Materials Science and Engineering Commons^™

Gerber Project For Lockheed Martin, Andrew Callahan, Sean Lawyer

Industrial Technology and Packaging

Lockheed Martin, the world’s premier aerial combat vehicle manufacturer was pressed to find an eco-friendly way to package their impregnated epoxy. In the current system, the epoxy would be cut on the Gerber table to a pre-determined length and then sandwiched inside of two corrugated fiberboard sheets for storage inside of a freezer. The current process was not only labor intensive, but the corrugated fiberboard had to be disregarded after one use. In conjunction with the Cal Poly San Luis Obispo Packaging program and Melmat Incorporated, we were able to find a corrugated plastic substrate to replace the currently non-reusable …

Peak Stir Zone Temperatures During Friction Stir Processing, Sprinivasan Swaminathan, Keiichiro Oh-Ishi, Alexander P. Zhilyaev, Christian B. Fuller, Blair London, Murray W. Mahoney, Terry R. Mcnelly

Materials Engineering

The stir zone (SZ) temperature cycle was measured during the friction stir processing (FSP) of NiAl bronze plates. The FSP was conducted using a tool design with a smooth concave shoulder and a 12.7-mm step-spiral pin. Temperature sensing was accomplished using sheathed thermocouples embedded in the tool path within the plates, while simultaneous optical pyrometry measurements of surface temperatures were also obtained. Peak SZ temperatures were 990 ⁰Cto 1015 ⁰C (0.90 to 0.97 TMelt) and were not affected by preheating to 400⁰C, although the dwell time above 900 ⁰C was increased by the preheating. Thermocouple data suggested little variation in …

Time-Temperature Curing Relationship Of An Adhesive Binder With Rice Straw, Kevin Ka-Wan Ng

Master's Theses

Rice straw is a global and proliferate agricultural waste whose production grossly outstrips viable uses. Current disposal methods are not sustainable, and more convenient methods – such as incineration – exude poor environmental stewardship. Although the direct use of straw bales in building construction presents a practical and sustainable alternative, engineering challenges associated with using it prevent its wide adoption. The Stak Block – a composite formed from compressed rice straw and a heat-cured adhesive – may overcome challenges associated with straw bale building. However, the times and temperatures needed to cure the binder with straw are not well understood. …

Application Of Self-Determination And Self-Regulation Theories To Course Design: Planting The Seeds For Adaptive Expertise, Linda Vanasupa, Jonathan Stolk, Trevor Harding

Materials Engineering

The paper is grounded in the premise that learning occurs within a dynamic system of social and ecological interactions in the learning environment. Our intent is to open the conversation about hose ac, as engineering educators, design effective learning experiences for this dynamic system, particularly in light of the deeply ethical, adaptive expertise required of today's graduates. Drawing from two well-researched theories of psychological development (self-determination and self-regulation), we assert that fostering the engagement and positive growth required for adaptive expertise necessitates a holistic educational approach. This approach requires us to consider both the psychological needs of the learner, and …

The Systemic Correlation Between Mental Models And Sustainable Design: Implications For Engineering Educators, Linda Vanasupa, Roger Burton, Jonathan Stolk, Julie B. Zimmerman, Larry J. Leifer, Paul T. Anastas

Materials Engineering

Many studies have illuminated our understanding of the kinds of competencies and behaviors exhibited by effective designers. Against the backdrop of global challenges made more urgent by unintentional negative impacts of engineered products and systems, however, we are left to deduce that our ways of educating engineering designers is fundamentally flawed. We assert that one can trace the cause of our collective, unintended negative consequences to the mental models of reality that we consciously or unconsciously carry. In this paper, we present the case for developing awareness and facility with mental models. We also suggest an alternate mental model as …

Simpler Packaging, Tomiko Oden

Graphic Communication

This project explains how product packaging is become more "green", and thus more simple. Packaging needs to go beyond just simplifying materials and graphics - it needs to create a simpler process in order to reduce wasted time, energy, and resources.

