Materials Science and Engineering Commons^™

Non-Linear Modeling Of Hysteresis In Piezoelectric Actuated Cantilever Beam Using The Bouc-Wen Model, Andrew Donald Maas

Master's Theses

Piezoelectric actuators frequently exhibit a time-dependent behavioral phenomenon known as hysteresis, resulting in a lag in the deformation of the actuator compared to linear models. The presence of hysteresis complicates control systems involving piezoelectric actuators. However, traditional modeling methods for piezoelectric actuated smart structures often treat the piezoelectric patches as linear actuators without considering hysteresis, leading to suboptimal controller performance.

This thesis aims to establish a comprehensive model by integrating the Euler-Bernoulli beam bending model with the hysteresis dynamics induced by two opposing piezoelectric patches attached to a beam. A model expansion method is employed to transform the partial differential …

Polypropylene As Partial Fine Aggregate Substitute In Concrete, Samuel E. Royston, Chrisitan G. Achkar, Nicholas B. Tabarez

Architectural Engineering

The objective of this project is to discover a structurally effective method in repurposing recyclable plastic waste through its partial substitution for traditional fine aggregate in concrete.

Results obtained from analysis indicate a 25 percent compressive strength reduction with polypropylene at a 10 percent partial substitution for total sand content. This material successfully performed as an alternative, presenting a ductile mode of failure.

Three material alternatives - polypropylene, polyethylene, and rubber - were substituted for a percentage of sand. These materials underwent concrete cylinder crushing tests to determine their ultimate crushing strength, with the intent of identifying the most effective …

Design, Modeling, And Testing Of A Novel Inductor For Electric Vehicles: Iron Nitride Soft Magnetic Composites, Cody Krawczyk, Lauren Walker

Materials Engineering

The purpose of this study is to develop a processing method to reduce the porosity of toroidal inductors, whose cores are composed of soft magnetic composites (SMCs) with 65 vol.%, 75 vol.%, and 85 vol.% iron nitride (γ′-Fe₄N) and to validate the results with a COMSOL^TM model. Using hot-pressing as the main process of manufacture, fourteen samples were fabricated and eight were wound with Litz wire. Four samples of 75 vol.% and four samples of 85 vol.% were fabricated by mixing the Fe₄N powder and epoxy at 150^oC and initially pressing at 5 …

Characterization Of High Albedo Ground Surface Treatments For Energy Harvesting By Bifacial Photovoltaic Power Plants, Roma C. Chatripally, Matthew Honda, James Vance

Materials Engineering

Bifacial photovoltaic (bPV) cells have higher solar efficiency than monofacial photovoltaic (mPV) cells due to having two sides of active layers. bPV cells also require less space to produce equivalent electricity, which is useful for solar farms that want to maximize energy output per unit area. Placing a sheet of highly reflective material on the surface beneath bPV cells further increases their efficiency due to increasing the amount of solar radiation that reaches the underside of the bPV cells. This study explores the effects of natural outdoor weathering, solar altitude angle, and accelerated exposure to UV radiation on the albedos …

Metallurgical Impact Of Switching From Hammer Units To Hydraulic Presses For Forging, Cole Hawker, Jacob Reed

Materials Engineering

Carlton Forge Works (CFW) is evaluating the retirement of its hammer units in favor of hydraulic presses to address safety concerns in forging aerospace components. This paper investigates the metallurgical implications of this transition, emphasizing the importance of superior microstructures and meeting industry standards and customer requirements. The alloys in question are Titanium-6Al-4V (Ti64) and Inconel 718 (INCO 718), which comprise a majority of CFW’s production. Ti64's high specific strength and thermal stability make it ideal for aerospace applications, while INCO 718 is recognized for superior high-temperature creep performance. Defects like freckles and white spots in INCO 718 are analyzed …

Predicting Rheology Of Uv-Curable Nanoparticle Ink Components And Compositions For Inkjet Additive Manufacturing, Cameron D. Lutz

Master's Theses

Inkjet additive manufacturing is the next step toward ubiquitous manufacturing by enabling multi-material printing that can exhibit various mechanical, electronic, and thermal properties. These characteristics are realized in the careful formulation of the inks and their functional materials, but there are many constraints that need to be satisfied to allow optimal jetting performance and build quality when used in an inkjet 3-D printer. Previous research has addressed the desirable rheology characteristics to enable stable drop formation and how the metallic nanoparticles affect the viscosity of inks. The contending goals of increasing nanoparticle-loading to improve material deposition rates while trying to …

