The Hashin failure criteria and damage evolution model for laminated fiber reinforced polymers are explored. A series of tensile coupon finite element analyses are run to characterize the variables in the physical model as well as modeling techniques for using an explicit dynamic solver for a quasi-static problem. An attempt to validate the model on an axial tube crush is presented. It was found that fiber buckling was not occurring at the impactor-tube interface. Results and speculation as to why the failure initiation is incorrect are discussed. Lessons learned from the tube crush are applied successfully to the quasi-static Formula SAE nosecone crush test. The model is validated by experimental data and the impact metrics between the test and model are within 5%. Future work and possible optimization techniques are discussed.

Present day composite sandwich panels provide incredible strength. Their largest problem, however, is early bonding failure between the core and the skin. This is due to the low bonding surface area of present cores like honeycomb. Corrugated structures could provide a remedy for this with their much larger bonding surface area. Corrugated structures have extreme mechanical properties deeming them particularly useful in aerospace and automotive applications. However, previous research has shown that the stiffness of carbon fiber causes debonding and drastic failure when used as both a core and a skin. Bio-composites have properties that could strengthen the corrugated sandwich panel against such debonding and increase the strength of the structure while making it cheaper and more environmentally friendly. This thesis presents the optimum design, manufacturing, and testing of corrugated sandwich panel structures with integrated bio-composites under edgewise compression loading. To do this, optimum corrugation geometry was identified using theoretical analysis of the moment and bonding area of the shape. Control tests with carbon fiber and hemp were conducted. The bio-composite was integrated in both the core and the skin individually in corrugated sandwich panels. The cases tested were all-carbon fiber, hemp skin with carbon fiber core, carbon fiber skin with hemp core, and all-hemp. These corrugated structures were analyzed by conducting compression loading tests on varying lengths of single-ligament panels utilizing trapezoidal corrugation as the core and a flat plate as the skin. The lengths tested were 1, 2, 3, and 4 inches. As many samples as possible were manufactured out of limited material with heavier focus on creating the shorter samples. The goal of this testing was, first, to determine if hemp fibers were viable as a substitute for certain sections of the traditional composite structure, and second, to see if integrating hemp fibers would solve the problems of debonding seen in the all-carbon fiber samples seen in previous research. To determine mechanical property viability, the ultimate load and stiffness were investigated for each sample, as well as investigation of the failure modes seen in the test. Secondary goals were to see at what length buckling behavior became an issue and to see if this corrugated structure and all its failure modes could be simulated in finite element analysis. At the 1-inch and 2-inch lengths where minimal buckling was encountered, the hemp core-carbon skin samples showed better results than both the all-carbon fiber and the all-hemp samples with a 4% and 6% increase in average ultimate load and a 11% and 47% increase in stiffness, respectively. From these results, it was concluded that hybrid bio-composite structures can have comparable mechanical properties to traditional composites and can solve bonding failure.

In Its first half this master's thesis describes composite materials with carbon fiber reinforced plastics being the main focus point. An overview of production technologies follows. The major objective of the second part of this master's thesis is to design and manufacture a simplified model of an optical device using prepregs.

