Materials Selection and Design Analysis Coffee Maker

MATE 110 Introduction to Materials Engineering Design

Freshman Year (11/30/12)
Jonas Zhang
OBJECTIVE
The purpose of this project is to analyze a product by working backwards
(i.e. taking it apart) to find out how it works and what it is made of.
Assessed the application and user needs in order to better understand the
design (i.e. simple, few mechanical parts, easy to clean, robust).
Performed an elementary life cycle analysis on recyclability of the materials
and various plastic processing techniques.
Learned to use a portable x-ray fluorescence
analyzer to characterize specific materials.
Gained experience using SolidWorks to
model 3D parts and dimension 2D drawings.
Designed a process flowsheet to visualize
how individual parts fit into the big picture.
Applied technical writing skills
to build a strong foundation in writing
technical reports.

RESULTS
Majority of polymer components contains blends of plastic #6 and #7 using
injection molding techniques for mass production.
Total of 6 types of plastics that can be recycled, along with reusable copper
and aluminum components.
Majority of metallic components consist of aluminum and aluminum alloys
due to necessary high heat conductivity; made using fabrication techniques
such as stamping, rolling, and casting.
Resistive heating coil uses a thyristor and transistors fit in a small
compartment to provide a simple and reliable heating unit.
Aluminum wires alloyed with 5% copper have a resistance of 0.4 ,
compared to heating coil with 22.5
Since conductivity in semiconductors rises as temperature increases,
thyristor doubles as a heat sink and a transistor.

PROCEDURE
Take preliminary measurements of the coffee-maker and record
observations/photos of how it was put together.
Disassemble the device and take dimensions of each component in order
to create a full-scale model of the coffee-maker in SolidWorks.
Use the XRF gun to classify each component of the device and identify its
relevant processing technique.
Analyze material and waste streams
associated with constructing the device.
Investigate functions of each individual
component and the necessary electrical
circuitry that powers them.
Evaluate user needs and how to improve
upon the design in future iterations.
Reassemble the coffee-maker using prior
observations and CAD models.

ANALYSIS
Even a simple household appliance is thoroughly engineered with specific
materials in mind to achieve certain properties.
European manufacturers are looking for ways to make coffee makers out of
one plastic blend in order to reduce processing costs and increase
recyclability.
Simple can be better in terms of
reliability and robustness.
Some components lack part numbers
on purpose as part of their
planned obsolescense.
Plastic blends allow manufacturers
to achieve necessary properties
lacking in conventional polymers.

Multidisciplinary Service Learning Project

MATE 130 Introduction to Materials Engineering Design III
Freshman Year (6/13/13)
Jonas Zhang
OBJECTIVE
The purpose of this project is to work collaboratively with the organization,
The Ranch SLO, in order to design a certain set of tools and facilities that
would help their community economically and socially.
The Ranch SLO is a community-driven endeavor that aims to foster and
empower special needs persons through a fully functional crop bearing
ranch.
Collected ideographic data through observation and communication with
the clients in order to determine critical and subcritical projects.
Improved the quality of the soil, reduce soil erosion, and conserve the soil
moisture to optimize efforts of crop production and thus generate larger
amounts of funding that could be used to fund future expansion projects.
Communicated effectively in 6 subgroups totaling 36 students and recruit
additional campus organizations through an extensive marketing campaign
to bring The Ranch SLOs mission into the spotlight and ensure lasting
success.

RESULTS
Recruited over one hundred Cal Poly orientation training leaders to
volunteer at The Ranch SLO for their annual hoe-down event.
Connected numerous local high schools as well as college organizations to
The Ranch SLOs public workdays and implemented a system of sending
new volunteers every month.
Successfully designed and fabricated a
vegetation ground cover, wind and frost crop
protection system, functional cart with replaceable parts, and several refurbished planter beds.
Met client needs enthusiastically and efficiently
in multidisciplinary teams of 6.
Completed tasks using ingenuity and came in
under-budget while delivering a proudly
engineered product.

