Experimentation exploring the movement of voids within carbon fiber reinforced plastics was performed using fluorescent dye infused into the laminates observed through a transparent mold under ultraviolet light. In situ photography was used as an inspection method for void content during Resin Transfer Molding for these laminates. This in situ inspection method for determining the void content of composite laminates was compared to more common ex-situ quality inspection methods i.e. ultrasonic inspection and cross-section microscopy. Results for localized and total void count in each of these methods were directly compared to test samples and linear correlations between the three test methods were sought. Test coupons were then cut from these laminates and were used to calculate the interlaminar shear strength at certain locations throughout the laminates. Although this research did not adequately observe correlations between results obtained from ultrasonic C-scans, cross-sectional microscopy and in situ photography of the surface, it was seen that the fluid dynamics of the thermosetting epoxy used in this experimentation correlated to results obtained from previous experimentation performed by students at Brigham Young University using vegetable oil as a substitute for resin.

This work correlates the chemistry of phenol-formaldehyde (PF) resins, its functionalities with their microstructural and mechanical properties in composite materials. The main focus is put on the development of the pores in dependence on the chemical composition of the resins and their influence on the structure of the material. Chemical characteristics of the synthesized resins are analyzed and physical/mechanical properties of the matrices based on PF resins are determined. Differences in the chemical properties are detected e.g. by FT-IR and NMR spectroscopy. They indicate the existence of similar molecular basic structure units, but different network conditions of the resins. DSC investigations point on different reaction mechanisms and temperatures; they reveal also their changed thermal behavior. The bulk matrix behavior differs from that of the composite based on the same resin due to the three dimensional stress and strain fields in the composites. The structure of the CFRP composites is strongly depended on the fiber/matrix interaction. The fiber matrix bonding (FMB) strength controls the load transfer via shear forces and therefore the segmentation of the fiber bundles.

A study was undertaken to determine if light-weighting orbital launch vehicles (rockets) improves lifetime environmental impacts of the vehicle. Light-weighting is performed by a material substitution where metal structures in the rocket are replaced with carbon fiber reinforced polymers (CFRP’s). It is uncertain whether light-weighting the rocket in the same way as traditional vehicles are light-weighted would provide similar environmental benefits. Furthermore, the rocket system is significantly different from traditional vehicles and undergoes an atypical lifecycle, making analysis non-trivial. Seventy rocket configurations were sized using a Parametric Rocket Sizing Model (PRSM) which was developed for this research. Four different propellant options, three staging options, and eighteen different lift capacities were considered. Each of these seventy rockets did not include CFRP’s, thus establishing a baseline. The seventy rockets were then light-weighted with CFRP’s, making a total of seventy pairs of rockets. An environmental Life Cycle Assessment (LCA) was performed on each of the rockets to determine lifetime environmental impacts. During the Life Cycle Inventory (LCI), a Carbon Fiber Production Model was developed to determine the environmental burdens of carbon fiber production and to address issues identified with carbon fiber’s embodied burdens. The results of the LCA were compared across all rockets to determine what effects light-weighting had on environmental impact. The final conclusion is that light-weighting reduces lifetime environmental impacts of Liquid Oxygen-Rocket Propellant 1 and Nitrogen Tetroxide-Unsymmetrical Dimethylhydrazine rockets, while it likely benefits Liquid Oxygen-Liquid Hydrogen rockets. Light-weighting increases lifetime environmental impacts of Solid Propellant rockets.

ABSTRACT The repair and strengthening of concrete bridge members with CFRP has become increasingly popular over recent years. However, significant research is still needed in order to develop more robust guidelines and specifications. The research project aims to assist with improving design prosedures for damaged concrete members with the use of CFRP. This document summarizes the analysis and testing of full-scale 40’ foot long prestressed concrete (PSC) bridge girders exposed to simulated impact damage and repaired with carbon fiber reinforced polymers (CFRP) materials. A total of five AASHTO type II bridge girders fabricated in the 1960’s were taken from an existing bridge, and tested at the Florida Department of Transportation FDOT structures lab in Tallahassee, Florida. The test specimens were tested under static loading to failure under 4-point bending. Different CFRP configurations were applied to each of the girders. Each of the test girders performed very well as each of them held a higher capacity than the control girder. The repaired girders 5, 6 and 7 surpassed the control girder’s capacity by 10.88%, 15.9% and 11.39%. These results indicate that repairing laterally damaged prestressed concrete bridge girders with CFRP is an effective way to restore the girders flexural capacity.

