Mechanical Engineering Commons^™

Relations Between Printability And Rheology In A Ceramic Paste Extrusion Process, Nicholas Durand

Open Access Theses & Dissertations

Ceramic additive manufacturing (AM) uses the same fundamentals as material extrusion (MEX) that utilizes polymers or resins for printing applications. Ceramic AM uses the same process of slicing an STL file to determine a toolpath for the printer that will facilitate material deposition to manufacture full parts; ceramic AM also provides a low-cost advantage when compared to processes that require high powered lasers for melting metal powders or heated nozzles used for dispensing thermoplastics. Despite having the similar design freedom and ability for rapid prototyping that other printing methods benefit from with the addition of low cost, ceramic AM has …

Analysis Of Drying Behavior Of Robocasted Barium Titanate, Abigail Ortega

Open Access Theses & Dissertations

Finding an adequate ceramic formulation for material extrusion is a time-consuming process. The necessary equipment may be unavailable to perform the desired test. This study demonstrated an alternative to observe a material after extrusion to understand its drying process. This study focused on 55 solid loading volume percent and a 39 solid loading volume percent, each with two different binder treatments focusing on fresh same day made binder, a 30 day old, aged binder and lastly an artificial binder obtained by a fuming process. Firstly, a formulation was created and loaded onto a pressure-based syringe to be extruded with a …

Prediction Modeling Of Foreign Object Impact Debris On Aircraft Through Digital Engineering, Luis Eduardo Rodriguez

Open Access Theses & Dissertations

The contribution of the research made is derived into two sections. The first topic discusses the prediction modeling of Foreign Object debris (FOd) impact on aircraft structures through the use of digital engineering. The program used in this project is Ansys Explicit Dynamics to evaluate the stress and strain caused by the initial conditions of flight trajectory and impact created from FOd found inside of aircraft structures. The prediction modeling consists of creating a repetition of simulations with different FOds to evaluate the damage created to subsystems of the wing bay such as the fuel system and internal structures. The …

Additive Manufacturing Of Composites For Sensing And Harsh Environments Application, Md Sahid Hassan

Open Access Theses & Dissertations

Composite materials are made by combining two or more materials, such as fibers and resins to create a material system that has improved mechanical and physical properties compared to its individual components. The use of 3D printing technology in composite manufacturing allows for the creation of complex and custom shapes with precise control over the placement of the materials. This makes it possible to create composite parts with enhanced performance characteristics and reduced weight. The work presented in this dissertation lies in the design and development of highly flexible impact propagation sensor through material extrusion 3D printing technique. By using …

An Optimization Procedure To Design Nozzle Contours For Hypersonic Wind Tunnels, Omar Antonio Dominguez

Open Access Theses & Dissertations

Supersonic wind tunnels allow scientists and researchers to evaluate and analyze the behaviors of objects under real-life conditions when subjected to supersonic speeds. One of the main complexities when building a wind tunnel is the design of the convergent-divergent nozzle that is used to produce high-speed and high-quality flows. To achieve supersonic speeds, this nozzle adopts a specialized approach that incorporates the complexities of flow compressibility. The compressible effect is accurately evaluated using isentropic relations, allowing for precise determination of stagnation pressure and temperature, and static pressure and temperature relevant to the desired Mach number. Isentropic equations used to define …

Additively Manufactured Cryogenic Engineered Heat Pipe For Lunar Ice Collection, Mahadi Hasan

Open Access Theses & Dissertations

Nowadays, one of the most talked-about subjects in space exploration is cryogenic heat pipes. These heat pipes are made in a way that allows them to operate without the need for additional power or energy. Evaporated vapor and condensed liquid can be moved by buoyancy forces or capillary forces that are subject to gravity because of the phase shifts of the working fluids moving inside. The cooling solution typically entails a phase transition from liquid to vapor, which can dissipate larger heat fluxes because of the fluid's high latent heat of vaporization. Recent developments in additive manufacturing and micro-nano structures …

Design And Implementation Of Laser Beam Measurements At The Extents Of The Build Platform: Impact Of Beam Location On Melt Pool Geometry, Alexandra Hernandez

