The standard for hybrid fuel grains is Hydroxyl-terminated polybutadiene (HTPB). With the advances in additive manufacturing, the promise of 3D printed fuel grains has become a possibility. Yet, 3D printed grains do not have as good of a regression rate as the casted HTPB grains. However, with 3D printing, the core of these grains can be printed to maximize surface area in contact with the oxidizer. The goal of this research is to print hybrid rocket fuel grains with various core geometries and test them on a small-scale hybrid test stand. While the hot fires are still under testing at the time of this abstract, the manufacturing posed an interesting outcome, being more time intensive than expected, contradicting the initial hypothesis of faster manufacturing. Future endeavors will continue research into the cores of the 3D printed grains, possible multi-material made grains and creating core structures for HTPB grains from 3D printed materials.

Characterization of particulate process and product design is a difficult field because of the unique bulk properties and behaviors of particles that differ from gasses and liquids. The purpose of this research is to develop an equation to relate the angle of repose and flowability, the ability of the particle to flow as it pertains to particulate processes and product design. This research is important in multiple industries such as pharmaceuticals and food processes.

Plastics make up a large proportion of solid waste that ends up in landfills and pollute ecosystems, and do not readily decompose. Composites from fungus mycelium are a recent and promising alternative to replace plastics. Mycelium is the root-like fibers from fungi that grow underground. When fed with woody biomass, the mycelium becomes a dense mass. From there, the mycelium is placed in mold to take its shape and grow. Once the growth process is done, the mycelium is baked to end the growth, thus making a mycelium brick. The woody biomass fed into the mycelium can include materials such as sawdust and pistachio shells, which are all cheap feedstock. In comparison to plastics, mycelium bricks are mostly biodegradable and eco-friendly. Mycelium bricks are resistant to water, fire, and mold and are also lightweight, sustainable, and affordable. Mycelium based materials are a viable option to replace less eco-friendly materials. This project aims to explore growth factors of mycelium and incorporate nanomaterials into mycelium bricks to achieve strong and sustainable materials, specifically for packaging materials. The purpose of integrating nanomaterials into mycelium bricks is to add further functionality such as conductivity, and to enhance properties such as mechanical strength.

In order to produce efficient reverse osmosis membranes, it is necessary to minimize the effects of outside factors on the membrane surface that can reduce the flux of water through the membrane. One such problem is fouling. Fouling happens when particles are deposited on the membrane surface, blocking water flow through the membrane. Over time, the collection of foulants will prevent water through the membrane, increasing the amount of energy required in the system. Microgel, a heat-responsive colloidal gel, shows promise as an anti-foulant coating as it possesses functional groups similar to the membrane and compatible with common foulants and changes volume due to temperature differences. By coating the membrane with the microgel, foulants will attach to the functional groups of the microgel instead of those of the membrane Our hypothesis is that the change in volume of the microgel with different temperatures will help reduce and remove foulants. By functionalizing the surface of the membrane and the microgel, the microgel can covalently bond to the membrane surface and avoid detachment under reverse osmosis conditions. Microgel-coated reverse osmosis membranes have been fluorescently fouled to measure the decrease in foulants with heated crossflow under fluorescent microscopy. This process has shown a 50% decrease in fluorescence on the surface of the membrane indicating a decrease in foulants due to the presence of microgel. Under cross-flow conditions with a low flow rate, the microgel remains on the functionalized membrane for 8 hours with similar anti-fouling performance as the dip-coating process.

Obtaining access to clean water is a global problem that is becoming more important with increasing population and advancing technology. Desalination through reverse osmosis (RO) is a promising technology takes advantage of the global supply of saline water to augment its limited freshwater reservoirs. To increase RO membrane performance, the feedwater is pretreated to take any excess pollutants out before the desalination. These pretreatment membranes are susceptible to fouling, which reduces efficiency and drives up costs of the overall process. Increasing the hydrophilicity of these membranes would reduce fouling, and electrospinning is a production method of pretreatment membranes with the capability to control hydrophilicity. This work explores how the composition of electrospun fibrous membranes containing blends of hydrophilic and hydrophobic polymers affects membrane characteristics such as wettability as well as filtration performance. Nonwoven, nanoscale membranes were prepared using electrospinning with a targeted application of pretreatment in water filtration. Using a rotating collector, electrospun mats of hydrophobic poly(vinyl chloride) (PVC) and hydrophilic poly(vinyl alcohol) (PVA) were simultaneously deposited from separate polymer solutions, and their polymer compositions were then characterized using Fourier Transform Infrared (FTIR) spectra. The data did not reveal a reliable correlation established between experimental control variables like flow rate and membrane composition. However, when the membranes' hydrophilicity was analyzed using static water contact angle measurements, a trend between PVA content and hydrophilicity was seen. This shows that the hypothesis of increasing PVA content to increase hydrophilicity is reliable, but with the current experimental design the PVA content is not controllable. Therefore, the primary future work is making a new experimental setup that will be able to better control membrane composition. Filtration studies to test for fouling and size exclusion will be performed once this control is obtained.

The story of graphene truly began in what was simply a stub in the journal Physical Review not two years after the end of World War II. In 1947, McGill University physicist P.R. Wallace authored “The Band Theory of Graphite” and attempted to develop a foundation on which the structure-property relationship of graphite could be explored; he calculates the number of free electrons and conductivity of what he describes as “a single hexagonal layer” and “suppos[es] that conduction takes place only in layers” in bulk graphite to predict wave functions, energies at specific atomic sites in the hexagonal lattice, and energy contours using a tight binding approximation for a hypothesized version of what we now call ‘armchair-style’ graphene. While Wallace was the first to explore the band structure and Brillouin Zones of single-layer graphite, the concept of two-dimensional materials was not new. In fact, for years, it was dismissed as a thermodynamic impossibility.

