Measurement error (ME) in the factor levels of designed experiments is often overlooked in the planning and analysis of experimental designs. A familiar model for this type of ME, called the Berkson error model, is discussed at length. Previous research has examined the effect of Berkson error on two-level factorial and fractional factorial designs. This dissertation extends the examination to designs for second order models. The results are used to suggest optimal values for axial points in Central Composite Designs. The proper analysis for experimental data including ME is outlined for first and second order models. A comparison of this analysis to a typical Ordinary Least Squares analysis is made for second order models. The comparison is used to quantify the difference in performance of the two methods, both of which yield unbiased coefficient estimates. Robustness to misspecification of the ME variance is also explored. A solution for experimental planning is also suggested. A design optimality criterion, called the DME criterion, is used to create a second-stage design when ME is present. The performance of the criterion is compared to a D-optimal design augmentation. A final comparison is made between methods accounting for ME and methods ignoring ME. / Ph. D.

abstract: During the initial stages of experimentation, there are usually a large number of factors to be investigated. Fractional factorial (2^(k-p)) designs are particularly useful during this initial phase of experimental work. These experiments often referred to as screening experiments help reduce the large number of factors to a smaller set. The 16 run regular fractional factorial designs for six, seven and eight factors are in common usage. These designs allow clear estimation of all main effects when the three-factor and higher order interactions are negligible, but all two-factor interactions are aliased with each other making estimation of these effects problematic without additional runs. Alternatively, certain nonregular designs called no-confounding (NC) designs by Jones and Montgomery (Jones & Montgomery, Alternatives to resolution IV screening designs in 16 runs, 2010) partially confound the main effects with the two-factor interactions but do not completely confound any two-factor interactions with each other. The NC designs are useful for independently estimating main effects and two-factor interactions without additional runs. While several methods have been suggested for the analysis of data from nonregular designs, stepwise regression is familiar to practitioners, available in commercial software, and is widely used in practice. Given that an NC design has been run, the performance of stepwise regression for model selection is unknown. In this dissertation I present a comprehensive simulation study evaluating stepwise regression for analyzing both regular fractional factorial and NC designs. Next, the projection properties of the six, seven and eight factor NC designs are studied. Studying the projection properties of these designs allows the development of analysis methods to analyze these designs. Lastly the designs and projection properties of 9 to 14 factor NC designs onto three and four factors are presented. Certain recommendations are made on analysis methods for these designs as well. / Dissertation/Thesis / Ph.D. Industrial Engineering 2012

abstract: In the interest of expediting future pilot line start-ups for solar cell research, the development of Arizona State University's student-led pilot line at the Solar Power Laboratory is discussed extensively within this work. Several experiments and characterization techniques used to formulate and optimize a series of processes for fabricating diffused-junction, screen-printed silicon solar cells are expounded upon. An experiment is conducted in which the thickness of a PECVD deposited anti-reflection coating (ARC) is varied across several samples and modeled as a function of deposition time. Using this statistical model in tandem with reflectance measurements for each sample, the ARC thickness is optimized to increase light trapping in the solar cells. A response surface model (RSM) experiment is conducted in which 3 process parameters are varied on the PECVD tool for the deposition of the ARCs on several samples. A contactless photoconductance decay (PCD) tool is used to measure the dark saturation currents of these samples. A statistical analysis is performed using JMP in which optimum deposition parameters are found. A separate experiment shows an increase in the passivation quality of the a-SiNx:H ARCs deposited on the solar cells made on the line using these optimum parameters. A RSM experiment is used to optimize the printing process for a particular silver paste in a similar fashion, the results of which are confirmed by analyzing the series resistance of subsequent cells fabricated on the line. An in-depth explanation of a more advanced analysis using JMP and PCD measurements on the passivation quality of 3 aluminum back-surface fields (BSF) is given. From this experiment, a comparison of the means is conducted in order to choose the most effective BSF paste for cells fabricated on the line. An experiment is conducted in parallel which confirms the results via Voc measurements. It is shown that in a period of 11 months, the pilot line went from producing a top cell efficiency of 11.5% to 17.6%. Many of these methods used for the development of this pilot line are equally applicable to other cell structures, and can easily be applied to other solar cell pilot lines. / Dissertation/Thesis / M.S. Electrical Engineering 2014

