The use of composite materials in vehicle structures could reduce the weight and thereby the fuel consumption of vehicles. As the road safety of the vehicles must be ensured, it is vital that the energy absorbing capability of the composite materials are similar to or better than the commonly used steel structures. The high specific bending stiffness of sandwich structures can with advantage be used in vehicles, provided that the structural behaviour during a crash situation is well understood and possible to predict. The purpose of this thesis is to identify and if possible to describe the failure initiation and progression in in-plane compression loaded sandwich panels. An experimental study on in-plane compression loaded sandwich panels with two different material concepts was conducted. Digital speckle photography (DSP) was used to record the displacement field of one outer face-sheet surface during compression. The sandwich panels with glass fibre preimpregnated face-sheets and a polymer foam core failed due to disintegration of the face-sheets from the core, whereas the sandwich panels with sheet molding compound face-sheets and a balsa core failed in progressive end-crushing. A simple semi-empirical model was developed to describe the structural response before and after initial failure. The postfailure behaviour of in-plane compression loaded sandwich panels was studied by considering the structural behaviour of sandwich panels with edge debonds. A parametrical finite element model was used to determine the influence of different material and geometrical properties on the buckling and postbuckling failure loads. The postbuckling failure modes studied were debond crack propagation and face-sheet failure. It could be concluded that the postbuckling failure modes were mainly determined by the ratio between the fracture toughness of the face-core interface and the bending stiffness of the face-sheets. / QC 20101111

An experimental investigation was undertaken to analyze the behavior of sandwich composite structures exposed to one-sided heating where a debond exists between the unexposed facesheet and core material. Sandwich composites of plain weave E-glass/epoxy facesheets and an end-grain balsa wood core manufactured using the Vacuum Assisted Resin Transfer Molding (VARTM) technique were the only materials analyzed. These were selected due to their current use in naval vessels and the heightened interest in the fire response properties of balsa wood and its utility as a core material. In order to better understand the interfacial behavior, Mode I Double Cantilever Beam (DCB) fracture tests were performed at ambient, 60 C, and 80 C to determine the influence of the decreased Mode I fracture toughness. While ambient testing showed that stable crack growth could be obtained, high temperature tests resulted in considerable damage occurring to the core at the crack-front preventing stable crack growth. This can be attributed to the significant decrease in the balsa core strength and material properties even for small increases in temperature. Additionally, Mode II Cracked Split Beam (CSB) tests were performed at ambient temperature to examine the sliding dominant crack-growth. Again, the occurrence of balsa core damage prevented stable crack-growth and an accurate measurement of Mode II fracture toughness was not obtained. Intermediate-scale compression testing with one-sided heating at two heat flux levels was performed with a custom designed load frame on sandwich composite columns. This enabled the influence of the debond to be measured using a 3D-Digital Image Correlation (DIC) technique spatially linked with a thermographic camera. The DIC allowed for a detailed observation of debond growth and buckling prior to global failure of the test article. A behavior similar to that observed in the Mode I DCB fracture tests occurred: as the interfacial temperature increased, the amount of crack growth decreased. This crack growth was followed by a core failure at the crack-front, triggering a global failure of the test article. This global failure for test articles containing a debond manifested itself primarily as an anti-symmetric post-buckling shape. Test articles with no debond exhibited the typical progression of the out-of-plane displacement profile for a fixed-fixed column. As the out-of-plane displacement increased, core failure ultimately occurred near the gripped region where the zero-slope condition is required, triggering global failure of the no debond test article. These tests highlight that the reduction in strength and material properties of the end-grain balsa wood core significantly outweigh the reduction in interfacial fracture toughness due to the increased temperatures. / Master of Science

<p>The use of composite materials in vehicle structures could reduce the weight and thereby the fuel consumption of vehicles.</p><p>As the road safety of the vehicles must be ensured, it is vital that the energy absorbing capability of the composite materials are similar to or better than the commonly used steel structures. The high specific bending stiffness of sandwich structures can with advantage be used in vehicles, provided that the structural behaviour during a crash situation is well understood and possible to predict. The purpose of this thesis is to identify and if possible to describe the failure initiation and progression in in-plane compression loaded sandwich panels.</p><p>An experimental study on in-plane compression loaded sandwich panels with two different material concepts was conducted. Digital speckle photography (DSP) was used to record the displacement field of one outer face-sheet surface during compression. The sandwich panels with glass fibre preimpregnated face-sheets and a polymer foam core failed due to disintegration of the face-sheets from the core, whereas the sandwich panels with sheet molding compound face-sheets and a balsa core failed in progressive end-crushing. A simple semi-empirical model was developed to describe the structural response before and after initial failure.</p><p>The postfailure behaviour of in-plane compression loaded sandwich panels was studied by considering the structural behaviour of sandwich panels with edge debonds. A parametrical finite element model was used to determine the influence of different material and geometrical properties on the buckling and postbuckling failure loads. The postbuckling failure modes studied were debond crack propagation and face-sheet failure. It could be concluded that the postbuckling failure modes were mainly determined by the ratio between the fracture toughness of the face-core interface and the bending stiffness of the face-sheets.</p>

