Date of Graduation

5-2025

Document Type

Thesis

Degree Name

Bachelor of Science in Mechanical Engineering

Degree Level

Undergraduate

Department

Mechanical Engineering

Advisor/Mentor

Huang, Adam

Committee Member

Jensen, David

Abstract

This thesis investigates the use of Nichrome 60 wire as a burn wire mechanism, commonly utilized in CubeSats and other aerospace engineering applications requiring precise, single-use release systems. The experiment focused on characterizing the thermal and resistive behavior of Nichrome 60 wire under Joule heating conditions. Four wire configurations were tested: 34-gauge and 36-gauge wires, each at lengths of 1 inch and 2 inches. Each configuration was subjected to a constant current until thermal failure occurred. During testing, real-time measurements of electrical resistance and wire temperature were recorded. This data was used to generate resistance vs. temperature profiles for each wire configuration. The resulting plots provide insight into the material behavior of Nichrome 60 wire leading up to failure and offer valuable information for predicting performance in burn wire applications. Additionally, the obtained experimental results were compared to prior research in the field to evaluate consistency and validate observed trends. The findings contribute to a deeper understanding of the thermal and resistive characteristics of Nichrome 60 and its suitability for controlled release systems, particularly in the context of CubeSat deployment mechanisms.

Keywords

burn wire; actuation; CubeSat; deployment; Nichrome; resistance vs temperature

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