This thesis focuses on the continued extension, validation, and application of combined thermal-structural reduced order models for nonlinear geometric problems. The first part of the thesis focuses on the determination of the temperature distribution and structural response induced by an oscillating flux on the top surface of a flat panel. This flux is introduced here as a simplified representation of the thermal effects of an oscillating shock on a panel of a supersonic/hypersonic vehicle. Accordingly, a random acoustic excitation is also considered to act on the panel and the level of the thermo-acoustic excitation is assumed to be large enough to induce a nonlinear geometric response of the panel. Both temperature distribution and structural response are determined using recently proposed reduced order models and a complete one way, thermal-structural, coupling is enforced. A steady-state analysis of the thermal problem is first carried out that is then utilized in the structural reduced order model governing equations with and without the acoustic excitation. A detailed validation of the reduced order models is carried out by comparison with a few full finite element (Nastran) computations. The computational expedience of the reduced order models allows a detailed parametric study of the response as a function of the frequency of the oscillating flux. The nature of the corresponding structural ROM equations is seen to be of a Mathieu-type with Duffing nonlinearity (originating from the nonlinear geometric effects) with external harmonic excitation (associated with the thermal moments terms on the panel). A dominant resonance is observed and explained. The second part of the thesis is focused on extending the formulation of the combined thermal-structural reduced order modeling method to include temperature dependent structural properties, more specifically of the elasticity tensor and the coefficient of thermal expansion. These properties were assumed to vary linearly with local temperature and it was found that the linear stiffness coefficients and the "thermal moment" terms then are cubic functions of the temperature generalized coordinates while the quadratic and cubic stiffness coefficients were only linear functions of these coordinates. A first validation of this reduced order modeling strategy was successfully carried out.

The focus of this research is to investigate methods for material substitution for the purpose of re-engineering legacy systems that involves incomplete information about form, fit and function of replacement parts. The primary motive is to extract as much useful information about a failed legacy part as possible and use fuzzy logic rules for identifying the unknown parameter values. Machine elements can fail by any number of failure modes but the most probable failure modes based on the service condition are considered critical failure modes. Three main parameters are of key interest in identifying the critical failure mode of the part. Critical failure modes are then directly mapped to material properties. Target material property values are calculated from material property values obtained from the originally used material and from the design goals. The material database is searched for new candidate materials that satisfy the goals and constraints in manufacturing and raw stock availability. Uncertainty in the extracted data is modeled using fuzzy logic. Fuzzy member functions model the imprecise nature of data in each available parameter and rule sets characterize the imprecise dependencies between the parameters and makes decisions in identifying the unknown parameter value based on the incompleteness. A final confidence level for each material in a pool of candidate material is a direct indication of uncertainty. All the candidates satisfy the goals and constraints to varying degrees and the final selection is left to the designer's discretion. The process is automated by software that inputs incomplete data; uses fuzzy logic to extract more information and queries the material database with a constrained search for finding candidate alternatives.

