Materials Science and Engineering Commons^™

Artificial Alveolar-Capillary Membrane On A Microchip, Keith Male

Materials Engineering

A microfluidic device was synthesized out of polydimethyl siloxane (PDMS) to simulate the structure of the alveolar-capillary interface of the human lung. Soft lithography techniques were used to build a mold structure out of SU-8 epoxy at heights ranging from 30µm to 110 µm on a silicon substrate, with the 70 µm structure working the best. A mixture of 10:1 Sylgard 184 elastomer was then cast using the mold, and cured at a temperature of 80^oC. For the porous membrane, the PDMS was spun on at 6000rpm for 30 seconds using a spin coater to produce a membrane …

Bond Strength Characterization Of Su-8 To Su-8 For Fabricating Microchannels Of An Electrokinetic Microfluidic Pump, Nash Anderson

Materials Engineering

Photosensitive negative resist polymer layers of SU-8 2050 were adhered to 100 mm n-type silicon and Pyrex wafers via spin coating. These wafers were then bonded together at various temperatures of 100 ͦC, 120 ͦC, 140 ͦC, 150 ͦC, 160 ͦC, and 180 ͦC. The target thickness of each SU-8 layer was 100 µm. Photolithography was used to create microfluidic channels within the SU-8. An n-type silicon wafer and a Pyrex wafer, each with an SU-8 layer, were brought together on the “hard bake” or final step of SU-8 polymerization. A pressure of ~300 KPa was applied during the hard …

Design And Fabrication Of Serpentine-Hinged Silicon Micro-Mirror Devices, Nicholas Wiswell

Materials Engineering

Seven different actuating micro-mirror designs were created and verified via finite element analysis. Two were straight torsion beam hinge designs representative of previous work at Cal Poly; the remaining five were new designs incorporating serpentine hinges. The surface area of these mirror devices ranged from 0.5 square millimeters to 12.5 square millimeters. Geometric patterns representing the device profiles were created and used to obtain photolithographic masks. Beginning with a 400μm thick, 100mm diameter silicon on insulator wafer, a silicon dioxide layer was thermally grown on the surface at 1050 degrees Celsius. Positive photoresist was then spun onto the wafer at …

Design And Development Of An Interactive Materials-Based Learning Kit For K-4 Grade Levels, Thomas Agasid, Santiago Caceres, James Woodhead

Materials Engineering

The Materials Safari Adventure kit was designed to help introduce basic materials concepts to young audiences in kindergarten through fourth grade levels. The primary goal of this project was to design a tool to spark an interest in materials science for young children, while revealing the field of materials science to parents and educators. The final kit design incorporates a safari theme to encourage imagination and promote self-directed learning through the interaction with materials. Materials were selected to showcase a range of properties within three materials classes: metals, polymers, and natural woods. A total of 9 materials were chosen for …

Improving Solar Cell Performance Using Cdse/Zns Core/Shell Quantum Dots In A Spectral Conversion System, Buddy Bump

Materials Engineering

Solar cells have been found to absorb light more efficiently and effectively when the energy of incoming photons matches the electronic band gap of the solar cell. Spectral conversion of light from UV to lower energy wavelengths can improve solar cell efficiency an estimated 14.5%. Cadmium Selenium/Zinc Sulfide Core/Shell quantum dots have been successfully embedded in PDMS silicone elastomer. Using a Keithley 2400 Electrometer with Labview software, voltage and current characteristics have been recorded in steps of 10 mV with a wait time of 250 ms on a commercially available solar cell using an artificial solar spectrum created by a …

Morphology And Roughness Of Al2o3 On Ferritic Stainless Steel Foil For Diesel Catalytic Converter Applications, Megan Butala

Materials Engineering

The improved thermal properties of metal-substrate catalytic converters enable effective catalysis sooner after ignition than traditional ceramic monoliths, resulting in less harmful emissions. ACAT Global, a manufacturer of stainless steel catalytic converters, uses ferritic stainless steel substrates for low temperature catalytic converters for diesel automobiles. Production begins with an oxidizing heat treatment to increase surface roughness. The success of the second production step, the application of catalyst-containing ceramic slurry (washcoat), depends on the surface roughness that results from oxidation. Formation of the primary oxide of interest, alumina (Al₂O₃), is controlled by the stainless steel foil composition, …

Discontinuous Grain Boundaries Of Forged René 41, Steven Crump

Materials Engineering

Forged components must pass a grain size specification (grain size, distribution) for acceptance in an application. The varying amounts of plastic deformation during forging can lead to abnormally large recrystallized grain sizes in certain regions of the part, which will not pass specification. The question exists whether these abnormally coarse grains are truly comprised of poly crystalline fine grains with grain boundaries resistant to etching techniques. To investigate this abnormal grain size effect, a cross section of a forged René 41 nickel-based superalloy aircraft engine ring was cut and sectioned into six segments. Those segments were then prepared for microstructural …

