To evaluate potential uses for friction stir welding in additive manufacturing, two separate parts were fabricated, one of 2195-T84 and the other 2219-T87, utilizing fixed pin techniques and additive lap welds. The parts were cut into samples, artificially aged and subjected to Rockwell hardness (HRB), Vickers hardness, micrographic photography, and metallographic imaging on both pre- and post- heat treatment. Additionally, tensile testing was performed on the heat-treated samples. A comparisons of test results showed a minimal increase in the yield strength of the 2195-T84 samples compared to as-welded tensile results obtained from a previous project. The ultimate tensile strength was reduced by approximately 16%. Further testing will be required to determine the nature of this reduction. No previous results were available for the as-welded 2219-T87, but UTS of the artificially aged samples was approximately 91% that of the parent material.

Active vibration control is a widely implemented method for the helicopter vibration control. Due to the significant progress in microelectronics, this technique outperforms the traditional passive control technique due to weight penalty and lack of adaptability for the changing flight conditions. In this thesis, an optimal controller is designed to attenuate the rotor blade vibration. The mathematical model of the triply coupled vibration of the rotating cantilever beam is used to develop the state-space model of an isolated rotor blade. The required natural frequencies are determined by the modified Galerkin method and only the principal aerodynamic forces acting on the structure are considered to obtain the elements of the input matrix. A linear quadratic regulator is designed to achieve the vibration reduction at the optimum level and the controller is tuned for the hovering and forward flight with different advance ratios.

When testing forgings for specifications, it was found that some parts did not meet the requirements for mechanical properties. This triggered an investigation into two of the parts from the lot that did not meet specification. The ultimate reason for failure was due to lower than necessary yield strength and ultimate tensile strength values, as well as unwanted variability between regions of the part. Therefore, samples of the regions were tensile tested to determine the differences that existed in yield strength, ultimate tensile strength, and elongation. After tensile testing, quantitative metallography and fractography were conducted to identify aspects of the microstructure and fracture surfaces that may have caused the variability. Three aspects of the microstructure that were identified as characteristics that may affect the mechanical properties were: grain size, Widmanstätten colony size, and volume fraction of the β phase. Based on measurements it was determined that a smaller Widmanstätten colony size found to be roughly 120 microns/colony was associated with a larger yield strength and UTS than larger colony sizes of roughly 170 microns/ colony. Grain size also played a role with smaller grain sizes of roughly 1550 microns/grain being associated with a higher yield strength and UTS than the larger grains of roughly 2000 microns/grain. Fractography also suggested that the presence of interlamellar decohesion and trans-lamellar failure may have created sites of further crack initiation, resulting in a lower ultimate tensile strength. These differences were theorized to be caused by a temperature gradient created during the heat treatment that created non-uniform cooling rates, resulting in the differences in microstructural characteristics.

