My STEP Signature Project was a research project through the Ohio State University that focused on Centrifugal Nuclear Thermal Propulsion. I worked as part of a team that designed and fabricated the engine testing structure. My main task was to design a filter attachment that would protect our measuring equipment from any harmful components in the exhaust. Over the two month period, I learned about design, manufacturing, and gained incredibly valuable research and development experience.
Before engaging with this project, I had participated in two other research projects, but neither offered this level of freedom in the design experience. Initially, I found myself struggling to find solutions to the problem of how to actually filter the exhaust, as I was approaching it from an academic perspective. I felt as if there was one right answer that I would be able to find in a textbook somewhere. This idea was unproductive however and I quickly realized that I needed to reframe the ‘problem – solution’ method in a more creative way. If I was able to come up with an idea first, I could then use my academic resources to prove the ideas value and improve its effectiveness.
The first couple ideas that I had were too expensive, elaborate, and would require extensive testing to validate. With a two month window and a short manufacturing timeline, these ideas needed to be improved. During this time, we had weekly meetings where each member of the group would share their progress and present any problems they had run into during their work. I found these sessions to be quite inspiring, as I got to listen and contribute to fascinating conversations. It was in one of these meetings where, after a discussing with my mentor and a few other members of the research group, I found an idea that would work: lowering the temperature of the filtering assembly in order to freeze and catch any harmful exhaust components.
Once I had settled on an initial idea, I once again reached out to my mentor in order to validate the idea and underlying physics. Once I had approval I started modeling the filter using SolidWorks, a 3D modeling software provided by OSU. I created 4 models with different filter geometries in order to test which would work best. I also created 2 models of the piping that would connect the filter to the rest of the assembly. After completing the initial modeling, I once again reached out to my mentor in order to verify the geometries. We performed a handful of heat transfer calculations in order to determine operating temperatures and adjusted some values of the models.
With the models completed, I moved to test them using ANSYS Fluent, a CFD software provided by OSU. This process was plagued with setbacks however, as after I had spent a few days learning the software, my access was revoked. While trying to resolve this issue, my access to the SolidWorks files I had previously made was also revoked. In total, these issues took about a week to resolve and set my timeline back significantly. Despite this, a final geometry was selected for the filter.
Because of the issues described previously, as of the writing of this reflection, the filter has not been printed/assembled. However, the plan still remains to manufacture and implement the filter into the engine system. Looking forward, I plan to continue contributing to this project even as my role/tasks change. Overall I have found this experience to be incredibly rewarding. From a networking standpoint I have developed relationships with the entire 7+ person team and gained valuable research and development experience. I have also found a new sense of confidence in my academic and occupational capabilities as even though I had a team to support me, I was able to complete this major developmental project independently. I believe I am becoming a more competitive candidate for future work/research opportunities as I now have more experience and insight to offer.
Isometric view of the filter I designed.
Cut out view of the filter I designed.