Master of Science / Department of Mechanical and Nuclear Engineering / Kevin Lease / Carbon fiber reinforced composites (CFRP’s) are a mainstay in many industries, including the aerospace industry. When composite components are damaged on an aircraft, they are typically repaired with a composite patch that is placed over the damaged material and cured into the existing composite material. This curing process involves knowledge of the curing time necessary to sufficiently cure the patch. The inexact nature of curing composites on aircraft causes a significant waste of time and material when patches are unnecessarily redone. Knowing how differences in cure cycle affect the strength of the final material could reduce this waste. That is the focus of this research. In this research, the interfacial shear strength (IFSS) of carbon fiber/epoxy composites was investigated to determine how changes in cure cycle affect the overall material strength. IFSS is a measure of the strength of the bond between the two materials. To measure this, the microbond method was used. In this method, a drop of epoxy is applied to a single carbon fiber. The specimen is cured and the droplet is sheared from the fiber. The force required to debond the droplet is recorded and the data is analyzed. The IFSS of AS4/Epon828, T650/Epon828, and T650/Cycom 5320-1 composites were evaluated. For the former two material systems, a cure cycle with two steps was chosen based on research from others and then was systematically varied. The final cure time was changed to determine how that parameter affected the IFSS. It was found that as the final cure time increased, so did the IFSS and level of cure achieved by the composite to a point. Once the composite reached its fully cured state, increasing the final cure time did not noticeably increase the IFSS. For the latter material system (T650/Cycom 5320-1), the two cure cycles recommended by the manufacturer were tested. These had different initial cure steps and identical final cure steps. Although both cure cycles caused high IFSS, the cycle with the higher initial temperature, but shorter initial cure time achieved a higher level of cure than that with a longer time, but shorter temperature.

Doctor of Philosophy / Department of Mechanical and Nuclear Engineering / Youqi Wang / Textile fabrics and textile composite materials demonstrate exceptional mechanical properties, including high stiffness, high strength to weight ratio, damage tolerance, chemical resistance, high temperature tolerance and low thermal expansion. Recent advances in weaving techniques have caused various textile fabrics to gain applications in high performance products, such as aircrafts frames, aircrafts engine blades, ballistic panels, helmets, aerospace components, racing car bodies, net-shape joints and blood vessels. Fabric mechanical properties are determined by fabric internal architectures and fabric micro-geometries are determined by the textile manufacturing process. As the need for high performance textile materials increases, textile preforms with improved thickness and more complex structures are designed and manufactured. Therefore, the study of textile fabrics requires a reliable and efficient CAD/CAM tool that models fabric micro-geometry through computer simulation and links the manufacturing process with fabric micro-geometry, mechanical properties and weavability. Dynamic Weaving Process Simulation is developed to simulate the entire textile process. It employs the digital element approach to simulate weaving actions, reed motion, boundary tension and fiber-to-fiber contact and friction. Dynamic Weaving Process Simulation models a Jacquard loom machine, in which the weaving process primarily consists of four steps: weft insertion, beating up, weaving and taking up. Dynamic Weaving Process Simulation simulates these steps according to the underlying loom kinematics and kinetics. First, a weft yarn moves to the fell position under displacement constraints, followed by a beating-up action performed by reed elements. Warp yarns then change positions according to the yarn interlacing pattern defined by a weaving matrix, and taking-up action is simulated to collect woven fabric for continuous weaving process simulation. A Jacquard loom machine individually controls each warp yarn for maximum flexibility of warp motion, managed by the weaving matrix in simulation. Constant boundary tension is implemented to simulate the spring at each warp end. In addition, process simulation adopts re-mesh function to store woven fabric and add new weft yarns for continuous weaving simulation. Dynamic Weaving Process Simulation fully models loom kinetics and kinematics involved in the weaving process. However, the step-by-step simulation of the 3D weaving process requires additional calculation time and computer resource. In order to promote simulation efficiency, enable finer yarn discretization and improve accuracy of fabric micro geometry, parallel computing is implemented in this research and efficiency promotion is presented in this dissertation. The Dynamic Weaving Process Simulation model links fabric micro-geometry with the manufacturing process, allowing determination of weavability of specific weaving pattern and process design. Effects of various weaving process parameters on fabric micro-geometry, fabric mechanical properties and weavability can be investigated with the simulation method.

