Here I am using a wrench to tighten and secure the spray coater nozzel mount
Author: Shae Threlfall | Major: Mechanical Engineering | Semester: Spring 2024
The summer after my freshman year in 2023, I completed a Research Experience Undergrad (REU) at the University of Arkansas in mechanical engineering where I chose to work with my mentor Dr. Zou in her Nanomaterials and Tribology Lab under the guidance of Dr. Afshar Mohajer. Throughout the summer, I developed a miniature conveyor belt to test a low-friction coating. I was even able to present this research in the fall of 2023 at the Arkansas capitol with help from the honors college. After completing this, the lab hired me to do research as a part-time mechanical engineering student, continuing the project by fine-tuning the device that will spray the low-friction coating (called a spray coater) which has been my main focus for the Spring 2024 grant period. Even after I complete the spray coater modifications, I plan to continue on the same project, using the knowledge I have gained so far to see the rest of the project through.
Supply chain industries like those involving package distribution, e-commerce, and manufacturing use large conveyor systems, where the costs due to friction are astoundingly high. This loss is illustrated in the figure to the right showing most of the extra energy consumption is a result of friction. The transformative potential of nanoscience provides a way to address these issues, using coatings to pave the way for new ideas, and reducing both the monetary and environmental burdens associated with friction. Solid lubricants, or coatings, specialize in lowering the coefficient of friction between the metal and non-metal sliding surfaces like those in conveyors. Our coating is made of graphite, a common carbon-based solid-lubricant material more environmentally friendly than typical oil-based lubricants. Crucially, this work stands as a pivotal contribution to a broader NSF project committed to overcoming the challenges in graphite coating commercialization. By advancing our understanding and implementation of nanoscience in this context, we aspire to not only transform the dynamics of conveyor technology but also to catalyze positive change within the broader landscape of supply chain sustainability.
Since my lab is developing this coating, they still need a way to test its performance, which is where I come in. By creating industry-accurate models like the miniature conveyor belt and spray coater, we can test how the coating will act outside of a perfect lab setting. During the spring grant period, my accomplishments on the spray coater have ranged from first getting it operational, then improving user experience, and finally optimizing the pressure and nozzle to get an ideal, uniform spray. It was a bit challenging at first, as I did not realize how much electrical work would be involved in this process, but researching this was vital in understanding how the spray coater works, as it performs similarly to a vertical CNC machine to spray any liquid onto a flat surface. These tests have mostly been carried out with colored water, which is close in performance to the adhesive the lab uses for our coating. In the future, I will test different pressures, flow rates, spray distances, and materials to get the optimal coating for both the graphite and the adhesive.
Because of this project, I gained vital knowledge in lab technology, machining, computer-aided design, and design of experiments. After starting in the lab, I did not know how much my past skills in robotics, and even art were helpful in a research setting. It helped me realize how much I enjoy working on a team, even if we may not be working on the same projects, my best accomplishments always came from brainstorming with my teammates. I am extremely grateful to my team and the honors college for making this all possible and helping to turn an idea into a real-life experience for me.