Master of Science / Department of Mechanical and Nuclear Engineering / Kirby S. Chapman / This thesis outlines the development of a centrifugal compressor model for the Turbocharger Component Matching System (TuCMS) software package that can be used to inexpensively analyze turbocharger performance. The TuCMS can also be used to match turbocharger components to integrate and optimize turbocharger-engine performance. The software system is being developed with the intent to reduce the time taken to experimentally match a turbocharger with an engine, a task that is key to engine emission reductions. The TuCMS uses one-dimensional thermo-fluid equations to analyze the compressor side of a turbocharger. For each compressor component, the program calculates the velocities, pressures, temperatures, pressure losses, work consumption, and efficiencies for a specified set of turbocharger geometry, atmospheric conditions, rotational speed, and fluid mass flow rate. The compressor includes established loss models found in the open literature. The TuCMS utilizes a component-based architecture to simplify model enhancements. The TuCMS can be used as a cost effective engineering tool for preliminary turbocharger testing during engine upgrades and modifications. In this thesis, the TuCMS compressor model was used as an analysis tool to further understand the Variable Geometry Turbocharger (VGT) experimental results. The VGT is a unique turbocharger that can change the diffuser vane angle over a wide range of positions. The change in diffuser vane angle results in optimal turbocharger performance at various operating conditions, and potentially increases the operating range. The purpose for the use of the TuCMS compressor model analysis is to identify the change in performance as the diffuser vane angles are adjusted. The TuCMS can ideally be used as a control program for the VGT to adjust the diffuser vane angles as the compressor load changes and insure the compressor is operating at the highest efficiency.

Master of Science / Department of Mechanical and Nuclear Engineering / Donald L. Fenton / Emergency cooling systems are applied to any application where the loss of cooling results in damage to the product, loss of data, or equipment failure. Facilities using chilled water for cooling that experience an electrical power outage, even a small one, would cause the chiller to shut down for 20 minutes or more. If emergency cooling is not available, temperatures would continue to increase to dangerous levels, potentially damaging the facility. Examples of facilities that could be protected by having emergency cooling systems are data centers, hospitals, banks, control rooms, laboratories, clean rooms, and emergency shelters among others. This project addresses the current lack of information and methods needed to correctly design emergency cooling systems. Three application uses were investigated for the possible benefits of having emergency cooling systems. The software TRNSYS was used to simulate five typical emergency cooling systems for each of the three applications. The characteristics and differences of the systems developed from the simulations were then analyzed and documented. The five systems simulated include a pressurized chilled water tank (parallel), atmospheric chilled water tank (parallel and series), low temperature chilled water tank (parallel), and ice storage tank (series). Simulations showed that low temperature chilled water tanks were less stratified than regular chilled water tanks by approximately 10%. Simulations also showed that the differences between atmospheric and pressurized tanks were negligible. Each tank discharged energy in the same manner and managed to replenish itself in the same amount of time. Examination of the different system configurations showed that tanks in series with the thermal load have issues with recharging due to its inability to isolate itself from the thermal load. It was also observed that while low temperature chilled water and ice storage tanks had the potential of reducing the storage tank volume, the amount of time ragged cooling will last is decreased by at least a factor of two. The examination of the five systems produced the desired design methodologies needed to address the lack of information on emergency cooling systems. With the reported information designers can effectively engineer systems to meet their needs.

Master of Science / Department of Mechanical and Nuclear Engineering / Guoqiang Hu / Warren N. White / In recent years, the concern has risen to establish clean sources for electric power generation. In 2009, Kansas established an RPS (Renewable Portfolio Standard) mandating utilities acquire 20% of their electricity from renewable energy by 2020 [32]. One of the most prominent renewable energy sources is wind energy. Utility companies now are investing more in wind capture systems to comply with this mandate. This increase in the manufacture of wind turbines has caused researchers to investigate methods to improve the efficiency of captured wind energy and where improvements can be made. This thesis takes a control theory approach to maximizing the power capture of a wind turbine using the concepts of robust estimation, nonlinear control, and Lyapunov-based maximization. A two step control approach to optimize the power capture of a wind turbine is proposed. First, a robust controller is used to estimate unknown aerodynamic properties and regulate the wind turbine tip-speed ratio as it tracks a desired trajectory. Once the tip-speed ratio is regulated within a given tolerance, a Lyapunov-based control approach is developed to provide the robust controller with a desired trajectory to track. This is done by estimating the unknown coefficient of performance of the wind turbine. A discrete update law is then developed to alter the tip-speed ratio and the blade pitch of the wind turbine so that the coefficient of performance is maximized. A simulation is provided of this control strategy and tested under time varying wind conditions and measurement noise in order to demonstrate the controller’s performance. The system simulated is intended to emulate a commercial wind turbine operating in a realistic environment. A detailed discussion of the simulation model, control scheme, and results will be provided to supplement the theoretical controller development, as well as future work for this control application.

