusable launch vehicles, military and commercial aircraft, and spacecraft. Overcoming the performance limitations associated with OoA, also known as low-pressure prepreg curing, methods (void count, energy absorption, etc.) will help decrease the costs associated with aerospace composite manufacturing and the negative environmental effects correlated with high-pressure composite curing methods. Experimental, theoretical, and numerical approaches are used to explore both low and high-pressure curing cycles and how the two different processes affect final cured parts. Quasi-static uniaxial compression …

The Effects Of Atomic Oxygen On Patch Antenna Performance And Lifetime, Max J. Barta

Master's Theses

The space environment is a volatile and challenging place for satellites to survive in. For Low Earth Orbiting (LEO) satellites, atomic oxygen (AO) is a constant corrosive effect that degrades the outer surface of satellites over long durations. Atomic oxygen exists in the atmosphere between 180 and 675 km and has a relatively high energy at 4.5 eV, which allows AO to break molecular bonds in materials on the surfaces of spacecraft. As the number and complexity of CubeSat missions increase, there is an increased risk that AO degradation on commercial off the shelf parts (COTS), such as antenna, could …

Effects Of Corrugations On Stiffness Properties Of Composite Beams For Structural Applications, Jane Xiao

Master's Theses

Composites have high strength-to-weight ratios, which is particularly desired for applications with weight restrictions. Common composite materials such as carbon fiber reinforced plastic (CF) and fiber glass reinforced plastic (FG) were used in this research. While composite materials possess high stiffness and strength properties, the stiffness of composite laminates may be maximized by changing the geometry. By adding corrugations, the flexural stiffness is increased in one direction compared to the stiffness of a flat part with the same amount of material. Thus, stiffness increases without a change in weight. The primary goal of this research was to investigate the stiffness …

Atomic Oxygen Effects On Particulate Contamination And Short Beam Strength Of Carbon Composites, Marlee K. Litzinger

Master's Theses

In order to design a successful space system, the unique challenges of the space environment it will operate in must be considered during the design process. Atomic oxygen (AO) is a detrimental environmental effect found in Low Earth Orbit (LEO) that affects spacecraft surfaces by oxidizing and eroding material over time, particularly polymers. Carbon fiber/epoxy composites are a commonly used spacecraft material affected by AO exposure. Carbon composites are used as a structural material, such as on solar panels; their large surface area therefore is a potential contamination source to sensitive components. The Space Environments and Testing Lab at California …

Effect Of Aerogel On The Thermal Performance Of Corrugated Composite Sandwich Structures, Jacob Dillon Chess

Master's Theses

Current insulation solutions across multiple industries, especially the commercial sector, can be bulky and ineffective when considering their volume. Aerogels are excellent insulators, exhibiting low thermal conductivities and low densities with a porosity of around 95%. Such characteristics make aerogels effective in decreasing conductive heat transfer within a solid. These requirements are crucial for aerospace and spaceflight applications, where sensitive components exist among extreme temperature environments. When implemented into insulation applications, aerogel can perform better than existing technology while using less material, which limits the amount of volume allocated for insulation. The application of these materials into composites can result …

An Evaluation Of Ultrasonic Shot Peening And Abrasive Flow Machining As Surface Finishing Processes For Selective Laser Melted 316l, Rhys Gilmore

Master's Theses

Additive Manufacturing, and specifically powder bed fusion processes, have advanced rapidly in recent years. Selective Laser Melting in particular has been adopted in a variety of industries from biomedical to aerospace because of its capability to produce complex components with numerous alloys, including stainless steels, nickel superalloys, and titanium alloys. Post-processing is required to treat or solve metallurgical issues such as porosity, residual stresses, and surface roughness. Because of the geometric complexity of SLM produced parts, the reduction of surface roughness with conventional processing has proven especially challenging. In this Thesis, two processes, abrasive flow machining and ultrasonic shot peening, …