PROCEDURE
Identify critical project areas by communicating with project managers and
surveying the ranch in operation.
Obtain contact information of campus organizations that would like to help
in order to obtain assistance when necessary and foster a long-term
relationship with these groups and The Ranch SLO.
Implement a ground cover system by buying bulk seed, spreading it over
tilled soil to be protected from weeds, and installing a ground cover that
helps return nitrogen to the soil
while also killing off weeds.
Design a simple, yet functional
multipurpose cart out of angle iron
and replaceable wooden cart beds
to replace broken wheelbarrows.
Construct watertight wooden
compost bins and planter boxes.

ANALYSIS
A process plan identified several unnecessary waste streams that we
capitalized upon in order to develop improved compost bins and reduce the
amount of future waste generated.
Strategically aligned economic and technical limitations with client needs
by keeping design simple and user-friendly, while structurally sound.
Identifying short-term and long-term outcomes allowed us to prioritize
projects while also incorporating longevity into our project constraints.
Short and long-term goals were met, along with
establishing a network of volunteers to address
ongoing needs of The Ranch SLO.
Incorporating materials design in a real world
situation enabled us to adapt to unexpected
roadblocks and learn how to bring ideas on
paper to reality.

Investigation of Solidification Rates during Bismuth Crystal Growth

MATE 225 Materials Laboratory II
Sophomore Year (1/27/14)
Jonas Zhang
OBJECTIVE
The purpose of this project is to grow bismuth crystals firsthand from a melt
using household tools, and to further explain the science behind crystal
solidification and effects of processing on final microstructure.
Gained experience through repetition of trial and error methods on multiple
hypotheses regarding the influential factors of solidification rates.
Identified and communicated common mistakes that may occur with a goal
in mind of producing large, multi-faceted bismuth crystals.
Established a safety protocol and emergency operating procedure when
dealing with multiple induction heaters and butane jet torches in close
proximity to each other.
Conducted two primary trials to draw preliminary conclusions and alter
additional trials to reflect and build on prior results.
Classified various bismuth crystal formations using observation and by
comparing process parameters with other teams.

RESULTS
The first trial produced smaller crystals along the bottom and sides of the
crucible where the bismuth had hardened into a shell.
There was evidence of crystals that had formed ledges that increased in
width as they rose, otherwise known as hopper crystals.
The crystals were iridescent with a blue and purple metallic tinge while the
edges of the bismuth shell were a golden and silvery gray color.
The second trial resulted in an anomaly
whereupon pouring the crucible that was
insulated and air cooled, there was a single
crystal pillar measuring approximately 8mm in
height while the surrounding area was smooth.
Trial 2 did not produce the same amount of
color and iridescence as trial 1; the crystals
appear to have taken on impurities as
evidenced by a thin layer of slag.

PROCEDURE
Obtain compositional bismuth pellets and melt in a ceramic crucible using
an even heat source such as a portable electric crucible heater.
Continuously remove oxide layer known as slag by skimming the melt with
a pair of tongs.
Alternate between selective heating using a jet torch to slow down the
solidification rate of crystals and applying no heat, thus allowing time for the
crystals to form.
Once crystals have formed along the walls
of the crucible, also known as the chill zone,
pour out the still molten center to reveal
solidified crystal structures underneath.
Repeat process according to initial
hypotheses including variations in heating
and cooling times, temperature, and
pouring of the melt.

ANALYSIS
The solidification rate of bismuth metal directly affects its unique ability to
form large faceted crystals upon cooling.
A slow cooling rate will allow a more heterogeneous nucleation of growth
and thus form larger, bi-faceted crystals.
In the first trial, cooling the bismuth metal slowly by applying continuous
heat and removing the oxide layer resulted in smaller crystals.
By supplying continual heat and touching the oxide layer on top of the
molten metal, we disrupted the growth of crystals below.
In the second trial, we succeeded in growing a large, faceted crystal by
using a glove as insulation and letting the melt cool on its own.
This resulted in a slow, controlled cooling rate that allowed us to achieve
our desired grain size and heterogeneous structure, but at the cost of
developing a surface oxide layer that dulled the external appearance of
the crystals.