Master of Science / Department of Architectural Engineering and Construction Science / Julia A. Keen / Nanofibers are classified as fibers less than 1 micrometer in diameter. These fibers can be layered to form nanofibrous membranes, and these membranes offer great potential in the filtration industry. The membranes' smaller fiber diameters and pore sizes permit such filters to filter out more and smaller particulate. Additionally, antimicrobial agents can be incorporated into the membrane to inhibit fungal and bacterial growth on the membrane’s surface. This report evaluates nanofibrous membranes with antimicrobial agents and their potential in two specific locations: cleanrooms and protective environment rooms, where bacterial and fungal growth would have a detrimental effect on the process or occupant of the space.

Master of Science / Department of Mechanical and Nuclear Engineering / Guoqiang Hu / In some types of renewable energy systems such as wind turbines or solar power plants, the optimal operating conditions are influenced by the intermittent nature of these energies. This fact, along with the modeling difficulties of such systems, provides incentive to look for non-model based adaptive techniques to address the maximum power point tracking (MPPT) problem. In this thesis, a novel extremum seeking algorithm is proposed for systems where the optimal point and the optimal value of the cost function are allowed to be time varying. A sinusoidal perturbation based technique is used to estimate the gradient of the cost function. Afterwards, a robust optimization method is developed to drive the system to its optimal point. Since this method does not require any knowledge about the dynamic system or the structure of the input-to-output mapping, it is considered to be a non-model based adaptive technique. The proposed method is then employed for maximizing the energy capture from the wind in a variable speed wind turbine. It is shown that without any measurements of wind velocity or power, the proposed method can drive the wind turbine to the optimal operating point. The generated power is observed to be very close to the maximum possible values.

Master of Science / Department of Mechanical and Nuclear Engineering / Bruce R. Babin / A significant body of literature exists for experiments in spray cooling applications that utilize one-dimensional heat transfer through a metal ingot to determine the average surface heat flux. Due to inherent non-uniformities in spray distributions, measurements that account for the two-dimensional effects are required. In this study, an infrared (IR) camera was used to capture the two-dimensional temperature distribution formed when spraying an electrically heated NiChrome surface with three different fluids. IR thermography captured the thermal response of the un-sprayed side of a 0.005-inch (0.125mm) think strip of NiChrome exposed to spray from a 90° full-cone nozzle at low mass fluxes (0.025 – 0.045 lb/ft[superscript]2-s / 0.122 – 0.220 kg/m[superscript]2-s) from a distance of approximately 5 to 11 inches (13 to 28cm). Results were measured for surface average temperatures ranging from 150 to 600°F (65 – 315°C).

Master of Science / Department of Mechanical and Nuclear Engineering / Youqi Wang / Two fiber reinforced polymer (FRP) bridge deck specimens were analyzed by means of acoustic emission (AE) monitoring during a series of loading cycles performed at various locations on the composite sandwich panels' surfaces. These panels were subjected to loads that were intended to test their structural response and characteristics without exposing them to a failure scenario. This allowed the sensors to record multiple data sets without fear of having to be placed on multiple panels that could have various characteristics that alter the signals recorded. The objective throughout the analysis ias to determine how the acoustic signals respond to loading cycles and various events can affect the acoustical data. In the process of performing this examination several steps were taken including threshold application, data collection, and sensor location analysis. The thresholds are important for lowering the size of the files containing the data, while keeping important information that could determine structurally significant information. Equally important is figuring out where and how the sensors should be placed on the panels in the first place in relation to other sensors, panel features and supporting beams. The data was subjected to analysis involving the response to applied loads, joint effects and failure analysis. Using previously developed techniques the information gathered was also analyzed in terms of what type of failure could be occurring within the structure itself. This somewhat aided in the analysis after an unplanned failure event occurred to determine what cause or causes might have lead to the occurrence. The basic analyses were separated into four sets, starting with the basic analysis to determine basic correlations to the loads applied. This was followed by joint and sensor location analyses, both of which took place using a two panel setup. The last set was created upon matrix failure of the panel and the subsequent investigation.