Design And Performance Of Load Bearing Shear Walls Made From Composite Rice Straw Blocks, Kevin Robert Camann

Master's Theses

Although rice straw and other grains have been used in building since pre-history, in the past two decades, there has been a move to utilize this rapidly renewable, locally available, agricultural byproduct as part of the sustainable construction movement. Up to this point, this has been done by simply stacking up the full straw bales. Stak Block, invented by Oryzatech, Inc., is a modular, interlocking block made of a composite of rice straw and binding agent that serves as an evolution in straw construction. This study investigates the feasibility of using these Stak Blocks as a structural system. The report …

Workshop - Feminist Engineering Education: Building A Community Of Practice, Alice L. Pawley, Donna Riley, Susan M. Lord, Trevor S. Harding

Materials Engineering

As a result of a series of papers and special sessions held at FIE between 2004 and 2008, a community of CSET educators interested in exploring feminist pedagogies has formed at FIE. Past participants in these sessions have expressed a desire to learn more about what makes a set of pedagogies "feminist." At the same time, there has been an increase in the number of research papers at FIE that draw on feminist research methods or topics. This workshop is designed to meet the needs of members of the FIE community who have some experience with feminist pedagogies or research …

Work In Progress - A Mixed-Methods Approach To Developing An Instrument Measuring Engineering Students' Positive Ethical Behavior, Mathew A. Holsapple, Cynthia J. Finelli, Donald D. Carpenter, Trevor S. Harding, Janel A. Sutkus

Materials Engineering

Ethics education and the drive to produce ethical professional engineers is an important focus of one body of research on engineering education. This research often defines the positive outcome of ethics education as students and professional engineers choosing not to engage in unethical behavior. This paper discusses a portion of a larger research project and details efforts to identify and validate a definition of ethical behavior that includes the decision to engage in a positive behavior, defined as a service to a larger community. Through a series of interviews and focus groups with engineering administrators, faculty, and students, the authors …

Feasibility Of Ellipsometric Sensor Development For Use During Pecvd Siox Coated Polymer Product Manufacturing, Daniel Lynn Helms

Master's Theses

Polymeric materials have provided pathways to products that could not be manufactured otherwise. A new technology which merges the benefits of ceramics into these polymer products has created materials ideally suited to many different industries, like food packaging. Nano Scale Surface Systems, Inc. (NS3), a company which coats polymers with ceramic oxides like SiO2 through a process known as plasma enhanced chemical vapor deposition (PECVD), was interested in the feasibility of an in line measurement system for monitoring the deposited films on various polymer products. This project examined two different coated polymer products, polyethylene terephthalate (PET) beverage containers and biaxially …

Assessment Of Electrospinning As An In-House Fabrication Technique For Blood Vessel Mimic Cellular Scaffolding, Colby M. James

Master's Theses

Intravascular devices, such as stents, must be rigorously tested before they can be approved by the FDA. This includes bench top in vitro testing to determine biocompatibility, and animal model testing to ensure safety and efficacy. As an intermediate step, a blood vessel mimic (BVM) testing method has been developed that mimics the three dimensional structure of blood vessels using a perfusion bioreactor system, human derived endothelial cells, and a biocompatible polymer scaffold used to support growth of the blood vessel cells. The focus of this thesis was to find an in-house fabrication method capable of making cellular scaffolding for …

Development Of A Low Cost Handheld Microfluidic Phosphate Colorimeter For Water Quality Analysis, Sean C. Kaylor

Master's Theses

This thesis describes the design, fabrication, and testing process for a microfluidic phosphate colorimeter utilized for water quality analysis. The device can be powered by, and interfaced for data collection with, a common cell phone or laptop to dramatically reduce costs. Unlike commercially available colorimeters, this device does not require the user to measure or mix sample and reagent. A disposable poly(dimethylsiloxane) (PDMS) microfluid chip, powered by an absorption pumping mechanism, was used to draw water samples, mix the sample at a specific ratio with a molybdovanadate reagent, and load both fluids into an onboard cuvette for colorimetric analysis. A …

Design And Development Of Rapid Battery Exchange Systems For Electric Vehicles To Be Used As Efficient Student Transportation, Jonathan A. Bevier