Doctor of Philosophy / Department of Mechanical and Nuclear Engineering / Liang-Wu Cai / X. J. Xin / Thin walled structures such as plates and shells have application in many fields of engineering because these structures are light weight and can support large loads when designed suitably. In real world, loads may cause these structures to vibrate which can be undesirable causing fatigue and failure of the structure. Such undesirable vibrations need to be reduced or eliminated. In this work, analytical studies of flexural wave propagation for idealized geometries are conducted and finite element method (FEM) is used to explore the effects of composite panel designs of finite size for the reduction of vibration transmission. In the analytical studies, the influence of the material properties on the reflection and transmission characteristics are explored for an infinite bi-material plate, and infinite plate with a strip inhomogeneity. In the analytical study of an infinite thin plate with a solid circular inclusion, the far and near field scattering characteristics are explored for different frequencies and material properties. All the analytical studies presented here and reported in the literature consider infinite plates to characterize the flexural wave propagation. Obtaining closed form solutions to characterize the flexural wave propagation in a finite plate with inclusions is mathematically difficult process. So, FEM is used to explore the composite panel designs. The understanding gained about the material properties influence on the flexural wave propagation from analytical studies helped with the choice of materials for FEM simulations. The concept of phononic crystals is applied to define the design variations that are effective in suppressing vibration transmission. Various design configurations are explored to study the effects of various parameters like scatterer’s material properties, geometry and spatial pattern. Based on the knowledge gained through a systematic parametric study, a final design of the composite sandwich panel is proposed with an optimum set of parameters to achieve the best vibration reduction. This is the first study focused on reducing vibration and wave transmission in composite rotorcraft fuselage panels incorporating the concept of phononic crystals. The optimum sandwich panel design achieved 98% vibration transmission reduction at the frequency of interest of 3000 Hz.

Master of Science / Department of Mechanical and Nuclear Engineering / Mohammad H. Hosni / Byron W. Jones / Gas turbine engine oil is contaminating the bleed air of an aircraft with enough frequency and intensity that health concerns are of public interest. While previous work measured micro particles and used only a simulator, this work mainly consists of measurements in the nanoparticle and ultrafine range using both the simulator and two different gas turbine engines. No previous research has been conducted using working jet engines to simulate a bleed air system and characterize the oil particulate contamination. Oil was injected into a bleed air simulator and an Allison 250 CC18 turbine engine in order to observe the particle size distributions resulting from thermal degradation and was measured with three particle sizing counters and an FTIR. The aerosol size distributions are given for various temperature and pressure ranges consistent with the process conditions associated with the bleed air in a commercial aircraft. Particle sizes of approximately 80nm to 100nm were observed at temperatures over 200°C while particles similar to injection distributions and smaller than measureable size were observed at lower power settings. Temperature is thought to be the controlling factor affecting particle size above 200°C while blade shear is likely the dominant factor for lower temperatures. The bleed air simulator produced results similar to the gas turbine engine results at higher temperatures, but did not replicate the size characteristics at lower temperatures. The observed particles are ultrafine and situated in the size range that may impact health safety more than larger particles.

Master of Science / Department of Mechanical and Nuclear Engineering / Amy R. Betz / The purpose of this research was to test if biphilic surfaces mitigate frost and ice formation. Frost, which forms when humid air comes into contact with a surface that is below the dew point and freezing temperature of water, hinders engineering systems such as aeronautics, refrigeration systems, and wind turbines. Most previous research has investigated increasingly superhydrophobic materials to delay frost formation; however, these materials are dependent on fluctuating operating conditions and surface roughness. Therefore, the hypothesis for this research was that a biphilic surface would slow the frost formation process and create a less dense frost layer, and water vapor would preferentially condense on hydrophilic areas, thus controlling where nucleation initially occurs. Preferential nucleation can control the size, shape, and location of frost nucleation. To fabricate biphilic surfaces, a hydrophobic material was coated on a silicon wafer, and a pattern of hydrophobic material was removed using photolithography to reveal hydrophilic silicon-oxide. Circles were patterned at various pitches and diameters. The heat sink was comprised of two parts: a solid bottom half and a finned upper half. Half of the heat sink was placed inside a polyethylene base for insulation. Tests were conducted in quiescent air at room temperature, 22 °C, and two relative humidities, 30% and 60%. Substrate temperatures were held constant throughout all tests. All tests showed a trend that biphilic surfaces suppress freezing temperature more effectively than plain hydrophilic or hydrophobic surfaces; however, no difference between pattern orientation or size was noticed for maximum freezing temperature. However, the biphilic patterns did affect other aspects such as time to freezing and volume of water on the surface. These effects are from the patterns altering the nucleation and coalescence behavior of condensation.