Qualification of the Bi-Sn Binary System in Lead-free Solders Using XRD and DSC
MATE 225 Materials Laboratory II
Sophomore Year (3/10/14)
Jonas Zhang
OBJECTIVE
The purpose of this project is to explore lead solder alternatives, namely
the bismuth-tin (Bi-Sn) alloy system, using XRD and DSC characterization
techniques to analyze solidification rates and optimize alloy compositions.
Produced Bi-Sn alloys by measuring various compositions of bismuth
powders and tin specimens and utilizing Kirkendall diffusion techniques for
substitutional alloying in a melt.
Gained experience using X-ray Diffraction (XRD) and Differential Scanning
Calorimetry (DSC) techniques to verify final alloy compositions
Analyzed phase diagrams of the unique binary systems, and detected
phase transitions in the alloy at quick solidification rates.
Explored two Bi-Sn alloy alternatives: Bi 45 atomic% Sn and Bi 85
atomic% Sn and identify ideal composition for use as a lead-free solder
alternative with low melting point and high solidification rate as criteria.
Compared results to existing lead solders and explained key differences.

RESULTS
The Bi 45 atomic% Sn sample was 31.73% Sn and 68.27% Bi by weight,
resulting in 1.902 grams of Sn and 4.098 grams of Bi.
The Bi 85 atomic% Sn sample was 76.3% Sn and 23.7% Bi by weight,
resulting in 4.578 grams of Sn and 1.422 grams of Bi.
The Bi 45 atomic% Sn reached its eutectic point at 143.1C and reached
the liquidus line where pro-eutectic solid began to form at 170.4C.
The Bi 85 at% Sn reached its eutectic point at 141.5C and reached the
liquidus line at 193.4C.
DSC software produced irregular results for
the Bi-85 atomic% Sn graph, where the
melting temperature is lower than expected
theoretical values.
Bi-45 atomic% Sn theoretical and
experimental value are the same.

PROCEDURE
Calculate weight percentages of atomic % compositions using a baseline of
6 grams of metal per alloy.
Place alloy in a crucible and melt in a furnace at 400C for 15 minutes to
facilitate diffusion of the substitutional alloy.
Section parallel slabs using a diamond wafering blade for characterization.
Use XRD to calculate the Braggs angle and confirm phases (Bi) and (Sn) present in the sample by matching with
a known Bi-Sn phase diagram.
Use DSC to detect heat differences between
the Bi-Sn sample and a reference material
during thermal cycling in order to detect
phase transitions in the alloy.
Determine eutectic temperatures and
solidification rates using thermograms
produced by the software.

ANALYSIS
Old circuit boards and other discarded electronic equipment contain high
amounts of lead solder that may be harmful to us and the environment. As
a result, the use of lead-free alloy solders have become a viable alternative
due to their low melting points and quick solidification rates.
Bi-Sn at the eutectic temperature has a lower melting temperature than PbSn. The eutectic point for Pb-Sn is at 183.8C whereas Bi-Sn is at 139C.
The alloying composition of Bi-45 atomic% Sn has a complete melting point
at 170C. This means that there are compositions of Bi-Sn that have the
same melting point as Pb-Sn.
Pb-Sn solder has a higher eutectic melting point than Bi-Sn. Bi-Sn could
be better in production since it doesnt need to be heated to as high of a
temperature.
One potential drawback is that the solder point could break when the
temperature of the point gets below 13C.

Metallographic Analysis of Annealed vs. Cold-Worked -Brass

MATE 225 Materials Laboratory II
Sophomore Year (4/28/14)
Jonas Zhang
OBJECTIVE
The purpose of this project is to use metallographic analysis to compare
the annealed state of -Brass to an identical cross section of cold-worked
-Brass.
Mastered metallography techniques such as mounting, abrading, polishing,
and etching to produce a scratch-free, reflective surface capable of
revealing crystal defects in the -Brass microstructure.
Performed the annealing process whereby recovery, recrystallization, and
grain growth restores the toughness and ductility of the alloy, but results in
a reduction of strength.
Investigated mechanisms of plastic deformation in ductile alloys such as
cold-working and their quantitative effects on mechanical properties.
Determined optimal amount of cold work to achieve maximum strength
using parameters (Ao-AD)/Ao where Ao represents cross-sectional area
and AD represents depth of the sample.