Open Access Theses & Dissertations

Laser powder bed fusion (LPBF) is a form of metal additive manufacturing that enables the development of complex parts that cannot readily be made with traditional manufacturing methods. The process utilizes a tightly focused laser beam to selectively melt and fuse layers of powdered metal to create a 3-D part.LPBF is a promising technology, but there are barriers to its adoption in most industries. Mainly, it is difficult to qualify these parts for use, since they are prone to processing defects and part-to-part variation. One source of this is part position on the building plane, especially for multi-part builds where …

Ultra Wide Band Gap Oxides For Advanced Optoelectronics And Supercapacitor Applications: A Case Study Of Intrinsic And Doped Germanium Dioxide, Paul Gaurav Nalam

Open Access Theses & Dissertations

Germanium dioxide (GeO2) is a metal oxide semiconductor with multiple polymorphs that has recently garnered a significant amount of scientific attention owing to its novel ultra-wide band gap and pseudo-capacitive properties, which can potentially transcend current power electronic, optoelectronic, and supercapacitor technologies. However, due to the difficulty in the synthesis of stable crystalline phases of individual polymorphs of GeO2 thin films, this material system demands complex and resource-intensive deposition techniques to synthesize. An attempt was made to develop cost-effective and scalable deposition techniques to stabilize specific crystalline phases of GeO2 thin films. These phases were further structurally fine-tuned to state …

Enhancing Damage Tolerance Of The Constituents Of Sandwich Composites, Zackery Nieto

Open Access Theses & Dissertations

Composite structures have become a lucrative material choice for researchers throughout various sectors such as green energy, arctic travel, and aerospace application due to their light weight, high-bending to stiffness ratio, and job tailorable applications through material selection. With the increasing demand for new and better composite technologies growing each year it is imperative to investigate new materials and analytical options to help the composite field as a whole grow. In this report various materials and statistical applications have been studied regarding the constituent materials in sandwich composites. For core materials an additive manufactured photoreactive resin has been characterized for …

Ultrasonic Non-Destructive Evaluation Of Additively Manufactured Polymer-Ceramic Composites, Christian Alexander Ruiz

Open Access Theses & Dissertations

Digital light processing (DLP) is an attractive additive manufacturing technique due to its ability to create ceramic parts with complex geometries. DLP uses ultraviolet light to polymerize a slurry comprised of ceramic powder and photosensitive resin in layers to create solid parts. Printing parameters such as light intensity and exposure time are critical when producing these parts. Improper parameters can lead to over or under-curing, adversely impacting print quality and strength. Samples were printed at varying layer exposure times and then tested using ultrasonics to determine the degree of conversion. Additionally, ultrasonics were used as a non-destructive technique to obtain …

Exploration Of Advanced Scan Strategy Capabilities On A Commercial Lpbf System Using Intervector Power Ramping, Antonio York

Open Access Theses & Dissertations

Lack of confidence in the quality of materials produced with metal AM has hinged on the unaddressed defects inherent to the process. Studies have worked to determine defect formation mechanisms and provide adjustments to key process controls. However, these advances have typically been developed in-house on research systems which offer increased and transparent control to the operator. A research gap exists in applying changes in approach of scan strategies to existing commercial systems, which can incentivize adoption while furthering development. The focus of this study is the implementation of inter-vector power ramping on a commercial laser powder bed fusion system …

Design And Customization Of 3d Printers For Advanced Materials Printing, Alan Omar Loera Martinez

Open Access Theses & Dissertations

This research is divided into two sections. The first section discusses modificationsperformed to two commercial printers. The first printer was modified from a thermoplastic polymer printer to a pneumatic printer by taking away its heating elements and print head. Circuits were directed to pneumatic dispensing system as well in order to automate the process. The second printer had mechanical modifications performed to be a multi-material gradient printer by controlling two stepper motors through an electronics board. Through code, a mixing ratio changed the motors' rotations to provide the desired gradient of two different materials. The second section of the present …

Double Cantilever Beam Mode-I Testing Validation In Large-Scale Additive Manufacturing Carbon Composite, Luis Alfonso Camacho

Open Access Theses & Dissertations

Testing for mechanical properties for additive manufacturing has been based on already existing standards for traditional manufacturing methods. For composites in large scale additive manufacturing there is a research gap in bond strength and fracture toughness for a single layer interface. By using Double cantilever beam Mode I, this thesis manuscript validates testing parameters and protocols to describe the intricacies of ABS matrix 20 wt.% carbon filled composite, specifically on the layer-to-layer interface. Studies suggest that fracture toughness is sensitive to process parameters, like deflection speed and sharpened crack tip at the layer interface of BAAM 3D printed part and …

