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Full-Text Articles in Manufacturing

An Investigation Of High-Speed Consolidation And Repair Of Carbon Fiber - Epoxy Composites Through Ultrasonic Welding, David A. Hoskins Nov 2019

An Investigation Of High-Speed Consolidation And Repair Of Carbon Fiber - Epoxy Composites Through Ultrasonic Welding, David A. Hoskins

LSU Master's Theses

Adhesive repair of carbon fiber composite structures is commonly done on damaged structures to extend the service life. This method requires careful preparation of the damaged surface with intricate steps to ensure good bonding between the repair patch and the parent structure by means of an adhesive film. As with many forms of composite manufacturing, it is required to perform vacuum bagging, debulking, and a heated cure depending on the resin. All these steps make the repair process costly and time consuming.

In this present work, an alternative method of repair is investigated which explores the experimental feasibility of using …


Redesign Of Cubesat For Beam Charging, Kuba Preis Jun 2019

Redesign Of Cubesat For Beam Charging, Kuba Preis

Industrial and Manufacturing Engineering

This paper is intended to be a study in the applications of the design freedom granted by additive manufacture in the design of a 1U CubeSat frame. The main loads experienced by a CubeSat are structural (during launch) and thermal (solar radiation). Beam charging is an emerging technology which involves charging a CubeSat using a laser beam. In this paper, a CubeSat frame was redesigned to account for the structural loads induced during launch and the thermal loads induced when beam charging. The thermal, weight, design, and structural requirements for a new CubeSat design were derived. The 1U CubeSat frame …


Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator Jun 2019

Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator

Materials Engineering

PCC Structurals, an industry leader in superalloy investment castings, has observed inconsistencies in the stress rupture performance of polycrystalline nickel-based superalloy PWA 1455. PCC has changed their casting parameters to reduce the thermal gradient during cooling but have been unable to correlate these changes with an increase in stress rupture elongation. Metallographic examination of past samples indicated microstructures composed of non- equiaxed dendritic grains with mean diameter of .021 inches along the test axis. A similar study on polycrystalline superalloys has indicated that excessive superheat temperatures above the liquidus can result in large grains identical to those observed, limiting the …


Development Of A Multi-Probe Kelvin Scanner Device For Industrially-Relevant Characterization Of Surface-Activated Carbon Fiber Reinforced Thermoplastic Composites, Kirby Simon May 2019

Development Of A Multi-Probe Kelvin Scanner Device For Industrially-Relevant Characterization Of Surface-Activated Carbon Fiber Reinforced Thermoplastic Composites, Kirby Simon

McKelvey School of Engineering Theses & Dissertations

Carbon fiber reinforced thermoplastic (CFRTP) composites are becoming increasingly attractive materials in manufacturing due to their lightweight nature, mechanical strength, and corrosion resistance. Surface activation of these materials is usually required during processing to increase the bond strength of assemblies (aerospace and automotive industries) or improve adhesion with implants (biomedical industry). Industrially-relevant, nondestructive quality control methods for assessing the activation state of these materials do not currently exist, however. Applying principles discovered through the use of scanning probe microscopy, a multiple-probe Kelvin scanning (MPKS) device has been developed that can assess the uniformity of the activation state of plasma-treated CFRTP …


Design And Manufacture Of An Inertial Cascade Impactor For Industrial Hygiene Purposes, Hector Joel Gortaire Apr 2019

Design And Manufacture Of An Inertial Cascade Impactor For Industrial Hygiene Purposes, Hector Joel Gortaire

Mechanical & Aerospace Engineering Theses & Dissertations

Inertial cascade impactors are devices commonly used for industrial hygiene and pharmaceutical studies. Their main purpose is to separate particulate matter suspended in aerosols according to their sizes, which can vary from over 10 µm to 0.5 µm. Their versatility and ease of operation make them suitable for on-site sampling; however, designing them requires a careful consideration of the different geometric parameters that characterize them.

