Structures and Materials Commons^™

Made On Mars: Design And Manufacturing Of Structural Polymer-Regolith Composites, Pailey M. Vitale

Williams Honors College, Honors Research Projects

Human exploration of Mars is constrained by harsh environmental conditions and the prohibitive cost of transporting materials from Earth. Long-term sustainability requires the local production of mechanical and structural components using resources available on Mars, thereby minimizing payload mass. This project investigates polymer–regolith composites derived from atmospheric CO₂ and mineral-rich regolith as a pathway toward in-situ manufacturing. These composites, when compatible with additive manufacturing, could replace imported plastics, enable on-demand fabrication, and support closed-loop recycling systems. The objective is to design and evaluate polymer–regolith composites that maintain mechanical integrity and environmental resistance under Martian conditions, including extreme temperature swings, radiation …

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 …

Predictive Structural Modeling In Ansys And Destructive Testing For Composite Structures, Dylan Matthews, Grant Abraham, Andrew Raineri

Williams Honors College, Honors Research Projects

Composite structures are central to the performance and reliability of Zips Racing’s Formula SAE vehicles, yet the team currently relies on historical data and partially unvalidated assumptions when selecting carbon fiber layups. This project aims to establish a quantitative, experimentally validated framework for designing composite components through the integration of simulation modeling, physical fabrication, and destructive mechanical testing. Analytical laminate theory models developed in MATLAB and laminate simulations created in Ansys ACP will be used to predict stiffness, strength, and failure characteristics for a range of candidate layups. These predictions will be validated through controlled testing of fabricated composite coupons …

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 …

Smart Material Actuated Flap, James Lyons, Kristofer Johnson

Williams Honors College, Honors Research Projects

The objective of this project is to develop and evaluate a smart material actuated aerodynamic control surface to determine the viability of these new systems as alternatives to conventional electromechanical and hydraulic systems. The research will begin with the selection of a control surface and actuator design. The concept will then be tailored to create an experimental model for the purposes of this project. Smart materials that suit the model requirements will be selected and procured. Next, the actuators will be shape trained and characterized to meet the model requirements. Then, a benchtop model will be produced for design verification, …

Short Strand Carbon Fiber Reinforced Polylactic Acid Filament For Additive Manufacturing, Dale Chenoweth, Lukas Seggi, Luke Phillips

Williams Honors College, Honors Research Projects

In this design project, the additive manufacturing filament of short strand carbon fiber (SSCF) reinforced polylactic acid (PLA) composite was developed. The micro-size, precision cut SSCFs were mixed with the PLA pellets through a melting homogenization process. Through this process the composite material block is cut and divided into pieces for ease of pelletizing. The material block pieces are then pelletized to be fed through the single screw extruder to develop the SSCF-PLA composite filament. The SSCF-PLA filaments were manufactured with a varying amount of SSCF ranging from 0.5% to 10% of the material block's weight. Development of a 1% …

Inspection/Fault Detection Team, James Worrall

Williams Honors College, Honors Research Projects

Our project deals with a common problem that is encountered with satellites in earth orbit or beyond. It is very common in space for there to be small collisions between satellites and foreign space debris, and it takes a lot of time and money to send a person out to repair the damage caused by the collision. Our goal is to develop a way to perform these repairs autonomously. We plan to develop a way to scan a satellite or spacecraft hull for damage using a robot and then repair the damage while still maintaining the material specifications required for …

Space Force Spacecraft Hull Inspection: Creation Of A Process To Inspect, Compare, And Fault Detect On The Surface Of A Spacecraft Hull, Ethan Rainsburg

Williams Honors College, Honors Research Projects

The Space Force Inspection design project aims to create a system for scanning the hull of a spacecraft, identifying any damage by cross-checking the new scan with a previous scan, and fixing any identified damage picked up by the scan. This project contains key objectives such as defining testable parameters for any given scanner, creating a repeatable process for comparing scans, and automating the process using open-source code and software. The ideal outcome for this project is to have the fully automated system implemented to a robot that is being designed and manufactured by a sister team. Some of the …

Uav To Carry Heavy Loads, Jacob Cannon, Robert Connor Downs, Anthony Orlando

Williams Honors College, Honors Research Projects

Our senior design project aims to develop an innovative Unmanned Aerial Vehicle (UAV) capable of carrying heavy payloads up to 50 lbs. This UAV will address the growing demand for efficient and autonomous cargo transportation, unlocking new possibilities in logistics and remote deliveries. The primary goal is to design, build, and test a robust UAV platform equipped with advanced propulsion systems, stabilizing mechanisms, and a secure payload attachment system. The heavy-lift UAV will be capable of transporting payloads in challenging environments, enhancing its versatility for various industries, including emergency response, disaster relief, and commercial logistics. For the extent of this …

