Structures and Materials Commons^™

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 …

Laser-Based Interfacial Patterning Enables Toughening Of Cfrp/Epoxy Joints Through Bridging Of Adhesive Ligaments, Ran Tao, Xiaole Li, Arief Yudhanto, Marco Alfano, Gilles Lubineau

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The ability to prevent catastrophic failures in secondary bonded CFRP adhesive joints is important for reliable automotive and aerospace structures. In a previous study, we proposed an innovative damage-tolerant interfacial design concept for adhesively bonded composite joints, which relied on the extrinsic dissipation of bridging adhesive ligaments enabled by controlling the adhesion at CFRP/epoxy interfaces. In this work, we experimentally validate this strategy by combining laser processing and mechanical testing using double cantilever beam (DCB) joints. Mechanical tests indicate that the pattern geometry, i.e., number and spacing of the areas with different adhesion, controls the formation of either single or …

Hexakis Icosahedron Frame-Skin Vacuum Lighter Than Air Vehicle, Brian Cranston, Anthony N. Palazotto

AFIT Patents

A vacuum lighter than air vehicle (VLTAV) includes a rigid frame of rods connected together to form a hexakis icosahedron. A membrane skin covers the rigid frame and defines therewith a vessel configured to hold an internal vacuum that allows the vessel to float in the air. The plurality of rods and membrane skin have weights and dimensions that result in a neutral and/or positive buoyancy for the vessel while preventing geometric instability.

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.

Enhancement Of Fracture Toughness In Secondary Bonded Cfrp Using Hybrid Thermoplastic/Thermoset Bondline Architecture, A. Yudhanto, M. Almulhim, F. Kamal, R. Tao, L. Fatta, M. Alfano, G. Lubineau

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Structures made of carbon fiber-reinforced polymer (CFRP) can be assembled using adhesive bonding. However, such bonding is prone to brittle delamination, and a method to improve delamination resistance is desirable. Here, we propose a technique to introduce crack-arrest features that increase the R-curve response by engineering the adhesive bond line/interface. We specifically designed a wavy net-like thermoplastic insert that was embedded into the thermoset adhesive bond line where the new mechanisms of energy dissipation were generated. We demonstrate that the technique is effective at improving mode I fracture toughness of secondary bonded carbon/epoxy by more than 400%. The hybrid thermoset/thermoplastic …

Inkjet-Printed Ti3c2tx Mxene Electrodes For Multimodal Cutaneous Biosensing, Abdulelah Saleh, Shofarul Wustoni, Eloise Bihar, Jehad K. El-Demellawi, Yizhou Zhang, Adel Hama, Victor Druet, Arief Yudhanto, Gilles Lubineau, Husam N. Alshareef, Sahika Inal

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Among the existing two-dimensional materials, MXenes, i.e. transition metal carbides, nitrides and/or carbonitrides, stand out for their excellent electrochemical properties. Due to their high charge storage capacity, metal-like conductivity, biocompatibility as well as hydrophilicity, Ti3C2Tx MXene-based inks hold great potential for scalable production of skin conformable electronics via direct printing methods. Herein, we develop an aqueous MXene ink and inkjet-print MXene films on freestanding, flexible, and conducting polymer-based substrates. These skin-adherent MXene electrodes detect electrocardiography signals with high signal-to-noise ratio while exhibiting preserved electrical performance after 1000 cycles of bending with a 50 d long shelf life in ambient conditions. …

Characterizing And Modeling The Progressive Damage Of Off-Axis Thermoplastic Plies: Effect Of Ply Confinement, Ditho Pulungan, Arief Yudhanto, Gilles Lubineau

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Although the mechanisms of degradation are, overall, quite similar between thermoset and thermoplastic composites, thermoplastic laminates exhibit a higher ductility. Because of that, classical models developed for thermosets fail in predicting accurately the response of thermoplastic-based laminates. Here, we demonstrate that simulations based on the properties identified on isolated thermoplastics unidirectional plies, as usually done for thermosets, result in large errors. This is explained by the significant load-bearing capacity of the ply in the transverse direction that remains even after the first-ply failure, as a result of the confinement provided by adjacent plies. This effect also exists in thermosets, but …

On The Effect Of Interfacial Patterns On Energy Dissipation In Plastically Deforming Adhesive Bonded Ductile Sheets, Arturo Pascuzzo, Arief Yudhanto, Marco Alfano, Gilles Lubineau