Composite materials are increasingly being used in aircraft, automobiles, and other applications due to their high strength to weight and stiffness to weight ratios. However, the presence of damage, such as delamination or matrix cracks, can significantly compromise the performance of these materials and result in premature failure. Structural components are often manually inspected to detect the presence of damage. This technique, known as schedule based maintenance, however, is expensive, time-consuming, and often limited to easily accessible structural elements. Therefore, there is an increased demand for robust and efficient Structural Health Monitoring (SHM) techniques that can be used for Condition Based Monitoring, which is the method in which structural components are inspected based upon damage metrics as opposed to flight hours. SHM relies on in situ frameworks for detecting early signs of damage in exposed and unexposed structural elements, offering not only reduced number of schedule based inspections, but also providing better useful life estimates. SHM frameworks require the development of different sensing technologies, algorithms, and procedures to detect, localize, quantify, characterize, as well as assess overall damage in aerospace structures so that strong estimations in the remaining useful life can be determined. The use of piezoelectric transducers along with guided Lamb waves is a method that has received considerable attention due to the weight, cost, and function of the systems based on these elements. The research in this thesis investigates the ability of Lamb waves to detect damage in feature dense anisotropic composite panels. Most current research negates the effects of experimental variability by performing tests on structurally simple isotropic plates that are used as a baseline and damaged specimen. However, in actual applications, variability cannot be negated, and therefore there is a need to research the effects of complex sample geometries, environmental operating conditions, and the effects of variability in material properties. This research is based on experiments conducted on a single blade-stiffened anisotropic composite panel that localizes delamination damage caused by impact. The overall goal was to utilize a correlative approach that used only the damage feature produced by the delamination as the damage index. This approach was adopted because it offered a simplistic way to determine the existence and location of damage without having to conduct a more complex wave propagation analysis or having to take into account the geometric complexities of the test specimen. Results showed that even in a complex structure, if the damage feature can be extracted and measured, then an appropriate damage index can be associated to it and the location of the damage can be inferred using a dense sensor array. The second experiment presented in this research studies the effects of temperature on damage detection when using one test specimen for a benchmark data set and another for damage data collection. This expands the previous experiment into exploring not only the effects of variable temperature, but also the effects of high experimental variability. Results from this work show that the damage feature in the data is not only extractable at higher temperatures, but that the data from one panel at one temperature can be directly compared to another panel at another temperature for baseline comparison due to linearity of the collected data.

Recent studies of the occurrence of post-flutter limit cycle oscillations (LCO) of the F-16 have provided good support to the long-standing hypothesis that this phenomenon involves a nonlinear structural damping. A potential mechanism for the appearance of nonlinearity in the damping are the nonlinear geometric effects that arise when the deformations become large enough to exceed the linear regime. In this light, the focus of this investigation is first on extending nonlinear reduced order modeling (ROM) methods to include viscoelasticity which is introduced here through a linear Kelvin-Voigt model in the undeformed configuration. Proceeding with a Galerkin approach, the ROM governing equations of motion are obtained and are found to be of a generalized van der Pol-Duffing form with parameters depending on the structure and the chosen basis functions. An identification approach of the nonlinear damping parameters is next proposed which is applicable to structures modeled within commercial finite element software.

The effects of this nonlinear damping mechanism on the post-flutter response is next analyzed on the Goland wing through time-marching of the aeroelastic equations comprising a rational fraction approximation of the linear aerodynamic forces. It is indeed found that the nonlinearity in the damping can stabilize the unstable aerodynamics and lead to finite amplitude limit cycle oscillations even when the stiffness related nonlinear geometric effects are neglected. The incorporation of these latter effects in the model is found to further decrease the amplitude of LCO even though the dominant bending motions do not seem to stiffen as the level of displacements is increased in static analyses.

CubeSats are a newly emerging, low-cost, rapid development platform for space exploration research. They are small spacecraft with a mass and volume of up to 12 kg and 12,000 cm3, respectively. To date, CubeSats have only been flown in Low Earth Orbit (LEO), though a large number are currently being designed to be dropped off by a mother ship on Earth escape trajectories intended for Lunar and Martian flyby missions. Advancements in propulsion technologies now enable these spacecraft to achieve capture orbits around the moon and Mars, providing a wealth of scientific data at low-cost. However, the mass, volume and launch constraints of CubeSats severely limit viable propulsion options.

We present an innovative propulsion solution using energy generated by onboard photovoltaic panels to electrolyze water, thus producing combustible hydrogen and oxygen for low-thrust applications. Water has a high storage density allowing for sufficient fuel within volume constraints. Its high enthalpy of formation provides more fuel that translates into increased ∆V and vastly reduced risk for the launch vehicle. This innovative technology poses significant challenges including the design and operation of electrolyzers at ultra-cold temperatures, the efficient separation of the resultant hydrogen and oxygen gases from liquid water in a microgravity environment, as well as the effective utilization of thrust to produce desired trajectories.

