In this thesis, the development of a structure for use in an educational CubeSat kit is explored. The potential uses of this kit include augmenting existing curricula with aspects of hands on learning, developing new ways of training students on proper space systems engineering practices, and overall contributing to academic capacity building at Cal Poly and its collaborators. The design improves on existing CubeSat kit structures by increasing accessibility to internal components by implementing a modular backplane system, as well as adding the ability to be environmentally tested. Manufacturing of the structure is completed with both additive (Fused Deposition Modeling with ABS polymer and Selective Laser Melting with AlSi10Mg metal) and subtractive (milling with Al-6061) technologies. Modal, harmonic, and random vibration analyses and tests are done to ensure the structure passes vibration testing qualification loads, as outlined by the National Aeronautics and Space Administration’s General Environmental Standards. Successful testing of the structure, defined as deforming less than 0.5 millimeters and maintaining a factor of safety above 2, is achieved with all materials of interest. Thus, the structure becomes the first publicly available CubeSat kit designed to survive environmental testing. Achieving this goal with a structure made of the cheap, widely available material ABS showcases the potential usability of 3D-printed polymers in CubeSat structures.

As applications for thermoplastic composites increase, the understanding of their properties become more important. Fabrication methods for thermoplastic composites continually improve to match designs specifications. These advanced thermoplastics have begun to show an improvement in mechanical properties over those found in thermoset composites commonly used in industry. Polyaryletherketones (PEK) have high service temperatures, good mechanical properties, and improved processing capabilities compared to thermoplastics used in the past making them important to the aerospace industry. The wide range of types of PEK make them suitable for a variety of applications, but selection of specific chemistries, processing parameters, and composite stack-ups determine the mechanical properties produced. Differential scanning calorimetry (DSC), and Fourier transform infrared spectroscopy (FTIR) were used to determine crystallinity and chemical properties of several polyaryletherketones. Tensile, compressive, and Mode I interlaminar fracture toughness tests were conducted to analyze mechanical properties of these advanced thermoplastics. Several fabrication processes were also tested to determine optimal consolidation and aesthetic appearance of structural members. All testing was conducted at The Boeing Company in Seattle, Washington. Because all testing and conclusions are proprietary a general synopsis of the experience will be presented.

This research effort explored the possibility of using interwoven conductive and nonconductive fibers in a composite laminate for structural health monitoring (SHM). Traditional SHM systems utilize fiber optics, piezoelectrics, or detect defects by nondestructive test methods by use of sonar graphs or x-rays. However, these approaches are often expensive, time consuming and complicated. The primary objective of this research was to apply a resistance based method of structural health monitoring to a composite structure to determine structural integrity and presence of defects. The conductive properties of fiber such as carbon, copper, or constantan - a copper-nickel alloy - can be utilized as sensors within the structure. This allows the structure to provide feedback via electrical signals to a user which are essential for evaluating the health of the structure. In this research, the conductive fiber was made from constantan wire which was embedded within a composite laminate; whereas prepreg fiberglass, a nonconductive material, serves as the main structural element of the laminate. A composite laminate was constructed from four layers of TenCate 7781 “E” fiberglass and BT250E-1 resin prepreg. Integrating the constantan within the composite laminate provides a sensory element which supplies measurements of structural behavior. Thus, with fiberglass, epoxy, and a constantan conductive element, a three-part composite laminate is developed. Test specimens used in this research were fabricated using a composite air press with the recommended manufacturer cure cycle. A TenCate BT250E-1 Resin System and 7781 "E" impregnated glass-fiber/epoxy weave was used. A constantan wire of 0.01” gauge diameter was integrated into the composite structure. The composite laminate specimen with the integrated SHM system was tested under tensile and flexural loads employing test standards specified by ASTM D3039 and D7264, respectively. These test methods were modified to determine the behavior of the laminate in the elastic range only. A tension and flexural delamination test case was also developed to investigate the sensitivity of the SHM system to inherent defects. Moreover, material characteristic tests were completed to validate manufacturer provided material characteristics. The specimens were tested while varying the constantan configurations, such as the sensor length and orientation. A variety of techniques to integrate the sensor were also investigated. Two different measurement methods were used to determine strain. Strain measurements were made with Instron Bluehill 2 software and correlated to strain obtained by the structural health monitoring system with the use of a data acquisition code written to interact with a micro-ohm-meter. The experimental results showed good agreement between measurements made by the two different methods of measurement. Observations discovered that varying the length of the sensor element improved sensitivity, but resulted in different prediction models when compared to cases with less sensor length. The predictions are based on the gauge factor, which was determined for the each test case. This value provides the essential relationship between resistance and strain. Experiments proved that the measured gauge factor depended greatly on the sensor length and orientation. The correlation was of sufficient accuracy to predict strain values in a composite laminate without the use of any added tools or equipment besides the ohm-meter. Analytical solutions to the loading cases were developed to validate results obtained during experiments. The solutions were in good agreement with the experimental results.