Modification Of A Ground Based Atomic Oxygen Simulation Apparatus To Accommodate Three Dimensional Specimens, Charles Ward

Master's Theses

The space environment presents various challenges when designing systems and selecting materials for applications beyond Earth’s atmosphere. For mission success, these challenges must be considered. One of the detrimental aspects of the space en- vironment is Atomic Oxygen, AO. Only present in harmful quantities in Lower Earth Orbit, LEO, AO causes significant damage to materials by breaking molecular bonds. California Polytechnic State University’s, Cal Poly’s, space environments laboratory features an apparatus capable of simulating this environment. Very thin or short samples were tested to observe the mass loss due to erosion of the sample material. Recent modifications to the system …

A Comparison Study Of Composite Laminated Plates With Holes Under Tension, Joun S. Kim

Master's Theses

A Comparison Study of Composite Laminated Plates with Holes under Tension

A study was conducted to quantify the accuracy of numerical approximations to deem sufficiency in validating structural composite design, thus minimizing, or even eliminating the need for experimental test. Error values for stress and strain were compared between Finite Element Analysis (FEA) and analytical (Classical Laminated Plate Theory), and FEA and experimental tensile test for two composite plate designs under tension: a cross-ply composite plate design of [(0/90)4]s, and a quasi-isotropic layup design of [02/+45/-45/902]s, each with a single, centered hole of 1/8” diameter, and 1/4" diameter (four sets …

Wing Deflection Analysis Of 3d Printed Wind Tunnel Models, Matthew G. Paul

Master's Theses

This work investigates the feasibility of producing small scale, low aerodynamic loading wind tunnel models, using FDM 3D printing methods, that are both structurally and aerodynamically representative in the wind tunnel. To verify the applicability of this approach, a 2.07% scale model of the NASA CRM was produced, whose wings were manufacturing using a Finite Deposition Modeling 3D printer. Experimental data was compared to numerical simulations to determine percent difference in wake distribution and wingtip deflection for multiple configurations.

Numerical simulation data taken in the form of CFD and FEA was used to validate data taken in the wind tunnel …

Optimum Design Of Composite Wing Spar Subjected To Fatigue Loadings, Juan Reuben Lazarin

Master's Theses

Composites are now being incorporated into aircraft designs because of their high strength to weight ratio compared to traditional metal materials. Due to the complexity of the material, composite parts are presently being over designed to satisfy static and fatigue requirements. A greater understanding of composite fatigue behavior will allow for even greater weight savings leading to increased fuel economy. A critical part of an aircraft that is subjected to fatigue bending loads are its wings. The forces acting on the wings include its lift distribution, powerplant, and fuel which can be carried in the wing body. When in flight …

The Effect Of Biocomposite Material In A Composite Structure Under Compression Loading, Benjamin Andrew Sweeney

Master's Theses

While composite structures exhibit exceptional strength and weight saving possibilities for engineering applications, sometimes their overall cost and/or material performance can limit their usage when compared to conventional structural materials. Meanwhile ‘biocomposites’, composite structures consisting of natural fibers (i.e. bamboo fibers), display higher cost efficiency and unique structural benefits such as ‘sustainability’. This analysis will determine if the integration of these two different types of composites are beneficial to the overall structure. Specifically, the structure will consist of a one internal bamboo veneer biocomposite ply; and two external carbon fiber weave composite plies surrounding the bamboo biocomposite. To acquire results …

Development Of Cal Poly's Shock Table, Christopher D. Risner

Master's Theses

Shock is one of the environmental tests that a spacecraft must pass before being cleared for launch. Shock testing poses a challenging data acquisition issue and careful selection of equipment is crucial to creating a successful shock test facility. Cal Poly’s CubeSat programs can currently perform all environmental testing other than shock themselves, so a quality shock table would be useful. Previous groups of students had developed a shock table, and this paper details the improvement and characterization of that shock table’s behavior. Several adjustable parameters were tested and documented to discover trends in the shock table’s response to an …