abstract: Temporary bonding-debonding of flexible plastic substrates to rigid carriers may facilitate effective substrate handling by automated tools for manufacture of flexible microelectronics. The primary challenges in implementing practical temporary bond-debond technology originate from the stress that is developed during high temperature processing predominately through thermal-mechanical property mismatches between carrier, adhesive and substrate. These stresses are relaxed through bowing of the bonded system (substrate-adhesive-carrier), which causes wafer handling problems, or through delamination of substrate from rigid carrier. Another challenge inherent to flexible plastic substrates and linked to stress is their dimensional instability, which may manifest itself in irreversible deformation upon heating and cooling cycles. Dimensional stability is critical to ensure precise registration of different layers during photolithography. The global objective of this work is to determine comprehensive experimental characterization and develop underlying fundamental engineering concept that could enable widespread adoption and scale-up of temporary bonding processing protocols for flexible microelectronics manufacturing. A series of carriers with different coefficient of thermal expansion (CTE), modulus and thickness were investigated to correlate the thermo-mechanical properties of carrier with deformation behavior of bonded systems. The observed magnitude of system bow scaled with properties of carriers according to well-established Stoney's equation. In addition, rheology of adhesive impacted the deformation of bonded system. In particular, distortion-bowing behavior correlated directly with the relative loss factor of adhesive and flexible plastic substrate. Higher loss factor of adhesive compared to that of substrate allowed the stress to be relaxed with less bow, but led to significantly greater dimensional distortion. Conversely, lower loss factor of adhesive allowed less distortion but led to larger wafer bow. A finite element model using ANSYS was developed to predict the trend in bow-distortion of bonded systems as a function of the viscoelastic properties of adhesive. Inclusion of the viscoelasticity of flexible plastic substrate itself was critical to achieving good agreement between simulation and experiment. Simulation results showed that there is a limited range within which tuning the rheology of adhesive can control the stress-distortion. Therefore, this model can aid in design of new adhesive formulations compatible with different processing requirements of various flexible microelectronics applications. / Dissertation/Thesis / Ph.D. Chemical Engineering 2011

No description available.

Fiber reinforced polymer (FRP) composites have been of interest to the structural engineering society since the earliest days of FRP composites industry. The use of such systems has been implemented in both new construction and for repair and rehabilitation of existing structures. Since the 1980s, researchers have developed a significant body of knowledge to use FRP composites in infrastructure applications; however, most of this established knowledge was concentrated on the use of traditional epoxy (EP) systems (epoxy matrix FRPs and epoxy adhesives). FRP composites with polyurethane (PU) matrices and adhesives have recently attracted the attention of a few researchers due to their potential advantages in constructibility and mechanical properties. The deployment of these systems is currently limited by a lack of knowledge on mechanical and durability performance. The objective of this research is to quantify the mechanical behavior of PU composites utilized in externally-bonded repair of common flexural and flexural-axial reinforced concrete systems. In addition, the mechanical performance, strength, and failure modes are compared directly with an epoxy-based composite by subjecting reinforced concrete specimens utilizing each of the matrix types (EP and PU) to the same protocols. The study presented therefore allows an objective comparison (advantages and disadvantages) between the two composite system used for repair and rehabilitation of concrete infrastructure. An experimental research program was designed with different length scales. Small-scale experiments were utilized to characterize the component level properties of the materials and bond to concrete, which include the flexural behavior as well as the pure shear behavior. The results of these small scale experiments were used to calibrate analytical models of the interface behavior between FRP laminate and concrete, and paved the way for the next level of the research which studied the behavior of each composite system at larger scales. The large scale experiments included flexural retrofitting of reinforced concrete girders and retrofitting of circular columns using FRP laminates. The large-scale experimental specimens were mechanically damaged prior to FRP repair and testing, making the testing more appropriate compared to common practice of repairing undamaged specimens.

