A commercial epoxy was modified by adding fluorinated poly (aryl ether ketone) and in turn metal micro powders (Ni, Al, Zn, and Ag) and coated on mild steel. Two curing agents were used; triethylenetetramine (curing temperatures: 30 oC and 70 oC) and hexamethylenediamine (curing temperature: 80 oC). Variation in tribological properties (dynamic friction and wear) and surface energies with varying metal powders and curing agents was evaluated. When cured at 30 oC, friction and wear decreased significantly due to phase separation reaction being favored but increased when cured at 70 oC and 80 oC due to cross linking reaction being favored. There was a significant decrease in surface energies with the addition of modifiers.

The objective of this research was to explore and demonstrate the production andperformance of fiber-reinforced polymer (FRP) rebar manufactured on a continuous threedimensionalbraiding machine for use as reinforcement in concrete structures. Differentconfigurations of fiberglass/epoxy composite cylindrical rebar rods were manufactured,embedded in concrete, and tested in axial tension to identify the relationships betweenmanufacturing parameters and tensile pull-out strength of the rebar. The strength of the bondbetween concrete and FRP rebar was investigated using the pull-out test detailed by ACI 440.3R-12. The rebar was a No. 4 size and produced by combining multiple tows of fiberglass/epoxyprepreg to form the core of cylindrical rods which were consolidated using spirally-woundaramid consolidation fibers. The manufactured rebar was cured at 121°C (250°F) as specified bythe material manufacturer, TCR Composites. Preliminary research performed on carbon/epoxyrebar guided the process of developing a test matrix based on multiple variables. Primaryvariables investigated included the nature of the consolidation fiber material (dry vs prepreg),and the use of sand coating as a secondary process. The rebar samples were cast in 200 mm x200 mm x 200 mm (8.0 in x 8.0 in x 8.0 in) concrete cubes to investigate bond strength. A testfixture was designed and fabricated for use on a universal tensile testing machine. Standard 12.7mm (0.5 in) diameter steel rebar and a commercially comparable fiberglass rebar were alsotested to provide baseline values. Measurements were collected at both the free and loaded endsof the rebar with free-end results being a more accurate presentation of rebar bond stress.Results showed that the bond strength was 6-13% higher for the free-end for rebarconsolidated with a dry tow compared to prepreg tow consolidated rebar. When sand was added,dry tow consolidated sand-coated samples showed higher bond stress in the range of 15-26% forthe free-end than samples consolidated with a dry tow but excluded sand coating. Samplesconsolidated with prepreg tow and coated with sand showed higher bond stress in the range of43-58% for the free-end compared to prepreg tow no-sand coating samples. Overall, for therebar manufactured on the 3-D braiding machine, the prepreg tow consolidated rebar samplesrecorded the highest bond strength values with a maximum average bond stress value of 15.2MPa (2.26 ksi). The dry tow sand consolidated rebar recorded a maximum average bond stressvalue of 11.4 MPa (1.65 ksi). The rebar purchased from American Fiberglass Rebar recorded amaximum average bond stress of 12.0 MPa (1.74 ksi) while the maximum average bond stress ofsteel rebar was 13.1 MPa (1.90 ksi). Results demonstrated that quality composite rebar can bemanufactured using the 3-D braiding machine and that consolidating the rebar with a prepregtow and coating the surface with sand resulted in a rebar which bonded well with concretecompared to commercialized FRP and steel rebar.

The objective of this research was to explore and demonstrate the production andperformance of fiber-reinforced polymer (FRP) rebar manufactured on a continuous threedimensionalbraiding machine for use as reinforcement in concrete structures. Differentconfigurations of fiberglass/epoxy composite cylindrical rebar rods were manufactured,embedded in concrete, and tested in axial tension to identify the relationships betweenmanufacturing parameters and tensile pull-out strength of the rebar. The strength of the bondbetween concrete and FRP rebar was investigated using the pull-out test detailed by ACI 440.3R-12. The rebar was a No. 4 size and produced by combining multiple tows of fiberglass/epoxyprepreg to form the core of cylindrical rods which were consolidated using spirally-woundaramid consolidation fibers. The manufactured rebar was cured at 121C (250F) as specified bythe material manufacturer, TCR Composites. Preliminary research performed on carbon/epoxyrebar guided the process of developing a test matrix based on multiple variables. Primaryvariables investigated included the nature of the consolidation fiber material (dry vs prepreg),and the use of sand coating as a secondary process. The rebar samples were cast in 200 mm x200 mm x 200 mm (8.0 in x 8.0 in x 8.0 in) concrete cubes to investigate bond strength. A testfixture was designed and fabricated for use on a universal tensile testing machine. Standard 12.7mm (0.5 in) diameter steel rebar and a commercially comparable fiberglass rebar were alsotested to provide baseline values. Measurements were collected at both the free and loaded endsof the rebar with free-end results being a more accurate presentation of rebar bond stress.Results showed that the bond strength was 6-13% higher for the free-end for rebarconsolidated with a dry tow compared to prepreg tow consolidated rebar. When sand was added,dry tow consolidated sand-coated samples showed higher bond stress in the range of 15-26% forthe free-end than samples consolidated with a dry tow but excluded sand coating. Samplesconsolidated with prepreg tow and coated with sand showed higher bond stress in the range of43-58% for the free-end compared to prepreg tow no-sand coating samples. Overall, for therebar manufactured on the 3-D braiding machine, the prepreg tow consolidated rebar samplesrecorded the highest bond strength values with a maximum average bond stress value of 15.2MPa (2.26 ksi). The dry tow sand consolidated rebar recorded a maximum average bond stressvalue of 11.4 MPa (1.65 ksi). The rebar purchased from American Fiberglass Rebar recorded amaximum average bond stress of 12.0 MPa (1.74 ksi) while the maximum average bond stress ofsteel rebar was 13.1 MPa (1.90 ksi). Results demonstrated that quality composite rebar can bemanufactured using the 3-D braiding machine and that consolidating the rebar with a prepregtow and coating the surface with sand resulted in a rebar which bonded well with concretecompared to commercialized FRP and steel rebar.

