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2022 UW MSE Capstone Design Symposium

Materials solutions for industry

Friday, June 3, 2022
8:30 a.m. - 12:00 p.m.

Please join us and our undergraduate senior Class of 2022 as they present their capstone design solutions for industry design challenges in the Materials Science and Engineering field.

Student presentations begin promptly at 8:30 a.m.

Registration for this event is required. As space for in-person attendance is limited, this event will be presented in a hybrid format.

Register now

 

Event Schedule

TBA

Project Details

Additive Manufacturing Data Analytics: Process to Performance Analysis

MSE students Esther Nicolaou, Anthony Passannante, Evan Truesdale, Mike Zhang
Team Members: Esther Nicolaou, Anthony Passannante, Evan Truesdale, Mike Zhang
Mentors: Robert Grube, Wentao Fu, Asya Lou, Professor Luna Huang
Company: Boeing
Abstract: Boeing has been incorporating additive manufacturing (AM) into their product line due to its improved buy-to-fly ratio, increased ease of prototyping, and the possibility of new part geometries and designs. However, the powder bed fusion processes that are typically used are less well-understood than traditional manufacturing methods. Data science could help fill in the gaps in our understanding. AM allows for in-situ imaging and shows the potential for high-throughout quality control in real-time without destructive testing or expensive scanning techniques. Using data science principles, we analyzed performance variability of parts made by EOS M290 printers using Grade 5 Ti6Al4V and attempted to build an in-situ detection model using optical thermography.

AM Powder Bed Fusion Part Porosity Sources

MSE students Bob Allen, Helen Carson, Gabe Howard, Nathan Lee, Bang Vu
Team Members: Bob Allen, Helen Carson, Gabe Howard, Nathan Lee, Bang Vu
Mentors: Stacey Huang, Professor Dwayne Arola
Company: Boeing
Abstract: Boeing is currently exploring metal additive manufacturing with a titanium alloy (Ti6Al4V), using a process called powder bed fusion (PBF) for prototyping and low-volume production. Currently, process reliability issues prevent PBF from more widespread use in aerospace applications. This capstone project seeks to explore how the machine’s argon gas flow (which prevents titanium oxidation and dissipates soot plumes) affects the porosity of sample coupons. A 1:1 scale mock build chamber was fabricated and assembled to visualize gas flow and validate computational fluid dynamics (CFD) models of the print chamber. Additionally, based on findings from literature review, a higher gas pressure of Argon gas was utilized in a sample test build. The coupons were analyzed for porosity and tensile properties and compared to previous sample test builds.

Characterization and Application of Recycled Carbon Fiber

Group members for the Boeing Characterization and Application of Recycled Carbon Fiber project, including MSE students Ryan Harris, Jiayang Li, Paul van Rijswijck, Noah Werner
Team Members: Ryan Harris, Jiayang Li, Paul van Rijswijck, Noah Werner
Mentors: Kelsi Hays, Pete George
Company: Boeing
Abstract: The purpose of this project is to characterize and explore the properties and applications for recycled carbon fiber. This research is important due to the ever-increasing usage of carbon fiber, necessitating further applications utilizing the material in its recycled waste. Recycled carbon fiber (rCF) is different from its virgin state in the way that it loses its fiber length and directionality through the recovery process. This makes the resin infusion uniquely challenging as well as making the mechanical properties slightly worse. In order to combat some of the shortcomings of the rCF hybrid, laminates can be made in which virgin carbon fiber layers are incorporated into the same composite as the recycled to improve part appearance, mechanical performance, and predictability. The team was tasked with conducting literature review to make informed decisions on deciding on a process, the material usage, the characterization, and an application that takes these parameters into account to fit this unique composite composition and executing on this plan.