Master of Agribusiness / Department of Agricultural Economics / Jason Bergtold / Efficiency and technology are increasingly important selling points for combine harvesters. Diesel-electric hybrid drives have taken hold in the construction equipment industry, and are providing marketable efficiency benefits for some heavy equipment customers. This thesis explores the technical and economic feasibility of utilizing diesel-electric hybrid drives on AGCO combine harvesters. To determine the technical feasibility of utilizing diesel-electric hybrid drives on AGCO combine harvesters, a search was conducted for prior literature relating to the use of electric drives on other heavy, off-highway equipment. This information, coupled with data provided by experts in the field, was used to determine if electric drives could fulfill the unique requirements of combine harvesters, and be practically utilized for this application. To determine the economic feasibility of utilizing diesel-electric hybrid drives on AGCO combine harvesters, an optimization model was constructed to seek out the most economically viable configuration of electric drives for this application. The model takes in to consideration the different use-cases in which this equipment is expected to perform, as well as the component costs and operating efficiencies of both the drives in place currently and the proposed electric drives. The outcome of the model was then utilized to compare the best-case configuration to the minimum requirement for economic feasibility. The technical feasibility assessment conducted for this thesis led to the conclusion that it would be technically feasible to utilize electric drives on a combine harvester. There are commercially available electric drive components which are suitable for use in the environment that this equipment is expected to operate in, and a prototype combine harvester having electric drives has previously been constructed. The economic feasibility assessment conducted for this thesis revealed that it is not economically feasible to utilize electric drives on AGCO combine harvesters at this time. Under the current circumstances, the most economically viable configuration would take nearly twice the machine’s usable operating life to provide a benefit to a customer from fuel savings. Sensitivity analysis revealed that significant changes in the price of fuel or electric drive components would be necessary to change the outcome of this study.

Doctor of Philosophy / Department of Mechanical and Nuclear Engineering / Steve Eckels / A new human thermal model was developed to predict the thermal responses of human body in various environments. The new model was based on Smith's model, which employed finite element method to discretize the human body. The body parts in our new model were not limited to the cylindrical shape as in Smith's model, but subjected to arbitrary shapes. Therefore, the new model is capable of dealing with more complicated shapes of the human body. Steady-state and transient temperatures of fifteen body parts were calculated for three environments: cold, neutral, and warm. Our results were compared with the data from Zhang's experimental research on the human subjects. For all three conditions, our results showed better agreement with experimental data than Smith's results did. The maximal deviation is 1ºC for neutral and warm condition; for cold condition, a maximal deviation of 3.5ºC is reported at hand. The comparison indicated that our new model could provide a more accurate prediction on the body temperatures. Follow-up experiments were conducted to investigate the local and overall heat transfer from a moving cylinder in air flow. This study was expected to provide the local convective heat transfer coefficients of the human body to our new human thermal model to simulate moving humans. An experiment of a stationary cylinder in cross flow was performed to verify the accuracy and consistency of our system. Then, the experiment of a transverse oscillating cylinder in cross flow was conducted, with a oscillation frequency of 0.15 and Strouhal number of 0.3 to 1.5, depending on wind velocity. The overall Nusselt number (Nu) of the oscillating cylinder remained unaffected, compared to the stationary cylinder. This observation showed agreement with previous studies. The pivot experiment was performed to investigate swinging movement of human arms. The cylinder was positioned axially in cross flow, and reciprocated on a fixed point between horizontal and vertical positions under three wind speeds and two oscillating frequencies. The results showed that the overall Nu was between the Nu at horizontal and vertical positions in stationary state. A correlation was presented to predict the Nu of pivotal moving cylinder by using stationary Nu at horizontal and vertical positions. The correlation was proved to be valid ( error less than 5%) within the range of conditions in our experiment.