No description available.

The primary differences between the solventborne and waterborne epoxy printed circuit board (PCB) impregnating resins arise from the distinct physical compositions and drying characteristics of the polymer solution and the latex emulsion. The presence of residual surfactant from the waterborne epoxy emulsion poses a concern for dielectric performance and adhesive durability. Another problem involves the crystallization of insoluble solid dicyandiamide (DICY), which is significantly different in morphology than that found in solution cast resins. A two-stage drying model was employed to gain a better understanding the drying and coalescence processes. The process of surface DICY crystal formation during the drying of glass prepreg sheet was related to a threshold concentration of the curing agent in the impregnating latex resin formulation. Conditions favoring faster drying lead to the rapid formation of a coalesced skin layer of latex resin, thereby trapping the curing agent in the bulk and reducing the surface deposition of DICY by percolating water. Surfactant is believed to remain concentrated in a receding wet zone until it is driven to the surfaces of the glass fibers upon the completion of drying. The copper foil/laminate interface was evaluated by a 90° peel test as part of two different studies: an analysis of the viscoelastic response of the interface during peel and a study of the thermal durability of the copper/laminate interfacial peel strength. The surfactant acted as a plasticizer to toughen the fiber/matrix interphase, resulting in larger observed peel strengths in the latex resin impregnated materials relative to the solventborne system. Surfactant segregated to the fiber surface during coalescence to form a plasticized fiber/matrix interphase; surfactant migrated into the bulk during postcure to yield a more homogeneously plasticized epoxy matrix. Dielectric measurements of neat resin and laminate materials revealed that the dielectric constants of the model resin-impregnated laminates met the performance criteria for PCB substrates of their class, regardless of surfactant content. Overall, the adhesive performance, adhesive durability, and dielectric properties of PCB systems fabricated with model latex epoxy resin, containing native surfactant (5 wt %), met or exceeded the performance of an equivalent solventborne resin impregnated system. / Ph. D.

The state of cure of epoxies is an important issue in the manufacture of graphite epoxy composites used in aerospace structures. Variations in the initial state and process used to cure the epoxy resin in a composite material lead to variations in the mechanical properties of the part manufactured from the composite._[12] Control of these variation can be accomplished by monitoring the bulk and shear moduli of the epoxy resin as it cures. The moduli properties of the resin determine the acoustic properties of the epoxy._{[12],[13],[14]} Hence measurement of the acoustic longitudinal velocity and attenuation of the epoxy during its cure cycle provides a good indicator of the state of cure. Optical fiber waveguides can be embedded within a host material and used to detect longitudinal acoustic waves._[15],[16] Herein, the mechanisms allowing the detection of ultrasound with optical fiber are presented. An analysis of optical fiber waveguides and optical fiber based interferometric detection methods is performed in detail. The interaction of radial strain fields, induced by longitudinal acoustic waves, with singlemode optical fibers is described. Experimental results obtained in epoxy cure monitoring, using an optical fiber based method for acoustic detection, are compared with results obtained using conventional piezoelectric based acoustic detection methods. / Master of Science