Analyzing The Corrosion Resistance Of Ni-Shield 200 Coatings At Different Temperatures When Exposed To Sulphuric Acid, Alex Hussinger

Materials Engineering

Six steel samples each were twin wire arc sprayed with Hastelloy C-276 or Nickel-Shield 200 coatings approximately 0.020″ thick. These samples were then cut into 3″ by 3″ squares. A 2″ diamond grit hole saw was used to abrade and polish to a smooth surface a ring in the middle in order to get an O-ring mechanical seal. The samples were then weighed and loaded into a jig that started from the bottom up with a stainless steel plate, then the sample, then a Viton O-ring, a ¾″ thick glass plate with a 1 3/4″ hole cut in it, another …

Al2O3 Oxide Morphology For Two Fe-Cr-Al Stainless Steel Foils Used In Gasoline Engine Catalytic Converters, Jennifer Suiter

Materials Engineering

Corrugated 0.05 in thick strips of Fe-Cr-Al ferritic stainless steel samples with 4% and 6% aluminum were heat treated, and the resulting Al₂O₃ oxide was analyzed using SEM imaging. Three heat treatment cycles were carried out for each sample. The heat treatments were based on future metal-substrate catalytic converter processing prior to applying the washcoat Each heat treatment started with a 90 minute ramp from room temperature to 538°C and a 32.5 minute ramp from 538°C to 899°C. The three different dwell periods at 899°C were 4 hours, 6 hours, and taking a sample out every hour …

The Mitigation Of Eutrophication Using Microporous Polymer Membranes To Control Algae Growth, Christopher R. Riley

Materials Engineering

A system was designed to mitigate the accelerated process of anthropogenic eutrophication. This system aimed to contain Chlorella Vulgaris microalgae cells within an enclosed polymer membrane pouch while allowing for water and nutrients to diffuse through the pouch. As a test model, a 10 gallon aquarium was partitioned into three sections using polycarbonate membranes with 1 micron pore diameters. Each section was then gradually filled with a deionized water and Bristol solution recommended for microalgae growth. Phosphate and nitrate were added to Section A of the aquarium and allowed to diffuse throughout the tank. A water pump was used to …

Corrosion Of Stainless Steel 316l And Astm F75 Cobalt Chromium Alloy During Immersion Testing In Silver Salt Solutions, Meagan Higgins

Materials Engineering

This study evaluates the potential effects of silver salts on biocompatible metals used for prostheses during the chemical reduction process to produce a silver antimicrobial layer on the metal’s surface. Samples of two biocompatible metals were obtained: Stainless Steel 316L and ASTM F75 Cobalt Chromium Alloy. Three different silver salts were also acquired: silver nitrate, silver sulfadiazine, and silver chloride. Specimens of each metal were cut to size using a 4-1/2 inch aluminum oxide, 40 grit, cut off wheel for metal, attached to a Dewalt Angle Grinder. The biocompatible metal samples were then subject to either Solution 1, water with …

Creating A Solar Cell Array From A Single Silicon Wafer, Samyukta Gade, Roderick Marstell

Materials Engineering

Two different processes to create multi-celled solar panels from single wafers were made and implemented. To do this, the cells must not have a common ground, and both designs use different approaches to solve this problem. One utilizes a 2.9 µm deep n-type well within a 10.74 µm deep p-type well in an n-type wafer. There are two cells in series, which has a theoretical voltage of 1 V. The cells are connected in series with 1.9 µm thick gold traces. Any area that the gold is not in contact with the silicon has a .5 µm layer silicon dioxide …

The Effects Of Concentration, Stir Rate, And Processing Temperature On The Iridescence Of Polymethyl Methacrylate Nanoparticles, David Baruela

Materials Engineering

Synthetic opals were synthesized by creating polymethyl methacrylate (PMMA) nanospheres in order to determine which conditions would create the best iridescent samples. The factors affecting the iridescence were nanosphere concentration, stir rate, and processing temperature. PMMA solutions were made by adding 17 mg of granular azobis to a solution of 16 mL of distilled water with 3 mL of methyl methacrylate (MMA). The solution was stirred at different rates, slow and fast, and different temperatures, 70 °C and 90 °C, under a constant flow of nitrogen gas for 40 minutes until the polymerization reaction was complete. Glass substrates were prepared …

Fabricating Replacement Glass Prisms For The Piedras Blancas Lighthouse, Daniel Garcken