Master's Theses

Rapid battery exchange systems were built for an electric van and pedal assist electric bike as a method of eliminating the need to recharge the vehicles batteries in order to increase the feasibility of using electric propulsion as a method of efficient student transportation. After selecting proper materials it was found that the systems would need a protective coating to ensure consistent operation. 1020 cold rolled steel samples coated with multiple thicknesses of vinyl resin paint, epoxy resin paint, and powder coating were subjected to environmental wear tests in order to determine if the type and thickness of common protective …

The Effect Of Particle Surface Area To Volume Ratio On Ion Release From Cocr Spheres, Darin J. Grandfield

Master's Theses

In 2005, over 200,000 Americans underwent a hip arthroplasty, the replacement of a hip joint with an artificial prosthesis. Of these arthroplasties, metal-on-metal type implants represent an increasing usage percentage. Metal-on-metal implants are selected largely for their low volumetric wear rate, durability, and resistance to corrosion. In spite of these advantages, little is known concerning the long-term consequences of heavy metal alloy use in the body, although early research indicates potentially carcinogenic results. This thesis is a preliminary investigation into these long term effects and their root causes.

An improved comprehension of the corrosion kinetics and the rate of ion …

Evaluating The Electrical Response Of Polyaniline To Mechanical Strain, Matthew L. Goebel

Master's Theses

This thesis focuses on the electrical output of polyaniline films subjected to uniaxial strain in hydrochloric acid solutions. Polyaniline belongs to novel class of materials known as conducting polymers. Alternating single and double bonds in the backbone of conducting polymers allow them to transmit electric charge when they are doped with negatively charged ions. Modifying the degree of doping and other electrical/chemical treatments allow conducting polymers to exhibit conducting, semi-conducting, or insulating electrical properties. Resilient mechanical properties, good processability, and low cost make conducting polymers good candidates for applications traditionally held by metals and semi-conductors.

When tensile strain is applied …

The Effects Of Thermal Annealing On The Obliquely Deposited Ag–Ge–S Thin Films, F. Wang, W. P. Dunn, M. Jain, C. De Leo, N. Vicker, Richard N. Savage, Xiaomin Jin, S. Mamedov, P. Boolchand

Materials Engineering

Obliquely deposited thin films of ternary Ag–Ge–S glasses are characterized in this work. Thin films are fabricated in a vacuum thermal evaporator at different evaporation angles and examined by Raman spectroscopy. The Raman mode frequency of GeS₄ corner-sharing (CS) structure of the as-deposited films display a red-shift as a function of Ag content due to reduced global connectivity, and therefore decreased network stress. Film thickness of normally deposited thin films is significantly less when compared against obliquely deposited ones. Sulfur-ring (S₈) modes are observed in thin films but not in corresponding bulk material. Thermal annealing of thin …

Shielding Effectiveness Of Superalloy, Aluminum, And Mumetal Shielding Tapes, Cindy Suit Cheung

Master's Theses

Using MIL-HDBK-419A, MATLAB and Nomographs, Shielding Effectiveness for the Magnetic Field, Electric Field, and Plane Wave were calculated over a frequency range from 10 Hz to 1 GHz. The three shielding tapes used included superalloy, aluminum, and mumetal. Calculations for Shielding Effectiveness involve the computation of Absorption Loss, Reflection Loss, and Re-Reflection Correction Factor. From the outcome of the calculations, it was suitable to conclude that all three metals fulfill the 40 dB Shielding Effectiveness requirements for SGEMP fields for frequencies greater or equal to 1 MHz. Accordingly, all three shielding tapes provide at least 40 dB of shielding to …

Potential Migration Of Ε-Caprolactam To Water And Wine As Affected By Transportation And Storage, Joseph C. Ianneo

