Structural Materials Commons^™

A Maximum Energy Release Rate Computational Framework For Fatigue Crack Trajectory And Life Prediction Under Mixed-Mode Proportional And Nonproportional Loading, Nahla Helmy Matar

Theses and Dissertations

The problem of mixed-mode fatigue crack growth has been a persistent research challenge. The determination of fatigue crack propagation direction directly impacts the safety and integrity of components and structures, making it crucial in various industrial applications, including welded drilling pipes, aerospace, and automotive engineering. Unlike uniaxial loading, mixed-mode cracks tend to change direction frequently (kinking), and nonproportional loading adds to the complexity of the problem. This research aims to estimate the crack propagation direction and fatigue crack life in linear elastic materials subjected to mixed-mode (I+II) loading conditions under proportional or non-proportional cyclic loading. Numerical software was developed based …

Investigating The Corrosion Behavior Of Stainless Steel 316 In Static Lead Lithium Eutectic Under Applied Stressed Conditions, Daniel E. Levario

Nuclear Engineering ETDs

As fusion power moves closer to feasibility, identifying structural materials compatible with breeding blanket environments remains a critical challenge. Lead-lithium eutectic (LLE) is a leading candidate breeder and coolant material due to its low melting point and combined tritium breeding and neutron multiplication capability. However, the corrosive nature of LLE toward structural steels at elevated temperatures must be characterized before these systems can be reliably deployed. This study investigates the corrosion behavior of Type 316 stainless steel in static LLE under applied stress conditions at 550°C using C-ring stress corrosion specimens. Post exposure analysis via optical microscopy, SEM, EDS, and …

Direct Ink Writing Of Functional Fiber/Granular Composites, Zhuoyuan Yang

Doctoral Dissertations and Master's Theses

Direct ink writing provides a versatile manufacturing route for fabricating functional fiber and granular composites with controlled architecture, tunable interfaces, and customized material distributions. Fiber reinforced composites offer high stiffness, strength, fatigue resistance, and functional anisotropy, while granular composites provide scalable access to particle based structures with high material efficiency and broad resource compatibility. However, the additive manufacturing of these composite systems remains challenging. For fiber based composites, precise control of fiber placement, matrix impregnation, interfacial bonding, and freestanding deposition is difficult to achieve during printing. For granular composites, stable particle flow, controllable packing, binder infiltration, and shape retention are …

Characterization Of The Thermally Driven Red Hue Effect In Coated And Uncoated Concrete Systems: Implications For Post-Fire Assessment In Wildland Urban Interface Communities, Juan C. Palominos Jr

Master's Theses

The increasing frequency and intensity of Wildland-Urban Interface (WUI) wildfires, such as the destructive 2025 Pacific Palisades Fire that destroyed over 6,000 structures, have underscored the urgent need for rapid post-fire safety assessment methodologies. This study sought to quantitatively characterize the Thermally Driven Red Hue Effect (TRHE), a unique, irreversible color shift observed in architectural coatings and concrete substrates, to determine its reliability as a permanent visual record of thermal exposure. Concrete substrates were formulated with three distinct coarse aggregates: gold granite (14.7% Fe), red cinder (22.4% Fe), and green rock (33.6% Fe) and coated with a 20 PVC waterborne …

An Analytical Framework For Quantifying Urban And Community Resilience To Natural Hazards From Cell-Phone Gps-Location And Traffic-Flow Data, Georgios Chatzikyriakidis

Civil and Environmental Engineering Theses and Dissertations

Urban areas are increasingly exposed to natural hazards while accommodating a growing share of the global population, yet a consistent science-based framework for quantifying urban and community resilience remains lacking. This dissertation develops a physics-based analytical framework grounded in statistical mechanics and the quantitative theory of Brownian motion. A city is conceptualized as a complex medium in which citizens move analogously to Brownian particles within a viscoelastic environment, influenced by socioeconomic interactions and infrastructure functionality.

