Structures and Materials Commons^™

Cubesat Adcs Validation And Testing Apparatus, Jacob Stevens

Honors Theses

The WALI team at Western Michigan University requested a test environment to validate their CubeSat’s de-tumbling control system and hardware. The test environment required a Helmholtz cage and spherical air bearing. The Helmholtz cage provides an adjustable magnetic field to simulate low earth orbit; the spherical air bearing simulates the friction free environment the CubeSat will experience in space. In conjunction, the two components create an adjustable system that simulates a satellite in low earth orbit.

Nanostructured Morphologies In Glassy Polymer Networks, Brian Greenhoe

Dissertations

The body of this work describes a novel approach for the dispersion of multi-walled carbon nanotubes in a high T_g epoxy prepolymer matrix using a twin screw high-shear continuous reactor. The method demonstrated improves on previous dispersion methods in several ways. It offers increased efficiency through excellent heat transfer, while being solvent-less, scale-able, and tailorable to drive dispersion states to judiciously chosen dispersion states. Furthermore, it was shown that dispersion state and agglomerate morphology can be directed, in several ways, through processing conditions and also by controlling the matrix viscosity profile through cure. Broadband dielectric spectroscopy, optical hot-stage microscopy, …

Performance Characterization Of Ceramic Matrix Composites Through Uniaxial Monotonic Tensile Testing, Jóhannes Pétursson

Doctoral Dissertations and Master's Theses

Ceramic matrix composite (CMC) samples were tested in order to characterize their mechanical performance and provide metrics for material process refinement and component design. Monotonic, uniaxial tensile testing of an uncoated carbon fiber reinforced silicon carbide ceramic at room temperature was performed following ASTM standard C1275 to measure ultimate tensile strength and elastic modulus. Equipment verification was carried out through alignment measurement with a gaged tensile specimen using ASTM E1012 to ensure the monotonic nature of the testing equipment. Tensile strength data was treated with Weibull statistical models to produce A and B-basis strength properties for design values.

An alternative …

Windshield Defrost And Deice Using Carbon Nanotube Composite, Santhosh Kumar Loganathan

Doctoral Dissertations and Master's Theses

Carbon nanotubes (CNT) are well known for their high thermal and electrical conductivities and can offer a great advantage by converting the applied electrical energy into instant heat with minimum energy loss. The goal of this research is to develop a very thin CNT layer sandwiched between two layers of glass substrate in order to generate instant heat through electrodes. The thin CNT layer is fabricated using the CNTRENETM solution, which is a mixture of single-walled nanotubes (SWNTs) (~75%), double-walled nanotubes (DWNTs), and multi-walled nanotubes (MWNTs) with an average CNT length of ~0.4 - 0.6 μm. The thin layer is …

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 …

Effects Of The Cooling Rate On The Shear Behavior Of Continuous Glass Fiber/Impact Polypropylene Composites (Gf-Ipp), H. Wafai, G. Lubineau, A. Yudhanto, M. Mulle, W. Schijve, N. Verghese

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Fiber-reinforced composites with improved dissipation of energy during impact loading have recently been developed based on a polypropylene copolymer commonly called impact polypropylene (IPP). Composites made of IPP reinforced with glass fibers (GF) are particularly attractive to the automotive industry due to their low cost and good impact resistance. In such composites, the cooling rate varies depending on processing techniques and manufacturing choices. Here, we study the effects of the cooling rate of GF-IPP composites on shear behavior, which is critical in impact applications, using [±45]s monotonic and cyclic (load/unload) tensile specimens. The specimens were manufactured under a wide range …

Finite Element Simulation Of Pzt-Aided Interrogation Of Composite Laminates Exhibiting Damage, Amany Micheal, Yehia Bahei-El-Din

Centre for Advanced Materials

Piezoelectricity has proved effective in capturing changes in structures caused by various damage mechanisms. In one approach, piezoelectric wafer active sensors (PWAS) are mounted on the surface of the host structure and utilized as both actuators and sensors to interrogate the structure and monitor its health. This is achieved by subjecting the PWAS to a transient electric pulse and reading the resulting voltage. Changes in the stiffness of the substrate due to structural damage affect the response of the PWAS, which could be correlated to integrity of the structure. Applying this technique to fibrous composite laminates encounters particular challenges due …