Everything seemed poised against any proposed physical and experimental stability of a structure like graphene. “Thermodynamically impossible”– a not uncommon shutdown to proposed novel physical or chemical concepts– was once used to describe the entire field of proposed two-dimensional crystals functioning separately from a three-dimensional base or crystalline structure. Rudolf Peierls and Lev Davoidovich Landau, both very accomplished physicists respectively known for the Manhattan Project and for developing a mathematical theory of helium superfluidity, rejected the possibility of isolated monolayer to few-layered crystal lattices. Their reasoning was that diverging thermodynamic-based crystal lattice fluctuations would render the material unstable regardless of controlled temperature. This logic is flawed, but not necessarily inaccurate– diamond, for instance, is thermodynamically metastable at room temperature and pressure in that there exists a slow (i.e. slow on the scale of millions of years) but continuous transformation to graphite. However, this logic was used to support an explanation of thermodynamic impossibility that was provided for graphene’s lack of isolation as late as 1979 by Cornell solid-state physicist Nathaniel David Mermin. These physicists’ claims had clear and consistent grounding in experimental data: as thin films become thinner, there exists a trend of a decreasing melting temperature and increasing instability that renders the films into islands at somewhere around ten to twenty atomic layers. This is driven by the thermodynamically-favorable minimization of surface energy.

Graphene has the ability to advance many common fields, including: membranes, composites and coatings, energy, and electronics. For membranes, graphene will be used as a filter for desalination plants which will reduce the cost of desalination and greatly increase water security in developing countries. For composites and coatings, graphene's strength, flexibility, and lightweight will be instrumental in producing the next generation of athletic wear and sports equipment. Graphene's use in energy comes from its theorized ability to charge a phone battery in seconds or an electric car in minutes. Finally, for electronics, graphene will be used to create faster transistors, flexible electronics, and fully integrated wearable technology.

This is a two-part thesis, completed in conjunction with my Materials Science and Engineering Capstone Project. The first part involves the design and testing of cold-extruded high-density polyethylene for student oboe reeds. The goal of this section was to create a longer-lasting reed that produces a similar sound to a cane reed, has less variation in quality, and costs less per year than cane reeds. For low-income students in particular, the cost of purchasing cane oboe reeds ($500-$2,000 per year) is simply not feasible. This project was designed to allow oboe to be a more affordable option for all students. Money should not be a factor that limits whether or a not a child is able to explore their interests. The process used to create the synthetic reed prototype involves cold-extrusion of high-density polyethylene in order to induce orientation in the polymer to replicate the uniaxial orientation of fibrous cane. After successful cold-extrusion of a high-density polyethylene (HDPE) cylinder, the sample was made into a reed by following standard reedmaking procedures. Then, the HDPE reed and a cane reed were quantitatively tested for various qualities, including flexural modulus, hardness, and free vibration frequency. The results from the design project are promising and show a successful proof of concept. The first prototype of an oriented HDPE reed demonstrates characteristics of a cane reed. The areas that need the most improvement are the flexural modulus and the stability of the higher overtones, but these areas can be improved with further development of the cold-extrusion process. The second part of this thesis is a survey and analysis focusing on the qualitative comparison of synthetic and cane oboe reeds. The study can be used in the future to refine the design of synthetic reeds, more specifically the cold-extruded high-density polyethylene student oboe reed I designed, to best replicate a cane reed. Rather than approaching this study from a purely engineering mindset, I brought in my own experience as an oboist. Therefore, the opinions of oboists who have a wide range of experience are considered in the survey. A panel of five oboists participated in the survey. They provided their opinion on various aspects of the five reeds, including vibrancy, response, stability, resistance, tone, and overall quality. Each of these metrics are rated on a scale from one to five, from unacceptable to performance quality. According to the survey, a participant's personal, hand-made cane reed is overall the most preferred option. My prototype HDPE student reed must be improved in many areas in order to rank near the other four reeds. However, its vibrancy and resistance already rival that of a Jones student reed. As this is just the first prototype, that is a significant accomplishment. With further refinement of the cold-extrusion and reedmaking method, the other areas of the HDPE reed may be improved, and the reed may eventually compete with the existing synthetic and cane reeds on the market.

This study analyzes mechanical properties of additively manufactured plastic materials produced in a conventional 3D printer. This topic has generally been studied in controlled scenarios, and this study aims to reflect the properties seen by consumers. Layered prints are inherently anisotropic due to the direction of the layers and associated weaknesses or stress concentrators. Thus, the ultimate strength and elastic modulus of plastic specimens produced using default settings are compared based on print orientation angle, and trends are observed. When a specimen is parallel to the build plate, it tends to have ultimate strength and elastic modulus near the published bulk values of 13.2MPa and 404-710MPa, but these values tend to decrease as the print angle increases.

Aerogels are among the best known thermally insulating materials due their high porosities (>90%). This, in conjunction with their high transparency make them ideal candidates for highly insulating window coatings. However, current state of the art techniques involve time-consuming drying steps and poor mechanical robustness, severely limiting their wide-scale adaptation. By using a dry aerosol impaction process, synthesizing nanoparticles in a plasma, upstream of a slit-shaped nozzle and impacting these particles onto a substrate below, a novel way for producing mesoporous silica aerogels is shown. This removes the need for solution-based processing, improving the potential for high throughput. Thick (~100um), 90% mesoporous silica has been characterized showing low effective thermal conductivity (~0.02 W/mK) and high transparency (>90%). The morphology of these coatings were analyzed showing tight pore distributions. Film adhesion and stress have shown themselves to be major hurdles during the development of these coatings and will be the focus of future work.