The Effects Of Process Parameters On The Cyclical Life Of Ti-6al-4v Manufactured Via Laser Powder Bed Fusion, Brandon Ramirez

Open Access Theses & Dissertations

Additive manufacturing via Laser Powder Bed Fusion (LPBF) has already proven revolutionary technology. Due to its favorable strength-to-weight ratio, ti-6Al-4V, a popular titanium alloy, has already been implemented in the aerospace industry for various components. However, the quality validation in additively manufactured parts has always been an issue of concern, specifically under cyclic loading. Ti-6Al-4V samples were printed using LPBF with various process parameters to investigate these conditions further. The build was stress-relieved; however, the samples underwent no other post-processes maintaining their as-built surface. The process parameters were separated into five categories, including various laser powers and printing speeds, allowing …

Geometrical And Surface Texture Characterization For Laser Powder Bed Fusion Process, Jesus Alfredo Rivas

Open Access Theses & Dissertations

Laser powder bed fusion (LPBF) is one of the most widely used additive manufacturing (AM) methods for metal parts. Geometrical tolerances required for industry applications are determined by geometrical measuring methods and process capability calculations. However, geometry characterization presents challenges for LPBF because measuring uncertainty values are not defined and the standardized measurement framework Geometric Tolerancing and Dimension (GD&T) is not fully adopted.

Measurement uncertainty is influenced by this process's high surface roughness (10 µm < Ra ⩽ 80 µm). As an example, when using multiple probing points or scanning pathways on a LPBF surface with the most accurate (+/- 0.004 mm) and traceable measurement method, the coordinate measuring machine (CMM), the results can vary by up to 0.050 mm to 0.070 mm. This measurement uncertainty leads to an imprecise benchmark reference for comparison with optical or X-ray computed tomography (XCT). These measurement variations also make it difficult to accurately characterize parts for automotive, aerospace, medical and other high-tech industries, such as a turbine blade geometry used in aircraft engines with a blade height tolerance of +/- 0.15 mm, which required a measurement uncertainty less than 30% of the tolerances. Mechanical properties such as tensile testing assessments useful in comparisons of materials, alloy development, quality control, and design under certain circumstances are also affected by this imprecise geometry characterization. Overestimating the diameter of the ASTM E8 sample by 0.100 mm can make up to a difference in stress results of 7%.

This research aimed to evaluate various measurement approaches (contact and non-contact) for surface texture and geometrical size dimension characterization and provide information regarding measurement uncertainty …

A Method For Measuring The Spectral Emissivity Of Metal Powders At Different Temperatures And Applications In Laser Powder Bed Fusion, Emmanuel Levario

Open Access Theses & Dissertations

Radiation thermometry monitoring methods used in powder bed fusion additive manufacturing (PBF-AM) are becoming increasingly more popular for quality assurance and repeatability. The dynamic nature of the PBF process and a lack of accuracy of metrics being captured for temperature monitoring lend great difficulty in the successful implementation of in-situ monitoring. There is currently no data on the emissivity, a metric used in non-contact temperature measurements, for metal powders used in AM. This work describes a method for measuring the spectral emissivity for metal powder sizes commonly used in AM using a multi-wavelength (MW), FMPI SpectroPyrometer, calibrated within the spectral …

Sensing Optimization Of Thermoplastics And Ceramics Fabricated Through Additive Manufacturing, Cory Marquez

Open Access Theses & Dissertations

The objective of this research is to fabricate and optimize thermoplastic and ceramic materials that can be fabricated for Laser Sintering (LS), Direct Ink Write (DIW), and Fused Filament Fabrication (FFF) 3D printing. The fabrication of High-Density Polyethylene (HDPE) thermoplastic particles into spherical allow for better flowability and packing density for LS printing which results in better printability and an increase in mechanical properties. The fabrication of clay ceramic allows the printability application for DIW with the implementation of an embedded wireless temperature and relative humidity sensor. The use of FFF multi-material printing allowed the capabilities of 3D printing a …

Study Of Different Heat Treatments And Aging Conditions For Observing Microstructures And Mechanical Properties Of Lpbf Fabricated F357 Alloy, Victor Adrian Medrano Balderas