<p>In this doctoral thesis work, the impacts of alternative constituent material’s impact on low-cost prepreg manufacturing for high volume applications will be considered. Unidirectional prepregs offer the potential for significant increase of specific-properties and thereby weight savings. Hence the automotive industry is seeking to utilize composite components in their design, in order to meet new fuel economy ratings and global emissions targets imposed by governments. New resin formulations to achieve 3-minute cycle times or low-cost carbon fiber manufacturing have been created to address the needs of the automotive and other cost-sensitive industries, however these innovations have led to challenges in the composites manufacturing process. Quality control issues may include variations in resin saturation of the fiber bed, consolidation, porosity, and fiber volume fraction. These quality issues arise in the part forming step or from the initial resin infiltration during prepregging.</p> <p> </p> <p>Some low-cost carbon fiber has a kidney-bean shaped cross-section which has implications on the compaction and permeability of the fiber bed. The kidney-bean shaped fibers were shown in this work to follow a different compaction trend compared to circular fibers. Furthermore, these fibers required an order of magnitude larger force to compact than circular fibers to achieve similar fiber volume fraction, which had implications on the infiltration and consolidation step. A shape correction factor based on the fiber cross-sectional aspect ratio was proposed to extend the existing compaction model to fibers with irregular cross-sectional shapes. Additionally, permeability simulations were performed on the kidney-bean shaped carbon fiber in various fiber packing unit cells. Since the kidney-bean shaped fiber had some degree of asymmetry, there are two valid hexagonal packing arrangements. At a minimum, the hexagonal packed unit cell orientation caused a 17% reduction in permeability for the same unit cell and fiber volume fraction between the <u>+</u>90° and 0° orientations. In the most extreme case, a 47% reduction in the permeability was observed between the <u>+</u>90° and 0° orientations. Depending on the fiber orientation, comparable permeabilities to circular fibers were attained or up to a 74% reduction in permeability. This means a selection of low-cost carbon fiber could cause the infiltration time to be up to 3.86 longer than for a traditional carbon fiber.</p> <p> </p> <p>The low-cost carbon fiber was paired with a rapid cure epoxy resin which contained internal mold-release to further improve part cycle times to 3-minutes and reduce part costs. The effect of polar and non-polar internal mold-release was studied for its potential influence on cure kinetics. The polar internal mold-release caused a 20 second delay in the 3-minute part cycle, which increased the cycle time by 10% and would therefore influence part production schedules. This prepreg system was reported to have prepreg quality issues related to solids filtering during infiltration. A hot-melt prepregging process was modeled for S-wrap and nip-roller configurations. The S-wrap process was found to better suited for prepregging multi-phase resins since lower pressures were used. Additionally, a general rule was established when working with multi-phase resins was established, particle diameters should not exceed fiber radii.</p> <p> </p> <p>The general design principles from the thermoset hot-melt prepregging were used to develop a thermoplastic prepreg tape line. Thermoplastic composites lend themselves to efficient manufacturing processes such as hybrid overmolding which is suitable for the automotive industry. polyamide-66/Kevlar^® prepreg tapes were manufactured at various line tensions. Neat, rubber toughened, and glass bead filled polyamide-66 based resins were considered. The neat polyamide-66 resin provided a baseline and was able to consistently saturate the fiber bed up to 400µm regardless of manufacturing conditions. The addition of rubber particles did reduce the infiltration distances from the base resin by 20% with significant a significant 50% reduction when the fiber volume fraction reached 0.70. While the addition of glass particles significantly reduced the infiltration distances by up to 70% across all manufacturing conditions. The reduction in flow distance resulted in poor infiltration in thicker fiber beds.</p>

The interlaminar region is a contributing factor to the limited electrical conductivity of carbon fiber/epoxy composites. Consisting of electrically insulating epoxy matrix between conductive layers of carbon fiber, the interlaminar region prevents electrical interaction between the carbon fiber layers and electrical conduction in the through thickness direction.The interlaminar region in thin [0,0] carbon fiber/epoxy composites has been reinforced by carbon nanotubes (CNT) by two methods. First by aligned CNT forests from N12 Technologies and secondly by self-produced Buckypapers, porous CNT films, of different areal densitites. Two batches of laminates modified by aligned CNTs, having different curing conditions, and laminates modified with Buckypapers were manufactured. The laminates were evaluated by their electrical conductivity and electromagnetic interference shielding efficiency (EMI SE). The addition of external pressure to the laminates during curing brought an increase in longitudinal conductivity, a consequence of higher fiber packing. Also, both reinforcement methods increased the longitudinal conductivity through improved electrical interaction between the carbon fiber layers. However, only the Buckypaper reinforcement augmented the transversal conductivity significantly, acting as a highly conductive route in the interlaminar region. Both batches of aligned CNT modified laminates exhibited equal EMI SE, questioning the influence of the conductivity of the laminate on its EMI SE. Also, the increase in EMI SE brought by the aligned CNT forests were negligible compared to the reference. However, the reinforcement by Buckypapers proved successful, reaching -45/-50 dB at 1000 MHz, improving from 30 dB of the unmodified reference at the same frequency.