Cellulose nanocrystals (CNCs) are crystalline nanoparticles that are extracted from renewable sources such as trees or bacteria through mechanical or chemical treatments of their source. CNCs are of interest to several research communities concerned with sustainable technologies. Specifically, CNCs have attracted great interest in the polymer composite community given their high theoretical specific strength and modulus. Two key obstacles surround the use of CNCs in polymer composites, namely their comparatively lower thermal stability and hydrophilicity render their dispersion, and therefore mechanical reinforcement, in polymer matrices challenging. This research considered a waterborne epoxy and a polyurethane elastomer for CNC/polymer composites since these composites are seldom reported in literature or often suffer from degraded mechanical properties. In the epoxy/CNC composites, samples were prepared by two methods, first an epoxy emulsion was mixed with an amine crosslinker and an aqueous based CNC suspension (1-step mixing), and second, the epoxy emulsion was premixed with the aqueous based CNCs and the amine crosslinker was added some time later (2-step mixing). Both composites were mixed by magnetic stirring, however the samples prepared by the 2-step mixing method exhibited enhanced dispersion and mechanical properties, specifically the storage modulus (E’), tensile strength, and work of fracture. Zeta potential measurements and chemical analysis by FTIR indicated that the dispersion mechanism was physical in nature, rather than chemical. In the second composite system, CNCs were chemically modified with an isophorone diisocyanate (IPDI) monomer having unequally reactive isocyanate groups. The goal of the modification step was to react only one isocyanate group with the CNC surface and have a free isocyanate group available for further modification. The chemical structure of one linked isocyanate (urethane bond) and one free isocyanate was confirmed by FTIR and 13C NMR. The particles modified by IPDI (m-CNC) and the neat particles (um-CNC) were incorporated into a polyurethane matrix based on IPDI and a triol crosslinker. Upon visual inspection of the cured composites, it was clear that the modification step produced homogeneously dispersed nanoparticles in the polyurethane while the um-CNCs were aggregated. When the mechanical properties were tested by uniaxial tensile testing, it was determined that the m-CNC composites resulted in improvements in the tensile strength and work of fracture without degradation of the elongation of break property when compared to the neat matrix. Overall the findings in this research highlight important considerations for designing CNC/thermoset composites with enhanced dispersion and mechanical performance.

No description available.

This research deals with the mechanical characterisation of thick composite laminates in the through-thickness direction. Three independent glass fibre/epoxy laminate configurations, namely cross, quasi-isotropic, and woven, plies were investigated. Six specimen configurations, of which two were developed herein, were employed in order to determine the strength behaviour of these three laminate configurations when subjected to interlaminar shear and interlaminar tensile stresses in isolation and in combination. The stress and strain distributions were estimated using the ABAQUS FEA package. The strain distribution obtained thereby was verified experimentally via Moirandeacute; interferometry which records the exact strain field at the test section. A two dimensional failure envelope is defined for each laminate configuration using the experimentally obtained data. All three independent laminate configurations exhibited almost identical failure envelopes. The woven laminate exhibited superior interlaminar shear strength when subjected to combined interlaminar shear and interlaminar tensile stresses, whereas the cross-ply laminate exhibited superior interlaminar tensile strength when subjected to the same combination of stress. The characteristics of the quasi-isotropic laminate were similar to that of the cross-ply laminate. A partial three dimensional failure envelope was also defined for the materials tested.

Lead-tin solder has been widely used as interconnection material in electronics packaging for a long time. In response to environmental legislation, the lead-tin alloys are being replaced with lead-free alloys and electrically conductive adhesives in consumer electronics. Lead-free solder usually require higher reflow temperatures than the traditional lead-tin alloys, which can cause die crack and board warpage in assembly process, thereby impacting the assembly yields. The high tin content in lead-free solder forms tin whiskers, which has the potential to cause short circuits failure. Conductive adhesives are an alternative to solder reflow processing, however, conductive adhesives require up to 80 wt% metal filler to ensure electrical and thermal conductivity. The high loading content degrades the mechanical properties of the polymer matrix and reduces the reliability and assembly yields when compared to soldered assemblies. Carbon nanotubes (CNTs) have ultra high aspect ratio as well as many novel properties. The high aspect ratio of CNTs makes them easy to form percolation at low loading and together with other novel properties make it possible to provide electrical and thermal conductivity for the polymer matrix while maintaining or even reinforcing the mechanical properties. Replacing the metal particles with CNTs in conductive adhesive compositions has the potential benefits of being lead free, low process temperature, corrosion resistant, electrically/thermally conductive, high mechanical strength and lightweight. In this paper, multiwall nanotubes (MWNTs) with different dimensions are mixed with epoxy. The relationships among MWNTs dimension, volume resistivity and thermal conductivity of the composite are characterized. Different loadings of CNTs, additives and mixing methods were used to achieve satisfying electrical and mechanical properties and pot life. Different assembly technologies such as pressure dispensing, screen and stencil printing are used to simplify the processing method and raise the assembly yields. Contact resistance, volume resistivity, high frequency performance, thermal conductivity and mechanical properties were measured and compared with metal filled conductive adhesive and traditional solder paste.