A central premise is that urban resilience, interpreted as engineering resilience (an outcome), can be quantified through a single metric: the mean-square displacement MSD=⟨r²(t)⟩, of …

Ballistics Characterization Of Micro-Truss Reinforced Lunar-Inspired Geopolymer Concrete For Space Construction, Phoebe G. Johnson

Honors Theses

This research investigates the ballistics response and compressive strength of a Fly Ash/ Lunar Regolith hybrid geopolymer concrete developed for space construction. The study aimed firstly to optimize the Fly Ash/ Regolith mix ratio for maximum mechanical performance and secondly, to evaluate the effectiveness of carbon-fiber micro-truss reinforcement, produced by 3D printing, in mitigating damage from high-velocity impacts. Concrete specimens with varying Fly Ash-to-Regolith ratios (100-50% Fly Ash) were fabricated and tested under compression and ballistic loading. Compressive strength tests followed ASTM C109 using a 110 Kip 810-MTS testing apparatus on both unreinforced and reinforced 2” cubes. For unreinforced samples, …

Plastic Material Analysis And Bonding In Small Aquatic Vessels, Andrew R. Orr

Honors College Theses

This project presents the design and development of a suitable vessel for small-scale aquatic applications. The developed project is used for a remote-controlled duck hunting system, and the parameters of the design are based on the requirements for the system as a whole. Traditionally, plastics are fabricated using blow molding to create a single seamless form. However, for small-scale prototyping with limited resources, this method of fabrication is unsustainable for short-term, non-industrial design applications. As a result, an existing longer hull is selected and shortened to meet the required project length. The project evaluates multiple initial hull designs, ultimately selecting …

Temperature And Environmental Implications On Ti3c2cl2 Mxene Degradation Process, Yang Yang

McKelvey School of Engineering Graduate Student Theses & Dissertations

MXenes, a rapidly emerging class of two-dimensional transition metal carbides and nitrides, have attracted considerable attention owing to their exceptional electrical, mechanical, and chemical properties. However, the inherent thinness of their atomic structure and the reactivity of their functional groups render MXenes susceptible to environmental degradation, whereby the lattice integrity is compromised and desirable material functionalities are dimin- ished. In this work, ex situ electron microscopy characterisation is performed on Ti₃C₂Cl₂ MXene specimens subjected to controlled gas environments — nitrogen gas (N₂) and air — at annealing temperatures of 200°C and 600°C, with …

Creation Of The 2-Way Cross Laminated Timber Subroutine For Computing Dynamic Analysis Parameters, Joseph Freitas

Architectural Engineering

This document will describe the inputs, methodology, and outputs for the CLT 2-way subroutine for cases with and without openings recently added to a proprietary structural analysis software. For the sake of simplicity, most of the discussion will be focused on cases without openings from here on out, as the verification process for a novel method for cases with openings is still in progress. The CLT 2-way module calculates multi-point resistance functions for panels without openings by automating the procedure outlined in an industry-standard structural design manual. The subroutine also finds the appropriate dynamic response factors, kinetic load multipliers, mass, …

Development Of A Novel Innovative Umbrella Falsework System For Concrete Slabs, Abdelazem Hashim

Theses and Dissertations

Formwork is one of the major elements that contribute to the cost and duration of concrete building projects. This is why optimizing such an element can lead to huge savings to all parties involved in the construction projects. With contractors facing huge challenges in such a competitive industry and employers seeking the least price and least duration for their projects, contractors are constantly under the obligations of finding the best alternatives to deliver their projects in terms of both time and money. Therefore, the main aim of this research project is to develop a falsework system, where the falsework system …

Metal-Free Nitrogen-Enriched Graphitic Carbon Nitride Architectures For Advanced Supercapacitor Energy Storage: Design, Synthesis, And Electrochemical Performance Optimization, Loujain Gamal Mohamed

Theses and Dissertations

Abstract

This thesis addresses the urgent global requirement for efficient energy storage materials by developing and characterizing advanced graphitic carbon nitride (g-C3N4)-based electrode materials for supercapacitors. A facile, low-cost thermal polymerization method produces 2D nitrogen-rich GCN nanosheets exhibiting excellent electrochemical stability and wide voltage windows, enabling symmetric devices with 19.33 Wh/kg energy density and remarkable cycling stability over 21,000 cycles. To overcome intrinsic limitations of pristine GCN, a 3D/2D metal free composite with bio-derived carbon (Bio-Cx) is synthesized, delivering high capacitance, wide potential windows, and ultrahigh energy density of 53.72 Wh/kg in asymmetric configurations paired with mesoporous nitrogen-doped carbon (MPNDC). …

Copper Metal Organic Framework-Based Nanomaterial For Non-Enzymatic Glucose Electrochemical Sensor, Sameha Mohamed Sadek

Theses and Dissertations

This thesis examines the development of non-enzymatic glucose sensors by engineering advanced electrode materials based on metal-organic frameworks (MOFs). Conventional enzymatic glucose sensors, although widely used, suffer from inherent limitations, including poor long-term stability, narrow operating conditions, and sensitivity to environmental factors, due to their reliance on biological enzymes. Non-enzymatic sensors offer a more robust alternative by enabling direct electrochemical oxidation of glucose on engineered electrode surfaces. MOFs represent a highly tunable class of hybrid materials with structural and chemical features that are ideal for sensor applications, including a high surface area, tailored porosity, and excellent thermal and chemical stability. …