RESULTS
The polycrystalline grain structure of brass can be clearly seen with
different regions of crystallographic orientations within the grain boundaries.
The parallel bands running across the grains reveal annealing twins that
appear consistently straight as mirror images of the other should be, but
distinct from twins in other grains.
The grain boundaries of the annealed sample can be clearly seen and vary
greatly in size.
The 47.2% cold work -Brass microstructure
revealed elongated grains and high densities of
dislocations between the grain boundaries as a
direct result of cold working.
The grains have become severely elongated in
the direction the sample was rolled through the mill
and the grain boundaries are not as obvious
compared to the annealed sample.

PROCEDURE
Two samples were prepared for -Brass metallography: an annealed
sample and a 47.2% cold-worked sample.
Cold work the sample using a rolling mill several times and section along
the longitudinal direction using an abrasive cutter.
Section the annealed sample along its transverse and cut again
longitudinally to reveal the same cross section as the cold worked sample.
Mount the samples in Bakelite resin and abrade up to 600 grit.
Polish the samples up to 1 using a diamond
abrasive solution and etch using a 3% Nital etch.
Briefly polish using a 0.5 solution to remove
the layer of disturbed metal and reveal the high
energy grain boundaries.
Perform metallographic analysis of the -Brass
samples using an optical microscope at 250X.

ANALYSIS
-Brass is composed of entirely a single phase with a composition of 65%
copper and 35% zinc by weight.
The large grain size of -Brass accentuates the effects of cold rolling on
the microstructure. Furthermore, the elongation of grains and the
deformation of stacking faults, or twins, in the crystal structure is a clear
sign of cold work.
In the heat treated sample, annealing has caused recrystallization of the
high energy microstructure full of dislocations and deformations. This new
recrystallized grain size is small due to the high density of nucleation sites
in the non-deformed structure.
-Brass is a relatively soft alloy which can be easily cold worked to
increase its strength. Cold working can increase the strength of the alloy
from 300 MPa in the annealed state to 525 MPa in the cold worked state,
although the ductility is then reduced from 68% to 7% elongation.

Optimizing Materials Selection of a High Performance Bicycle Frame

MATE 222 Materials Selection Life Cycle
Sophomore Year (5/10/14)
Jonas Zhang
OBJECTIVE
The purpose of this project is to find one material system to meet the
criteria and constraints set by our user for a high performance bike frame.
Performed sensitivity analysis of weighting factors that best reflect user
needs and use Saatys Method to find the closest fit material.
Optimized design by minimizing mass, cost, and environmental impact,
while maximizing durability and functionality.
Set a baseline for materials selection such as a minimum fracture
toughness of 15 MPA and high corrosion resistance.
Prepared a full cost accounting report of potential materials in order to
assess embodied energy in terms of environmental impact.
Used materials selection databases to generate trade-off curves comparing
various mechanical and material properties.
Researched titanium and carbon-fiber processing techniques that give
those materials unique capabilities such as single-butted tubing with a high
strength-to-weight ratio, as compared to heavier triple-butted tubing.

RESULTS
The three performance indices are

PROCEDURE
The five most suitable materials were initially selected using the CES
Edupack materials database.
Assign weighting factors to criteria that accurately reflect the users needs
while also separating needs from wants during the selection process.
Evaluate multiple, distinct categories to ensure proper consideration of a
wide range of materials.
Generate graphs to visualize potential
materials using three performance
indices that account for embodied
energy, density, and cost.
Normalize weighting factors to conduct
a Weighted Property Index analysis on
material property values from the best
candidate from each category.

ANALYSIS
, for density, cost, and

embodied energy respectively.

Since density and cost are the two most heavily weighted factors, this
graph in the previous section is more useful than the others. Upperrightmost materials as most desirable.
Normalizing material values results in carbon fiber being the preferred
candidate for a bike frame. Steel and fiberglass followed because of
cheaper material costs and lower embodied energy. Aluminum did not
score high as it is expensive and requires a lot of electric power to produce.