The purpose of this research is to investigate the influence of stitching architectures by using different stitching periodic patterns on the in-plane and out-of-plane mechanical properties. By using the inherent periodic architecture of these composites, their mechanical properties may be tailored for specific applications. Composite structures are extensively used in several industries such as aerospace, automotive, sports, and construction due to their many advantages, which include tailorable mechanical properties, high strength-to-weight ratios, and high specific stiffness. However, due to their low interlaminar tensile strength, composites are prone to delaminations, which can degrade the overall mechanical performance of the structure. Through-thickness stitching provides the third-direction reinforcement to enhance the interlaminar tensile and shear strengths. In this study, quasi-isotropic composite test articles were manufactured and stitched through-thickness using different chain stitch patterns. Full-field surface strain measurements were collected through the non-contact digital image correlation (DIC) technique. A design of experiments (DoE) approach was used to investigate the stitch parameters, such as stitch density (number of stitches per unit area), stitch angle (stitch seam orientation), and linear thread density (thread diameter), and their interactions on the in-plane and out-of-plane mechanical properties. Experimental results are then used to develop a statistically informed response surface model (RSM) to find optimal stitching parameters based on a maximum predicted tensile strength, tensile modulus and flexural strength.

In this study, ABS Publication 115, “Guidance on Fatigue Assessment of Offshore Structures” is briefly reviewed. Emphasis is on the S-N curves based fatigue assessment approach of non-tubular joints, and both size and environment effects are also considered. Further, fatigue tests are performed to study the fatigue strength of load-carrying and non-load-carrying steel cruciform joints that represent typical joint types in marine structures. The experimental results are then compared against ABS fatigue assessment methods, based on nominal stress approach, which demonstrates a need for better fatigue evaluation parameter. A good fatigue parameter by definition should be consistent and should correlate the S-N data well. The equivalent structural stress parameter is introduced to investigate the fatigue behavior of welded joints using the traction based structural stress approach on finite element models of specimens, and representing the data as a single Master S-N curve.

The exceptional flying characteristics of airborne insects motivates the design of biomimetic wing structures that can exhibit a similar structural dynamic behavior. For this purpose, this investigation describes a method for both manufacturing a biomimetic insect-sized wing using the photolithography technique and analyzing its structural dynamic response. The geometry of a crane fly forewing (family Tipulidae) is acquired using a micro-computed tomography scanner. A computer-aided design model is generated from the measurements of the reconstructed scanned model of the insect wing to design the photomasks of the membrane and the venation network required for the photolithography procedure. A composite material wing is manufactured by patterning the venation network using photoresist SU-8 on a Kapton film for the assembling of the wing. A single material artificial wing is fabricated using the photoresist SU-8 for both the membrane and the network of veins. Experiments are conducted using a modal shaker and a digital image correlation (DIC) system to determine the natural frequencies and the mode shapes of the artificial wing from the fast Fourier transform of the displacement response of the wing. The experimental results are compared with those from a finite element (FE) model of the wing. A numerical simulation of the fluid-structure interaction is conducted by coupling the FE model of the artificial wing with a computational fluid dynamics model of the surrounding airflow. From these simulations, the deformation response and the coefficients of drag and lift of the artificial wing are predicted for different freestream velocities and angles of attack. Wind-tunnel experiments are conducted using the DIC system to determine the structural deformation response of the artificial wing under different freestream velocities and angles of attack. The vibration modes are dominated by a bending and torsional deformation response. The deformation along the span of the wing increases nonlinearly from the root of the wing to the tip of the wing with Reynolds number. The aerodynamic performance, defined as the ratio of the coefficient of lift to the coefficient of drag, of the artificial wing increases with Reynolds number and angle of attack up to the critical angle of attack.

