Here I am using a wrench to tighten and secure the spray coater nozzle mount

Author: Shae Threlfall | Major: Mechanical Engineering | Semester: Fall 2024

My name is Shae Threlfall, and I am an honors mechanical engineering student at the University of Arkansas. Under the mentorship of Dr. Min Zou in the Department of Mechanical Engineering, I have significantly contributed to a project dedicated to improving the efficiency of conveyor systems. Throughout Spring and Fall of 2024, I have created vital testing methods and machines to aid in this research. I first joined Dr. Zou’s lab in a Research Experience for Undergraduates (REU) program in the summer of 2023 where I improved a mini conveyor tester to test low-friction coatings. After the REU ended, I was hired to see through the rest of the project allowing me to apply the machine design and analysis coursework I am studying to make advancements in environmental sustainability, a topic I am deeply committed to pursuing throughout my research career.

In industries that use large conveyor systems like supply chains, the costs due to friction are astoundingly high. Solid lubricants, or coatings, can mitigate these issues, reducing not just the monetary and environmental burdens associated with friction, but also cutting down repair costs so vital packages can be distributed smoothly. My research focuses on developing and optimizing graphite-based coatings to reduce the environmental and economic impacts of friction. These coatings provide a sustainable alternative to petroleum-based lubricants, enabling smoother operation of conveyors while cutting repair costs and waste.

Working with Dr. Zou’s Nano Mechanics and Tribology Lab, I’ve spent the past year building and improving devices to test these coatings in industry-like conditions. The goal? To ensure these coatings are not just scientifically sound but practical and scalable for real-world use. Diving into this project has taught me more than just technical skills. On the research side, I’ve learned about the complexities of creating and applying graphite coatings and the importance of designing experiments that simulate real-world conditions. One of the most significant things I learned is the balance between precision and practicality. For example, efficiently preparing graphite coatings on a large scale requires creativity and problem-solving. I developed a method using sonication to prepare larger batches of graphite while maintaining quality. This approach not only reduced preparation time but also scaled up production to meet industry needs.

This project wasn’t without hurdles either. The spray-coating device was initially a proof-of-concept with significant limitations. Calibrating the stepper motors, programming precise spray paths, and resolving nozzle inconsistencies were all challenges that I had not encountered before, but in taking them on, I became increasingly familiar with the spray coater. For example, I discovered a pressure gauge in the system that was causing inconsistencies—it took careful testing and troubleshooting to pinpoint and resolve the issue.

Dr. Zou played a crucial role in guiding my research. Her weekly meetings kept me on track, and her suggestions for experiments and deadlines pushed me to think critically and stay organized. Additionally, I received valuable support from my lab mentor, Dr. Mahyar Afshar Mohajer, who helped me navigate the technical challenges of coding and device calibration.

Collaborating with other researchers in the lab was also an enriching experience. Whether we were troubleshooting equipment or brainstorming new approaches, the teamwork makes challenges feel manageable and the successes even more rewarding.

A highlight of this year was presenting my research at the Arkansas State Capitol during a student research conference. Explaining my project to a broader audience was a great opportunity to showcase the practical applications of my work and connect with others passionate about engineering and sustainability.

Looking ahead, I plan to optimize the spray settings for graphite coatings to ensure uniform application across industrial conveyor beds. My goal is to create a first author publication on these findings. Beyond this project, I’m eager to apply my engineering skills in industry, where I hope to tackle more sustainability-focused challenges. This research experience has solidified my commitment to creating practical solutions that make a difference in the real world. This journey has been one of growth, discovery, and innovation. I am deeply grateful for the support of the Honors College, Dr. Zou, and my lab team, who have paved the way for this experience. Research has taught me that the most meaningful work often comes from overcoming challenges and turning ideas into reality. If you’re a student considering research, my advice is simple: go for it. It’s an opportunity to not only learn about your field but also to discover what you’re capable of.