Mechanical Engineering Commons^™

Portable Ice Cube Maker, Ayden Ziegler, Emiliano Hansen, Wyatt Engdahl, Dane Hansen

Mechanical Engineering

This Final Design Report outlines the senior design project undertaken by a team of mechanical engineering students at California Polytechnic State University, San Luis Obispo, for the development of a portable backpacking ice cube maker. The project aims to design, build, and test a lightweight, compact device that produces ice cubes for backpackers in remote outdoor environments. The goal is to create a functional prototype that is durable, user-friendly, and suitable for backcountry use. This document details background research, project objectives, and project plan, and current design status.

Simulation Study On Nh3 Combustion And NoX Emissions Under Gas Turbine-Relevant Conditions, Kumeesha Arumawadu, Braxton Wiggins, Ziyu Wang

Mechanical and Aerospace Engineering Student Publications and Presentations

Ammonia (NH₃) is a zero-carbon fuel and an attractive hydrogen (H₂) carrier for gas turbine power generation due to its high energy density, ease of storage, and transportation. This study numerically investigates NH₃/air combustion using a hybrid Well-Stirred Reactor (WSR) and Plug Flow Reactor (PFR) model in Cantera at pressures of 1–20 atm, temperatures of 1850–2150 K, and equivalence ratios (ϕ) of 0.7–1.2. The effects of pressure, equivalence ratio, and temperature on NH₃ conversion and NO formation are examined. Results show that NH₃ exhibits a non-monotonic conversion curve with pressure after the …

Numerical Investigation Of Heat Transfer And Aero-Acoustic Response In Deep Cavity Flows Using Urans Simulations, Abdul Hamid Jabado, Ali Hammoud, Bilal El Zohbi, Bilal Taher, Hassan Assoum

BAU Journal - Science and Technology

This paper presents a numerical study to investigate a deep cavity flow, in order to better understand the underlying mechanisms involved in it, such as flow dynamics, heat transfer, and aeroacoustics. A 2-D Unsteady Reynolds Averaged Navier Stokes model (URANS) was implemented using an SST k-ω turbulence closure simulated over a rectangular deep cavity. Previous experimental results were used to validate the numerical results, to confirm the accuracy of the flow field patterns reproduced. Both controlled and uncontrolled cases were analyzed. Heat transfer was also investigated on both configurations, showing the effect of cavity geometry and inlet conditions on heat …

Experimental Thermal Characterization And Comparison Of Direct Liquid Cooling And Air Cooling For A High-Density Gpu Server Thermal Test Vehicle, Oluwagbolahan Esan

Mechanical and Aerospace Engineering Theses

As the power density of artificial intelligence (AI) and high-performance computing (HPC) servers escalates, air cooling is approaching fundamental scaling limits set by air's low convective heat transfer coefficient and rising parasitic fan power. This thesis presents an experimental comparison of direct-to-chip liquid cooling and air cooling for a high-density GPU server, using a Thermal Test Vehicle (TTV) that emulates the device layout and power-density regime of an 8-GPU SXM5-class baseboard (eight emulated GPU blocks and four NVLink Switch modules). The liquid configuration was tested at 8.8 kW (8.0 kW GPU, 800 W switch) across three Coolant Distribution Unit (CDU) …

Characterization Of Tomographic Piv System For Single-Phase Immersion Cooling Applications, Joel Joshua Oommen

Mechanical and Aerospace Engineering Theses

As the rapid expansion of Artificial Intelligence (AI) infrastructure and High-Performance Computing (HPC) pushes power requirements to new heights, traditional air-cooling methods have become inadequate for modern server demands. Consequently, single-phase immersion cooling (SPIC) has emerged as one of the effective and sustainable alternatives, utilizing dielectric fluids to remove heat through direct contact with electronic components. Despite numerous thermal and reliability studies, the complex three-dimensional movement of buoyant thermal plumes around intricate component shapes are not yet fully understood in confined spaces.

This thesis provides a detailed characterization of Tomo-PIV and a component level experimental study of flow patterns in …

Simulation And Characterization Of Fuel Cell System Incorporated Internet Of Things, Ahmad N. Alhjouj

Mechanical Engineering Theses

Small air-cooled proton exchange membrane fuel cell (PEMFC) systems are increasingly relevant for portable and distributed applications, yet practical modeling and monitoring methods remain limited: high-fidelity physics-based models are too costly for real-time use, while purely data-driven models discard physical interpretability. This thesis develops an experimentally grounded gray-box framework for the characterization, reduced-order modeling, and IoT-enabled monitoring of a small hydrogen PEMFC system. A low-order nonlinear state-space model couples an electrochemical voltage layer to a lumped thermal layer, with parameters identified in stages using self-adaptive differential evolution. Identifiability analysis shows that static loss parameters are well constrained, while dynamic parameters …