Impact strength is one of the most important structural properties for a designer to consider, but is often the most difficult to quantify or measure. A constant concern in the field of composites is the effect of foreign object impact damage because it is often undetectable by visual inspection. An impact can create interlaminar damage that often results in severe reductions in strength and instability of the structure. The main objective of this study is to determine the effectiveness of a damage arrestment device (DAD) on the mechanical behavior of composite sandwiches, following a low-velocity impact. A 7.56-lbf crosshead dropped from a height of 37.5-inches was considered for the low-velocity impact testing. In this study, the experimental and numerical analysis of composite sandwiches were investigated, which included static 4-point bend and vibration testing. Composite sandwiches were constructed utilizing four-plies of Advanced Composites Group LTM45EL/CF1803 bi-directional woven carbon fiber face sheets with a General Plastics Last-A-Foam FR-6710 rigid polyurethane core. Specimens were cured in an autoclave, using the manufacturer’s specified curing cycle. In addition to the experimental and numerical analysis of composite sandwiches, developing and building a data acquisition (DAQ) system for the Dynatup 8250 drop weight impact tester was accomplished. Utilizing National Instruments signal conditioning hardware, in conjunction with LabView and MATLAB, complete testing software was developed and built to provide full data acquisition for an impact test. The testing hardware and software provide complete force vs. time history and crosshead acceleration of the impact event, as well as provide instantaneous impact velocity of the projectile. The testing hardware, software, and procedures were developed and built in the Aerospace Structures/Composites laboratory at Cal Poly for approximately 15% of the cost from the manufacturer. In the first study, static 4-point bend testing was investigated to determine the residual flexural strength of composite sandwich beams following a low-velocity impact. Four different specimen cases were investigated in the 4-point bend test, with and without being impacted: first a control beam with no delamination or DAD, second a control beam with a centrally located 1-inch long initial delamination, third a DAD key beam with two transverse DADs centrally located 1-inch apart, and finally a DAD key beam with a centrally located initial delamination between two transverse DADs. The specimens used followed the ASTM D6272 standard test method. The specimens were 1-inch wide by 11-inch long beams. The experimental results showed that the presence of DAD keys significantly improved both the residual stiffness and ultimate strength of a composite sandwich structure that had been damaged under low-velocity impact loading, even with the presence of an initial face-core delamination. In the second study, vibration testing was investigated as a means to detect a delamination in the structure and the effect of impact damage on the vibrational characteristics, such as damping, on composite sandwich plates. Four different specimen cases were investigated in the vibration test, both with and without being impacted: first a control plate with no delamination or DAD, second three control plates with varying 1-inch initial delamination locations at the 1st, 2nd, and 3rd bending-mode nodes, third a DAD key plate with one DAD running the entire length longitudinally along the center of the plate, and finally three DAD key plates with one DAD running the entire length longitudinally along the center of the plate and varying 1-inch delamination locations at the 1st, 2nd, and 3rd bending mode-nodes. The response accelerometer location was varied at 1-inch increments along the length of the plate. From the experimental results, it was determined that varying the location of the accelerometer had a significant effect on the detection of face-core delamination in a composite sandwich structure. Additionally, it was shown that damping characteristics significantly degraded in control case plates after a low-velocity impact, but they were better retained when a DAD key was added to the structure. Numerical analysis utilizing the finite element method (FEM) was employed to validate experimental testing, as well as provide a means to examine the stress distribution and impact absorption of the structure. The impact event was modeled utilizing the LS-Dyna explicit FE solver, which generated complete force vs. time history of the impact event. Static 4-point bending and vibration analysis were solved utilizing the LS-Dyna implicit solver. Finally a damaged mesh was obtained from the explicit impact solution and subjected to subsequent static 4-point bending and vibration analysis to numerically determine the residual mechanical behavior after impact. All cases showed good agreement between the numerical, analytical, and experimental results.

The purpose of this research was to investigate the surface modifications that take place during the machining of NiTi SMA and Ti-6Al-4V with micro-EDM. This was done by creating an array of blind holes and micro-patterns on both work-pieces. To analyze the machined surface and investigate the results, scanning electron microscope (SEM), energy dispersive X- ray spectroscopy (EDS) and X-ray diffraction (XRD) techniques were employed. In addition, the effects of various operating parameters on the machining performance was studied to identify the optimum parameters for micro-EDM of NiTi SMA and Ti-6Al-4V. Recently, aerospace and biomedical industries have placed a high demand on nonconventional machining processes, which can be used to machine high strength and hardto- cut materials such as Titanium alloys, Shape Memory Alloys (SMA) and Super Alloys. Electrical Discharge Machining (EDM) is one of the non-traditional technologies that remove materials from the workpiece through a series of electrical sparks that occur between the workpiece and cutting tool with the presence of dielectric liquid. Obtaining smooth and defect-free surfaces on both workpieces was one of the challenges due to the re-solidified debris on the machined surface. The experimental results showed that there was significant amount of re-casting and formation of resolidification of debris on the Ti surface after machining. On the other hand, the surface generated in NiTi SMA were comparatively smoother with lesser amount of resolidified debris on the surface. By analyzing the results from XRD and EDS, some elements of electrode and dielectric materials such as Tungsten, Carbon and Oxygen were observed on NiTi and Ti surface after machining. In the study of effect of operating parameters, it was found that the voltage, capacitance and tool rotational speed had significant effect on machining time. The machining time was reduced by increasing the voltage, capacitance and tool rotational speed. The machining time was found to be comparatively higher for machining NiTi SMA than Ti alloy. Comparing all the parameters, the voltage of 60 V, capacitance of 1000 PF, and tool rotational speed of 3500 RPM were selected as optimum parameters for this study. Although signs of tool electrode wear and debris particles on the machined surface were observed for both workpieces during the micro-EDM process, Ti alloy and NiTi SMA could be machined successfully using the micro-EDM process.