Analysis of the gas combustion and flow through the nozzle using both theoretical equations and finite-volume CFD modeling suggests an expected specific impulse of 360 s. Preliminary results from AGI's Satellite Toolkit (STK) indicate that the ΔV produced by the system for an 8kg CubeSat with 6kg of propellant in a LEO orbit (370 km altitude) is sufficient for an earth escape trajectory, lunar capture orbit or even a Mars capture orbit. These results suggest a promising pathway for an in-depth study supported by laboratory experiments to characterize the strengths and weaknesses of the proposed concept.

Stereolithography files (STL) are widely used in diverse fields as a means of describing complex geometries through surface triangulations. The resulting stereolithography output is a result of either experimental measurements, or computer-aided design. Often times stereolithography outputs from experimental means are prone to noise, surface irregularities and holes in an otherwise closed surface.

A general method for denoising and adaptively smoothing these dirty stereolithography files is proposed. Unlike existing means, this approach aims to smoothen the dirty surface representation by utilizing the well established levelset method. The level of smoothing and denoising can be set depending on a per-requirement basis by means of input parameters. Once the surface representation is smoothened as desired, it can be extracted as a standard levelset scalar isosurface.

The approach presented in this thesis is also coupled to a fully unstructured Cartesian mesh generation library with built-in localized adaptive mesh refinement (AMR) capabilities, thereby ensuring lower computational cost while also providing sufficient resolution. Future work will focus on implementing tetrahedral cuts to the base hexahedral mesh structure in order to extract a fully unstructured hexahedra-dominant mesh describing the STL geometry, which can be used for fluid flow simulations.

The subject of this thesis is concerned with the amount of cooling air assigned to seal high pressure turbine rim cavities which is critical for performance as well as component life. Insufficient air leads to excessive hot annulus gas ingestion and its penetration deep into the cavity compromising disc life. Excessive purge air, adversely affects performance. Experiments on a rotating turbine stage rig which included a rotor-stator forward disc cavity were performed at Arizona State University. The turbine rig has 22 vanes and 28 blades, while the rim cavity is composed of a single-tooth rim lab seal and a rim platform overlap seal. Time-averaged static pressures were measured in the gas path and the cavity, while mainstream gas ingestion into the cavity was determined by measuring the concentration distribution of tracer gas (carbon dioxide). Additionally, particle image velocimetry (PIV) was used to measure fluid velocity inside the rim cavity between the lab seal and the overlap. The data from the experiments were compared to an 360-degree unsteady RANS (URANS) CFD simulations. Although not able to match the time-averaged test data satisfactorily, the CFD simulations brought to light the unsteadiness present in the flow during the experiment which the slower response data did not fully capture. To interrogate the validity of URANS simulations in capturing complex rotating flow physics, the scope of this work also included to validating the CFD tool by comparing its predictions against experimental LDV data in a closed rotor-stator cavity. The enclosed cavity has a stationary shroud, a rotating hub, and mass flow does not enter or exit the system. A full 360 degree numerical simulation was performed comparing Fluent LES, with URANS turbulence models. Results from these investigations point to URANS state of art under-predicting closed cavity tangential velocity by 32% to 43%, and open rim cavity effectiveness by 50% compared to test data. The goal of this thesis is to assess the validity of URANS turbulence models in more complex rotating flows, compare accuracy with LES simulations, suggest CFD settings to better simulate turbine stage mainstream/disc cavity interaction with ingestion, and recommend experimentation techniques.

From 2001-2011, the General Aviation (GA) fatal accident rate remained unchanged (Duquette & Dorr, 2014) with an overall stagnant accident rate between 2004 and 2013. The leading cause, loss of control in flight (NTSB, 2015b & 2015c) due to pilot inability to recognize approach to stall/spin conditions (NTSB, 2015b & 2016b). In 2013, there were 1,224 GA accidents in the U.S., accounting for 94% of all U.S. aviation accidents and 90% of all U.S. aviation fatalities that year (NTSB, 2015c). Aviation entails multiple challenges for pilots related to task management, procedural errors, perceptual distortions, and cognitive discrepancies. While machine errors in airplanes have continued to decrease over the years, human error still has not (NTSB, 2013).