Characterising The Loading Direction Sensitivity Of 3d Woven Composites: Effect Of Z-Binder Architecture, Mohamed Nasr Saleh, Arief Yudhanto, Prasad Potluri, Gilles Lubineau, Constantinos Soutis

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Three different architectures of 3D carbon fiber woven composites (orthogonal, ORT; layer-to-layer, LTL; angle interlock, AI) were tested in quasi-static uniaxial tension. Mechanical tests (tensile in on-axis of warp and weft directions as well as 45° off-axis) were carried out with the aim to study the loading direction sensitivity of these 3D woven composites. The z-binder architecture (the through-thickness reinforcement) has an effect on void content, directional fiber volume fraction, mechanical properties (on-axis and off-axis), failure mechanisms, energy absorption and fiber rotation angle in off-axis tested specimens. Out of all the examined architectures, 3D orthogonal woven composites (ORT) demonstrated a …

Simulation Investigation Of Temperature Distribution In Large Aluminium Panel During Autoclave Age Forming Process, Yongqian Xu

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

Multi-Dome Forming Of A Ti–Al–Mn Alloy, Sergey Aksenov, Aleksey Kolesnikov, Ivan Zakhariev

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

Large Linear Magnetoresistance In Heavily-Doped Nb:Srtio3 Epitaxial Thin Films, Hyunwoo Jin, Keundong Lee, Seung-Hyub Baek, Jin-Sang Kim, Byung-Ki Cheong, Bae Ho Park, Sungwon Yoon, B. J. Suh, Changyoung Kim, Sung S. Ambrose Seo, Suyoun Lee

Physics and Astronomy Faculty Publications

Interaction between electrons has long been a focused topic in condensed-matter physics since it has led to the discoveries of astonishing phenomena, for example, high-T_c superconductivity and colossal magnetoresistance (CMR) in strongly-correlated materials. In the study of strongly-correlated perovskite oxides, Nb-doped SrTiO₃ (Nb:SrTiO₃) has been a workhorse not only as a conducting substrate, but also as a host possessing high carrier mobility. In this work, we report the observations of large linear magnetoresistance (LMR) and the metal-to-insulator transition (MIT) induced by magnetic field in heavily-doped Nb:STO (SrNb_0.2Ti_0.8O₃) epitaxial thin …

Mechanical Properties And Fatigue Behavior Of Unitized Composite Airframe Structures At Elevated Temperature, Mohamed Noomen

Theses and Dissertations

The tension-tension fatigue behavior of a newly developed unitized composite material system was investigated. The unitized composite consisted of a polymer matrix composite (PMC) co-cured with a ceramic matrix composite (CMC). The PMC portion consisted of an NRPE high-temperature polyimide matrix reinforced with carbon fibers woven in an eight harness satin weave (8HSW). The CMC layer is a single-ply non-crimp 3D orthogonal weave composite consisting of ceramic matrix reinforced with glass fibers. In order to assess the performance and suitability of this composite for use in aerospace components designed to contain high-temperature environments, mechanical tests were performed under temperature conditions …

From Xst To F-117a, Alan Brown

ERAU Prescott Aviation History Program

Learn the remarkable story of stealth technology from the man often referred to as “Mr. Stealth.” From 1975-1989 Alan Brown was a member of Lockheed “Skunk Works”, becoming program manager & chief engineer for the F-117A Stealth Fighter from initial concept until the first production aircraft was built, 1978 to 1982. Hear the inside story of the many challenges faced by the stealth program and how they were solved.