Computational Study Of Rotating Detonation Combustors, Aditya Balasubramaniam

Mechanical and Aerospace Engineering Theses

Rotating detonation combustors (RDCs) are pressure-gain combustion devices that sustain one or more continuously rotating detonation waves, offering potential thermodynamic and performance advantages over conventional deflagration-based systems. Their behavior depends strongly on combustor geometry and operating conditions. Understanding these effects is therefore essential for the design and optimization of practical RDCs. Accordingly, this thesis numerically investigates annular RDCs with two primary objectives: (1) to evaluate the effects of propellant mass flux and (2) to assess the influence of annular width on detonation-wave dynamics and combustor performance.

A finite-volume framework is used to solve the compressible reactive Euler equations with hydrogen–air …

Multiphysics Transport In Porous Thermal Protection Systems: Experimental Characterization Of Gas Permeability And Radiative Properties, Yejajul Hakim

Theses and Dissertations--Mechanical and Aerospace Engineering

Porous thermal protection systems (TPS) used in hypersonic vehicles exhibit coupled gas and radiative transport across multiple regimes and length scales. Accurate performance prediction requires reliable characterization of permeability, slip-flow behavior, and radiative transport properties, particularly for low-permeability and charred materials where existing data are limited. This dissertation presents experimental methods for characterizing multiphysics transport in porous TPS materials. A modular flow system was developed to measure permeability and slip behavior in both virgin and charred materials under relevant environments. A transient pressure decay method enables accurate permeability estimation in low-permeability regimes and provides insight into effective pore structure. Results …

Lumacurve Control System Update, Jacob Kustra, Caleb Wengerd

Williams Honors College, Honors Research Projects

The existing track heater control system used by Lumacurve has become outdated and requires frequent maintenance due to inconsistent operation and component failures. This project aims to modernize the system through the implementation of a programmable logic controller (PLC), infrared non-contact temperature sensing, and an automated pneumatic ejection mechanism.

The redesigned system improves temperature monitoring accuracy and reduces operator intervention by automatically ejecting heated plastic tracks from the heater once the desired temperature is reached. An emergency ejection subsystem is also incorporated to safely clear tracks from the heater in the event of improper operation or system faults. Additional emphasis …

Breaking The Vapor Barrier And Scale: Revolutionizing Steel Quenching With Ultrasound Technology, Anthony O. Santos

Williams Honors College, Honors Research Projects

The quenching process is a fundamental heat treatment used to enhance material properties by heating steel to its austenitizing temperature and rapidly cooling it to form high-strength martensite. However, this process is often hindered by two surface barriers: the Leidenfrost effect (vapor blanket) and oxide scale. These cooling limitations restrict the use of steel in high-performance aerospace applications due to inconsistent material properties and unpredictable engineering properties. This research investigates the use of fully submersible, 50-watt 40 kHz ultrasound technology to improve cooling rates in a Jominy test [4]. Through numerical simulations and experimental validation, the study demonstrates that acoustic …

Thermal Radiation Effects On Particles From Plasma Arc Radiation, Reece Davis, Joseph Mcgee

Williams Honors College, Honors Research Projects

Understanding the radiation heating and transport of both microparticles and nanoparticles is a phenomenon that is critical for both space and Earth sciences. In space, these particles are heated by plasma arcs within ionized space clouds or solar flares and can be present the path of deep space missions and orbital satellites. While on Earth, processes such as forest fires, nuclear fusion, and microchip manufacturing include the plasma arc heating of particles. These particles lay within the Mie Scattering Regime and Rayleigh Scattering Regime and emit radiation differently based on their diameter. New mathematical and computational modeling has been conducted …

Akron Soap Box Derby Super Kids Car, Alexis Schultz, Cooper Sites, Sean Stevenson

Williams Honors College, Honors Research Projects

This project aims to redesign the All-American Soap Box Derby Super Kids vehicle to enhance safety, accessibility, and performance while maintaining full compliance with official regulations. The Super Kids program enables children with physical and cognitive disabilities to race alongside a co-pilot, but the current vehicle design presents challenges in stability, entry/exit accessibility, and control—especially following recent regulation changes that increased vehicle speed. The redesigned car will focus on improved ergonomics, lightweight construction, and structural integrity within a $1,000 budget and a 165 lb weight limit.