Testing Of Recycled Polypropylene As A Viable Structural Material (Quarter 2), Isabella Jimenez-Melendrez, Katherine Timbes, Jocelyn Embleton, Tauni Dela Cruz, Zyra Kingston, Emily Byrd, Jacob Stinger

Architectural Engineering

5.25 trillion plastic particles have been found in the oceans each year, 3 million water bottles are consumed each hour, and one million plastic bags are used each minute in the United States of America (Williams). The vast majority of conventional plastics such as polyethylene, polypropylene, polystyrene, and more, are non-biodegradable (Tokiwa). To make matters worse, 70% of this non-biodegradable plastic is discarded into landfills and inevitably makes its way into the environment (Williams,). Plastic products have become vital to the United States economy due to their many uses in the construction, packaging, transportation, and health care industries. However, this …

Fabrication Of Alumina Membranes From Uv Resin– Alumina Particle Slurries, Dominique Henry Porcincula

Master's Theses

Ceramics membranes are made in a wide variety of different techniques using a wide variety of different materials. However, many of the common techniques utilize a slurry of ceramic particles, additives, and either organic solvent or water that is shaped into a membrane, left to dry, and then sintered together. Drying is a time consuming process, often requiring several hours for the liquid medium to evaporate. Defect formation caused by development of partial pressures across the drying membrane, including cracks and warpage, also typically occurs during the drying process. To address this, slurries of ceramic particles made with a low …

Characterization Of Ground Albedo Materials For Bifacial Solar Farms, Fernanda De Los Angeles Garcia, Benny Tam, Jean Lee, James Vance

College of Engineering Summer Undergraduate Research Program

Bifacial photovoltaics can collect solar energy from both sides, unlike regular one-sided solar panels. With the ability to collect energy from both sides, the energy production of bifacial photovoltaic farms is about 2-6% more efficient than typical solar farms. However, the increase in efficiency is highly dependent on the reflectivity of the ground material. This project explores six different materials to determine which material would be best to implement as a ground material for a bifacial photovoltaic farm, based on their mechanical properties and albedo value. Albedo refers to the ratio between the reflected solar radiation to the incident solar …

Machine Learning Prediction Of Hea Properties, Nicholas J. Beaver, Nathaniel Melisso, Travis Murphy

College of Engineering Summer Undergraduate Research Program

High-entropy alloys (HEA) are a very new development in the field of metallurgical materials. They are made up of multiple principle atoms unlike traditional alloys, which contributes to their high configurational entropy. The microstructure and properties of HEAs are are not well predicted with the models developed for more common engineering alloys, and there is not enough data available on HEAs to fully represent the complex behavior of these alloys. To that end, we explore how the use of machine learning models can be used to model the complex, high dimensional behavior in the HEA composition space. Based on our …

Additive Manufacturing For Medical Education, Michael Noon

College of Engineering Summer Undergraduate Research Program

A growing body of evidence is suggesting that anatomical knowledge, the keystone of many medical specialties, is suffering among new graduates. While a host of reasons are provided, one common thread that many point to is the decline of cadaver dissections in the classroom. Many virtual audio-visual tools are used to address this gap, yet evidence has shown their ineffectiveness. Given this gap, the high degree of flexibility found in additive manufacturing (AM), and the many uses AM has already found in the medical field, we propose its use to fill this gap, allowing for students to learn with touch …

Improving The Tensile Mechanical Properties Of Direct Energy Deposited (Ded) Inconel 718 Aircraft Components Using A Standard Heat Treatment, Spencer Vincent Flynn

Materials Engineering

This project aimed to improve the mechanical properties of as-printed additively manufactured Inconel 718 samples using a heat treatment usually used for cast and wrought Inconel 718. The mechanical properties sought to be optimized were yield strength, ultimate tensile strength, elongation, and reduction in area. The property goals were to match or exceed those of cast and heat treated Inconel 718. Wire-fed electron beam direct energy deposition (DED) was used to manufacture the samples, which were then heat treated using the AMS 5663 standard in an inert atmosphere. The samples were then tested in tension to obtain data on their …