Experimentation Of Mode I And Mode Ii Fracture Of Uni-Directional Composites And Finite Element Analysis Of Mode I Fracture Using Cohesive Contact, Joseph Daniel Garrett

Master's Theses

As the use of fiber-reinforced composites has increased over the decades, so has the need to understand the complexity of their failure mechanisms as engineers seek to improve the damage tolerance of composite laminated structures. One of the most prevalent and limiting mode of failure within composite laminates is delamination, since it not only reduces a structures stiffness and strength, but can be very difficult to detect without the use of special non-destructive equipment. Industry testing organizations have utilized several fracture tests in order to characterize the fracture toughness of composite materials under different loading conditions. For this research, ASTM …

Evaluation Of Strain Distortion Correction Protocol Using Scanning Electron Microscopy And Digital Image Correlation, Alexandra Mallory, Alberto Mello, Michael Sangid

The Summer Undergraduate Research Fellowship (SURF) Symposium

Scanning electron microscopy in combination with digital image correlation (SEM-DIC) is a useful technique for measuring strain in materials at the micro-scale. In particular, it can be used to identify micro-scale strain localizations that are the precursor to material failure. While SEM produces high resolution images of the microstructure, the images also contain a large amount of distortion that, during DIC, will result in distorted strain values that require correction. In this project, a nickel-based alloy underwent cyclic mechanical fatigue at three different high temperatures to a targeted maximum strain. Scanning electron microscopy imaging was done on a 200x150μm area …

Metamodels Of Residual Stress Buildup For Machining Process Modeling, Stuart B. Mccrorie, Michael Sangid

The Summer Undergraduate Research Fellowship (SURF) Symposium

In the process of machining materials, stresses, called residual stresses, accumulate in the workpiece being machined that remain after the process is completed. These residual stresses can affect the properties of the material or cause part distortion, and it is important that they be calculated to prevent complications from arising due to the residual stresses. However, these calculations can be incredibly computationally intensive, and thus other methods are needed to predict the residual stresses in materials for quick decision-making during machining. By using metamodels - a method of representing data where few data points exist - we can achieve an …

Predicting Flexural Strength Of Composite Honeycomb Core Sandwich Panels Using Mechanical Models Of Face Sheet Compressive Strength, Nicholas Bruffey, William Shiu

Materials Engineering

The design process at Zodiac Aerospace requires the ability to accurately predict the strength of a composite honeycomb core sandwich panel to adhere to strict FAA regulations. The most common failure mode in long beam composites is in compression. Following ASTM D7249 for a four-point bend test of a long beam flexural test, a mechanical model has been developed that relates the compressive strength of glass fiber face sheets to the flexural strength of the sandwich panel. Zodiac does not currently have data on the compressive strength of the face sheets, so testing was performed to find this property. Asymmetric …

Controlling Grain Size In Cold Worked And Annealed 1100 Aluminum To Optimize Ductility In Rocket Diaphragm Systems, Ryan Lewis, Bryce Simmons, Jessica Williams

Materials Engineering

Liquid propellant rocket diaphragms require extreme ductility. 1100 Aluminum is used for its high ductility, but the post-processing cold work and subsequent anneal result in excessively large grains. The effect of heat treatment and cold work on grain size in 1100 aluminum was explored. The samples were cold worked to 0, 5, 10, 15 and 30% using tensile elongation. The samples were then heat treated per AMS 2770 with either a "Steel Conduction" (1000 – 1150°F/min) or a "Production" (16 – 18°F/min) heating rate. The grain size of the samples were measured using the mean lineal intercept method. The grain …

Design, Manufacture, Dynamic Testing, And Finite Element Analysis Of A Composite 6u Cubesat, Yanina Soledad Hallak

Master's Theses

CubeSats, specially the 6U standard, is nowadays the tendency where many developers point towards. The upscaling size of the standard and payloads entail the increase of the satellite overall mass. Composite materials have demonstrated the ability to fulfill expectations like reducing structural masses, having been applied to different types of spacecraft, including small satellites.

This Thesis is focused on designing, manufacturing, and dynamic testing of a 6U CubeSat made of carbon fiber, fiberglass, and aluminum.