Nanotechnology offers significant opportunities in providing solutions to existing engineering problems as well as breakthroughs in new fields of science and technology. In order to fully realize benefits from such initiatives, nanomanufacturing methods must be developed to integrate enabling constructs into commercial mainstream. Even though significant advances have been made, widespread industrialization in many areas remains limited. Manufacturing methods, therefore, must continually be developed to bridge gaps between nanoscience discovery and commercialization. A promising technology for integration of top-down nanomanufacturing yet to receive full industrialization is equal channel angular pressing, a process transforming metallic materials into nanostructured or ultraine grained materials with significantly improved performance characteristics. To bridge the gap between process potential and actual manufacturing output, a prototype top-down nanomanufacturing system identified as indexing equal channel angular pressing (IX-ECAP) was developed. The unit was designed to capitalize on opportunities of transforming spent or scrap engineering elements into key engineering commodities. A manufacturing system was constructed to impose severe plastic deformation via simple shear in an equal channel angular pressing die on 1100 and 4043 aluminum welding rods. 1/4 fraction factorial split-plot experiments assessed significance of five predictors on the response, microhardness, for the 4043 alloy. Predictor variables included temperature, number of passes, pressing speed, back pressure, and vibration. Main effects were studied employing a resolution III design. Multiple linear regression was used for model development. Initial studies were performed using continuous processing followed by contingency designs involving discrete variable length work pieces. IX-ECAP offered a viable solution in severe plastic deformation processing. Discrete variable length work piece pressing proved very successful. With three passes through the system, 4043 processed material experienced an 88.88% increase in microhardness, 203.4% increase in converted yield strength, and a 98.5% reduction in theoretical final grain size to 103 nanometers using the Hall-Petch relation. The process factor, number of passes, was statistically significant at the 95% confidence level; whereas, temperature was significant at the 90% confidence level. Limitations of system components precluded completion of studies involving continuous pressing. Proposed system redesigns, however, will ensure mainstream commercialization of continuous length work piece processing.

The thesis is focused on testing of the cutting tools for machining on five axis machine tools and possibility of implementation of designed experiments in this area. The theoretical section focuses attention on analysis of specific features during five axis machining, including chip cross section and particularity of tool testing under high speed cutting conditions with consideration of dynamic stability of cutting tools. In the thesis force loading of the tool is discussed as well as its measurement process, considering force development caused by tool wear and data analysis. Description of designed experiment and its application to the area of tool testing is included as well. All theoretical predictions are followed by experimental verifying by extensive number of experimental tests, including evaluation of cutting tool condition, influence of hard coatings on cutting power of the tools, etc. For each of testing conditions are designed specific methods of processing of gathered data as well as evaluation of power of the cutting tools. Gathered data were processed by means of statistical evaluation and by statistical methods of designed experiments. The thesis contains also the extensive number of records and analysis, documented by means of light microscopy as well as electron microscopy.

The objective of this research is to thoroughly investigate the shape memory effect in polymers, characterize, and optimize these polymers for applications in information storage systems. Previous research effort in this field concentrated on shape memory metals for biomedical applications such as stents. Minimal work has been done on shape memory poly- mers; and the available work on shape memory polymers has not characterized the behaviors of this category of polymers fully. Copolymer shape memory materials based on diethylene glycol dimethacrylate (DEGDMA) crosslinker, and tert butyl acrylate (tBA) monomer are designed. The design encompasses a careful control of the backbone chemistry of the materials. Characterization methods such as dynamic mechanical analysis (DMA), differential scanning calorimetry (DSC); and novel nanoscale techniques such as atomic force microscopy (AFM), and nanoindentation are applied to this system of materials. Designed experiments are conducted on the materials to optimize spin coating conditions for thin films. Furthermore, the recovery, a key for the use of these polymeric materials for information storage, is examined in detail with respect to temperature. In sum, the overarching objectives of the proposed research are to: (i) design shape memory polymers based on polyethylene glycol dimethacrylate (PEGDMA) and diethylene glycol dimethacrylate (DEGDMA) crosslinkers, 2-hydroxyethyl methacrylate (HEMA) and tert-butyl acrylate monomer (tBA). (ii) utilize dynamic mechanical analysis (DMA) to comprehend the thermomechanical properties of shape memory polymers based on DEGDMA and tBA. (iii) utilize nanoindentation and atomic force microscopy (AFM) to understand the nanoscale behavior of these SMPs, and explore the strain storage and recovery of the polymers from a deformed state. (iv) study spin coating conditions on thin film quality with designed experiments. (iv) apply neural networks and genetic algorithms to optimize these systems.

The thesis is focused on testing of the cutting tools for machining on five axis machine tools and possibility of implementation of designed experiments in this area. The theoretical section focuses attention on analysis of specific features during five axis machining, including chip cross section and particularity of tool testing under high speed cutting conditions with consideration of dynamic stability of cutting tools. In the thesis force loading of the tool is discussed as well as its measurement process, considering force development caused by tool wear and data analysis. Description of designed experiment and its application to the area of tool testing is included as well. All theoretical predictions are followed by experimental verifying by extensive number of experimental tests, including evaluation of cutting tool condition, influence of hard coatings on cutting power of the tools, etc. For each of testing conditions are designed specific methods of processing of gathered data as well as evaluation of power of the cutting tools. Gathered data were processed by means of statistical evaluation and by statistical methods of designed experiments. The thesis contains also the extensive number of records and analysis, documented by means of light microscopy as well as electron microscopy.