Open Access Theses & Dissertations

Aluminum F357 is a widely used material for casting in the aerospace and additive manufacturing industry. Heat treatments are commonly applied to some aluminum alloys to modify their properties. With a further study on the aging and performance of the F357 with 3D printing technology, several industries benefit from this; military, automotive, and aerospace are some examples because of the numerous components cast in service. This work presents the mechanical properties of F357 specimens fabricated with EOS technology and subjected to heat treatments. Heat treatment conditions were applied to tensile specimens and tested. Furthermore, the specimens were subjected to artificial …

Metal Fused Filament Fabrication: Distortion Compensation & Co2 Electrochemical Reduction, Jean Emmanuel Montes Ramirez

Open Access Theses & Dissertations

Metal fused filament fabrication (MF3) is a rapidly growing additive manufacturing technology that enables the creation of complex metal parts with high accuracy and precision. Copper, a highly conductive metal with various applications in industries such as electronics and aerospace, is a promising material for MF3. In this study, we investigated the use of MF3 copper parts to fabricate copper electrodes for CO2 electrochemical reduction. We examined the post-processing manufacturing process of debinding and sintering to obtain fully 3D printed copper parts in an air environment. Our results demonstrate that MF3 copper parts have high porosity, providing a larger active …

Computational Analysis Of Water Braking Phenomena For High-Speed Sled And Its Machine Learning Framework, Jose A. Terrazas

Open Access Theses & Dissertations

Specializing in high-speed testing, Holloman High-Speed Test Track (HHSTT) uses a process called "water braking" as a method to bring vehicles at the test track to a stop. This method takes advantage of the higher density of water, compared to air, to increase braking capability through momentum exchange. By studying water braking using Computational Fluid Dynamics (CFD), forces acting on track vehicles can be approximated and prepared for prior to the actual test. In this study, focus will be made on the brake component of the track sled that is responsible for interacting with the water for braking. By discretizing …

Heat Transfer Of A 1n Thruster In A 2.5u Cubesat Module, Javier Madrid

Open Access Theses & Dissertations

With the aerospace industry expanding and moving forward with more ambitious missions, small satellites such as CubeSats have proven to be at the forefront of innovation for research satellites. This innovation have introduced complications which if gone unattended can lead to the loss of the satellite; one such complication coming in the form of propulsion heat transfer. This paper presents an investigation into the propagation of heat transfer within a 2.5 CubeSat module when a 1N thruster is fired inside it. This is done by leveraging the equation of heat transfer and comparing results to those simulated by ANSYS. Not …

Fabrication And Characterization Of Germanium Functionalized Porous Nickel Oxide Electrodes For Application In Supercapacitors, Cristina Gonzalez

Open Access Theses & Dissertations

Limited fossil fuel, increasing population, pollution, and climate change are motivating society to use renewable and clean energy techniques. However, the intermittent nature of renewable sources hinders their continuous availability and use. Energy storage devices such as supercapacitors and batteries are essential for sustainable development but their high cost limits its bulk use. The cost of energy storage devices mainly depends on materials, synthesis process and device fabrication. Therefore, low cost 3-D mesoporous nickel germanium fictionalize nickel oxides electrode materials has been developed by using facile fabrication techniques for supercapacitor application. 3-D mesoporous nickel provides the high surface area and …

Synthetic Data Generation For Intelligent Inspection Of Structural Environments, Noshin Habib

Open Access Theses & Dissertations

Automated detection of cracks and corrosion in pavements and industrial settings is essential to a cost-effective approach to maintenance. Deep learning has paved the path for vast levels of improvement in the area. Such models require a plethora of data with accurate ground truth and enough variation for the model to generalize to the data, which is notwidely available. There has been recent progress in computer graphics being used for the creation of synthetic data to address the issue of deficient data availability, but it is limited to specific objects, such as cars and human beings. Textures and deformities within …

Compact Electrospray Propulsion Systems For Small Form-Factor Satellites: An Orbital Performance Survey & Platform Design, Alberto Meza

Open Access Theses & Dissertations

Over the past decades, small form-factor satellites such as CubeSats have remained as one of the most accessible platforms to reach space for universities, research institutions, private and governmental entities to perform a wide range of missions. This paper presents a survey into the design and implementation of an electrospray rail thruster, to be integrated to the CubeSat platform. The design investigated features propellant tanks for each individual thruster embedded inside the rail of a standard 1U CubeSat. The capabilities of utilizing the electrospray thruster as an attitude & determination control system was also investigated in which, a pointing accuracy …