The main objective of this study was obtaining a mass reduction of a 6U CubeSat structure, maintaining the stiffness and strength. Considering the thermal effects …

Improving Damage Tolerance Of Composite Sandwich Structures Subjected To Low Velocity Impact Loading: Experimental And Numerical Analysis, Ravi B. Gondaliya

Doctoral Dissertations and Master's Theses

Sandwich structures with composite facing skins have seen applications in variety of sectors including aerospace and automobile, owing to their high specific mechanical properties. However, there is a need to develop better damage tolerant sandwich structures since conventional composite facing skins exhibit low impact resistance in the transverse direction. Here, composite skin sandwich structures with three different impact resistant core materials were fabricated and tested both experimentally and numerically. Neat CFRP and 2024-T3 aluminum alloy sheets were also investigated. Cores utilizing impact resistant D3O® were found to have very favorable weight specific energy absorbing properties at higher impact velocities as …

Effects Of Curing Cycle And Loading Rates On The Bearing Stress Of Double Shear Composite Joints, Mateja Andrejic

Master's Theses

In the last few decades, there has been a shift to using more lightweight materials for the potential of fuel consumption reduction. In the Aerospace Industry, conventional metal structures are being replaced by advanced composite structures. The major advantage of an advanced composite structure is the huge reduction in the number of parts and joints required. Also composite materials provide better resistance to creep, corrosion, and fatigue. However, one cannot eliminate all the joints and attachments in an aircraft’s structure. Eliminating structural joints is impractical in present-day aircraft because of the requirements for inspection, manufacturing breaks, assembly and equipment access, …

Effects Of Additive Manufacturing Methods On The Dynamic Properties Of 15-5ph Stainless Steel, Allison A. Dempsey

Theses and Dissertations

Experimental research was conducted to determine the dynamic properties and characterize the microstructure of 15-5PH Stainless Steel manufactured through Direct Metal Laser Sintering (DMLS) additive manufacturing (AM) processes and heat treated using common heat treatment protocols. A thorough understanding of the material's properties is necessary before such parts are utilized in an operational capacity. Of the five builds, two deviated significantly from the specified composition of 15-5PH stainless steel. The remaining three builds, possessing the desired composition and crystalline structure, were tested in compression and tension at two strain rates. Tension tests using a reflected wave and a momentum trap …

Fatigue Behavior Of An Advanced Sic/Sic Composite At 1300° C In Air And Steam, Michael D. Lee

Theses and Dissertations

The fatigue behavior of an advanced silicon carbide/silicon carbide (SiC/SiC) ceramic matrix composite (CMC) was investigated at 1300 ºC in laboratory air and in steam environments. The composite was manufactured using chemical vapor infiltration (CVI). The composite consisted of an oxidation-inhibited matrix, which was comprised of alternating layers of silicon carbide and boron carbide and was reinforced with laminated Hi-Nicalon™ fibers woven in a plain weave. Fiber preforms had pyrolytic carbon fiber coating with boron carbon overlay applied. Two specimen geometries were evaluated, a dog bone and an hourglass geometry. Tensile stress-strain behavior and tensile properties were evaluated at 1300 …

Creep Of Hi-Nicalon™ S Ceramic Fiber Tows At 700°C In Air And In Silicic Acid-Saturated Steam, Matthew W. Piper

Theses and Dissertations

Aircraft structural and engine components are subjected to elevated temperature and steam environments during operation. Turbine blades experience particularly harsh conditions that are approaching the operating temperature limits of current Nickel-based superalloys even with active cooling. Ceramic matrix composites (CMCs), which demonstrate high specific strength and specific stiffness and maintain these properties at elevated temperatures such that active cooling is not required, are prime candidates to replace superalloys as the materials for turbine blades. Ceramic matrix composites are composite materials that consist of a ceramic matrix with fiber reinforcement. This research investigated a silicon carbide (SiC) fiber, Hi-Nicalon™ S, which …

Effect Of Low Velocity Impact On The Vibrational Behavior Of A Composite Wing, Richard M. De Luna

Master's Theses

Impact strength is one of the most important structural properties for a designer to consider, but it is often the most difficult to quantify or measure. A major concern for composite structures in the field is the effect of foreign objects striking composites because the damage is often undetectable by visual inspection. The objective for this study was to determine the effectiveness of using dynamic testing to identify the existence of damage in a small scale composite wing design. Four different impact locations were tested with three specimens per location for a total of 12 wings manufactured. The different impact …