Materials Engineering

The objective of this project was to design and create a process for manufacturing replacement glass prisms for the Piedras Blancas lighthouse and several other lighthouses nationwide. The prisms were designed to be in multiple metal arrays spread across the floor of the beacon room (the topmost room of the lighthouses). The prisms functioned to transmit extra, radiant light from the beacon light through the floor of the beacon room and disperse it into the maintenance room below. Using computer aided drafting (CAD) software, an original prism was measured and modeled; the corresponding mold was also modeled. G-codes for controlling …

Effects Of Abrasive Particles On The Projected Fatigue Life Of Nylon Climbing Rope, Casey Johnson, Charlie Klonowski

Materials Engineering

When climbing rope is used outdoors, it is exposed to foreign particles such as sand and silt. These particles can potentially work their way through a rope’s sheath and damage the load bearing core decreasing the rope’s strength without exhibiting obvious wear. This project quantified the effect of abrasive particles on the fatigue life of nylon climbing rope. The experimental design involved 18 pieces of static nylon rope of kernmantle construction. 9 of these samples were heavy agitated in a slurry of water, silt, sand and soil, and left to sit for 24 hours. The remaining 9 samples were submerged …

Synthesis Of White Cadmium-Selenium Quantum Dots, Kyle Reilly

Materials Engineering

A process was developed for the synthesis of cadmium-selenium quantum dots that fluoresce at multiple wavelengths, giving a white color to the solution. The process involved making a selenium pre-cursor, then a cadmium precursor, then injecting the selenium precursor into the cadmium precursor and extracting a sample. Once the a repeatable process for synthesizing white quantum dots was developed, the absorption and fluorescence was measured and recorded over a period of two weeks. In the development of the process, the key variables were the temperature of the cadmium precursor and the time between injecting the selenium precursor and extracting the …

Characterization Of Positive Macrosegregation At The Subsurface Of Direct-Chill Cast 7050 Aluminum Forging Billets, Aaron Youril

Materials Engineering

Segregation of alloying elements during casting of forging billets may persist to the final forged component leading to unacceptable surface appearance. Determination of the elements or compounds that segregate is the essential first step to solving this problem. Differential Scanning Calorimetry (DSC) was used to determine a composition profile of the macrosegregation occurring at the subsurface of an as-cast 7050 aluminum alloy billet. Data collection was carried out by separating 10 to 20 mg samples from the outer centimeter along the radius of the billet, as well as samples from the bulk interior of the billet for comparison with the …

Analysis Of Failed Forging Saddling Mandrels And Process Improvements For Increased Mandrel Lifespan, Brock Costalupes

Materials Engineering

This project seeks to increase the lifespan of steel mandrels used by Schlosser Forge in the saddling process, which is part of the production of forged rings for the aerospace and power generation industries. All saddle mandrel samples were taken from used 4340 steel mandrels. Hardness profiles were measured across rectangular bars cut from the transverse direction of a completely fractured piece of a 7″ diameter mandrel. The hardness near one outer surface of the tested bar was 36 HRC and gradually decreased to 30.5 HRC at the opposite surface. Macroscopic examination of the primary fracture surface along with light …

Effect Of Heating Temperature, Heating Time And Initial Microstructure On Recrystallization Of Waspaloy During Heating For Forging, Marissa Hill

Materials Engineering

A fine, uniform grain size is required for creep limited Waspaloy in aircraft engine applications. Upon heating, Waspaloy does not always recrystallize in a uniform manner resulting in occasional large grains with a majority of the grains meeting the grain size requirements. Waspaloy’s microstructure was analyzed with different heat treatments and in the as-forged condition. The strengthening mechanism is the gamma prime phase. The gamma prime solvus temperature is 1908°F so the different heat treatments were determined around that temperature, as well as the forging temperature range of 1800-2150°F. At the 1850°F heat treatment, the microstructure recrystallized with small grains, …

Correlation Between 90o Tensile And 90o Flexural Properties For Thermoplastic Based Carbon-Fiber Composites, Amy Lautenbach

Materials Engineering

Thermoplastic matrix composites containing carbon fibers and 4 different resins (TP 1-TP 4) were tested in tension with the fibers at 90 degree to the longitudinal axis following ASTM D 3039-00. The tensile strengths varied from 5.07-13.87 ksi with TP 1 as the strongest, and TP 4 as the weakest. SEM images were taken of the fracture surface of the samples to explore the fiber-matrix interaction. The SEM images showed significantly more wetting of the fibers in the higher strength materials. The SEM images of the two stronger materials showed resin coating the fibers even after fracture while the two …

Lunalight Project: Solar-Rechargeable Led Lantern And Cell Phone Charger, Sean C. Dawson, Michael E. Deagen, Francisco N. Dye, Brian S. Mircheff, Ryan O. Ramelb

Materials Engineering

Today, 1.6 billion people in the world do not have access to grid electricity. Villagers living off the grid in developing nations resort to kerosene lanterns to light their homes. The fumes from burning kerosene are toxic and lead to respiratory illnesses over time. Our sponsor, OneMillionLights, plans to help people to escape poverty by providing them with a clean source of light at night. Children that must work in the fields during the day can use a solar-rechargeable lantern at night to read or study, and street vendors can use the lanterns at night to improve their businesses.