Ambient Temperature Strength Degradation Of A Ceramic Matrix Composite Due To Solid Particle Erosion, Jonathan Clawson

Williams Honors College, Honors Research Projects

Solid particle erosion (SPE) is an issue for aircraft exposed to hard, fine particles, such as sand or dust, that can be ingested into the engine at a high velocity without reaching their melting point, resulting in material removal. SPE can be attributed to the intake of particulate debris from the runway or from airborne particulates. The cumulative mass loss from SPE damage affects the structural integrity and performance of the engine; however, its effects on ceramic matrix composites (CMCs), that are being employed in the aerospace industry, are not well understood in literature. The limited SPE research studies that …

Surface Preparation Study, Ryan Ferguson

Williams Honors College, Honors Research Projects

This work explores a custom air atmospheric pressure plasma treatment (APPT) machine’s effectiveness in cleaning and chemically activating a CFRP surface. It is explore by implementing water contact angle (WCA) measurements, water-break free (WBF) testing, and adhesive tubular lap-joint (TLJ) tensile testing. An 8x3 test matrix of different machine parameters is defined with the bounding conditions being the machine’s capabilities and industry standard recommendations. Each configuration of the test matrix is explored after treatment at multiple time intervals up to 2 weeks afterwards to gain insight into the outlife of the treatments with the intention of adhesively bonding to the …

The Effects Of Geometry And Architecture Of Polymer Matrix Composites On Acoustic Emissions, John J. Bush, Alex D. Swartzentruber, Lukas B. Thompson, Sarah R. Pratt, Chris J. Kuhn

Williams Honors College, Honors Research Projects

The purpose of this project is to study how the variance of the geometry and architecture of polymer matrix composites (PMCs) affect the acoustic emissions measured whilst said structures are subjected to tensile stress. In these tests, a method called Modal AE will be utilized. In Modal AE, some relationships between sources and waves in various materials and geometries are presented in other papers/research. This study will focus on how different thickness and different makeup/ply patterns affect the acoustic emission tests. Some research has been completed and shown how energy attenuation affects the frequency content on PMCs similar to the …

Fuel System To Envelope Interface, James Campbell

Williams Honors College, Honors Research Projects

*NOTE THIS PROJECT IS CONFIDENTIAL*

In this project, I will investigate solutions to interfacing a fuel system with a fabric skin section

Digital Image Correlation System Design, Verification And Analysis, Tyler Kraft, Matthew J. Riczo, Andrew Chong

Williams Honors College, Honors Research Projects

Two dimensional digital image correlation provides an accurate and effective way to capture strain data on test sections with unusual or oblique geometries. The system requires a camera to record video footage, alignment fixtures and software to convert the footage into strain values. The system works by capturing the video footage of a specific portion of the specimen and comparing the movement of selected pixels. This is all done in the software GOM Correlate and Tracker. This test document outlines the setup, procedure, and validation steps to fulfill this goal. The setup involves a camera, tripod, blue lighting, and laser …

Autonomous Payload Design With Systems Engineering, Michael Downs, Christopher James Liebhart 2nd

Williams Honors College, Honors Research Projects

The design will be an autonomous payload consisting of auto deployment of a drone running an autonomous mission of mapping the terrain around a grounded rocket. The project is part of the Akronauts payload project for the 2022 Spaceport competition. It will include the development of a ground station for monitoring and controlling the drone and the transfer of live data to the station and a computer on board the rocket. The project will aim to use system engineering techniques to accomplish this in the hope of providing documentation and thus insight into the best way to develop a multi-disciplinary …

The Design Of The Payload System Of An Aircraft, Ryan Cooper

Williams Honors College, Honors Research Projects

The project group will design and build a system to unload packages for the Zips Aero Design Team's aircraft for the 2021-22 competition year.

Design Of Banner Tow Mechanism For Bush Plane, Kyle Ciarrone, Ivan Martin, Rishabh Gadi, Tyler Brandt

Williams Honors College, Honors Research Projects

The 2019-2020 AIAA DBF objective was to design, build, and test a banner-towing bush plane that carries wooden passengers and luggage. Senior members on the team undertook the creation of the banner tow mechanism subsystem as their senior design project on behalf of the design team due to the challenge of its mechanical design and the aerodynamic considerations regarding its placement and enclosure aboard the aircraft. The competition as well as access to campus resources were canceled due to COVID-19, so full testing and integration of the mechanism was not achieved. However, the engineering design process was experienced from the …

Redesign And Analysis For Landing Gear Components, Daniel Clarke

Williams Honors College, Honors Research Projects

A project for Collins Aerospace, the company I co-op at, where I will redesign several components of a landing gear for a military program. Any structural/stress analysis will also be performed. The goal is to reduce weight while maintaining strength and structural integrity.