A carbon fiber composite was selected as the preferred material for a high
performance bike frame using a WPI and sensitivity analysis.
The perfect bicycle frame material may not align with our goals and our
users needs. Through the use of CES software, engineering constraints,
and material selection indices, a best-fit, ideal material can be determined
from the long list of possible candidates.
The user is willing to pay more for less overall mass of a bike frame, so
density has the greatest weighting factor and dominates the two other
criteria.
Our analysis does not account for geometry and physical design of a bike
frame, since parameters specified that the cross section was circular.
To test sensitivity of our results, we increased and reduced the value of our
primary weighting factor, density, by 20%. These variances did not change
the final order of preference in our selected materials, thus showing that
our WPI analysis results are robust.

Life Cycle Assessment and Full-Cost Accounting of a Reusable Water Bottle

MATE 222 Materials Selection Life Cycle
Sophomore Year (5/27/14)
Jonas Zhang
OBJECTIVE

PROCEDURE

The purpose of this project is to optimize the design of a

reusable water bottle targeted at backpackers and to improve
upon existing designs.
Objectives include low cost, low mass, high UV resistance,
high corrosion resistance to acids and bases, low CO2
footprint, and durability.
Constraints include nontoxicity, excellent impermeability to
water and air, and it must be durable enough to collapse
inwards upon itself.
Used performance indices dependent upon
damage tolerant design and displacement
control as main parameters.
Conducted an energy eco-audit as part of
the full-cost accounting of the
manufacturing life cycle.

Polymer
Exrtrusion

RESULTS
The WPI Analysis reveals high-density polyethylene to be the best fit
material in terms of cost, density, fracture toughness, and fatigue strength.
CES process selection resulting in two possible processing techniques
calendering and polymer extrusion.
Polymer extrusion selected as optimal process due to projected cost
modeling factors.
Eco-audit revealed energy in fabricating the polymer was the highest factor
while the biggest contributor of CO2 emissions was during manufacturing.
Material

FEP
PP
PE

Cost
($/kg)
26.30
2.06
2.77

0.08
1.00
0.74

Densty
kg/m^3
2140.00
904.00
940.00

0.42
1.00
0.96

Fracture Toughness
KIC/E
7.24
1.23
3.21

1.00
0.17
0.44

Fatigue
Strength
MPa
8.00
9.59
17.40

The CES Edupack database supplied a list of possible polymer candidates

limited by tradeoff curves based on cost, density, fracture toughness, and
fatigue strength.
The CES database also aided in process selection of continuous polymer
processing techniques limited by section thicknesses of <1mm.
Use cost modeling to factor in tooling, capital, batch size, utility, etc. to
determine optimal processing technique.
Perform a WPI and Sensitivity analysis on best-fit materials to select the
ideal polymer for the intended application.
Evaluate life cycle of a reusable bottle compared to a plastic water bottle
to determine the
Toolin Capital Mat.
n-dot
environment impact of Processes
g Cost Cost
Util. (m/hr)
C
the product using the
298.00 298000 0.94
72.00 0.5521
eco-audit feature in CES. Calendering

0.46
0.55
1.00

0.65
0.47
0.74

2110.0
0 267000

0.94

90.00

0.4531

ANALYSIS
Objectives such as high UV resistance, high corrosion resistance to acids
and bases, low CO2 footprint, and durability were taken into account during
the sensitivity analysis, leading to the three possible candidates
Fluorinated ethylene propylene (FEP), Polypropylene (PP), and our winner
Polyethylene (PE), specifically high-density polyethylene (HDPE).
To test sensitivity of our results, we increased and reduced the value of our
primary weighting combination, cost and density, by 10%. These variances
did not change the final order of preference in our selected materials, thus
showing that HDPE is the optimal material.
Polymer extrusion verified as the most cost-efficient process using full-cost
accounting of the bottles entire life cycle.
Secondary processes such as joining were identified as possible additional
steps necessary to assemble the bottle.

Fabrication and Testing of Microfluidic Devices with Geometric Variations

MATE 225 Materials Laboratory II
Sophomore Year (6/3/14)
Jonas Zhang
OBJECTIVE
The purpose of this project is to encompass the design, fabrication, and
test of a microfluidic device known as a PDMS chip for use in biomedical
applications.
Designed a 100mm silicon wafer mask using AutoCad, including expected
dimensions of the T-mixer devices based on theoretical flow calculations.
Gained familiarity to cleanroom lab apparatus and standard operating
procedures for equipment such as the argon plasma torch, de-gassing
vacuum chamber, and spin coater.
Developed a safety protocol and receive cleanroom training for working
with chemicals such as photoresist and etchants.
Compared calculated versus measured diffusion rates, flow rates, and
Reynolds numbers at micron levels with a high degree of accuracy.
Communicated test results and findings to improve upon future iterations of
the design and identify sources of error in the fabrication and test process.