An iterative engineering design process will guide the project through research, CAD modeling, FEA …

Kruss Modifications, Anderson W. Howard

Williams Honors College, Honors Research Projects

My project focuses on modifying a test device in the AETL to allow for high temperature test to be performed. I am also adding modifications to make it safer to perform tests using the high-pressure system.

Development And Validation Of A Multi-Output Neural Network-Based Virtual Temperature Sensor For Electric Vehicle Thermal Management, Dalton Michael Wiggins

Graduate Theses, Dissertations, and Problem Reports (ETD)

Battery electric vehicles (BEVs) rely on accurate thermal management to ensure component performance, efficiency, safety, and long-term durability. Critical propulsion system components, including electric motors and high-voltage battery packs, are commonly monitored using physical temperature sensors. However, these sensors increase system cost, introduce additional hardware complexity, and may be impractical for directly measuring temperatures at critical internal locations. Virtual temperature sensors (VTSs) provide a software-based alternative by estimating component temperatures using readily available vehicle operating data.

This research presents the development and validation of a long short-term memory (LSTM) neural network-based virtual temperature sensor capable of simultaneously estimating the motor …

Physics-Informed Machine Learning Methods To Predict Heavy-Duty Diesel Engine Performance And Emissions, Sandeep Guguloth

Graduate Theses, Dissertations, and Problem Reports (ETD)

The development of internal combustion engines for increased efficiency and reduced emissions demands improved design tools that are cost-effective, fast, and easy to integrate into existing engineering workflows. Low-dimensional physically based engine models serve this role by reducing the need for iterative experimental prototyping but historically rely on empirical correlations that sacrifice fidelity compared to CFD. Machine learning (ML) approaches, conversely, achieve high predictive accuracy but lack interpretability and generalize poorly beyond their training data. Physics-informed machine learning (PIML) bridges this gap by constraining the solution space to physically feasible predictions, offering a more reliable way to model in-cylinder phenomena. …

Machine Learning-Based Prediction Of Heavy-Duty Diesel Engine Emissions And Comparative Analysis Against Statistical Models, Abdullah Ahmad Khan

Graduate Theses, Dissertations, and Problem Reports (ETD)

The increasing stringency of emissions regulations for heavy-duty (HD) diesel engines necessitates the development of accurate, efficient, and general predictive models for engine-out emissions under steady-state operating conditions. Traditional statistical approaches, while computationally efficient, often fail to capture the inherent nonlinear relationships between the engine operating parameters and emissions formation. In contrast, machine learning (ML) techniques offer a promising alternative by learning the complex patterns directly from experimental data. The present thesis summarizes a comprehensive study on the prediction of steady-state, HD diesel engine emissions using ML models, along with a comparative analysis against conventional statistical modeling approaches.

A high-quality …

Effects Of Hydrogen Enrichment And Premixing On Flame Stability In A High-Pressure Axial-Stage Combustor, Alexandre Fernandes C. Santiago Filho

Honors Undergraduate Theses

The addition of hydrogen to conventional fuels enhances reactivity and can increase the risk of flashback in premixed gas turbine combustors. This study investigates the effects of premixing length and hydrogen concentration on flame stability in a high-pressure axial-stage combustor. Experiments were conducted at the UCF Propulsion and Energy Research Laboratory using a two-stage configuration, where the primary stage provided a high-temperature vitiated crossflow using a hydrogen-piloted, premixed methane–air mixture, and hydrogen-enriched methane–air mixtures were injected through a concentric fuel-tube injector in the axial stage. Premixing length was varied for pure hydrogen flames, and hydrogen concentration was varied at a …

Thermomechanical Modeling Of Transpiration Surfaces For Hypersonic Propulsion, Spencer D. Smith

Graduate Studies Theses and Dissertations 2026

Hypersonic flight vehicles are a promising form of high speed passenger transport and efficient space access architectures. However, they are fundamentally a thermally limited technology. High heat fluxes exceeding 10 MW/m2 and gas temperatures between 3000-4000K can be found both within the engine, and on the outer surface. Current conventional engineering materials are non-viable at these conditions. In order to make these materials viable, active cooling strategies could be utilized. One particularly promising type is transpiration cooling, where a coolant is diffused through a porous surface. Although researched heavily in the 1960s, adoption is still minimal. Part of the reason …

Cfd Analysis Of A Full Heat Exchanger Between Ammonia And Supercritical Co2 In Aviation Application, Mairah Ahmed

