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In injection molded plastic parts, knit lines occur where opposing streams of material fuse together while the mold cavity fills. When parts with knit lines experience external loading, the knit lines cause areas of mechanical weakness. This weakness is especially drastic in fiber-reinforced polymers due to an unfavorable orientation of fibers at the knit line. A possible way to reduce the impact of knit lines is to incorporate overflow tabs into the mold design. An overflow tab is a chamber attached to the mold cavity that provides an extra space for the end of material flow to occur. Research shows that overflow tabs improve the fiber orientation at the knit line, resulting in increased mechanical strength. The goal of this study is to utilize overflow tabs to optimize the knit line strength of nylon 6-6 that is 30% carbon fiber reinforced. In this project, an initial overflow tab is first designed. Then four modifications are made to the tab design, each altering a separate variable while holding the others constant. The design changes explored for the tab in this project include adding radii to the inlet, shifting the inlet location, increasing the inlet cross-sectional area by 50%, and increasing the tab chamber volume by 50%. Specimens were molded using the initial tab design and the modified tab designs. Testing for this experiment consists of three specimens of each type for three-point bending tests, and five specimens of each type for tensile tests. The material properties analyzed are the flexural modulus, flexural strength, tensile modulus, and tensile strength. From the testing, the tab with the 50% increased volume consistently yielded the highest results and showed large improvement from the initial tab design. However, the other three tab modifications either showed negative change or slight improvement from the initial tab design. Based on the results of this study, the overflow tab volume is the most beneficial design parameter to adjust.
ContributorsJones, Justin Michael (Author) / Adams, James (Thesis director) / Wamsley, Steven (Committee member) / Computer Science and Engineering Program (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2017-05
Description
The purpose of this honors project is to analyze the difference between different powder separation techniques, and their suitability for my capstone project – ‘Effect of Powder Reuse on DMLS (Direct Metal Laser Sintering) Product Integrity’. Due to the nature of my capstone project, my group needs to characterize foreign contaminants in IN 718 (Ni-based superalloy) powder with a mean diameter around 40um. In order to clearly analyze the contaminants and recycle useful IN 718 powders, powder separation is favorable since the filtered samples will be much easier to characterize rather than inspect all the powders at once under microscope. By conducting literature review, I found that powder separation is commonly used in Geology, and Chemistry department. To screen which combination of techniques could be the best for my project, I have consulted several research specialists, obtained adequate knowledge about powder separation. Accordingly, I will summarize the pros and cons of each method with regard the specific project that I am working on, and further explore the impacts of each method under economical, societal, and environmental considerations. Several powder separation techniques will be discussed in details in the following sections, including water elutriation, settling column, magnetic separation and centrifugation. In addition to these methods, sieving, water tabling and panning will be briefly introduced. After detailed comparison, I found that water elutriation is the most efficient way to purity IN718 powder for reuse purpose, and recovery rate is as high as 70%, which could result in a significant reduction in the manufacturing cost for Honeywell since currently Honeywell only use virgin powders to build parts, and 90% of the leftover powders are discarded.
ContributorsLuo, Zheyu (Author) / Adams, James (Thesis director) / Tasooji, Amaneh (Committee member) / Materials Science and Engineering Program (Contributor) / School of Sustainability (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
Honeywell is currently extending the reach of additive manufacturing (AM) in its product line and expects to produce as much as 40% of its inventory through AM in five years. Additive manufacturing itself is expected to grow into a $3.1 billion dollar industry in the next 5 to 10 years. Reusing IN 718 powder, a nickel-based super alloy metal powder, is an ideal option to reduce costs as well as reduce waste because it can be used with additive manufacturing, but the main obstacles are lack of procedure standardization and product quality assurances from this process. The goal of the capstone project, "Effect of Powder Reuse on DMLS (Direct Metal Laser Sintering) Product Integrity," is to create a powder characterization protocol in order to determine if the IN 718 powder can be reused and what effect the IN 718 reused powder has on the mechanical properties of the products Honeywell fabricates. To provide context and impact of this capstone project, this paper serves to identify the benefits of AM for Honeywell and the cost effectiveness of reusing the powder versus using virgin powder every time. It was found that Honeywell's investment in AM is due to the cost effectiveness of AM, versatility in product design, and to ensure Honeywell remains competitive in the future. In terms of reducing expenses, reusing powder enables costs to be approximately 45% less than using virgin powder. With these key pieces of information, the motivations for this capstone project are understood to a fuller and more profound degree.