Experimental Characterization And Computer Vision-Assisted Detection Of Pitting Corrosion On Stainless Steel Structural Members, Riley J. Muehler

Master's Theses

Pitting corrosion is a prevalent form of corrosive damage that can weaken, damage, and initiate failure in corrosion-resistant metallic materials. For instance, 304 stainless steel is commonly utilized in various structures (e.g., miter gates, heat exchangers, and storage tanks), but is prone to failure through pitting corrosion and stress corrosion cracking under mechanical loading, regardless of its high corrosion resistance. In this study, to better understand the pitting corrosion damage development, controlled corrosion experiments were conducted to generate pits on 304 stainless steel specimens with and without mechanical loading. The pit development over time was characterized using a high-resolution laser …

Interlaminar Tensile Properties Of Unidirectional And Woven Carbon Fiber Reinforced Toughened Epoxy Laminates, Eric Timothy Casey, Sean Mckalip Thompson

Materials Engineering

This project aims to develop a dataset on interlaminar tensile strength comparing unidirectional and woven thermoset matrix carbon fiber composites keeping ply count, matrix material, and fiber diameter constant. The interlaminar tensile strength is an important property relating to the delamination failure mode. Interlaminar tensile strength is determined using the ASTM D6415 testing standard. This test is a modified four-point bend test using a 90° curved beam test specimen. Laminates were produced by laying up pre-impregnated carbon fiber sheets onto a curved beam tooling. The unidirectional laminate was produced with 20 plies in a [0,0,90,0,0]₄ layup pattern. The woven …

Failure Analysis Of Variably Sized 4340 Steel Mandrels Utilized In The Production Of Seamless Superalloy Rings Through The Vertical Ring Rolling Process, Mikhail Alexeyevich Vasilyev, Joshua Brady Venz

Materials Engineering

Vertical ring rolling is a forging process which forms seamless metal rings through applying a large force at elevated temperatures onto component materials stabilized by cylindrical mandrels. Carlton Forge Works, a company which produces rings of superalloy materials such as INCO718 and 718Plus, is experiencing a consistent failure of mandrels due to extreme conditions. An analysis of the lifetime (bulk material, heat treatment, and use) was performed, which aided in the identification of process variables tied to mandrel failure. Experiments were formed surrounding three variables of the mandrel heat treatment: Austenitization temperature, quenching temperature, and tempering conditions, with the goal …

Effect Of Environmental And Ultraviolet Degradation On The Albedo Of Polyethylene Sheet Materials For Improved Energy Harvesting By Bifacial Photovoltaic Power Plants, William A. Jang, Roxy H. Jackson-Gain

Materials Engineering

Solar energy farms typically utilize monofacial photovoltaic (mPV) cells in their arrays to capture direct sunlight to produce renewable energy. However, the efficiency of these farms can be increased by 2 – 6% through the implementation of bifacial photovoltaic cells (bPV). These bPV cells function by capturing incident ultraviolet (UV) light energy that is reflected off the surface to increase its overall energy production. The amount of UV energy that is reflected is dependent on the albedo value of surface, which is a measure of energy reflectance. In this study, samples of unreinforced polyethylene (PE), scrim-reinforced polyethylene (SR-PE), and woven …

Covalent Adaptable Networks For Wood Coatings, Jachin Boaz Clarke

Materials Engineering

Wood swells and shrinks causing problems with seasonal humidity. Applying thick coatings of reactive finishes based on cross-linked polyurethane, epoxy, or polyesters can slow moisture-vapor exchange. However, the use of thick coatings leads to cracking and crazing sooner than thin finishes. This research proposes the addition of 3.3 mol % triazabicyclodecene, a conventionally used covalent adaptable network catalyst, in a commercially available polyester-based wood coating. The self-healing of the wood coating is tested using DMA stress relaxation and compression molding. The result from DMA renders inconclusive and compression molding indicates the novel wood coating oxidizes at elevated temperatures. The wood …

Design, Modeling, And Testing Of A Novel Inductor For Electric Vehicles: Iron Nitride Soft Magnetic Composites, Sydney F. Fultz-Waters, Jacob Krynock