Areosense, Josephine Turney

Williams Honors College, Honors Research Projects

The AeroSense growing system is designed to make indoor aeroponic gardening easy and accessible for everyone. By combining sensors, automation, and AI, the system can monitor and adjust humidity, lighting, and nutrient levels to help plants thrive without requiring expert knowledge. The goal is to create a self-regulating garden that takes the guesswork out of growing fresh herbs and vegetables at home. The project involves building a working aeroponic prototype equipped with misters, pumps, and environmental sensors, all managed by a Raspberry Pi. Using computer vision and machine learning, AeroSense will be able to assess plant health and respond automatically …

Buckling Analysis Of Auxetic Composite Laminates And Optimal Design Using Lamination Parameters And Machine Learning, Hans Bendon Maria Tamil Selvan

Mechanical and Aerospace Engineering Theses

Composite materials are widely used as structural panels in aerospace, automotive, and civil engineering applications, where buckling is often a critical failure mode. This thesis focuses on the analysis and design of composite laminates that maximize buckling performance under prescribed stiffness and thickness constraints.

The first part of the study investigates the buckling behavior of auxetic laminates, which exhibit a negative Poisson's ratio. While previous studies suggest that auxetic laminates can achieve higher critical buckling loads than non-auxetic laminates under simply supported boundary conditions with lateral restraint, the influence of other boundary conditions and plate aspect ratios has not been …

Innovative Strategies For Stabilizing Zinc Anodes: From Molecular Design To Practical Zinc-Ion Batteries, Nhat Anh Thi Thieu

Graduate Theses, Dissertations, and Problem Reports (ETD)

Aqueous zinc-ion batteries (AZIBs) have become increasingly attractive as grid-scale energy storage solutions due to their safety, low cost, and environmental friendliness. However, the anode-electrolyte interface in AZIBs is prone to instability due to severe dendrite growth, self-corrosion, parasitic water-induced side reactions, and hydrogen evolution reactions (HER), which collectively lead to poor cyclability. To date, various interfacial engineering strategies have been investigated to address these challenges and improve the stability of Zn metal anodes. This dissertation presents a unified strategy for regulating Zn deposition through synergistic electrode and electrolyte design in laboratory-scale coin cells and then applies these concepts to …

Made On Mars: Design And Manufacturing Of Structural Polymer-Regolith Composites, Pailey M. Vitale

Williams Honors College, Honors Research Projects

Human exploration of Mars is constrained by harsh environmental conditions and the prohibitive cost of transporting materials from Earth. Long-term sustainability requires the local production of mechanical and structural components using resources available on Mars, thereby minimizing payload mass. This project investigates polymer–regolith composites derived from atmospheric CO₂ and mineral-rich regolith as a pathway toward in-situ manufacturing. These composites, when compatible with additive manufacturing, could replace imported plastics, enable on-demand fabrication, and support closed-loop recycling systems. The objective is to design and evaluate polymer–regolith composites that maintain mechanical integrity and environmental resistance under Martian conditions, including extreme temperature swings, radiation …

Utilizing Coal For Mesophase Pitch-Based Carbon Fiber Production: Precursors, Processes, And Progress, Christina M. Thompson

Theses and Dissertations--Chemistry

Graphitic materials possess unique properties due to the unique combination of layered crystalline structure and carbon’s low atomic weight. High performance carbon fiber is one such example, displaying exceptional strength-to-weight ratios, stiffness, and thermal and chemical resistance. These properties render high performance carbon fiber a critical structural reinforcement material in the manufacture of composites across various industries, such as for automotive and aerospace applications. However, balancing fiber performance with precursor and processing costs remains a challenge. As alternative carbonaceous feedstocks are explored, coal has gained interest for utilization in graphitic products as a relatively abundant and low-cost source of aromatic …

Castrip Process Technology: Non-Grain Oriented (Ngo) Si Steels Extension And Carbide-Free Bainitic (Cfb) For Flat Products, Naram Naidu Meesala

Masters Theses

"This research explores the development of advanced steel grades manufactured through Castrip® twin-roll thin strip casting technology, with particular attention to non-grain-oriented electrical Si-Steels (NGOES) and carbide-free bainitic (CFB) steels. The Castrip® process offers a near-net-shape route for producing thin steel strips, which greatly decreases the number of processing stages, lowers energy demand, and reduces carbon dioxide emissions when compared with traditional steel production methods.