RESULTS
The area of flow was measured to be 3 x 10-8 m2 for channels in T-mixers
A and B and 4.5 x 10-8 m2 for T-mixer C.
Since devices A and B had the same flow-rate and cross-sectional area,
the fluid in each had a velocity of 5.567 mm/s while the fluid in T-mixer C
had a velocity of 3.71 mm/s.
The hydraulic diameter was measured to be 1.07 x 10-4 m for T-mixers A
and B and 1.11 x 10-4 m for T-mixer C, resulting in a Reynolds number of
0.596 for T-mixers A and B and 0.412 for T-mixer C.

PROCEDURE
A mask of the PDMS chip was drawn in AutoCAD and printed onto a silicon
wafer.
Pattern the wafer with SU-8 photoresist and pour prepared
Polydimethylsiloxane(PDMS). De-gas in a vacuum before curing in an oven
at 60C for 2 hours.
Cut out the base and channel layers of the T-mixer devices and punch
input and output holes using a 16-gauge needle.
Plasma bond the two layers using an argon plasma torch in a Class 1000
or better cleanroom.
Test the microfluidic devices using
a solution of 6:1 H2O to dye run
through 12 lengths of Tygon tubing
attached at input and output ports.
Conduct mixing using a syringe pump
set at a flow rate of 10 L/min .

ANALYSIS
The T-mixers fabricated in this experiment operate through laminar flow
rather than turbulent flow. Laminar flow is achieved for Reynolds
numbers Re 2000 in non-compressible fluids such as liquids.
The laminar flows observed in the T-mixers result from two parallel streams
that meet at a T-junction and rely solely on diffusion to mix the two fluids.
Mixing appears in the plane of contact between two fluids known as the
interdiffusion zone and strongly depends on features within the device and
the devices geometry.
Diffusive mixing of the two fluids is dependent on the time it takes to mix
and the length of the channel occupied until completely mixed.
Even though the theoretical mixing time for a standard T-mixer can be quite
long, mixing efficiency can be increased by adding in features such as
barriers and zig-zags that produce additional points of perturbations.

Investigation of 3D Printed Orthopedic Casts

MATE 350 Structural Materials Systems
Junior Year (3/17/15)
Jonas Zhang
OBJECTIVE
The purpose of this project is to improve upon the design of two major
aspects of a traditional plaster cast material and shape.
Designed and fabricated an open cell structure cast using 3D printed ABS
using a fused deposition modeling 3D printer and compare its ability to
immobilize movement with a plaster cast.
Tested multiple designs of an ABS printed shell with various geometries
and with the addition of a carbon fiber lay-up.
Designed with constraint in mind described as effective immobilization,
which is considered to be the resistance of a cast to bending under stress.
Produced a benchmark
immobilized wrist using
traditional plaster bandage
methods and compare
properties to printed models.

RESULTS
The ABS open cell design deflected 5.6 degrees whereas the ABS
reinforced cell design only deflected 3.0 degrees.
Out of all 4 designs the 2 carbon fiber composites were the stiffest, each
with an angle of deflection smaller than 2.
The carbon fiber was so much stronger than the ABS that the two different
cell patterns, open and reinforced made almost no difference.
Deflection of the wooden wrist analog
under a 7.5lb load resulted in 2.8
deflection in the traditional plaster,
compared to the highest performing
ABS+Carbon fiber reinforced
design deflection only 0.8.

PROCEDURE
Form a wooden wrist support structure to test effective immobilization of
the cast prototypes.
Two cast designs were made, with the primary design utilizing a tesselated
series of hexagons elongated along the expected axis of bending.
The second design incorporates support structures in the base cells,
sacrificing openness for increased transverse stiffness.
3D-print two of each design as flat surfaces and thermoform to the desired
wrist analog shape using a heat gun.
Perform a carbon fiber hand lay-up over
one sample from each design and once
it has cured, carefully cut out open cells
using a dremel.