Master of Science / Department of Mechanical and Nuclear Engineering / Akira T. Tokuhiro / The Secure Transportable Autonomous Reactor – Liquid Metal system combines a Generation IV nuclear reactor with an advanced Supercritical Carbon Dioxide (S-CO[subscript]2) Brayton power conversion cycle. The Brayton cycle was selected as the power conversion cycle due to its high efficiency, small turbomachinery size, and competitive cost due to reduced complexity as compared to a traditional Rankine cycle. Overall system thermal efficiency is closely tied to the performance of the precooler and recuperators. The Printed Circuit Heat Exchanger (PCHE) manufactured by Heatric is being considered for use as both the precooler and recuperator in the STAR-LM system due to its high effectiveness, wide temperature and pressure operating range, small size, and low cost. PCHEs have been used primarily in the hydrocarbon processing industry to date, and are relatively new in being considered for nuclear applications. In this study, a PCHE is investigated using S-CO[subscript]2 and water as the heat transfer media in conditions relevant to the precooler in the STAR-LM system. Experiments conducted with small temperature differences across the PCHE revealed that the heat transfer coefficient is strongly correlated with the temperature-dependent specific heat near the pseudocritical point. The STAR-LM precooler outlet temperature is near the pseudocritical point, making this region of interest to this work. Testing was conducted to determine the effect of property variation near the precooler outlet in conditions with large temperature differences in the PCHE. These tests revealed that maintaining the precooler outlet temperature near the pseudocritical point does not have a significant effect on heat transfer coefficients in the PCHE under large temperature difference test conditions. Computational Fluid Dynamics (CFD) models were developed to simulate fluid flow and heat transfer in the PCHE. A 2D, 4-channel, zig-zag model was found to reproduce the outlet temperatures to within approximately 15% relative error. The 3D straight channel model reproduced the experimental data to within 3% relative error for the cases simulated. Both of these models predicted the water side outlet temperatures to within 20% relative error.

Master of Science / Department of Mechanical and Nuclear Engineering / Kevin B. Lease / The purpose of this study was to experimentally characterize the compressive and shear behavior of square cell titanium honeycomb cores according to the American Society of Testing and Materials Standards C 365-05 and C 273-06. By varying the honeycomb cell size and height as well as the foil thickness, many configurations of titanium honeycomb were manufactured utilizing a laser welding and expansion method. The test matrix consisted of 1080 compression and 1080 shear specimens. The compression specimens were split evenly into stabilized and unstabilized tests, and the shear specimens were split evenly to test three different shear orientations. At the conclusion of the characterization, a comprehensive statistical analysis was performed on the data. It was determined that both the compressive and shear strengths have a strong dependence on the relative density of the honeycomb. The compressive strength was found to be slightly affected by the presence of a stabilizing face sheet, and largely unaffected by specimen core height. The compressive modulus was affected by both the core height and the presence of a face sheet. Shear strength was found to decrease with increasing core height and was influenced by the shear orientation. Additionally, the rate of increase of shear modulus with respect to relative density was proportional to core height. Although no clear trend was observed, orientation did seem to have an effect on shear modulus. The compression and shear behavior of the honeycomb was compared with experimental results of honeycomb from existing publications and found to be consistent.

Master of Science / Department of Mechanical and Nuclear Engineering / Youqi Wang / Electrospinning is one of the most versatile methods used to fabricate nanofibers. Sub micron and nano level fibers can be continuously produced with the help of an external electric field induced on the polymer melt. These nanofibers can be used in a large variety of applications such as biosensors, three dimensional tissue scaffolds, composites, electronic devices, etc. A unique feature of electrospinning is its ability to work with different fiber assemblies. This helps in making application specific changes and also increases the quality and performance of the fibers. PEO (polyethylene oxide) and electrostrictive graft elastomer (an electroactive polymer developed by NASA) were used in our experiments which focus on controlling the shape and alignment of the fibers. Electroactive polymers (EAP’s) are seen as the basis for future artificial muscles because of their ability to deform when external voltage is applied and quickly recover to their original form when the polarity of the applied voltage is reversed. Hence, aligned fibers of the electrostrictive graft elastomer were produced to mimic the alignment in human muscle fibers. Alignment of fibers is the main objective of this research and was facilitated using vacuum technology. The research was basically divided into three phases, starting with checking of the repeatability of the previously developed techniques using polyethylene oxide. Next, the electrostrictive graft elastomer was spun using the electrospinning techniques and was checked for alignment using the Coaxial Electrode method and PLC controlled secondary electric field method. Finally, a vacuum chamber was designed and built with new components and the elastomer was tested for improved alignment in vacuum using the PLC controlled secondary electric field method.