Graduate Studies Theses and Dissertations 2026

The aviation industry’s transition toward lower-carbon propulsion systems has accelerated interest in alternative fuels, including ammonia–hydrogen fuel blends. In this work, a supercritical CO2 Brayton cycle is integrated with the exhaust stream of a turbofan engine to recover waste heat and utilize it for ammonia preheating and cracking. The recovered thermal energy raises the ammonia temperature to the level required for catalytic decomposition, enabling onboard hydrogen production. The proposed architecture combines ammonia cracking with a high-bypass, two-shaft turbofan engine representative of the propulsion system employed on the Boeing 737 MAX 8. This approach addresses the challenges associated with onboard hydrogen …

Pseudo-Boiling Of Supercritical Co2 In A Parallel-Flow Microchannel And A Micro-Jets Impingement Device And Single-Phase And Two-Phase Heat Transfer Of Subcritical Co2 Jets, Pranzal Ahmed

Graduate Studies Theses and Dissertations 2026

Carbon dioxide (CO2) is gaining attention as a low-toxicity, zero-ozone-depletion refrigerant with a global warming potential of 1, making it an attractive alternative to synthetic HFCs/HFOs. Near its critical point, CO2's thermophysical properties change sharply with small shifts in temperature and pressure — a behavior that can be exploited to enhance heat transfer in trans-critical power cycles and electronics cooling. This dissertation experimentally investigates heat transfer during the pseudo-boiling of supercritical CO2 in a parallel-flow microchannel and a micro-jet impingement device, alongside CO2 flow boiling and single-phase water heat transfer in micro-jet impingement. Using microfluidic devices instrumented with embedded resistance …

Performance Analysis Of Labyrinth And Hybrid Seals For Supercritical Co₂ Turbomachinery Applications, Ghanshyam Sarobar Mandal

Graduate Studies Theses and Dissertations 2026

Leaks account for large losses in turbomachinery systems, which has led to research on sealing technologies. The work presented studies the effect of a hybrid seal combining conventional labyrinth geometry and honeycomb structure by simulating supercritical carbon dioxide (sCO₂) flow through this geometry. The CFD solver compares effects such as changes in mass flow rate, formation of vortices, pressure profile, and seal performance as geometry angles of labyrinth teeth and honeycomb walls change at conditions normally found at higher pressures in these seals. Honeycomb walls were placed on the stator, ranging from 125°< θc< 55°. Labyrinth teeth were placed on the rotor at the same degrees. Honeycomb cell diameters were also varied, creating more resistance and turbulence within the flow. It was discovered that the honeycomb angle created stronger effects on vortices and boundary layer formation, while the labyrinth angle mainly affected the throttling of flow and loss generation. Combining all three angles created a relationship dictating the seal leakage. Dimensions of seals were based on gas turbine seals with changes to meet sCO₂ conditions. ANSYS was used to simulate static and rotating conditions until convergence on a specific geometry

Experimental Demonstration Of A Laboratory Scale Packed Bed Reactor For Thermochemical Energy Storage Using Embedded Heating Elements, Zachary Monem

Graduate Studies Theses and Dissertations 2026

Thermochemical energy storage (TCES) is an emerging technology that is being studied as a carbon-neutral renewable alternative to conventional methods of large-scale power generation, such as the utilization of fossil fuels. TCES makes use of thermochemical materials to store and discharge energy in two-step reversible chemical reactions. Among the most promising TCES materials are metal oxides, which possess significantly higher energy storage densities compared to other TCES materials; consequently, thermochemical reactors are used to store and discharge large amounts of energy during reduction-oxidation cycles using metal oxide materials. The current work focuses on the design and experimental demonstration of a …

Two-Phase Transcritical Carbon Dioxide Flow At The Microscale For Thermal Management Applications, Soroush Niazi

Graduate Studies Theses and Dissertations 2026

High-power electronic and power-conversion devices now generate heat fluxes that exceed what conventional air- and single-phase-liquid cooling can dissipate, motivating the search for more capable coolants and cooling mechanisms. Carbon dioxide is an attractive candidate for this role: it is inexpensive, non-toxic, and environmentally friendly, and near its critical point its thermophysical properties change rapidly, which raises the heat-transfer coefficient. In addition, a large pressure drop produces strong cooling through the Joule–Thomson effect and phase change, so that the throttling element itself becomes a source of cooling. This dissertation studies the throttling, phase change, and choking of high-pressure carbon dioxide …

A Framework For Optimizing Creep Model Parameters From Conventional And Accelerated Creep Tests, William D. Day

Graduate Studies Theses and Dissertations 2026

The demand for efficiency in power generation and propulsion requires higher firing temperatures and reduced cooling air consumption which raises metal temperatures. This makes simplistic creep evaluations, such as Larson-Miller and Orr-Sherby-Dorn parameters, inadequate. Finite element analysis (FEA) must simulate primary and secondary creep, predict failure, and provide design guidance. Gas turbine components, expected to last over 100,000 hours, often require extrapolation of limited test data for new materials. It is essential that robust creep simulations be developed efficiently, accurately, and effectively use limited test data.