ANALYSIS

3D printing composites for a cast could utilize the customizability of rapid

prototyping and the process of 3D scanning to produce perfect fit casts
in a relatively short amount of time.
Plotting the mean deflection of each cast design and material
combination gave a rough comparison of each design.
The carbon fiber casts were found to have a statistically lower deflection
than the three other non-carbon fiber casts, the ABS-only reinforced cell
cast was not significantly different from the plaster cast, and the ABSonly open cell cast was found to have a statistically higher deflection than
the other four casts.
In addition to ANOVA, a 2x2 Full Factorial Analysis was run on the data
to assess the effect of the two factors: cell design and material choice.
Both factors were found to have a statistically significant effect on cast
stiffness, with the addition of carbon fiber having approximately twice the
reducing effect on deflection as the reinforced cell design.

Flexural Testing and Failure Analysis of Glass/Carbon Fiber Reinforced Polymers

MATE 330 Composite Materials Systems
Junior Year (5/22/15)
Jonas Zhang
OBJECTIVE
The purpose of this project is to conduct mechanical tension and
compression testing on pre-fabricated specimens from Zodiac Aerospace.
Performed failure analysis on destructively tested samples to determine
optimal failure modes in the fibers/resins.
Followed the three point bending test proposed in ASTM D-790 was used
to determine the flexural properties of carbon fiber reinforced polymers
(CFRP) and glass fiber reinforced polymers (GFRP).
Utilized standardized test methods with reference to the American Society
for Testing and Materials (ASTM) in order to maintain consistency among
procedures and test specimens.
Calculated and program appropriate test parameters into an Instron
method to obtain maximum displacement and ultimate tensile strength
values.
Plotted results using statistical analysis to extrapolate mean values of the
GFRP and CFRP samples.

RESULTS
The average flexural stress was calculated to be approximately 61.9 ksi
with a standard deviation of 6.17 ksi in the GFRP samples and 60.3 ksi with
a standard deviation of 1.73 ksi for the CFRP samples.
The GFRP samples exhibited a statistically identical slope up until regions
of maximum extension as well as a general tighter fit of data values
compared to the CFRP samples.
Each of the GFRP test specimens failed on the outward tensile surface with
respect to the loading nose, while
all CFRP specimens failed on the
inward, compressive surface.

PROCEDURE
A sufficient span-to-depth ratio of 32:1 was chosen to ensure failure that
occurred in the outer fibers of the specimens was primarily due to the
bending moment at the center.
An intermediary support span of 2 inches was chosen for the three point
bend tests to ensure efficiency and repeatability of tests.
Samples were then loaded under a linear progression of normal force until
a maximum load was achieved at failure. Displacement was also recorded
as max extension by the Instron software.
The CFRP samples were taken from a non-crimp, modified epoxy pre-preg
laminate while the GFRP samples were taken from a 7781-weave, phenolic
pre-preg laminate.

ANALYSIS
The inward curved surface of the test specimen relative to the loading nose
experiences a compressive stress equal and opposite to the tensile stress
generated on the outward side of the test specimen.
Since each of the GFRP samples failed visibly on the tensile face, we can
deduce that the flexural strength of the composite is limited by the tensile
strength of the glass fibers.
In contrast, each of the CFRP samples failed on the compressive face,
indicating that the compressive strength of the carbon fibers is the limiting
factor in flexural strength.
Therefore, we can conclude from our three point bend testing that the
GFRP samples are stronger in compression than tension and vice versa
for the CFRP samples.

Outside Endeavor

Mountain biking has been my favorite way to pass the time outside of labs and
projects here in San Luis Obispo. Cal Poly is lucky to have miles and miles of
singletrack in the surrounding hills and neighboring mountains. Trails I frequently ride
include the Irish Hills, Johnson Ranch (pictured above), West Cuesta, Madonna,
Stenner Creek, and Poly Canyon. I just recently bought a Trek X-Calibur 7 that I enjoy
riding at night after classes with powerful flashlights and fearless friends. It is a surreal
experience to say the least. Mountain biking is a unique sport that allows me to elevate
my interests in engineering, gadgets and modifications, and fitness to a new level.