The …

Transformational Innovation: Reflections On How To Foster It In Engineering Education Systems, Roger Burton, Lizabeth Schlemer, Linda Vanasupa

Materials Engineering

This paper describes the educators’ disposition that we believe is required for transformational innovation. Innovating in this domain relies on interrupting existing patterns. This interruption requires the conscious recognition of patterns through an active practice of self observation. Though self observation does not necessarily need a collective process, it is served by encountering the diversity of views present in groups. Innovation in this sense consists of a fundamental identity shift in the human system and the innovators themselves. Unlike the processes of problem solving and process improvement, transformational innovation requires insight into the individual and collective attention of the designers. …

Energy - Activities, Jane Qiong Zhang, Linda Vanasupa

Materials Engineering

The document contains activities for students in higher education. These activities are focused on energy issues related to sustainability. It is designed for the general engineering or science audience. Its design is based on the framework of the Fink Taxonomy of Significant Learning. Each activity includes a profile that indicates whether the activity involves direct or indirect information sources, whether the experience is doing or observing and whether it involves individual or group reflection. The profile also includes notes for faculty, an estimate of the time investment, a graphic of the developmental aims with respect to the six areas of …

Fink Taxonomy Of Significant Learning, Jane Qiong Zhang, Linda Vanasupa

Materials Engineering

This document is graphical summary of the framework within the Fink Taxonomy of Significant Learning and the definition of each of the six areas of significant learning.

Sustainable Development, Jane Qiong Zhang, Linda Vanasupa

Materials Engineering

This document is a set of learning materials to support the teaching of Sustainable Development issues particularly related to sustainability in engineering. It is designed for the general engineering or science audience. Its design is based on the framework of the Fink Taxonomy of Significant Learning. The document is a fully-editable set of slides in open source format (pptx) that includes references to targeted learning objectives on each slide and annotations in the notes section of each slide.

Water - Activities, Jane Qiong Zhang, Linda Vanasupa

Materials Engineering

The document contains activities for students in higher education. These activities are focused on water issues related to sustainability. It is designed for the general engineering or science audience. Its design is based on the framework of the Fink Taxonomy of Significant Learning. Each activity includes a profile that indicates whether the activity involves direct or indirect information sources, whether the experience is doing or observing and whether it involves individual or group reflection. The profile also includes notes for faculty, an estimate of the time investment, a graphic of the developmental aims with respect to the six areas of …

Population, Jane Qiong Zhang, Linda Vanasupa

Materials Engineering

This document is a set of learning materials to support the teaching of population issues particularly related to sustainability in engineering. It is designed for the general engineering or science audience. Its design is based on the framework of the Fink Taxonomy of Significant Learning. The document is a fully-editable set of slides in open source format (pptx) that includes references to targeted learning objectives on each slide and annotations in the notes section of each slide.

Sustainable Development - Learning Objectives, Jane Qiong Zhang, Linda Vanasupa

Materials Engineering

This document is a list of learning objectives based on the framework of Fink’s taxonomy of significant learning: foundational knowledge, application, integration, human dimension, caring, and learning how to learn. It represents the aspirations for learning that the sustainable development is based on.

Systems Thinking - Assessment, Jane Qiong Zhang, Linda Vanasupa

Materials Engineering

The document contains an assessment activity for an individual or team project in higher education. These assessments are focused on systems thinking issues related to sustainability. It is designed for the general engineering or science audience. Its design is based on the framework of the Fink Taxonomy of Significant Learning. Each assessment consists of a scenario in which the student is an actor who must address some design dilemma. The assessment also includes an estimate of the time investment, a detailed list of learning objectives with respect to the six areas of development within the Fink Taxonomy, and a suggested …

Materials - Learning Objectives, Jane Qiong Zhang, Linda Vanasupa

Materials Engineering

This document is a list of learning objectives based on the framework of Fink’s taxonomy of significant learning: foundational knowledge, application, integration, human dimension, caring, and learning how to learn. It represents the aspirations for learning that the materials is based on.