Master of Science / Department of Mechanical & Nuclear Engineering / Dale Schinstock / This thesis describes the design, development, and initial testing of the Mobile Reduced Gravity Simulator (MoRGS). MoRGS is a hoist with active force control, to be used in terrestrial environments with human test subjects for the simulation of partial gravity or zero gravity environments. It is to be used with the subject performing activities while being harnessed to the hoist. The following work here describes the mechanical design, structural and dynamic analyses, simulations used to aid in the control design and component selection, the development of unique control algorithms tailored to the objectives and uncommon dynamics of MoRGS, and initial testing performed without the use of human subjects. Major components of the MoRGS system include: AC servo motor, gearbox, custom-designed drum, pneumatic muscle, load cell, and a microprocessor. The system is designed to track the motion of the test subject over several meters of vertical travel at speeds of up to 2 Gs of acceleration. This allows for high performance during subject’s physical tests, including running on a treadmill and a climbing ladder. It is capable of offloading 50 lb. to 600 lb. and the level of desired reduced gravity is programmable. Results from testing of the system demonstrate that MoRGS system achieves its goals. It performs well, and the sensitivity of the force controller enables it to compensate for the most minute human motion disturbance.

Doctor of Philosophy / Department of Industrial and Manufacturing Systems Engineering / Shuting Lei / Shuting Lei / Femtosecond (fs) laser ablation possesses unique characteristics for micromachining, notably non-thermal interaction with materials, high peak intensity, precision and flexibility. In this dissertation, the potential of fs laser ablation for machining polyurea aerogel and scribing thin film solar cell interconnection grooves is studied. In a preliminary background discussion, some key literature regarding the basic physics and mechanisms that govern ultrafast laser pulse interaction with materials and laser micromachining are summarized. First, the fs laser pulses are used to micromachine polyurea aerogel. The experimental results demonstrate that high quality machining surface can be obtained by tuning the laser fluence and beam scanning speed, which provides insights for micromachining polymers with porous structures. Second, a new fs laser micro-drilling technique is developed to drill micro-holes in stainless steel, in which a hollow core fiber is employed to transmit laser pulses to the target position. The coupling efficiency between the laser and the fiber is investigated and found to be strongly related to pulse energy and pulse duration. Third, the fs laser with various energy, pulse durations, and scanning speeds has been utilized to pattern Indium Tin Oxide (ITO) glass for thin film solar cells. The groove width decreases with increasing pulse duration due to the shorter the pulse duration the more effective of the energy used to material removal. In order to fully remove ITO without damaging the glass, the beam scanning speed need to precisely be controlled. Fourth, fs laser has been utilized to scribe Molybdenum thin film on Polyimide (PI) flexible substrate for Copper Indium Gallium Selenide (CIGS) thin film solar cells. The experimental parameters and results including ablation threshold, single- and multiple-pulse ablation shapes and ablation efficiency were discussed in details. In order to utilize the advantages of the fs lasers, the fabrication process has to be optimized for thin film patterning and structuring applications concerning both efficiency and quality. A predictive 3D Two Temperature Model (TTM) was proposed to predict ablation characteristics and help to understand the fs laser metal ablation mechanisms. 3D temperature field evolution for both electrons and lattice were demonstrated. The ablation model provides an insight to the physical processes occurring during fs laser excitation of metals. Desired processing fluence and process speed regime can be predicted by calculating the ablation threshold, ablation rate and ablation crater geometry using the developed model.

Master of Science / Department of Chemical Engineering / Mary E. Rezac / Mary E. Rezac / Energy consumption due to heating, ventilation, and air conditioning amounts to 10-20% of global electrical energy usage. Air conditioning alone uses one trillion kilowatt hours globally. This energy is required for the dehumidification of air in addition to its cooling. New membrane technologies have the potential to decrease air conditioning energy requirements by significant amounts. A membrane acts as a partial heat and mass exchanger in conjunction with a traditional air conditioning system to remove water content and reduce the cooling load. Membranes vary according to their properties and method of mass transport. Liquid membranes have high permeability and selectivity, dense membranes have high selectivity and low permeability, and porous membranes have low selectivity and high permeability. A theoretical model was created to observe how membrane properties affected the potential energy savings of such systems. The most influential properties were flow rate, water permeability and selectivity, membrane area and thickness, and the purge flow temperature. Other properties were determined to be minimally important such as outdoor temperature and humidity. The effect on energy savings in many cases was not a linear relationship but suggested an optimal value beyond which energy savings did not significantly increase. The best simulations showed electrical energy savings of 86-95%.