Portable Plasma Process Window Definition for Thermoplastic Surface Treatment

MSE students Sophia Barrett, Alex Gibbs, Chelsea Ho, Mike Holden, Andy Luong, Yujiro Osawa, Reid Skidmore, Henry Song
Team Members: Sophia Barrett, Alex Gibbs, Chelsea Ho, Mike Holden, Andy Luong, Yujiro Osawa, Reid Skidmore, Henry Song
Mentors: Mohammad Azdamou, Ashley Tracey, Pradeep Krishnaswamy, Larry Ridgeway
Company: Boeing
Abstract: Plasma surface treatment is a promising method, particularly in thermoplastic materials, to provide robust surface treatments for structural repair applications. Such treatments could enable repair of damaged thermoplastic components by bonding damaged components with a thermoset material. This project seeks to determine the ideal processing parameters required to promote adhesion between a thermoset epoxy and a thermoplastic carbon fiber panel composite. A 3^k factorial design of experiments was used to examine the effects of the speed of the plasma head nozzle and overlap on the final surface treatment. The surface treatments were evaluated through a combination of double cantilever beam test and contact angle testing to evaluate the adhesion between the thermoplastic panel combined with the adhesive and surface energy respectively.

Powder Bed Fusion Build Process Interruption Study

Group members for the Powder Bed Fusion Build Process Interruption Study project, including MSE students Bror Ekdahl, Christoph Thompson, Victoria Wagner
Team Members: Bror Ekdahl, Christoph Thompson, Victoria Wagner
Mentors: Professor Dwayne Arola, Stacey Huang, Patrick Buffington, Cory Cunningham
Company: Boeing
Abstract: When build interruptions have occurred during the Powder Bed Fusion (PBF) manufacturing process, parts have been considered inferior and are discarded. We designed an interruption to investigate the effects on a laser-PBF device used for making Ti-6Al-4V parts for aerospace use and to determine if there is any significant effect of an interruption on the material made. Ti-6Al04V was made into coupons for mechanical testing, fractography, and microstructural analyses. Through these methods, we looked into the effect that the pause interruption had on the quality and strength of the material formed. Data generated from this study was also compared to data from the UW Round Robin study to see if there were any differences in behavior of the formed material.

Thermoplastic Additive Manufacturing Finishing Processes

Group members for the Boeing Thermoplastic Additive Manufacturing Finishing Processes project, including MSE students Nozomu Nandate, Mina Song
Team Members: Nozomu Nandate, Mina Song
Mentors: Kjersta Larson-Smith, Eric Moyer, Zach Renwick
Company: Boeing
Abstract: To create a finished product from additive manufacturing processes, post processing is necessary. It can be used to reduce surface roughness, improve aesthetics, as well as improving mechanical properties. For our project, we focused on improving the aesthetic of the printed part as well as decreasing the surface roughness. Through additive, mechanical, chemical, or thermal processes, we aimed to smoothen the surface and determine which method we would recommend for future use. This was done through characterization of the surface of our samples as well as taking into consideration the effect each post processing technique had such as added weight, aesthetic appeal, and adhesion to our sample. Through this analysis we hope to create suggestions for the Boeing company to utilize as methods of post processing in additive manufacturing processes of PEKK.

Assess the Effect of Crystallinity Degree on Mechanical Properties of a Thermoplastic Composite Structure

MSE students Griffin Chase, Ford Gross, Nathan Isler, Josiah Mace, Naomi Nelson, Logan Oster
Team Members: Griffin Chase, Ford Gross, Nathan Isler, Josiah Mace, Naomi Nelson, Logan Oster
Mentors: Stephanie Patel, Maggy Goudeau
Company: Daher
Abstract: The Daher Capstone group worked to develop methodology for assessing the effect of cooling rate on the crystallinity and mechanical properties of thermoplastic composites. The material consisted of carbon fiber and Polyether ether ketone (PEKK) resin. Originally obtained as prepreg tape, the material was analyzed through Differential Scanning Calorimetry (DSC) prior to layup and then consolidated through the use of hot pressing. By establishing crystallinity values of the PEKK material in the original state, the behavior of the composite at different cooling rates and temperatures was modeled for comparison to the actual part’s properties. Multiple different cooling methods were established in line with the original DSC tests in order to change the cooling rate after consolidation, and with it, the crystallinity of the material after processing, mechanical and thermal data was collected using 3-point bend testing and DSC, then used to form a Time-Temperature-Transition lot for use in future projects and work by Daher. This project serves to advance the information known about the crystalline kinetics of thermoplastic composites and strives to increase their usability within the aerospace industry.