Materials Engineering

New technology for electric vehicles (EVs) must meet the requirements of higher energy usage, lower costs, and more sustainable source materials. One promising material for EV power system components is iron nitride (IN) soft magnetic composites (SMCs) because of their competitive magnetic properties and high abundance of the source materials. As part of an ongoing program at Sandia National Laboratories, this project focused on using computer modeling to optimize the prototyping process for an iron nitride SMC toroidal inductor to reach a target inductance of 600 μH. Four inductors with different combinations of wiring (26 AWG and 20 AWG) and …

Investigation Into Oxygen Diffusion As It Relates To Alpha Case Formation In Ti-6al-4v Based On Different Forging Thermal Cycles, Tyler J. Meador, Jon Leduc, Francesca Hope

Materials Engineering

An investigation into the growth kinetics of alpha case in Ti-6Al-4V in the presence of oxygen was conducted for different forging thermal cycles. This was done to determine whether the alpha case should be removed after each thermal cycle or as the final step after forging. The thermal cycles consisted of four hours at 1750 °F. Samples were subjected to this treatment one, two, three, and four times along with a continuous sixteen hour hold. Four cycle and Hold samples were subjected to an additional thermal cycle above the beta transus at 1925 °F. These then went through a final …

Surface Characterization Of Low-Density Polyethylene Mulch, Risha Shah

Materials Engineering

Plastic pollution in aquatic systems has traditionally been highlighted in past and current research due to the increase in plastic production every year. Unfortunately, quantitative and qualitative data regarding plastic pollution on land systems such as agricultural mulch is limited. Agricultural mulch breaks down into macroplastics and then degrades into microplastics. The microplastics investigated in this study are all secondary microplastics: microplastics that form due to weathering of larger fragments of plastic. Weathering can occur due to a variety of factors; however, UV radiation and mechanical weathering have been the factors of focus on most current research in microplastic formulation. …

3d Printed Aircraft, Matthew Nagy, Charles D'Amico, Alexis Salgado Medina

Mechanical Engineering

This project is to design, build, and test a 3D-printable aircraft. The goal is to create a final design that will be able to fly for the longest duration possible, around 20 seconds. To determine the correct preliminary design and manufacturing process for a 3D printed RC aircraft, an analysis of multiple design options and manufacturing materials was performed. This allowed for a variety of choices for aircraft type, airfoil design, structure, among other topics to be narrowed down to the most promising option. It has been found that the aircraft will follow a design similar to industry motor-gliders, with …

Exploring The Potential Of Pavegen’S Kinetic Energy Generating Floor For Sustainable Energy Solutions: A Proposal For Cal Poly Slo, Brandon J. Cuneo

Construction Management

This paper proposes the installation of Pavegen's kinetic energy generating floors at Cal Poly’s campus as a sustainable energy solution. Pavegen has developed a pioneering technology that converts footsteps into clean and renewable energy. The versatility of these floors is demonstrated through successful implementations in various settings, such as transportation hubs and public spaces, generating power from foot traffic. Collaborations with Schneider Electric, installation at Dupont Circle, and integration at Heathrow Airport showcase the potential for sustainable urban infrastructure. This paper outlines research conducted on Pavegen and similar solutions, including communication with company representatives and examining proposed installation locations at …

Precious Plastics - Plastic Brick Machine Fabrication, Timothy Ukaobasi Kanu, Evi Paraskevi Troulis

Architectural Engineering

The goal of this research is to determine the structural parameters of the recycled plastic polypropylene when molded into bricks resembling CMU blocks. To accomplish this, three mechanisms had to be assembled: the shredder, the injector, and the 1x1 mold. A tensile and compression test were to be performed on the plastic brick, and the values would be used to compare the tensile and compressive strength of PP plastic bricks, as well as their modulus of elasticity and stress vs. Strain performance. These values would be analyzed to determine whether it would be feasible to build an entire plastic wall. …

Building Structures From Mycelium, Noah M. Brown

Physics

The purpose of this project was to develop a method for creating bricks from mycelium and agricultural waste. The bulk of the research happened in two parts, the first part being a period in which different substrates, strains, and methods were used build the bricks. This research took place in San Luis Obispo and was aided by a group of students in PSC392 under Dr. Pete Schwartz in early 2022. After developing a method for constructing these bricks, the research was moved to St. Thomas, Jamaica, in collaboration with an ecovillage called The Source Farm from July to September. The …