Large scale structures such as those in aerospace flight vehicles are made in parts and assembled. Joints are inevitable in these systems and they are potential threats to the structural integrity of the flight vehicles. Fastener and bonded joints are the most commonly used methods of joining in these structures. Among these, adhesive bonding has become more popular with the advent of composite structures, due to the presence of less number of points of stress concentration and the resulting benefit for static strength and fatigue life. In modern aircraft in which maximum percentage of composite materials are being employed due to several benefits, designers are contemplating to replace discrete joints with adhesively bonded joints wherever possible. A detailed literature survey shows that the field of adhesively bonded joints has been extensively studied in the past. Initial publications appeared in late 1950’s and early 1960's, but many of the initial attempts were based on one dimensional (1-D) approximation of the adherents due to lack of computing power. With the current day emphasis on safety and damage tolerance, there is a definite need to study these joints with 2-D and 3-D idealization. In spite of valuable contributions in the literature from several researchers in past 4-5 decades, one finds that there are gaps to be filled, in particular, with reference to static strength prediction and de-bond growth to failure under fatigue loading. This thesis is intended as a modest contribution in this direction covering the methods of strength prediction and also correlations between de-bond growth and fracture parameters. Most commonly used bonded joints are single lap joints. The primary issue in their analysis is the geometric nonlinearity resulting in large deformations due to eccentricity of load path between the adherents. Further, adhesives have very low yield strength and plastic deformation in thin adhesives could affect the mechanics of load transfer. The current work is initiated by carrying out geometric and material nonlinear analysis of adhesively bonded single lap joints between metal-metal (aluminum-aluminum) adherents using standard NASTRAN finite element software. Modified Newton-Raphson iterative technique has been used to economize the computer time and also achieve fast convergence. A convergence study has been conducted to determine the order of mesh size required. Preliminary results are obtained on configurations analysed by earlier workers and the current results are compared with their results. Later, extensive experimental and numerical studies have been taken up on the numerical strength prediction of these joints correlating them to the experimental values. Cohesive failure along the centre line of the adhesive is assumed under both static and fatigue loading. The bonded joints are studied with both 2-D plane stress and plane strain nonlinear FE analysis. The issue in this type of analysis is the presence of theoretical elastic singularity at the ends of the lap length. The normally used maximum stress criterion can not be used in such circumstances. There were attempts in the past to use point stress or average stress criteria for this purpose. In point stress criterion the shear stress (or von-Mises stress) is picked at a characteristic distance away from the ends of the lap length and compared with the corresponding strength value to predict failure. In the average stress criterion the stresses are averaged over a characteristic distance from the ends of lap length and this is compared with the corresponding strength to predict failure. Determination of the characteristic distance in both the cases needs extensive experimental results on static strength of joints. The static strength data is to be correlated with numerical results to determine the characteristic distance in various specimens. In the current thesis a series of specimens with aluminum-aluminum, aluminum-CFRP composite and CFRP-CFRP composite adherents were tested to determine the static strength. In all the specimens the adhesive used was Redux 319 A. These experimental strength data was used to determine characteristic distance using point stress criterion. The consistency of estimates of the characteristic distances in all the specimens shows that the approach is capable of predicting the static strength. The above approaches are capable of predicting the strength of joints with linear material and nonlinear geometric analysis. But when the adhesive yield strength is low, a novel approach is required to predict the static strength. Numerical analysis is conducted using a combined material and geometric nonlinear analysis in NASTRAN software. The plastic zone size from the ends of the lap length is determined at different load levels. Combining the numerical results with experimental failure load data, a failure criterion based on plastic zone size (PZS) is proposed in this thesis and validated. It has been observed that the validation is with limited testing carried out and further experimental programs are required to complete the validation. To the best of the knowledge of the author PZS criterion is used for the first time for failure prediction of bonded joints. The structural integrity of the joints also requires a study of de-bond growth and damage tolerance assurances in the presence of de-bond type of defects. The first step in this direction is to estimate the fracture parameters at the tips of de-bond in the adhesive of lap joints between various adherents. Modified virtual crack closure integral (MVCCI) technique has been developed in the past for estimating Strain Energy Release Rates (SERR) in several crack problems. Large contributions for developing this technique have come from the group where the author has worked. This technique is simple and has the ability to estimate individual SERR components GI and GII in cases of mixed mode fracture. It is seen clearly that the de-bond growth in bonded joint is one of mixed mode. The mode-II component is because of shear stresses transferring the load across the adherents and mode-I component is due to peel stresses developed during the deformation. The mode I SERR component is primarily responsible for de-bond growth and the effect of mode II component on de-bond growth is insignificant. The mesh details for accurately estimating the SERR components are evaluated and those meshes are used to estimate these values for the cases of aluminum-aluminum, aluminum-CFRP composite and composite-composite joints. Obviously, when the adherents are dissimilar, mode I SERR components are the highest and assist faster de-bond growth. Painstaking fatigue de-bond growth experiments were conducted and de-bond growth rate with number of cycles of fatigue loading was determined. MVCCI method is used to estimate SERR components at maximum load and zero load in the fatigue cycle, to determine the SERR range in the fatigue cycle. Since the stress ratio, R of the loading cycle is -1, the minimum load for estimating SERR components is taken as zero. From the experimental data and numerical estimates, a Paris type of equation was developed for the de-bond growth. The thesis concludes with a summary of the achievements in the current work with respect to the structural integrity of adhesively bonded joints and also with suggestions for future work.