This dissertation describes an optimized framework for efficient creep testing and rapid construction of …

Chemical Kinetic Experiments Of Monomethyl Hydrazine Combustion Products At High Pressures And High Temperatures In A Shock Tube, Cooper Q. Mills

Graduate Studies Theses and Dissertations 2026

This study presents experimental shock tube laser absorption spectroscopy data to validate high-pressure and high-temperature chemical kinetic mechanisms for mixtures of H₂/air, NH₃/air, and H₂/CO/NO₂/air diluted in argon (95-98%) at high pressures (5, 10, 25 bar) and high temperatures (1000 to 2150 K). The mixtures were at equivalence ratios of 0.5, 1.0, and 1.5 to cover the range of possible conditions experienced throughout practical combustors. Laser absorption spectroscopy data was measured for NH₃, H₂O, CO, and NO using a novel multi-species setup. Chemical kinetic mechanisms contain the fundamental …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Components, Logan Trimmer

Harrisburg University Other Works

The goal of this research was to establish the viability of using hybrid manufacturing for automotive applications. By verifying that high-stress components can be created, it can be assumed that any other lower stress part could be made to match the strength requirements. A limiting factor of adoption for hybrid manufacturing is how new the technology is. Studies on time and cost were performed allowing for comparisons with traditional manufacturing technologies (casting, forging, milling) used in automotive applications. This research utilized a Haas Automation UMC750 5-axis CNC mill with a Meltio laser wire direct energy deposition attachment. Fusion 360 was …

Experimental Investigation Into The Effects Of Air Staging On Fouling In A Fixed-Bed Biomass Combustor, Akram Elsebaie

Theses: Doctorates and Masters

Biomass offers significant potential as a sustainable and renewable substitute for fossil fuels in energy generation, playing a critical role in the reduction of global warming. However, despite its environmental benefits, biomass combustion faces persistent operational challenges, particularly fouling, which reduces efficiency and increases maintenance costs. Although fouling mechanisms have been studied in various combustion systems, there is limited research which addresses its formation and behaviour in fixed-bed biomass combustors under different air staging conditions. This research investigates fouling behaviour in a counter-current combustor, focusing on the influence of design (secondary air location), operational (air staging flowrates between the primary …

Impact Of Slot Liner Compression On The Total Thermal Resistance Of The Stator-Winding Assembly In Electric Motors, Lindsay Sutherland

The Journal of Purdue Undergraduate Research

The increasing demand for high-performance electric motors, driven by the rapid adoption of electric vehicles, necessitates effective thermal management techniques that improve their safety, efficiency, and reliability. Heat must be transferred from the current-carrying copper windings to the metallic stator body through an electrically insulating material called the slot liner. However, little research has focused on the interactions between the slot liner and the windings. This study examines the impact of slot liner compression on the thermal resistance across the stator-winding assembly considering two common slot liners: Nomex® 410 and Kapton® MT+. A mock stator-winding assembly was developed by stacking …

Design And Development Of Evacuated Photovoltaic-Thermal Systems For Efficient Cogeneration Of Heat And Electricity, Behnam Roshanzadeh

Mechanical Engineering ETDs

In conventional PV systems, most of the solar energy is dissipated into the environment as heat. Accordingly, hybrid Photovoltaic-thermal systems have been developed to utilize the waste heat from PV cells for various thermal applications. However, most PVT systems suffer from low thermal performance compared to solar thermal collectors, as the absorber plate in PVT systems is partially or fully covered by PV cells. This dissertation focuses on improving the thermal performance of PVT systems by introducing the evacuated PVT systems.

An evacuated-tube PVT system was designed and simulated for domestic hot water supply. The evacuated-tube PVT system demonstrated 40% …

Investigation Of The Flow Field Morphology Of Film Cooling In Supersonic Flow, Umberto Sandri, Massimiliano Ferro, Alessio Picchi, Antonio Andreini, Bruno Facchini, Marc D. Polanka

Faculty Publications

Film cooling is widely implemented in highly thermally stressed gas turbine components. Its performance has been extensively investigated for several decades and many results are available in the literature. In conventional gas turbines, regions of supersonic flow are not prevalent and should generally be avoided. For this reason, results relative to film cooling in supersonic flow are limited. Nevertheless, a new interest related to Rotating Detonation Combustors (RDC) and supersonic turbines is growing. The implementation of those engine components in a gas turbine is likely to need film cooling for thermal protection. In this context, it becomes crucial to gain …