Thermoplastic composite filament winding is an on-line consolidation process, where the composite experiences a complex temperature history and undergoes a number of temperature history affected microstructural changes that influence the structure's subsequent properties. These changes include melting, crystallization, void formation, degradation and consolidation. In the present study, models of the thermoplastic filament winding process were developed to identify and understand the relationships between process variables and the structure quality. These include models that describe the heat transfer, consolidation and crystallization processes that occur during fabrication of a filament wound composites structure. A comprehensive thermal model of the thermoplastic filament winding process was developed to calculate the temperature profiles in the composite substrate and the towpreg temperature before entering the nippoint. A two-dimensional finite element heat transfer analysis for the composite-mandrel assembly was formulated in the polar coordinate system, which facilitates the description of the geometry and the boundary conditions. A four-node 'sector element' was used to describe the domain of interest. Sector elements were selected to give a better representation of the curved boundary shape which should improve accuracy with fewer elements compared to a finite element solution in the Cartesian-coordinate system. Hence the computational cost will be reduced. The second thermal analysis was a two-dimensional, Cartesian coordinate, finite element model of the towpreg as it enters the nippoint. The results show that the calculated temperature distribution in the composite substrate compared well with temperature data measured during winding and consolidation. The analysis also agrees with the experimental observation that the melt region is formed on the surface of the incoming towpreg in the nippoint and not on the substrate. Incorporated with the heat transfer analysis were the consolidation and crystallization models. These models were used to calculate the degree of interply bonding and the crystallinity achieved during composite manufacture. Bonding and crystallinity developments during the winding process were investigated using the model. It is concluded that lower winding speed, higher hot-air heater nozzle temperature, and higher substrate preheating temperature yield higher nippoint temperature, better consolidation and a higher degree of crystallization. Complete consolidation and higher matrix crystallization will result in higher interlaminar strength of the wound composite structure. / Master of Science

The aim of this study is to determine the mechanical characteristics of the filament wound composite tubes working under internal pressure loads, generating data for further investigation with a view of estimating the remaining life cycle of the tubes during service. Data is generated experimentally by measuring the mechanical behavior like strains in hoop direction, maximum hoop stresses that are formed during internal pressure loading. Results have been used to identify and generate the necessary data to be adopted in the design applications. In order to determine these parameters, internal pressure tests are done on the filament wound composite tube specimens according to ASTM D 1599-99 standard. The test tubes are manufactured by wet filament winding method, employing two different fiber types, two different fiber tension settings and five different winding angle configurations. The internal pressure test results of these specimens are studied in order to determine the mechanical characteristics, and the effects of the production variables on the behavior of the tubes. Pressure tests revealed that the carbon fiber reinforced composite tubes exhibited a better burst performance compared to the glass fiber reinforced tubes, and the maximum burst performance is achieved at a winding angle configuration of [&plusmn / 54&deg / ]3[90&deg / ]1. In addition, the tension setting is found not to have a significant effect on the burst performance. The burst pressure data and the final failure modes are compared with the results of the ASME Boiler and Pressure Vessel Code laminate analysis, and it was observed that there is a good agreement between the laminate analysis results and the experimental data. The stress &ndash / strain behavior in hoop direction are also studied and hoop elastic constants are determined for the tubes.

Ces travaux concerne le développement de capteurs/effecteurs piézoélectrique et pyroélectrique de faible diamètre intégrable dans des structures textiles par exemple les tissus, ce qui permet soit d’avoir différentes informations sur le comportement mécanique et de température de ces structures (piézoélectricité directe) ou bien de changer les propriétés mécaniques de ces structures (piézoélectricité inverse), ce qui permettrait d’avoir des tissus à contention variable.A ce jour, sur le marché il n’existe pas de capteurs/effecteurs filamentaires piézoélectriques et/ou pyroélectriques flexibles de faibles diamètres intégrables dans les structures textiles. Les instrumentations des structures textiles qui existent se font par le biais de filaments résistifs agissant comme résistances entrecroisées qui permettent seulement d’avoir une information sur la localisation d’une pression sur ces structures textiles. Le but ces travaux est de remédier aux inconvénients des procédés connus ci-dessus. Ce but est atteint grâce à la fabrication de câbles filamentaires à l’aide d’un procédé de filage par voie fondue.Ces composites filamentaires sont caractérisé puis polariser avant de les introduire dans différents textiles par exemple les tissus, ce qui permet soit d’avoir différentes informations sur le comportement mécanique et de température de ces structures (capteurs de déformations et de température) ou bien de changer leurs propriétés mécaniques (effecteurs).Ces travaux ont été brevetés par la cellule Conectus Alsace et ils ont été sélectionnés pour le second prix International Théophile Legrand de l’innovation textile 2012. / The objective of this work is the development of composite filaments with piezoelectric and pyroelectric properties. These composite filaments will be used as sensors or effectors into textile structures (e.g weaving structures). The instrumentation of textile structures with piezoelectric composite filaments (sensors) will give information about the deformations of these structures when they are submitted to stresses. If we focus on the pyroelectric properties, this integration will allow detection of temperature variation of the operating environment. By using inverse piezoelectricity (effectors), we could change mechanical properties of textiles structures. The decision to develop this type of composites filaments was take due to the literature review which shows that composite filamentous sensors or effectors does not exist commercially. The objective of this work was achieved through the development of ferroelectric composite filament by using a melt spinning process. These composite was constituted by a portion of ferroelectric copolymer P(VDF-TrFE), an inner conductive core acting as an inner electrode and an outer conductive layer serving as an outer electrode These composite filaments were characterized with mechanical and rheological tests before being polarized by an alternating field. Then we integrate them into weaving structures using an industrial weaving machine. The result of the stressing of this structure was a variation of the field across the composite electrodes This work has been patented with the help of Conectus Alsace and it was selected for the second International Award Théophile Legrand for Textile Innovation 2012.