Thermal Gravimetric Analysis of Composites for Architecture

MSE students Kyle Bainbridge, Izabela Carpenter, Jackson Delaney, Connor Gaspar, Megan Hong
Team Members: Kyle Bainbridge, Izabela Carpenter, Jackson Delaney, Connor Gaspar, Megan Hong
Mentor: Jed Brich
Company: Janicki Industries
Abstract: The architecture industry has been researching ways to increase the shape complexity of buildings for some time. Composite materials are of particular interest for use in complex buildings with their large range of mechanical and material properties. A specific formulation of composite materials and gel coats was postulated for use in buildings by Janicki industries, but this design unfortunately failed fire testing due to the shape that caused heat to concentrate based on the chimney effect created by its hollow space and column structure. The purpose of our project is to characterize the thermal behavior of the materials used in the original design and to help in the creation of a design that can pass fire testing and be safe for use in architecture. These properties were characterized by a combination of thermogravimetric analysis and optical microscopy to determine which materials could be used in the composite paneling.

PACCAR New Stress Durability Fixture

MSE students Sylvia Chen and Gautama Bhamidi
Team Members: Gautama Bhamidi, Sylvia Chen
Mentors: Jordan Kiesser and George Mehler
Company: PACCAR
Abstract: The PACCAR New Stress Durability Fixture is an interdisciplinary capstone project that aims to build and test a bespoke test fixture for adhesive stress durability performance in various environmental conditions. The MSE team’s objective is to solve an automotive component adhesion issue through adhesive testing and characterization. The team aims to research and recommend alternative adhesives that are more durable than the current adhesive, primer, and bonding process for a stainless-steel (SS) to fiber-reinforced polymer (FRP) component on PACCAR’s Class 8 heavy-duty trucks. Initial mechanical adhesion testing is to be performed on a selection of the researched adhesives through single lap shear and T-peel tests. The best performing adhesives are to be chosen to go through stress durability testing using the new fixture. The end goal of this project is to find a better performing adhesive for this SS-FRP bonding to solve a pressing automotive materials engineering problem.

Impact of Machining

Team Members: Maria Deming, Simba Huang, Arusha Misra, Gerardo Pina
Mentor: Don Lee
Company: Toray
Abstract: Standardization and quality control are key challenges Toray endures in the material industry. A current limitation that Toray faces is a lack of knowledge on the mechanical properties of near resins, specifically the impact of defects caused by machining on the mechanical properties of neat resins. This project aims to narrow down the types of defects that can arise in machining situations and gauge the conditions in which failures happen due to these defects in a resin material. An experimental plan will be designed in order to evaluate a ductile and brittle resin material with applied and standardized defects. The scope of the project will span from research, coupon machining, tensile and bending tests, and characterization of samples, and a recommendation to Toray about whether a defected part decreases the mechanical properties enough that the part should no longer be used.

Additional capstone projects

MSE students have the option of participating in capstone projects managed by other College of Engineering departments. In 2021-2022, MSE students participated in the following Mechanical/Engineering Innovation in Health Projects:

Project Title MSE Student(s) Mentor(s) Company
Reducing Risk of Central Line Associated Bloodstream Infections (CLABSI) Taylor Juenke Megan Stimpson, Jonathan Posner Vascular Access, Seattle Children’s Hospital
Gastrointestinal (GI) Anastomoses  Gillian Pereria, Brandon Lou Dr. James Park, Professor Eric Seibel General Surgery, UW Medicine
Nasogastric (NG) Tip Position Jasmine Hathaway Dr. Kenneth Gow General Surgery, Seattle Children’s Hospital
MSE students Taylor Juenke, Gillian Pereira, Brandon Lou, Jasmine Hathaway
Abstract: These three projects are involved in multiple departments including Materials Sciences and Engineering, Mechanical Engineering, and Engineering Innovation in Health (EIH). These students will not be presenting at the MSE Symposium on 6/3. The CLABSI project incorporates antimicrobial protection for implanted port access equipment to streamline access procedures. The NG tip position project involves creating a safe, reliable, and accessible method to verify NG tube tip placement. The GI Anastomoses project aims to create surgical connections in the GI tract by using a bioresorbable stent and compressive band combination which minimizes leakage of GI content.