A preliminary analysis of a PC-based, Garmin G1000 flight deck was conducted with 3 professional pilots. Analyses revealed increased task load, opportunities for distraction, confusing perceptual ques, and hindered cognitive performance. Complex usage problems were deeply ingrained in the functionality of the system, forcing pilots to use fallible work arounds, add unnecessary steps, and memorize knob turns or button pushes.

Modern computing now has the potential to free GA cockpit designs from knobs, soft keys, or limited display options. Dynamic digital displays might include changes in instrumentation or menu structuring depending on the phase of flight. Airspeed indicators could increase in size to become more salient during landing, simultaneously highlighting pitch angle on Attitude Indicators and automatically decluttering unnecessary information for landing. Likewise, Angle-of-Attack indicators demonstrate a great safety and performance advantage for pilots (Duquette & Dorr, 2014; NTSB, 2015b & 2016b), an instrument typically found in military platforms and now the Icon A5, light-sport aircraft (Icon, 2016).

How does the design of pilots’ environment—the cockpit—further influence their efficiency and effectiveness? To explore the possibilities for small aircraft displays, a participatory design investigation was conducted with 9 qualified instrument pilots. Aviators designed mock cockpits on a PC using pictorial cutouts of analog (e.g., mechanical dials) and digital (e.g., dynamic displays) controls. Data was analyzed qualitatively and compared to similar work. Finally, a template for GA displays was developed based on pilot input.

Modern aircraft are expected to fly faster and more efficiently than their predecessors. To improve aerodynamic efficiency, designers must carefully consider and handle shock wave formation. Presently, many designers utilize computationally heavy optimization methods to design wings. While these methods may work, they do not provide insight. This thesis aims to better understand fundamental methods that govern wing design. In order to further understand the flow in the transonic regime, this work revisits the Transonic Similarity Rule. This rule postulates an equivalent incompressible geometry to any high speed geometry in flight and postulates a “stretching” analogy. This thesis utilizes panel methods and Computational Fluid Dynamics (CFD) to show that the “stretching” analogy is incorrect, but instead the flow is transformed by a nonlinear “scaling” of the flow velocity. This work also presents data to show the discrepancies between many famous authors in deriving the accurate Critical Pressure Coefficient (Cp*) equation for both swept and unswept wing sections. The final work of the thesis aims to identify the correct predictive methods for the Critical Pressure Coefficient.

CubeSats offer a compelling pathway towards lowering the cost of interplanetary exploration missions thanks to their low mass and volume. This has been possible due to miniaturization of electronics and sensors and increased efficiency of photovoltaics. Interplanetary communication using radio signals requires large parabolic antennas on the spacecraft and this often exceeds the total volume of CubeSat spacecraft. Mechanical deployable antennas have been proposed that would unfurl to form a large parabolic dish. These antennas much like an umbrella has many mechanical moving parts, are complex and are prone to jamming. An alternative are inflatables, due to their tenfold savings in mass, large surface area and very high packing efficiency of 20:1. The present work describes the process of designing and building inflatable parabolic reflectors for small satellite radio communications in the X band.

Tests show these inflatable reflectors to provide significantly higher gain characteristics as compared to conventional antennas. This would lead to much higher data rates from low earth orbits and would provide enabling communication capabilities for small satellites in deeper space. This technology is critical to lowering costs of small satellites while enhancing their capabilities.

Principle design challenges with inflatable membranes are maintaining accurate desired shape, reliable deployment mechanism and outer space environment protection. The present work tackles each of the mentioned challenges and provides an

understanding towards future work. In the course of our experimentation we have been able to address these challenges using building techniques that evolved out of a matured understanding of the inflation process.

Our design is based on low cost chemical sublimates as inflation substances that use a simple mechanism for inflation. To improve the reliability of the inflated shape, we use UV radiation hardened polymer support structures. The novelty of the design lies in its simplicity, low cost and high reliability. The design and development work provides an understanding towards extending these concepts to much larger deployable structures such as solar sails, inflatable truss structures for orbit servicing and large surface area inflatables for deceleration from hypersonic speeds when re-entering the atmosphere.