NiTiHf shape memory alloys have been receiving considerable attention for high temperature and high strength applications since they could have transformation temperatures above 100 °C, shape memory effect under high stress (above 500 MPa) and superelasticity at high temperatures. Moreover, their shape memory properties can be tailored by microstructural engineering. However, NiTiHf alloys have some drawbacks such as low ductility and high work hardening in stress induced martensite transformation region. In order to overcome these limitations, studies have been focused on microstructural engineering by aging, alloying and processing. Shape memory properties and microstructure of four Ni-rich NiTiHf alloys (Ni50.3Ti29.7Hf20, Ni50.7Ti29.3Hf20, Ni51.2Ti28.8Hf20, and Ni52Ti28Hf20 (at. %)) were systematically characterized in the furnace cooled condition. H-phase precipitates were formed during furnace cooling in compositions with greater than 50.3Ni and the driving force for nucleation increased with Ni content. Alloy strength increased while recoverable strain decreased with increasing Ni content due to changes in precipitate characteristics. The effects of the heat treatments on the transformation characteristics and microstructure of the Ni-rich NiTiHf shape memory alloys have been investigated. Transformation temperatures are found to be highly annealing temperature dependent. Generation of nanosize precipitates (~20 nm in size) after three hours aging at 450 °C and 550 °C improved the strength of the material, resulting in a near perfect dimensional stability under high stress levels (> 1500 MPa) with a work output of 20–30 J cm– 3. Superelastic behavior with 4% recoverable strain was demonstrated at low and high temperatures where stress could reach to a maximum value of more than 2 GPa after three hours aging at 450 and 550 °C for alloys with Ni great than 50.3 at. %. Shape memory properties of polycrystalline Ni50.3Ti29.7Hf20 alloys were studied via thermal cycling under stress and isothermal stress cycling experiments in tension. Recoverable strain of ~5% was observed for the as-extruded samples while it was decreased to ~4% after aging due to the formation of precipitates. The aged alloys demonstrated near perfect shape memory effect under high tensile stress level of 700 MPa and perfect superelasticity at high temperatures up to 230 °C. Finally, the tensioncompression asymmetry observed in NiTiHf where recoverable tensile strain was higher than compressive strain. The shape memory properties of solutionized and aged Ni-rich Ni50.3Ti29.7Hf20 single crystals were investigated along the [001], [011], and [111] orientations in compression. [001]-oriented single crystals showed high dimensional stability under stress levels as high as 1500 MPa in both the solutionized and aged conditions, but with transformation strains of less than 2%. Perfect superelasticity with recoverable strain of more than 4% was observed for solutionized and 550 °C-3h aged single crystals along the [011] and [111] orientations, and general superelastic behavior was observed over a wide temperature range. The calculated transformation strains were higher than the experimentally observed strains since the calculated strains could not capture the formation of martensite plates with (001) compound twins.

The incorporation of inflatable structures into aerospace systems can produce significant advantages in stowed volume to mechanical effectiveness and overall weight. Many applications of these ultra-lightweight systems are designed to precisely control internal or external surfaces, or both, to achieve desired performance. The modeling of these structures becomes complex due to the material nonlinearities inherent to the majority of construction materials used in inflatable structures. Furthermore, accurately modeling the response and behavior of the interfacing boundaries that are common to many inflatable systems will lead to better understanding of the entire class of structures. The research presented involved using nonlinear finite element simulations correlated with photogrammetry testing to develop a procedure for defining material properties for commercially available polyurethane-coated woven nylon fabric, which is representative of coated materials that have been proven materials for use in many inflatable systems. Further, the new material model was used to design and develop an inflatable pathfinder system which employs only internal pressure to control an assembly of internal membranes. This canonical inflatable system will be used for exploration and development of general understanding of efficient design methodology and analysis of future systems. Canonical structures are incorporated into the design of the phased pathfinder system to allow for more universal insight. Nonlinear finite element simulations were performed to evaluate the effect of various boundary conditions, loading configurations, and material orientations on the geometric precision of geometries representing typical internal/external surfaces commonly incorporated into inflatable pathfinder system. The response of the inflatable system to possible damage was also studied using nonlinear finite element simulations. Development of a correlated material model for analysis of the inflatable pathfinder system has improved the efficiency of design and analysis techniques of future inflatable structures.