This work correlates the chemistry of phenol-formaldehyde (PF) resins, its functionalities with their microstructural and mechanical properties in composite materials. The main focus is put on the development of the pores in dependence on the chemical composition of the resins and their influence on the structure of the material. Chemical characteristics of the synthesized resins are analyzed and physical/mechanical properties of the matrices based on PF resins are determined. Differences in the chemical properties are detected e.g. by FT-IR and NMR spectroscopy. They indicate the existence of similar molecular basic structure units, but different network conditions of the resins. DSC investigations point on different reaction mechanisms and temperatures; they reveal also their changed thermal behavior. The bulk matrix behavior differs from that of the composite based on the same resin due to the three dimensional stress and strain fields in the composites. The structure of the CFRP composites is strongly depended on the fiber/matrix interaction. The fiber matrix bonding (FMB) strength controls the load transfer via shear forces and therefore the segmentation of the fiber bundles.:1 Introduction 2 Theoretical Overview 2.1 Phenol-Formaldehyde Resins 2.1.1 Overview 2.1.2 Reactions of phenol-formaldehyde resin 2.1.2.1 Addition reaction 2.1.2.2 Condensation reaction 2.1.2.3 Curing 2.1.3 Application of phenol-formaldehyde resin 2.2 Carbon-Fiber 2.2.1 PAN type carbon fiber 2.2.2 Pitch type carbon fiber 2.2.3 Application of carbon fiber 2.3 Composites 2.3.1 Carbon fiber composites 2.3.2 Matrix 2.3.3. Interfaces 2.3.3.1 Carbon fiber side interface between carbon fiber and matrix 2.3.3.2 Matrix side interface between carbon fiber and matrix 2.3.3.3 Toughening of fiber-reinforced polymer 3 Goal and Works 3.1 Problem and Motivation 3.2 Objective and Works plan 4 Experiments and Methods 4.1 Materials 4.1.1 Chemical reagents 4.1.2 Carbon fiber weave 4.2 Synthesis of Resin 4.3 Fabrication of Matrix 4.4. Measurement methods and Experimental approach 4.4.1 Chemical analysis 4.4.2 Microstructure characterization 4.4.3 Mechanical test 5 Chemical characterization of modified phenol-formaldehyde resin 5.1 Fourier Transformed Infrared spectroscopy (FT-IR) 5.1.1 Introduction 5.1.2 Preparation and Measurement 5.1.3 Results and Discussion 5.2 Nuclear Magnetic Resonance spectroscopy (NMR) 5.2.1 Liquid 13C Nuclear Magnetic Resonance spectroscopy 5.2.1.1 Introduction 5.2.1.2 Preparation and Measurement 5.2.1.3 Results and Discussion 5.2.2 Solid 13C CP-MAS Nuclear Magnetic Resonance spectroscopy 5.2.2.1 Introduction 5.2.2.2 Preparation and Measurement 5.2.2.3 Results and Discussion 5.3 Simultaneous Thermal Analysis (STA) 5.3.1 Introduction 5.3.2 Preparation and Measurement 5.3.3 Results and Discussion 5.3.3.1 Simultaneous Thermal Analysis 5.3.3.2 Different Scanning Calorimetry 5.4 Conclusion 6 Microstructural Characterization 6.1 Porosity 6.1.1 Introduction 6.1.2 Preparation and Measurement 6.1.3 Results and Discussion 6.1.3.1 Density 6.1.3.2 Porosity 6.2 Morphology 6.2.1 Introduction 6.2.2 Preparation and Measurement 6.2.3 Results and Discussion 6.2.3.1 Optical Microscopy 6.3.3.2 Scanning Electron Microscopy 6.3.3.2.1 Observation of the bulk matrix 6.2.3.2.2 Structural observation of the composite 6.3 Conclusion 7 Mechanical Properties 7.1 Hardness test 7.1.1 Introduction 7.1.2 Preparation and Measurement 7.1.3 Results and Discussion 7.2 Micro-bending test 7.2.1 Introduction 7.2.2 Preparation and Measurement 7.2.3 Results and Discussion 7.3 Conclusion 8 Summary and Conclusion 8.1 Summary 8.2 Conclusion 9 References

Fiber-reinforced plastics for industrial applications face constantly increasing demands regarding efficiency, reliability, and economy. Furthermore, it was shown that fiber-reinforced plastics with tailored reinforcements are superior to metallic or monolithic materials. However, a trustworthy description of the load-specific failure behavior and damage evolution of composite structures can hardly be given, because these processes are very complex and are still not entirely understood. Among other things, several research groups have shown that material damages like fiber fracture, delamination, matrix cracking, or flaws can be discovered by analyzing the electrical properties of conductive composites, for example, carbon fiber–reinforced plastics. Furthermore, it was shown that this method could be used for structural health monitoring or nondestructive evaluation. Within this study, magnetic induction tomography, which is a new imaging approach, is introduced in the topic of nondestructive evaluation of carbon fiber–reinforced plastics. This non-contacting imaging method gains the inner spatial distribution of conductivity of a specimen and depicts material inhomogeneity, like damages, not only in two-dimensional images but also in three-dimensional images. Numerical and experimental investigations are presented, which give a first impression of the performance of this technique. It is demonstrated that magnetic induction tomography is a promising approach for nondestructive evaluation. Potentially, it can be used for fabrication quality control of conductive fiber–reinforced plastics and as a structural health monitoring system using an integrated or superficially applied magnetic induction tomography setup.

In recent years the use of carbon fiber reinforcing polymers (CFRP) to repair damaged structural components has become more accepted and practiced. However, the current reference for designing FRP systems to repair and strengthen reinforced concrete (RC) and prestressed concrete (PSC) girders has limitations. Similarly, very few resources address solutions for the debonding problem associated with CFRP laminates or the use of CFRP laminates to repair structural members with pre-existing damage. The included experimental program consists of testing both RC and PSC girders with simulated lateral damage and CFRP repairs. A total of 34 RC beams were statically tested under a 4-point loading until failure and had cross-section dimensions of 5” x 10” (14cm x 25.4cm), were 8’ long (2.44m), and were reinforced with either #3 or #4 mild steel rebar. 13 PSC girders having cross-section dimensions representing a half-scaled AASHTO type II shape, were 20’ long (6.1m), and were prestressed with five 7/16” (11.1mm) diameter low-lax 7-wire strands. Ten of the PSC girders were statically loaded until failure under a 4-point testing setup, but 3 PSC girders were dynamically tested under fatigue loading using a 3-point arrangement. Different configurations of CFRP laminates, number and spacing of CFRP transverse U-wraps, and amount of longitudinal CFRP layers are studied. The results present the flexural behavior of all specimen including load-deflection characteristics, strain characteristics, and modes of failure. Ultimately, results are used to recommend important considerations, needed criteria, and proper design procedures for a safe and optimized CFRP repair configuration.