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Toughening of brittle adhesive joints is a topic of great interest for the fabrication of layered structures. Recent experimental work by the authors indicated that spatially varying interface properties (i.e., patterned interfaces obtained using laser irradiation) could tune energy dissipation in plastically deforming adhesive joints. In this study, we use a cohesive zone approach to ascertain the interplay between fracture process zone size and pattern geometry on the overall work of separation. The analysis is carried out in the context of the elasto-plastic peeling response of adhesive bonded ductile thin sheets. The mating surfaces of the adherents feature alternating strips …

Improving Mode Ii Fracture Toughness Of Secondary Bonded Joints Using Laser Patterning Of Adherends, A. Wagih, R. Tao, A. Yudhanto, G. Lubineau

Mechanical and Aerospace Engineering Faculty Research & Creative Works

We improve mode II fracture toughness of secondary bonded joints based on the laser treatment of adherend surfaces. We applied CO₂ Laser treatment to adherend surface alternatively with low and high energy, resulting in a repeated pattern of rough and smooth surfaces. We used ENF test to characterize mode II fracture toughness, GII, of the bonded CFRP substrates. The results demonstrated that our proposed pattern arrested the crack propagation and triggered new damage mechanisms, such as adhesive cracking, adhesive failure and crack migration to the other interface. These additional mechanisms, some of them were non-local in nature, resulted in …

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 …

Development Of High-Density Propulsion System Technologies For Interplanetary Small Satellites And Cubesats, Morgan Andrew Roddy

Graduate Theses and Dissertations

The goal of this research was to support the development of a novel propulsion system for small satellites (<180 kg) and CubeSats. This was pursued by conducting a collection of studies that were designed to provide engineering data that would be critical in designing a functional prototype. The novel propulsion system was conceived by the author to provide best-in-class performance for the small satellite and CubeSat families of spacecraft. This context presents specific design requirements that the presented technology attempts to satisfy. The most critical among these is high density; the propellant was designed to be stored with high density and the thruster was designed to be as compact as possible. The propulsion system is composed of two primary elements, a propellant generator and a thruster. The propellant generator works by sublimating a solid crystal into vapor and then using this vapor to etch a dense metal. The resulting gaseous byproducts of this reaction are the propellant. This dissertation used xenon difluoride (XeF2) vapor to etch tungsten (W) which react to form xenon gas (Xe) and tungsten hexafluoride (WF6). This approach gave a theoretical propellant storage density 5.40 g/cm3; and 5.17 g/cm3 was demonstrated. The sublimation dynamics of the XeF2 were studied as a function of surface area and temperature and it was found to be suitable for the intended application due to its high effluence rate; that is, it sublimates fast enough to be useful. The sublimation rates are on the order of 10’s of µg/s. The etch rate of XeF2 on W was also studied and found to be suitably fast to provide useful amounts of reactants for use as a propellant, again on the order of 1’s of µg/s. The thruster is an electrostatic radio frequency (RF) ion thruster design and is manufactured with Low Temperature Co-Fired Ceramic (LTCC) materials system and manufacturing technology. Manufacturing samples of the thruster were built at the University of Arkansas in July 2015 and tested at NASA’s Marshall Space Flight Center in May 2018. Testing validated the viability of the LTCC thruster and provided valuable information on how to improve the thruster’s design.

How The Spatial Correlation In Adhesion Properties Influences The Performance Of Secondary Bonding Of Laminated Composites, Xiaole Li, Ran Tao, Arief Yudhanto, Gilles Lubineau

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Spatial heterogeneity of adhesion properties is known to result in bridging during debonding of secondary bonded composite joints. The ligaments that bridge both substrates have crack-arrest features and thus significantly enhance the fracture resistance of joints. We have investigated the effect of randomly distributed adhesion properties between the adhesive layer and each composite substrate in previous works; however, the spatial correlation of adhesion heterogeneity within or between the substrates and how it effects the failure of secondary bonded composites is still poorly understood. In this current work, we assume that the spatial heterogeneity of adhesion follows a log-normal distribution. The …

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 …

Vibration Isolation System, Bradley Y. Kwan, Bailey Groh, Max Wu, Nicole Yen

Mechanical Engineering

The Vibration Isolation System Senior Project is a collaborative group project between its sponsor, Maxar Technologies, and a team of students from Cal Poly - SLO to effectively design, manufacture, and test a structural assembly for satellites, isolating vibrations during launch and orbit conditions. After initial sponsor contact, requirements and needs were set which dictated deliverables for the senior project group. The group performed analyses to validate all design decisions, including a modified concept and design direction, selection of a prototype viscoelastic damping material, preliminary testing to validate design specifications, and detailed design and analysis toward a finalized design. Instead …