In this thesis, a 5-stage inertial cascade impactor was designed, modelled, constructed, and tested. The main design parameter was the volumetric flow rate, 40 l/min, which was provided by a vacuum pump. By continuous iterations, …


3d Textile Preforms And Composites For Aircraft Strcutures: A Review, Abbasali Saboktakin Jan 2019

3d Textile Preforms And Composites For Aircraft Strcutures: A Review, Abbasali Saboktakin

International Journal of Aviation, Aeronautics, and Aerospace

Over the last decades, the development of 3D textile composites has been driven the structures developed to overcome disadvantages of 2D laminates such as the needs of reducing fabrication cost, increasing through-thickness mechanical properties, and improving impact damage tolerance. 3D woven, stitched, knitted and braided preforms have been used as composites reinforcement for these types of composites. In this paper, advantages and disadvantages of each of them have been comprehensively discussed. The fabric architects and their specification in particular stitched preforms and their deformation mode for aerospace applications have been reviewed. Exact insight into various types of damage in textile …


Laser Machining Countersinks In Carbon Fiber Reinforced Polymer, Leon James Neely Hill Jan 2019

Laser Machining Countersinks In Carbon Fiber Reinforced Polymer, Leon James Neely Hill

Masters Theses

“Laser machining countersinks with a frequency doubled Q-switched diode pumped Nd:YAG laser is demonstrated. Tests were conducted in 0.100" thick IM7 prepreg CFRP with [0,90]3S orientation. The HAZ is minimized to avoid stress concentrations in the epoxy matrix. A chamber and filtration system was designed and built to contain the byproducts produced in the machining process. The variables investigated are the number of repetitions in the offset path, the plunge rate, and the line energy. The research was performed over one baseline study, one parameter space exercise, two full factorial experiments, and one repeatability study. Assessment was done under an …


Composite Recycler: Delamination, Nathan Sauer Jan 2019

Composite Recycler: Delamination, Nathan Sauer

All Undergraduate Projects

A great deal of composite waste is generated in the construction of wings for the Boeing 777. These carbon fiber “wing trimmings” are currently being disposed of in a landfill. These carbon fiber boards are made of several layers laminated together, making them very rigid and hard to recycle. This report proposes a method to delaminate the layers of these composite wing trimmings using a hydraulic press and a V-shaped steel die so that they may be more easily shredded and thus recycled. A top, “male” die with two points is pressed into a bottom, “female” die with three points …


Enhanced Surface Integrity With Thermally Stable Residual Stress Fields And Nanostructures In Cryogenic Processing Of Titanium Alloy Ti-6al-4v, James R. Caudill Jan 2019

Enhanced Surface Integrity With Thermally Stable Residual Stress Fields And Nanostructures In Cryogenic Processing Of Titanium Alloy Ti-6al-4v, James R. Caudill

Theses and Dissertations--Mechanical Engineering

Burnishing is a chipless finishing process used to improve surface integrity by severe plastic deformation (SPD) of surface asperities. As surface integrity in large measure defines the functional performance and fatigue life of aerospace alloys, burnishing is thus a means of increasing the fatigue life of critical components, such as turbine and compressor blades in gas turbine engines. Therefore, the primary objective of this dissertation is to characterize the burnishing-induced surface integrity of Ti-6Al-4V alloy in terms of the implemented processing parameters. As the impact of cooling mechanisms on surface integrity from SPD processing is largely unexplored, a particular emphasis …


Space Dynamics Laboratory Payload Challenge: Autonomous Water Sampling Uav, Thomas Wheeler, Zachary Williams, Joseph Stack Jan 2019

Space Dynamics Laboratory Payload Challenge: Autonomous Water Sampling Uav, Thomas Wheeler, Zachary Williams, Joseph Stack

Williams Honors College, Honors Research Projects

The following report has been completed over the course of the Fall 2018 and Spring 2019 semesters at The University of Akron by Joseph P. Stack (Aerospace Systems Engineering), Thomas J. Wheeler (Mechanical Engineering) and Zachary M. Williams (Mechanical Engineering). The purpose of this project was to create a payload system for the Akronauts Rocket Design Team to use at the Intercollegiate Rocket Engineering Competition (IREC) Spaceport America Cup. The Competition as a challenge that is sponsored by Space Dynamics Laboratory specifically regarding payload systems. The challenge in very open-ended and allows student to identify their own scientific experiment and …


Generator Design: A Study Of Optimized Airflow, Rachel Wattleworth Jan 2019

Generator Design: A Study Of Optimized Airflow, Rachel Wattleworth

Williams Honors College, Honors Research Projects

The core goal of this project was to prototype, test, and evaluate a new type of fan for the Safran Electrical & Power air-cooled generators. The idea of a new fan being made for these two generators arose when they were not adhering to design requirements. A base mixed-flow fan was created to test on multiple generators. Upon creating a prototype, it will be tested to prove if it can increase the air flow, decrease temperatures, and increase power and life of the machines. They all proved to be successful and achieve the main objectives for this project. Data such …