Master's Theses

Abstract: Under normal sealing and storage conditions, Nylon-6, poly-caprolactam-based plastic laminates may release impurities to packaged foods and liquids and the application of heat for cooking often increases the rate of migration. Epsilon-caprolactam is one of the main contaminates found to migrate from a Nylon-6 poly-caprolactam plastic film. The objectives of this study were to determine the effects of solvent, transportation and storage time on the migration of ε-caprolactam from a Nylon-6-based lidding material into water or a white wine substitute (12% ethanol). Polypropylene plastic cups were filled, sealed, packaged, stacked and exposed to a simulated 3-day cross-country shipment. Cups …

Optimization Of Gan Laser Diodes Using 1d And 2d Optical Simulations, Sean Richard Keali'i Jobe

Master's Theses

This paper studies the optical properties of a GaN Laser Diode (LD). Through simulation, the GaN LD is optimized for the best optical confinement factor. It is found that there are optimal thicknesses of each layer in the diode that yield the highest optical confinement factor. There is a strong relationship between the optical confinement factor and lasing threshold—a higher optical confinement factor results in a lower lasing threshold. Increasing optical confinement improves lasing efficiency. Blue LDs are important to the future of lighting sources as they represent the final color in the RGB spectrum that does not have a …

Characterization Of A Viscoelastic Response From Thin Metal Films Deposited On Silicon For Microsystem Applications, Steven L. Meredith

Master's Theses

Understanding the mechanisms that control the mechanical behavior of microscale actuators is necessary to design an actuator that responds to an applied actuation force with the desired behavior. Micro actuators which employ a diaphragm supported by torsional hinges which deform during actuation are used in many applications where device stability and reliability are critical. The material response to the stress developed within the hinge during actuation controls how the actuator will respond to the actuating force. A fully recoverable non-linear viscoelastic response has been observed in electrostatically driven micro actuators employing torsional hinges of silicon covered with thin metal films. …

Effectiveness Of Thermal Oxidation In Relation To Anterior Cervical Plates, Katherine A. Miyashiro

Master's Theses

Ti-6Al-4V anterior cervical plates (ACP) are used in spinal fusion surgeries to fixate cervical vertebrae during graft adhesion. However, documented cases of implant failure and the potential for ACP corrosion raise concerns regarding any degradation of material resulting from extended implantation. In addition, abrasion during implantation may damage a section of the protective oxide layer, potentially exposing surrounding tissues to the harmful effects of bare titanium, aluminum, and vanadium. Thermal oxidation has been shown to improve corrosion-resistance and wear-resistance, depending on temperature and time. To quantify the attributes of the thermally grown oxide layer, Ti-6Al-4V coupons underwent thermal oxidation treatments …

Design, Fabrication, Modeling And Characterization Of Electrostatically-Actuated Silicon Membranes, Brian C. Stahl

Master's Theses

This thesis covers the design, fabrication, modeling and characterization of electrostatically actuated silicon membranes, with applications to microelectromechanical systems (MEMS). A microfabrication process was designed to realize thin membranes etched into a silicon wafer using a wet anisotropic etching process. These flexible membranes were bonded to a rigid counterelectrode using a photo-patterned gap layer. The membranes were actuated electrostatically by applying a voltage bias across the electrode gap formed by the membrane and the counterelectrode, causing the membrane to deflect towards the counterelectrode. This deflection was characterized for a range of actuating voltages and these results were compared to the …

Utilizing Quantum Dots To Enhance Solar Spectrum Conversion Efficiencies For Photovoltaics, Richard N. Savage, Hans Mayer, Matthew Lewis, Dan M. Marrujo

Materials Engineering

Silicon-based photovoltaics typically convert less than 30% of the solar spectrum into usable electric power. This study explores the utilization of CdSe based quantum dots as spectral converters that absorb the under utilized UV portion of the solar spectrum and fluoresce at wavelengths near the band-gap of silicon-based solar cells. A flexible 1 mm thick thin-film structure that contains an array of microfluidic channels is designed and fabricated in polydimethylsiloxane (PDMS) using soft-lithographic techniques. The channels are approximately 85 microns wide by 37 microns tall and are filled with a solution containing the quantum dots. The thin-film structure can easily …

Work In Progress - Attaining And Measuring Global Competency For Engineering Graduates, James Widmann, Linda Vanasupa