In the NGOES part of the study, several industrial Fe–Si steel compositions were cold rolled to final thicknesses ranging from 0.35 mm to 0.15 mm. These materials were then exposed to short-duration continuous annealing at …

Critical Parameters Controlling Oxide Scale Formation And Hydro-Descaling Efficiency During Steelmaking, Tochukwu Princewill Ojiako

Doctoral Dissertations

In modern steelmaking, cast slabs are exposed to high-temperature oxidizing environments during secondary cooling, reheating, and hot rolling, resulting in the formation of multilayer oxide scales on the steel surface. These scales interact with mold-flux residues originating from the casting process (CC). The morphology, chemistry, and adhesion of oxide scale strongly influence its removability during high-pressure hydraulic descaling and ultimately determine the surface quality of hot-rolled products. However, the mechanistic relationship between oxide scale evolution, scale-steel interfacial structure, and hydraulic descaling performance remains poorly understood.

This dissertation investigates oxide scale formation, modification, and removal in low-carbon thin-slab steels produced by …

Compression Forming Of Basic Oxygen Furnace Slag-Gypsum Blocks: Performance Enhancement And Environmental Assessment, Fengyi Zhang

Student Works (2020-2029)

The construction industry plays a crucial role in global development but faces significant environmental challenges, particularly CO2 emissions from cement production. Gypsum blocks provide a sustainable alternative to traditional cement concrete blocks. However, the low mechanical strength and water resistance of gypsum materials limit the widespread adoption of gypsum-based materials in the construction industry. This study initially produced gypsum-based blocks using compression forming, adding supplementary cementitious materials (SCMs), and subjecting accelerated carbonation curing (ACC). It was found that compression forming addressed the shortcomings of traditional block manufacturing (high energy consumption and long production time), and the addition of SCMs generated …

Material Extrusion 3d Printing Of Metal Alloy: Material, Methods And Application., Sihan Zhang

Electronic Theses and Dissertations

Material extrusion (MEX) additive manufacturing presents a promising pathway for producing metal components with complex geometries while avoiding the safety hazards associated with loose powder handling in conventional metal additive manufacturing processes. This dissertation investigates the development and optimization of MEX processes for aluminum alloys, addressing critical challenges in feedstock formulation, printing parameter optimization, and post-processing strategies. Three distinct approaches were explored to advance the capabilities of aluminum MEX: filament-based processing of 6061 aluminum, paste-based extrusion of 6061 aluminum, and development of a novel aluminum-magnesium-tin alloy system for space manufacturing applications. The filament-based approach successfully demonstrated the production of 6061 …

Shape Memory Behavior In Medium To High Entropy Shape Memory Alloys: Design, Prediction, And Experimental Analysis, Hatim Raji

Theses and Dissertations

This dissertation provides a data-driven system integrating synthetic data generation and machine learning (ML) techniques to create multicomponent SMA compositions with specific transformation temperatures (TTs). Models were trained to represent the nonlinear dependencies influencing martensitic transformation behavior by using elemental, thermodynamic, and process-related aspects. The capacity of the ML models on medium entropy NiTiHfPd and high entropy NiTiHfZrCu systems accuracy was confirmed by experimental validation showing TTs closely matched with model outputs.

Mno2 Nanoscale Interface Modification, Alexander C. Skoppe

Doctoral Dissertations and Master's Theses

Interface modification of carbon fibers has been shown to improve the mechanical performance of composites. In addition, interface modification of carbon fiber composites can impart multifunctionality into the resulting composite. This work will explore ZnO and MnO2 as interface modifications for use on carbon fibers. When exposed to high temperatures, carbon fibers undergo fiber degradation, leading to the need for low-temperature hydrothermal processes. This work will develop and characterize a nanoscale ZnO and MnO2 interface modification for use on carbon fibers. These nanomodifications will be developed with low-temperature processes, minimizing the fiber degradation that the fibers undergo. Fourier transform infrared …

Effect Of Manufacturing And Machining Process On Recycled Composite Connecting Rods Under Tension And Compression, Walter W. Oppelt

Master's Theses

Carbon fiber reinforced polymer (CFRP) is an engineering material renowned for its high-strength and low-density material properties. Such properties make CFRPs especially useful for applications across many industries, including aerospace, automotive, marine, sporting goods, oil and gas, and more. However, with such favorable material properties comes the cost of high energy usage required to produce raw carbon fiber. Recycled carbon fiber (rCF) has emerged as a promising alternative, offering a significant reduction in energy usage. This research explores the viability of applying recycled CFRPs to internal combustion engines to both reduce energy costs during manufacturing and while in use. Mechanical …