Electrical Discharge Machining (EDM) is a non-traditional machining process that uses hundreds of thousands of minute electrical sparks per second to machine any electrically conductive material, no matter the hardness or how delicate it is. EDM allows a much greater range of design possibilities, unconstrained from the traditional machining processes, in which material is removed mechanically by either rotating the cutting tool or the work piece. Shapes that were impossible to machine by any other method, such as deep, precision, square holes and slots with sharp inside corners, are readily produced. It provides accurate geometries in high- aspect ratio holes and slots, blind undercuts, small holes adjacent to deep sidewalls, and complex cuts in thin, fragile parts. Micro-EDM is a growing form of manufacturing and will continue to expand within various production fields. Micro-EDM is especially attractive for the applications where the cutting time is minimal, but precision and accuracy are maximized. Micro- EDM is a non-traditional cutting process, which consistently produces ultra-precise holes with fine surface finishes and better roundness, while holding extremely close diameter tolerances. The process could be an excellent problem-solving tool for configurations that are difficult or impossible to produce using conventional machining processes. This study presents a comparative experimental investigation on the micro-EDM machinability of difficult-to-cut Ti-6Al-4V and soft brass materials. As both materials are electrically conductive, they were machinable using the micro-EDM process irrespective of their hardness. The machining performance of the two materials was evaluated based on the quality of the micro-features produced by the micro-EDM process. Both blind and through micro-holes and micro-slots were machined on brass and Ti-6Al-4V materials. The quality of micro-features was assessed based on the shape accuracy, surface finish and profile accuracy of the features. Finally, the arrays of micro-features were machined on both materials to compare the mass production capability of micro-EDM process on those materials.

Thesis (M.Eng.Sc.)--University of Adelaide, School of Mechanical Engineering, 2005. / Includes bibliographical references (leaves 131-137). Also available electronically as part of the Australian Digital Theses Program.

Thesis (M.Eng.Sc.)--University of Adelaide, School of Mechanical Engineering, 2005. / Title from screen page; viewed 16 Aug. 2005. Includes bibliographical references (leaves 131-137). Also available in print format.

Shock is one of the environmental tests that a spacecraft must pass before being cleared for launch. Shock testing poses a challenging data acquisition issue and careful selection of equipment is crucial to creating a successful shock test facility. Cal Poly’s CubeSat programs can currently perform all environmental testing other than shock themselves, so a quality shock table would be useful. Previous groups of students had developed a shock table, and this paper details the improvement and characterization of that shock table’s behavior. Several adjustable parameters were tested and documented to discover trends in the shock table’s response to an impact from a pendulum hammer. Then a test meant to mimic an actual shock test was performed. The CubeSat program provided a component to be tested and a requirement to be met. The nominal requirement is proprietary and cannot be given here, and additional stipulations included the test data being within a given tolerance band and at least 50% of the test data having a larger magnitude than the nominal requirement. The requirement needed to be met in all three of the component’s axes. The component was mounted to the shock table and acceleration data was collected and analyzed. A successful test was conducted in one axis, which was the result of impacting the large face of the aluminum shock table plate. The tests in the other two axes, conducted with impacts to the side of the aluminum plate, failed to meet the requirement. A finite element model of the table was developed and correlated to the test data. A new way of attaching the test component to the table was developed that would allow for testing in all three axes to be performed with impacts to the large face of the aluminum plate. A dynamic finite element analysis was performed, and the results indicate that this new attachment method should allow the requirement to be met in all three axes. The shock table is currently fully operational and can be used for testing and teaching purposes. With the implementation of the new attachment method, it is believed that the CubeSat program’s requirements can be met as well.

The space environment presents various challenges when designing systems and selecting materials for applications beyond Earth’s atmosphere. For mission success, these challenges must be considered. One of the detrimental aspects of the space en- vironment is Atomic Oxygen, AO. Only present in harmful quantities in Lower Earth Orbit, LEO, AO causes significant damage to materials by breaking molecular bonds. California Polytechnic State University’s, Cal Poly’s, space environments laboratory features an apparatus capable of simulating this environment. Very thin or short samples were tested to observe the mass loss due to erosion of the sample material. Recent modifications to the system allow it to expose surfaces of three dimensional objects to AO rather than only those two dimensional objects. Simulating this effect on taller samples makes available the opportunity to test coupons that are then used in additional testing to measure the effect of that erosion on other properties. Challenges in adapting the AO system are explored and addressed, as well as some possible use cases for future work. As a use case, bending moment specimens were exposed to AO prior to testing in four point bending. Multiple regression models were constructed to determine variables contributing to slope changes between specimen pairs’ linear-elastic regions of force-displacement graphs. Results show that AO exposed specimens had significantly gentler slopes in the linear elastic region of the force-displacement curve, meaning that AO exposure reduced structural rigidity of the coupons.