Materials Engineering

Downey et al. laid out a clear path of learning criteria and outcomes for global competence in their 2006 Journal of Engineering Education publication. We build on their work by integrating other disciplinary perspectives to expand upon the questions: "How can global competency be learned?", and "How can we assess it?" In this work-in-progress paper, we propose an expanded framework for global competence and identify the use of Fink's taxonomy of significant learning as a tool to consider how it can be achieved through careful design of classroom learning experiences. Drawing heavily from other models, our framework attempts to articulate …

Work In Progress - A Design Guide To Retain Female (And Male) Students In Engineering, Linda Vanasupa, Katherine C. Chen, Stacey Breitenbach, Karen R. Bangs

Materials Engineering

Despite a rich body of research on factors contributing to attrition of women during the college, women continue to be underrepresented in the graduating classes of most traditional engineering disciplines. We present our Four-Domain Development Diagram (4DDD) in an attempt to enable a systems approach to managing all the factors that contribute to retention. This diagram makes explicit the connections between the learners' response factors in the learning environment, including motivation, interest, and ultimately retention. Although we are only three years into our use of the diagrams' relationships, we have seen a lower overall net attrition rate (male and female) …

Work In Progress – Building The Survey Of Engineering Ethical Development (Seed) Instrument, Janel A. Sutkus, Donald D. Carpenter, Cynthia J. Finelli, Trevor S. Harding

Materials Engineering

When developing surveys, researchers can readily identify the concepts they intend to study, but how do they create individual survey items that will most accurately measure those concepts? Here we describe the first year of a four-year NSF project in which the E³ Team (Exploring Ethical Decision Making in Engineering) prepared to develop a national survey of the curricular and cocurricular activities, events, and experiences affecting the ethical development of engineering undergraduates. As this survey is likely to be the most comprehensive assessment of ethical development - both in content and scope - ever administered to engineering undergraduates, it …

The Psychology Of 'Ought', Trevor S. Harding

Materials Engineering

As educators, we would like to believe that we can influence the ethical growth of our students. If we are to do this, it seems worthwhile to first understand what ethical decision-making is and how it happens. For millennia, ethical decision-making has fallen within the domain of philosophy. However, recent evidence suggests that the average person does not consider ethical dilemmas in the abstract. Instead, ethical decision-making appears to be a complex dance between an individual’s rational calculus of the ethical dilemma and their emotional response to the context of the dilemma. I will present an argument that in the …

A Longitudinal Study Of The Ethical Development Of Engineering And Non-Engineering Students At A National Research University, Cynthia J. Finelli, Janel A. Sutkus, Donald D. Carpenter, Trevor S. Harding

Materials Engineering

No abstract provided.

The Four-Domain Development Diagram: A Tool For Designing Development-Centered Teaching, Linda Vanasupa, Trevor S. Harding, William L. Hughes

Materials Engineering

Research in education has brought to light the complexity of the learning process, demonstrating that students' development is influenced by a myriad of cultural and social factors, as well as the environment in which learning takes place. Engineering curricula, however, are primarily focused on teaching content knowledge, often resulting in a gap between what is taught and what is learned. We propose that shifting some of the focus onto the process of learning that occurs within the student and leveraging multiple known connections from educational psychology can result in more effective engineering education. Here we define “effective” engineering education as …

Converting Traditional Materials Labs To Project-Based Learning Experiences: Aiding Students' Development Of Higher-Order Cognitive Skills, Linda Vanasupa, Katherine C. Chen, Jonathan Stolk, Richard N. Savage, Trevor S. Harding, Blair London, William L. Hughes

Materials Engineering

Against a backdrop of compelling societal needs, graduates in science and engineering now must master their disciplines and demonstrate a sophisticated level of cognitive, affective and social development. This has lead a number of national and international commissions on science and engineering to urge educators to re-think the way in which STEM disciplines are taught. We have chosen to "repackage" a traditional undergraduate materials engineering curriculum in a form designed to promote the development of higher-order cognitive skills like self-directed learning and design. Classic metallurgy experiments have been converted to project-based learning experiences where students are put in the role …