Thermal Transport Properties Of Dry Spun Carbon Nanotube Sheets, Heath E. Misak, James L. Rutledge, Eric D. Swenson, Shankar Mall

Faculty Publications

The thermal properties of carbon nanotube- (CNT-) sheet were explored and compared to copper in this study. The CNT-sheet was made from dry spinning CNTs into a nonwoven sheet. This nonwoven CNT-sheet has anisotropic properties in in-plane and out-of-plane directions. The in-plane direction has much higher thermal conductivity than the out-of-plane direction. The in-plane thermal conductivity was found by thermal flash analysis, and the out-of-plane thermal conductivity was found by a hot disk method. The thermal irradiative properties were examined and compared to thermal transport theory. The CNT-sheet was heated in the vacuum and the temperature was measured with an …

Process Monitoring Of Glass Reinforced Polypropylene Laminates Using Fiber Bragg Gratings, M. Mulle, H. Wafai, A. Yudhanto, G. Lubineau, R. Yaldiz, W. Schijve, N. Verghese

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Hot-press molding of glass-fiber-reinforced polypropylene (GFPP) laminates was monitored using longitudinally and transversely embedded fiber Bragg gratings (FBGs) at different locations in unidirectional laminates. The optical sensors proved to efficiently characterize some material properties; for example, strain variations could be related physical change of the laminate, revealing key transition points such as the onset of melt or solidification. These results were confirmed through some comparison with traditional techniques such as differential scanning calorimetry. After the GFPP plate was released from the mold, residual strains were estimated. Because cooling rate is an important process parameter in thermoplastics, affecting crystallinity and ultimately …

Growth Control Of Oxygen Stoichiometry In Homoepitaxial Srtio3 Films By Pulsed Laser Epitaxy In High Vacuum, Ho Nyung Lee, Sung S. Ambrose Seo, Woo Seok Choi, Christopher M. Rouleau

Physics and Astronomy Faculty Publications

In many transition metal oxides, oxygen stoichiometry is one of the most critical parameters that plays a key role in determining the structural, physical, optical, and electrochemical properties of the material. However, controlling the growth to obtain high quality single crystal films having the right oxygen stoichiometry, especially in a high vacuum environment, has been viewed as a challenge. In this work, we show that, through proper control of the plume kinetic energy, stoichiometric crystalline films can be synthesized without generating oxygen defects even in high vacuum. We use a model homoepitaxial system of SrTiO₃ (STO) thin films on …

Characterization Of Dispersion And Residual Stress In Nanoparticle Reinforced Hybrid Carbon Fiber Composites, Alex Selimov

Honors Undergraduate Theses

Hybrid carbon fiber reinforced composites are a new breed of materials that are currently being explored and characterized for next generation aerospace applications. Through the introduction of secondary reinforcements, such as alumina nanoparticles, hybrid properties including improved mechanical properties and stress sensing capabilities can be achieved. In order to maximize these properties, it is necessary to achieve a homogeneous dispersion of particulate filler. Utilizing the photoluminescent properties of alumina, it is possible to compare local levels of particle concentration through emission intensities as a way to determine the effectiveness of the tested manufacturing parameters in increasing material homogeneity. Parameters of …

Cryogenic Processing Of Al 7050-T7451 Alloy For Improved Surface Integrity, Bo Huang

Theses and Dissertations--Mechanical and Aerospace Engineering

Al 7050-T7451 alloy with good combinations of strength, stress corrosion cracking resistance and toughness, is used broadly in the aerospace/aviation industry for fatigue-critical airframe structural components. However, it is also considered as a highly anisotropic alloy as the crack growth behavior along the short transverse direction is very different from the one in the long transverse direction, due to the inhomogeneous microstructure with the elongated grains distributed in the work material used in the sheet/plate applications. Further processes on these materials are needed to improve its mechanical and material properties and broaden its applications.

The material with ultra-fine or nano …