Model-Based Design Of Compressed Lithium-Metal Pouch Cell Battery Modules For Evtol Applications, Scott J. Stirling

Master's Theses

Batteries with higher specific energy and power are essential for extending the range and performance of electric vertical takeoff and landing aircraft (eVTOLs). Anode-free lithium-metal pouch cells offer strong potential at the cell-level but require high compressive pressures to enhance cycle life and discharge performance. These pressures necessitate heavier structural components, reducing packaging efficiency at the module level.

To evaluate this tradeoff, a full-factorial enumeration model was developed to explore viable module designs within a constrained packaging volume. The model scales subsystem masses, enforces design rules and material limits, and accounts for large (~20%) cell thickness changes during cycling.

Results …

Comparative Study Of Experimental And Fea Strain Data For Cnt-Coated Fiberglass Sensors, Extensometers, And Metal Foil Strain Gauges, Omar Dwidar

Master's Theses

Material testing is essential across industries such as aerospace, automotive, and construction, playing a critical role in verifying material selection, diagnosing failures, and understanding the development of flaws in structures. These insights are key to designing successful, reliable systems. Conventional metal foil strain gauges are low cost and reliable but provide limited sensitivity with a typical gauge factor around 2. Extensometers provide highly sensitive strain measurements with the disadvantage of a bulky form factor. With advanced materials such as carbon nanotubes, it is possible to manufacture a sensor with the sensitivity closer to that of an extensometer with the small …

Fire Fossils: Biomineral Infrastructures In Untangling Climates, Tanmayee More

Masters Theses

Diatoms drift, sediments sink, wildfires generate their own weather. Lightning strikes can blast sand into glass, and microscopic organisms do the same in the cold recesses of the ocean. What alchemies and metabolisms catalyze space, time, and energy? What are the thermodynamics of infrastructure in Climate Change?

Places, materials, and beings are afterimages. Through alchemical experiments, and multi-scalar imaging, I develop simulations of wildfires, and their profound, reverberating effects. In this thesis, a glass-meets-landscape experimental process enters these obscured conditions and renders new material relations for the built environment.

Exploring Metal Additive Manufacturing In Martian Atmospheric Environments, Zane Mebruer

Mechanical Engineering Undergraduate Honors Theses

On-surface manufacturing is key to the success of a planetary colonization, especially that of Mars. However, traditional subtractive manufacturing processes are equipment, energy, and material intensive, meaning novel additive manufacturing (AM) processes must be pursued for this end. Selective laser melting, one of the most effective and versatile AM methods, would be incredibly beneficial to a Martian mission but requires an artificial argon atmosphere to create effective parts. The purpose of this study was to examine if carbon dioxide, the gas that makes up over 95% of Mars’ surface atmosphere, would be a sufficient substitute for argon in SLM fabrication. …

Adjustable Dynamometer Motor Mount, Garrett Carson Ng, Elijah Siegel Reuven, Ethan Fong, Daniel Larimer

Mechanical Engineering

The Cal Poly Electrical Engineering Department and sponsor Dr. Dolan needs a manufacturable motor fixture that securely aligns motors of various sizes with dynamometers. Previous lab motor fixtures could not accommodate motors of different sizes, making precise alignment between motors and dynamometers time-consuming and unreliable. Our team developed a modular, manufacturable fixture capable of aligning various motor sizes quickly, accurately, and securely, enhancing lab consistency and usability.

Incorporating Recycled And Repurposed Plastic Into 100% Reclaimed Asphalt Pavement, Basant Bhatt

Graduate Theses and Dissertations (2019 - present)

The increasing awareness of sustainability in the asphalt industry has driven the use of recycled materials like reclaimed asphalt pavement (RAP) and waste plastic. This study examines the incorporation of recycled polypropylene (rPP), recycled high-density polyethylene (rHDPE), and recycled low-density polyethylene (rLDPE) at 0.3%, 0.6%, and 0.8% dosages into 100% RAP, along with the warm mix asphalt additive Evotherm® P25. Laboratory tests were conducted to evaluate the mechanical and durability performance of the modified asphalt mixtures while rutting and fatigue life were evaluated using mechanistic-empirical (ME) analysis in PerRoad software. Both plastic type and dosage had a statistically significant impact …