ABSTRACT Multidisciplinary Design Optimization of an Extreme Aspect Ratio HALE UAV Bryan J. Morrisey Development of High Altitude Long Endurance (HALE) aircraft systems is part of a vision for a low cost communications/surveillance capability. Applications of a multi payload aircraft operating for extended periods at stratospheric altitudes span military and civil genres and support battlefield operations, communications, atmospheric or agricultural monitoring, surveillance, and other disciplines that may currently require satellite-based infrastructure. Presently, several development efforts are underway in this field, including a project sponsored by DARPA that aims at producing an aircraft that can sustain flight for multiple years and act as a pseudo-satellite. Design of this type of air vehicle represents a substantial challenge because of the vast number of engineering disciplines required for analysis, and its residence at the frontier of energy technology. The central goal of this research was the development of a multidisciplinary tool for analysis, design, and optimization of HALE UAVs, facilitating the study of a novel configuration concept. Applying design ideas stemming from a unique WWII-era project, a “pinned wing” HALE aircraft would employ self-supporting wing segments assembled into one overall flying wing. The research effort began with the creation of a multidisciplinary analysis environment comprised of analysis modules, each providing information about a specific discipline. As the modules were created, attempts were made to validate and calibrate the processes against known data, culminating in a validation study of the fully integrated MDA environment. Using the NASA / AeroVironment Helios aircraft as a basis for comparison, the included MDA environment sized a vehicle to within 5% of the actual maximum gross weight for generalized Helios payload and mission data. When wrapped in an optimization routine, the same integrated design environment shows potential for a 17.3% reduction in weight when wing thickness to chord ratio, aspect ratio, wing loading, and power to weight ratio are included as optimizer-controlled design variables. Investigation of applying the sustained day/night mission requirement and improved technology factors to the design shows that there are potential benefits associated with a segmented or pinned wing. As expected, wing structural weight is reduced, but benefits diminish as higher numbers of wing segments are considered. For an aircraft consisting of six wing segments, a maximum of 14.2% reduction in gross weight over an advanced technology optimal baseline is predicted.

Additive Manufacturing, and specifically powder bed fusion processes, have advanced rapidly in recent years. Selective Laser Melting in particular has been adopted in a variety of industries from biomedical to aerospace because of its capability to produce complex components with numerous alloys, including stainless steels, nickel superalloys, and titanium alloys. Post-processing is required to treat or solve metallurgical issues such as porosity, residual stresses, and surface roughness. Because of the geometric complexity of SLM produced parts, the reduction of surface roughness with conventional processing has proven especially challenging. In this Thesis, two processes, abrasive flow machining and ultrasonic shot peening, are evaluated as surface finishing processes for selective laser melted 316L. Results of these experiments indicate that AFM can reliably polish as-built internal passages to 1 µm Ra or better but is unsuitable for passages with rapidly expanding or contracting cross-sections. AFM can also polish relatively small passages, but lattice components may prove too complex for effective processing. USP cannot achieve such low surface roughness, but it is a versatile process with multiple advantages. Exterior surfaces were consistently processed to 1.7 to 2.5 µm Ra. Interior surfaces experienced only partial processing and demonstrated high geometric dependence. USP significantly hardened the surface, but steel media hardened the surface better than ceramic media did. Both AFM and USP are recommended processes for the surface finishing of SLM manufactured parts. Good engineering judgement is necessary to determine when to use these processes and how to design for post-processing.