ContributorsQuigley, Elizabeth (Co-author) / Luo, Zheyu (Co-author) / Murella, Anoosha (Co-author) / Lee, Wey Lyn (Co-author) / Adams, James (Thesis director) / Tasooji, Amaneh (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
The vastly growing field of supercomputing is in dire need of a new measurement system to optimize JMRAM (Josephson junction magnetoresistive random access memory) devices. To effectively measure these devices, an ultra-low-noise, low cost cryogenic dipping probe with a dynamic voltage range is required. This dipping probe has been designed by ASU with <100 nVp-p noise, <10 nV offsets, 10 pV to 16 mV voltage range, and negligible thermoelectric drift. There is currently no other research group or company that can currently match both these low noise levels and wide voltage range. Two different dipping probes can be created with these specifications: one for high-use applications and one for low-use applications. The only difference between these probes is the outer shell; the high-use application probe has a shell made of G-10 fiberglass for a higher price, and the low-use application probe has a shell made of AISI 310 steel for a lower price. Both types of probes can be assembled in less than 8 hours for less than $2,500, requiring only soldering expertise. The low cost and short time to create these probes makes wide profit margins possible. The market for these cryogenic dipping probes is currently untapped, as most research groups and companies that use these probes build their own, which allows for rapid business growth. These potential consumers can be easily reached by marketing these probes at superconducting conferences. After several years of selling >50 probes, mass production can easily become possible by hiring several technicians, and still maintaining wide profit margins.
ContributorsHudson, Brooke Ashley (Author) / Adams, James (Thesis director) / Anwar, Shahriar (Committee member) / Materials Science and Engineering Program (Contributor) / W. P. Carey School of Business (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
Building construction, design and maintenance is a sector of engineering where improved efficiency will have immense impacts on resource consumption and environmental health. This research closely examines the Leadership in Environment and Energy Design (LEED) rating system and the International Green Construction Code (IgCC). The IgCC is a model code, written with the same structure as many building codes. It is a standard that can be enforced if a city's government decides to adopt it. When IgCC is enforced, the buildings either meet all of the requirements set forth in the document or it fails to meet the code standards. The LEED Rating System, on the other hand, is not a building code. LEED certified buildings are built according to the standards of their local jurisdiction and in addition to that, building owners can chose to pursue a LEED certification. This is a rating system that awards points based on the sustainable measures achieved by a building. A comparison of these green building systems highlights their accomplishments in terms of reduced electricity usage, usage of low-impact materials, indoor environmental quality and other innovative features. It was determined that in general IgCC is more holistic, stringent approach to green building. At the same time the LEED rating system a wider variety of green building options. In addition, building data from LEED certified buildings was complied and analyzed to understand important trends. Both of these methods are progressing towards low-impact, efficient infrastructure and a side-by-side comparison, as done in this research, shed light on the strengths and weaknesses of each method, allowing for future improvements.
ContributorsCampbell, Kaleigh Ruth (Author) / Chong, Oswald (Thesis director) / Parrish, Kristen (Committee member) / Civil, Environmental and Sustainable Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
How can we change what it means to be a human? Products can be used that will allow for near-instantaneous communication with one’s friends and family wherever they are: and the newest devices do not have to be even carried around, as they can be worn instead. Wearable electronics are quickly becoming very popular, with 232.0 million wearable devices sold in 2015. This report provides an overview of current and developing wearable devices, investigates the characteristics of the average buyer for these different types of devices. Finally, marketing strategies are suggested. This work was completed in conjunction with a capstone project with Intel, where three objectives were achieved: First, a universal strain tester that could strain samples cyclically in a manner similar to the body was designed. This equipment was especially designed to be flexible in the testing conditions it could be exposed to, so samples could be tested at elevated temperatures or even underwater. Next, dogbone shaped samples for the testing of Young’s Modulus and elongation to failure were produced, and the cut quality of laser, water-jet, and die-cutting was compared in order to select the most defect-free method for reliable testing. Polydimethylsiloxane (PDMS) is a fantastic candidate material for wearable electronics, however there is some discrepancies in the literature—such as from Eleni et. al—about the impact of ultraviolet radiation on the mechanical properties. By conducting accelerated aging tests simulating up to five years exposure to the sun, it was determined that ultraviolet-induced cross-linking of the polymer chains does occur, leading to severe embrittlement (strain to failure reduced from 3.27 to 0.06 in some cases, reduction to approximately 0.21 on average). As simulated tests of possible usage conditions required strains of at least 0.50-0.70, a variety of solutions were suggested to reduce this embrittlement. This project can lead to standardization of wearables electronics testing methods for more reliable predictions about the device behavior, whether that device is a simple pedometer or something that allows the visually impaired to “see”, such as Toyota’s Blaid.
ContributorsNiebroski, Alexander Wayne (Author) / Adams, James (Thesis director) / Anwar, Shahriar (Committee member) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
The work for this thesis was done in conjunction to that of my capstone project, which focused on understanding the effects of powder re-use on products built via Direct Metal Laser Sintering (DMLS), a specific additive manufacturing (AM) technique where powder particles are sintered together to form final parts. Honeywell Aerospace helped support this research by providing materials and mentorship; this work will play a key role in their decision to implement DMLS and other AM methods on a larger scale. Whereas the capstone focuses on the technical details of constructing characterization equipment, analyzing data, and formulating a concluding recommendation on whether the powder can be re-used, the thesis attempts to put this body of work in its greater context, surveying the economic and environmental effects of additive manufacturing technologies with a slant towards the aerospace industry. Shifts in the supply chain with aircraft parts and how this affects costs are explored, as well as how the quality and reliability of additively manufactured parts differs from their traditionally manufactured counterparts and the effects of this on related industries and purchasers.