Rocket Motor Nozzle, Corey Hillegass

Williams Honors College, Honors Research Projects

For this honors research and senior design project, the authors will research, analyze, and manufacture a rocket motor nozzle for the Akronauts rocket design team. This research and design project will improve how the rocket design team will decide and manufacture nozzles going forward. The impact of this improvement allows the rocket design team to take steps toward being self-sustaining by manufacturing student designed parts as opposed to commercially bought parts. This will not only be successful in increasing student impact on future designs, but also provides a technical challenge for the authors and will present as an impressive feat …

Improving The Delivered Specific Impulse Of Composite Rocket Propellant Through Alteration Of Chemical Composition: Methodology And Parameters For Characterization Of Propellant And Validation Of Simulation Software Common To The Amateur Rocketry Community, Isaac O'Brien, Austin Ryan

Williams Honors College, Honors Research Projects

In this study, two solid composite rocket propellants were designed utilizing ProPEP, a rocket propellant formulation software common in the amateur and hobby rocketry communities. The two propellants were designed to optimize specific impulse relative to a literature propellant designed by 1020 Research Labs. The literature propellant was also tested in order to validate the design of experiment as well as the mixing and testing procedures. All three propellants, which includes the literature propellant RCS-P, and the two novel propellants AKR-P1 and AKR-P2 were characterized with static tests. The results of the static tests provide data on propellant performance and …

Prototype Landing Gear Conceptual And Embodiment Design, Derek Carr

Williams Honors College, Honors Research Projects

Collin’s Aerospace Mechanical systems engineering was tasked with designing a set of landing gear for an undisclosed project. The landing gear is required to comply with customer specifications, coordinate systems, and overall landing gear performance. The purpose of this project is to document the conceptual and embodiment design process for an articulated main landing gear system. Unfortunately, due to high expenses and high lead times required for 300M stainless steel components, no full size prototype can be produced within the timeframe of this report. Instead, this document should be viewed as a process mapping guide for initial landing gear design …

Interlaminar Damage Detection In Composite Materials, Hariharan Rangarajan

Williams Honors College, Honors Research Projects

Using ceramic matrix composites (CMCs) for high-temperature applications in jet engines increases durability and reduces weight and cooling requirements resulting in improved efficiency and fuel savings. Understanding, detecting, and monitoring different types of damage is essential to achieve optimal performance of CMC components. The Direct Current Potential Drop (DCPD) method is a non-destructive technique of estimating damage in composite materials.

DCPD technique works by measuring nodal potential differences when current is flown through the material. Direct current spreading in different woven and laminate composites is modeled to follow a ladder resistor network in which the nodal voltages decrease exponentially as …

Guardian Condor, Kevin Bayonnet

Williams Honors College, Honors Research Projects

Our group has teamed up with Dr. Williams from Discovery Lab Global to research the capabilities of 3D printed Unmanned Aerial Vehicles (UAVs). The goal of our project is to deliver a 3D printed glider prototype which can later be fitted with electronics for controlled flight. The glider must also carry a payload of 2 to 3 pounds in addition to the electronics. These requirements must be met all while using a basic 3D printer with low cost plastic

Throughout the Fall 2017 semester, our group made a significant amount of progress by completing the conceptual design portion of the …

Design Of Shape-Conforming Nosecone For Optimal Fluid Flow From Transonic To Supersonic Range, Anna Tombazzi

Williams Honors College, Honors Research Projects

Modern flight vehicles, such as rockets, missiles, and airplanes, experience a force caused by forebody wave drag during the flight. This drag force is induced when the frontal point of each vehicle breaks the pressure wave during flight. Efforts to reduce this wave drag force to improve flight efficiency include modifying the nosecone profile of the flight vehicles to lower the drag force.

This project revolved around creating a design to make the transformation of nosecone shapes from a ¾ Parabolic profile to a ½ Power Series profile possible, mid-flight. Using a novel nosecone assembly, shape memory alloys (SMAs) and …

Design Of The Structural And Propulsion Systems For The 2015 University Of Akron Rocket Team, Kyle W. Dehoff, Nicholas J. Hrusch

Williams Honors College, Honors Research Projects

No abstract provided.