Direct Ink Write And Thermomechanical Characterization Of Thermoset Composites, Sergio Dante Favela

Open Access Theses & Dissertations

This research will be divided into two sections. The first section discusses direct ink writing and thermomechanical characterization for thermoset composites. The thermoset ink is prepared with fillers aiding the printing process by modifying the rheology of the ink and geometry retention by allowing for the part to have an initial UV cure step. Three specimen formulations with different weight percentages were printed by material extrusion in the shape of tensile specimens following ASTM standard D638 to characterize the mechanical properties at room temperature, 100â?? and 200â??. Furthermore, the ink resin was characterized through DSC, TGA, and rheology testing. The …

The Qualification Of Sealability And Creep Relaxation Of Additively Manufactured Zytel Gaskets For Pem Fuel Cells, Robert Lazarin

Open Access Theses & Dissertations

The purpose of this thesis is to study the feasibility of low-cost additive manufacturing of gaskets for proton exchange membrane fuel cells exposed to extreme temperature conditions ranging from -55°C to 100°C. With the growing popularity and decreasing costs of additive manufacturing technologies, specifically Material Extrusion (ME), research is being conducted to determine the feasibility of ME components. Thermally cycled PEMFCs may exhibit accelerated gasket deterioration, therefore, the mechanical stability of material extruded gaskets following a harsh thermal cycle must be assessed. The feasibility of the material extruded gaskets will be proven by manufacturing optimization and mechanical testing. The target …

High-Temperature Valve Design For A Solid Oxide Fuel Cell/Gas Turbine Hybrid System Utilizing Smart Materials, Alba Jazmin Leyva

Open Access Theses & Dissertations

The topic of this project includes extensive research on the Solid Oxide Fuel Cell Gas Turbine (SOFC/GT) hybrid system located at the National Energy Technology Laboratory. The goal is to reduce pollution and generate energy by using natural gas and a combination of fuel cells, heat exchangers, bypass valves, turbines, and combustors as components working together to produce clean energy. The SOFC/GT system works by having the fuel cell pressurized by the gas turbine. The turbine then produces exhaust gas for the fuel cell, because the turbine recovers the majority of the heat and the pressurization contributes to the enhancement …

Novel Interlaminar Reinforcement To Enhance The Impact Damage Resistance Of Carbon Fiber-Reinforced Polymer Matrix Composites, Daisy Haidee Mariscal

Open Access Theses & Dissertations

Aerospace, aircraft, marine, and automobile applications are increasingly using composite materials for lighter, higher stiffness, and strength properties. Despite these advantages, composite materials have one major disadvantage. The through-thickness properties are extremely weak when subjected to impact damage. When a composite material is subjected to a low-velocity impact, there is hardly any visible damage on the surface compromising the composite material internally without any external notice. Internal damage may be delamination, which is the most common, matrix cracking, and fiber breakage. A composite material is made up of layers of fiber. The interlaminar region is located in between these layers. …

Cryogenic Flow Boiling Heat Transfer On Additively Manufactured Liquid Rocket Engine Cooling Channels, Debra Jazmin Ortega

Open Access Theses & Dissertations

The enhancement of flow boiling heat transfer is critical because it can solve thermal management issues seen across all engineering and manufacturing applications. Even though advancements are being made, more studies are needed to understand the behavior of forced convective boiling further.Currently, there are four major issues in the field of regenerative cooling of liquid rocket engines. 1. The cooling channels are typically manufactured using conventional machining, while aerospace industries are currently exploring the additive manufacturing approach. 2. The experimental critical heat flux values for cryogenic fluids are either lower or very close to the model predictions; however, the effect …

Cad-Based Aerial Trajectory Generation And 3d Mapping For Close-Quarter Inspection, Angel Guillermo Ortega Castillo

Open Access Theses & Dissertations

Robotic technologies for inspection purposes of large-scale structures have grown in interest.Such technologies are encouraged to reduce the risk in which human operators are involved and to reduce costs due to downtime of the equipment. In the Energy sector, high interest is placed on power plant components where their correct operation is paramount. This work is inspired by the synthetic vision systems for aerial vehicles that use three-dimensional space (3D) to provide pilots with clear and intuitive means of understanding their flying environment. This work can be separated into three main sections: Trajectory Generation from Computer-Aided Design (CAD) Models, Crack …