ContributorsMurella, Anoosha Sainagaki (Author) / Adams, James (Thesis director) / Tasooji, Amaneh (Committee member) / Materials Science and Engineering Program (Contributor) / School of Molecular Sciences (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05
Description
This paper describes the research done to quantify the relationship between external air temperature and energy consumption and internal air temperature and energy consumption. The study was conducted on a LEED Gold certified building, College Avenue Commons, located on Arizona State University's Tempe campus. It includes information on the background of previous studies in the area, some that agree with the research hypotheses and some that take a different path. Real-time data was collected hourly for energy consumption and external air temperature. Intermittent internal air temperature was collected by undergraduate researcher, Charles Banke. Regression analysis was used to prove two research hypotheses. The authors found no correlation between external air temperature and energy consumption, nor did they find a relationship between internal air temperature and energy consumption. This paper also includes recommendations for future work to improve the study.
ContributorsBanke, Charles Michael (Author) / Chong, Oswald (Thesis director) / Parrish, Kristen (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
The Chinese Construction Industry has grown to be one of the largest construction markets in the world within the last 10 years. The size of the Chinese Construction Industry is on par with many developed nations, despite it being a developing country. Despite its rapid growth, the productivity and profitability of the Chinese Construction Industry is low compared to similar sized construction industries (United States, United Kingdom, etc.). In addition to the low efficiency of the Chinese Construction Industry, there is minimal documentation available showing the performance of the Chinese Construction Industry (projects completed on time, on budget, and customer satisfaction ratings).
The purpose of this research is to investigate potential solutions that could address the poor efficiency and performance of the Chinese Construction Industry. This research is divided into three phases; first, a literature review to identify countries that have similar construction industries to the Chinese Construction Industry. The second phase is to compare the risks and identify solutions that are proposed to increase the performance of similar construction industries and the Chinese Construction Industry. The third phase is to create a survey from the literature-based information to validate the concepts with the Chinese Construction Industry professionals and stakeholders.
The purpose of this research is to investigate potential solutions that could address the poor efficiency and performance of the Chinese Construction Industry. This research is divided into three phases; first, a literature review to identify countries that have similar construction industries to the Chinese Construction Industry. The second phase is to compare the risks and identify solutions that are proposed to increase the performance of similar construction industries and the Chinese Construction Industry. The third phase is to create a survey from the literature-based information to validate the concepts with the Chinese Construction Industry professionals and stakeholders.
ContributorsChen, Yutian (Author) / Chong, Oswald (Thesis advisor) / Kashiwagi, Dean T. (Committee member) / Badger, Willliam (Committee member) / Arizona State University (Publisher)
Created2020
Description
Organic light-emitting diodes (OLEDs) have been successfully implemented in various display applications owing to rapid advancements in material design and device architecture. Their success in the display industry has ignited a rising interest in applying OLEDs for solid-state lighting applications through the development of white OLEDs (WOLEDs). However, to enter the market as a serious competitor, WOLEDs must achieve excellent color quality, high external quantum efficiency (EQE) as well as a long operational lifetime. In this research, novel materials and device architectures were explored to improve the performance of single-stack WOLEDs. A new Pt-based phosphorescent emitter, Pt2O2-p2m, was examined as a single emissive emitter for the development of a stable and efficient single-doped WOLED. A bilayer structure was employed to balance the charges carriers within the emissive layer resulting in low efficiency roll-off at high brightness, realizing a peak EQE of 21.5% and EQEs of 20% at 1000 cd m-2 and 15.3% at 7592 cd m-2. A novel phosphorescent/fluorescent, or hybrid, WOLED device architecture was also proposed. To gather a thorough understanding of blue fluorescent OLEDs prior to its use in a WOLED, a study was conducted to investigate the impact of the material selection on the device performance. The use of an anthracene type host demonstrated an improvement to the operational stability of the blue OLED by reducing the occurrence of degradation events. Additionally, various dopant concentrations and blocking materials revealed vastly different efficiency and lifetime results. Finally, a Pd (II) complex, Pd3O8-Py5, with efficient amber-colored aggregate emission was employed to produce a WOLED. Various host materials were investigated to achieve balanced white emission and the addition of an interlayer composed of a high triplet energy material was used to reduce quenching effects. Through this strategy, a color stable WOLED device with a peak EQE of 45% and an estimated LT95 over 50,000 hours at 1000 cd m-2 was realized. The comprehensive performance of the proposed device architecture competes with WOLED devices that are commercially available and reported within the literature domain, providing a strong foundation to further advance the development of highly efficient and stable single-stack WOLEDs.
ContributorsAmeri, Lydia (Author) / Li, Jian (Thesis advisor) / Adams, James (Committee member) / Alford, Terry (Committee member) / Arizona State University (Publisher)
Created2022