Liquid composite molding (LCM) is growing in importance alternative to traditional prepreg-autoclave methods for manufacture aerospace composites. The most significant roadblock to industry's implementation of LCM is the optimization of resin flow to ensure high quality parts. This study developed process optimization tools to foster the adaptation of LCM. The following dissertation characterized the permeability of reinforcement fabrics under various processing conditions, and investigated in-situ bubble flow with carbon fiber. The purpose of this research is to extend the understanding of LCM and push forward the state of the art via sub-studies captured in five chapters, or manuscripts. Research from these manuscripts is as follows. Chapter 3 sets the groundwork for LCM optimization by extending the current theory for assessing 3D permeability of reinforcement fabrics using an ellipsoidal point infusion experiment. The aim was to improve 3D permeability measurement accuracy for LCM processing models. This work is the first to compare solutions in the context of 75 experiments. Chapters 4 and 5 extend permeability analysis to curved and sheared geometries, typical to real-world aerostructures. Chapter 4 demonstrates a method for measurement of curvature effects on permeability with vacuum infusion. A correlation was shown between curvature (as evaluated over four radii) and effective permeability. Chapter 5 researches the shearing of reinforcement fabric (e.g. when reinforcements are draped over double curvature). The study shows that permeability actually increases for mid-range shear angles beyond the shear-locking angle, and develops a technique for obtaining the 3D permeability of sheared fabric.Chapter 6 investigates carbon fiber voids in situ. LCM optimization requires improved void monitoring for carbon fiber. It is challenging to monitor void flow in situ with carbon fiber reinforcements because of fiber opacity. The research builds upon a new automated fluorescent imaging method to monitor void flow in-situ. Results include high-resolution and high-contrast images and 230 data points for infusion velocity vs. void content data.Chapter 7 contributes to the growing interest in LCM processes for aerospace applications by providing a short cost summary of typical processes for manufacturing aerospace composite parts. Data shows that LCM is a financially wise alternative to automated fiber placement (prepreg-autoclave) manufacturing when a void content of 2-2.5% is acceptable. Work on LCM processes optimization indicates that these percentages will reduce in coming years.

Studies of single, isolated nanoparticles provide better understanding of the structure-function relationship of nanoparticles since they avoid complications like interparticle distance and nanoparticle loading that are typically associated with collections of nanoparticles distributed on electrode supports. However, interpretation of results obtained from single nanoparticle immobilization studies can be difficult to interpret since the underlying nanoelectrode platform can contribute to the measured current, or the immobilization technique can adversely affect electron transfer. Here, we immobilized ligand-free gold nanoparticles on relatively electrocatalytically inert nitrogen-doped carbon ultramicroelectrodes that were prepared via a soft nitriding method. Sizes of the particles were estimated by a recently reported electrochemical method and were found to vary linearly with deposition time. The particles also exhibited electrocatalytic activity toward methanol oxidation. This immobilization strategy shows promise and may be translated to smaller nanoelectrodes in order to study electrocatalytic properties of single nanoparticles.

A variety of retrofitting methods are used to upgrade existing structures. For example, steel plates and Fiber Reinforced Polymer (FRP) jackets are externally bonded to members to increase their capacity in flexure and shear. However, due to the issue of corrosion these strengthening systems may lose their efficiency with time. FRP materials have been used to strengthen many structural components of different shapes and types. FRP jackets, FRP Strips, and FRP rods have commonly been used to rehabilitate existing structural components. The many advantages of using FRP as strengthening materials have made this material an attractive alternative: advantages such as lightweight, high strength, and ease of setting up. Among the many applications using FRP, Near Surface Mounted -- Fiber Reinforced polymer (NSM-FRP) is a promising technique used to strengthen concrete members. However, de-bonding issues have to be overcome to make this technique efficient and reliable. The NSM-FRP technique consists of making a groove along the surface of the concrete member to be retrofitted with depth less than the cover of the member. After cleaning the groove, epoxy paste is used to fill two-thirds of the groove's depth. The FRP element is then mounted in the groove. Finally, the groove is filled with epoxy and the excessive epoxy is leveled with surface of the concrete. This technique makes the FRP material completely covered by epoxy in the cover of the concrete. This method can be used for strengthening both the positive and negative moment regions of girders and slabs. Groove size, paste, concrete, and rods properties are the main variables that control the efficiency of the NSM-FRP rods. The main objective of this research project is to determine the behavior of reinforced concrete beams that are strengthened with NSM-CFRP reinforcement bars. In this research project, the bond characteristics of NSM-CFRP reinforcement bars are first determined from pullout tests. Then, NSM-CFRP rods are installed in reinforced concrete beams and the beams are tested. Loads, strains, and deflections are measured and theoretical and measured capacities are compared. Finally, the reliability and efficiency of using NSM-CFRP rods technique in retrofitting existing structures is observed.

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A material’s Coefficient of Thermal Expansion (CTE) is a valuable physical property, particularly for structural fiber reinforced composites that are routinely used in satellite/aerospace applications. Satellite space structures are routinely designed with a high degree of dimensional and thermal stability. Designing and verifying for near zero CTE performance is a common design requirement. The CTE is routinely a physical property with known values for common materials. However, the strength, stiffness and CTE properties on a multi-ply graphite fiber reinforced laminate composite can be tailored to specific engineering requirements. Because of this, a method of verification (testing) is routinely performed to ensure these requirements are met.