Fabrication Of Thin-Film Composite, Reverse-Osmosis Membranes With Polyethylenimine Modifications For Enhancing Membrane Fouling Resistance, Stephanie N. Hamilton

Master's Theses

Increasing water reuse opportunities for communities has become increasingly important as access to clean water is becoming more scarce. Reverse Osmosis (RO) is an advanced treatment technology used in water recycling wastewater for potable reuse applications. RO is a promising technology; however, the membranes have limitations including their high energy demand and their susceptibility to membrane fouling. The main objective of this study was to develop a reproducible method for the fabrication of RO membranes with enhanced flux and reduced susceptibility to fouling. Literature contains numerous publications on fabrication of thin film composite (TFC) RO membranes with high performance. However, …

Developing Positive Thermal Coefficient (Ptc) Heaters For Solar Electric Cooking, Katarina Ivana Brekalo, Andrew Shepherd

Physics

Positive Thermal Coefficients, PTCs, are materials that abruptly change in resistance in response to changes in temperature. The purpose of this experiment is to explore the viability of using the switching type ceramic PTC thermistor as a replacement for current resistive heaters. These types of PTCs have a nonlinear change in resistance with increases in temperature. This device will be used as a temperature-controlling heating element intended to power an Insulated Solar Electric Cooker (ISEC). The ISEC is designed to cook meals throughout the day for impacted communities as an alternative cooking method that doesn’t require biofuel as an energy …

In-Situ Defect Detection Using Acoustic Vibration Monitoring For Additive Manufacturing Processes, Ali Harake

Master's Theses

The world of additive manufacturing revolves around speed and repeatability. Inherently, the process of 3D printing is plagued with variability that fluctuates with every material and parameter modification. Without proper qualification standards, processes can never become stable enough to produce parts that may be used in aerospace, medical, and construction industries. These industries rely on high quality metrics in order to protect the lives of those who may benefit from them. To establish trust in a process, all points of variation must be controlled and accounted for every part produced. In instances where even the best process controls are enacted, …

Dynamic Response Of Elastic Two-Story Steel Moment Frame Scaled Structure Equipped With Viscous Dampers, Garrett L. Barker, Alexander L. Poirier

Architectural Engineering

The authors of this report are Architectural Engineering undergraduate students at California Polytechnic State University, San Luis Obispo. Damping is a complex, experimentally derived value that is affected by many structural properties and has a profound effect on the dynamic response of structures. Deducing the inherent damping of a steel moment frame and affecting the damping ratio with viscous dampers are two topics explored in this paper. Dampers are commonly implemented in resilient structures that perform better in a design basis earthquake, reducing the seismic cost and downtime. Undergraduate coursework does not delve into the factors that affect damping and …

Stabilization Of Palm Wood Using Water-Based Impregnation, David A. Barnes

Materials Engineering

Impregnation is a technique for stabilizing wood that involves saturating the material in a liquid and allowing it to cure before use. Stabilization methods such as this are employed for a variety of reasons; chiefly, the low dimensional stability of wood and palm means that they are subject to several failure modes that arise from changing environmental conditions, such as cracking, warping, and bending. Samples of Borassus flabellifer, black palm, provided by DuraPalm were impregnated with solvent-based and water-based stabilizers, and untreated wood samples used as a control group. Kop-Coat WoodYouth® Plus was used as a solvent-based stabilizer, and impregnation …

Effects Of Release Materials And Temperature Ramp Rates On The Surface Finish Of Carbon-Fiber Composite Components, Sudeep Louis, Thucmy Dang, Ethan Schlocker

Materials Engineering

Toray Advanced Composites is interested in improving their carbon fiber reinforced polymers (CFRP) manufacturing process by enhancing their control on the amount of surface roughness for varied customer preference. Surface roughness of CFRP is important in post-production processes including coating, priming, and painting. This project seeks to determine the effects of three release materials and two temperature ramp rates on the surface finish of CFRP. The release materials used were Tooltech, FEP, and Frekote 770-NC. The two initial temperature ramp rates were 1°F/min and 2°F/min. Surface roughness was measured using a profilometer and analyzed using Ra values. Ra is an …