Miniaturized Ultraviolet Imager Phase Iii, Bradley D. Albright, Nicolas A. Armenta, Colin W. Harrop

Mechanical Engineering

This document details the work to date, June 9, 2020, done by the Cal Poly Mechanical Engineering senior project team, Miniaturized Ultraviolet Imager: Phase III (MUVI III), sponsored by the University of California, Berkeley – Space Sciences Laboratory (UCB SSL). MUVI III is the third senior project team of an ongoing design, MUVI: the prototype of a 2U sized CubeSat intended to capture aurora images in the ionosphere. The first team, MUVI I, finished development of the UV imager. The second team, MUVI II, designed the mirror mounting and deployable door mechanisms. The goal of MUVI phase III is to …

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 …

Post-Impact Flexural Behavior Of Carbon-Aramid/Epoxy Hybrid Composites, A. Wagih, T. A. Sebaey, A. Yudhanto, G. Lubineau

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Hybrid polymeric composites are currently used in aerospace structures due to their specific strength and stiffness as well as larger design space. This paper presents an experimental study on residual flexural strength of impacted Carbon-aramid/Epoxy hybrid composite laminates. Specimens are designed in a sandwich form in which plies of aramid/epoxy represent the core and carbon/epoxy plies play the role of face sheets. This design is expected to take advantage of the high energy absorption capabilities of aramid/epoxy composites. We pre-damage such composites by performing low-velocity impact at different energy levels. Three-point bending tests then are used to measure the residual …

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 …

Thermal Modeling Of Additive Manufacturing Using Graph Theory: Validation With Directed Energy Deposition, Jordan Severson

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Metal additive manufacturing (AM/3D printing) offers unparalleled advantages over conventional manufacturing, including greater design freedom and a lower lead time. However, the use of AM parts in safety-critical industries, such as aerospace and biomedical, is limited by the tendency of the process to create flaws that can lead to sudden failure during use. The root cause of flaw formation in metal AM parts, such as porosity and deformation, is linked to the temperature inside the part during the process, called the thermal history. The thermal history is a function of the process parameters and part design.

Consequently, the first step …

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 …

Development And Testing Of Novel Antimicrobial Materials For Additive Manufacturing With Application In Space, Michael Thompson, Jorge Zuniga, Christopher Copeland, Roberto Saavedra, Claudia Cortes Reyes, Andres Acuña Velásquez, Daniel Martínez Pereira, Claudio Soto

UNO Student Research and Creative Activity Fair

PURPOSE: The purpose of the study was twofold: (i) develop and test the antimicrobial properties of a polylactic acid- and a polyurethane-based filament, and (ii) use these filaments to manufacture a socket-based prosthesis to verify printability and longevity of the antimicrobial properties. It was hypothesized that the formulation of a novel biocidal copper-based nanocomposite with a biocompatible 3D printing polymer/copolymer can be used for the development of antimicrobial medical devices to mitigate microbial risks during long space flight missions [1, 2, 3].

METHODS: Polylactic Acid-based Filament Development-The development of a polylactic acid-based filament involved several processes, such as fermentation …

On Controlling Interfacial Heterogeneity To Trigger Bridging In Secondary Bonded Composite Joints: An Efficient Strategy To Introduce Crack-Arrest Features, Ran Tao, Xiaole Li, Arief Yudhanto, Marco Alfano, Gilles Lubineau

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Secondary adhesive bonding of carbon fiber-reinforced polymer laminates is of great interest for the aerospace and automotive industries. However, joint reliability is still a major concern because of fabrication-induced or service-related cracks that are difficult to monitor and can lead to catastrophic failure. In this work, we propose a patterning strategy where the careful design of spatially varying interface properties enables the formation of an adhesive ligament that acts as a crack-arrest feature. Bi-dimensional finite element models of adhesively bonded double cantilever beams were employed to investigate the role of the main parameters of the pattern (i.e., geometrical parameters and …

Structural Dynamic And Inherent Damping Characterization Of Additively Manufactured Airfoil Components, Andrew W. Goldin

Theses and Dissertations

The push for low cost and higher performance/efficient turbine engines have introduced a new demand for novel technologies to improve robustness to vibrations resulting in High Cycle Fatigue (HCF). There have been many proposed solutions to this, some passive and some active. With the advent of Additive Manufacturing (AM), new damping techniques can now be incorporated directly into the design and manufacture process to suppress the vibrations that create HCF. In this study, this novel unfused pocket damping technology is applied to a blade structure and the resulting damping effectiveness is quantified. The application of this technology to complex geometries …