Within this research, factors affecting the orientation of injection molded long fiber composites in an end-gated plaque were investigated. Matrix viscosity was found to have a small effect on fiber orientation. The impact matrix viscosity had on orientation was dependent on fiber loading. At lower fiber loadings, the higher viscosity material had a more asymmetric orientation profile throughout the samples and less of a shell-core-shell orientation. At higher fiber loadings, there were few differences in orientation due to matrix viscosity. Fiber concentration was found to have a larger influence on fiber orientation than matrix viscosity. Increased fiber concentration led to a lower degree of flow alignment and a broader core region at all locations examined, following the trend previously reported for short fiber composites. The orientations of three different fiber length distributions of glass fiber (GF) were compared. The longer fibers in the fiber length distribution were shown to have a disproportionate effect on orientation, with weight average aspect ratio being better than number average aspect ratio at indicating if the GF and CF samples orientated comparably. To improve properties transverse to the main flow direction, the super critical carbon dioxide aided deagglomeration of multi-walled carbon nanotubes (CNTs) was used to create injection molded multiscale composites with CNT, CF, and polypropylene. The addition of CNTs greatly improved the tensile and electrical properties of the composites compared to those without CNTs. The degree of improvement from adding CNTs was found to be dependent on CF concentration, indicating that the CNTs were most likely interacting with the CF and not the polymer. A CNT concentration of 1 wt% with a tenfold degree of expansion at 40 wt% CF proved to be optimum. A large improvement in the tensile properties transverse to the flow direction was found implying that the CNTs were not highly flow aligned. Tensile and electrical properties began to fall off at higher CNT loadings and degrees of expansion indicating the importance of obtaining a good dispersion of CNTs in the part. / Ph. D.

This work is concerned with determining empirical parameters in stress and fiber orientation models required to accurately simulate the fiber orientation in injection molded composites. An independent approach aims to obtain the material parameters using a sliding plate rheometer to measure the rheology of fiber suspensions at increased fiber lengths subjected to transient shear flow. Fiber orientation was measured in conjunction with shear stress to determine the relationship between stress and fiber orientation. Using a compression molding sample preparation procedure, the transient shear stress response was measured for glass and carbon fiber suspensions up to a number average fiber aspect ratio (length/diameter) of 100. Increases in concentration or fiber aspect ratio caused the magnitude of the stress response to increase by as much as an order of magnitude when compared to the suspending matrix. The degree of shear thinning at low shear rates also increased with increases in aspect ratio and concentration. The compression molding sample preparation procedure provided poor control of the initial fiber orientation which led to the investigation of samples subjected to flow reversal and samples generated through injection molding. The samples prepared through injection molding provided improved repeatability in the measured shear stress response and fiber orientation evolution during the startup of flow compared to compression molded samples and samples subjected to flow reversal. From repeatable stress and orientation evolution data, models for stress and fiber orientation were assessed independently. Current theories for stress were unable to reflect the overshoot in the measured stress response and could at best capture the steady state. The transient behavior of the fiber orientation models were found to be highly dependent on the initial fiber orientation. The repeatable orientation data obtained from the injection molding sample preparation procedure provided material parameters in the strain reduction factor and reduced strain closure models. The injection molded samples provided evolution data from different initial fiber orientations to provide further scrutiny or validation of the material parameters. Orientation model parameters that provided reasonable agreement to multiple sets of fiber evolution data in simple shear flow should allow for a better assessment of the orientation models in complex flow simulations. / Ph. D.

The design of fiber-reinforced thermoplastic (FRT) parts is hindered by the determination of the various empirical parameters associated with the fiber orientation models. A method for obtaining these parameters independent of processing doesn't exist. The work presented here continues efforts to develop a rheological test that can obtain robust orientation model parameters, either by fitting directly to orientation data or by fitting to stress-growth data. First, orientation evolution in a 10 wt% long-glass-fiber-reinforced polypropylene during two homogeneous flows (startup of shear and planar extension) was compared. This comparison had not been performed in the literature previously, and revealed that fiber orientation is significantly faster during planar extension. This contradicts a long-held assumption in the field that orientation dynamics were independent of the type of flow. In other words, shear and extension were assumed to have equal influence on the orientation dynamics. A non-lubricated squeeze flow test was subsequently implemented on 30 wt% short-glass-fiber-reinforced polypropylene. An analytical solution was developed for the Newtonian case along the lateral centerline of the sample to demonstrate that the flow is indeed a superposition of shear and extension. Furthermore, an existing fiber orientation model was fit to the gap-wise orientation profile, demonstrating that NLSF can, in principle, be used to obtain fiber orientation model parameters. Finally, model parameters obtained for the same FRT by fitting to orientation data from startup of steady shear are shown to be inadequate in predicting the gap-wise orientation profile from NLSF. This work is rounded out with a comparison of the fiber orientation dynamics during startup of shear and non-lubricated squeeze flow using a long-fiber-reinforced polypropylene. Three fiber concentrations (30, 40, and 50 wt%) were used to gauge the influence of fiber concentration on the orientation dynamics. The results suggest that the initial fiber orientation state (initially perpendicular to the flow direction and in the plane parallel to the sample thickness) and the fiber concentration interact to slow down the fiber orientation dynamics during startup of shear when compared to the dynamics starting from a planar random initial state, particularly for the 40 and 50 wt% samples. However, the orientation dynamics during non-lubricated squeeze flow for the same material and initial orientation state were not influenced by fiber concentration. Existing orientation models do not account for the initial-state-dependence and concentration-dependence in a rigorous way. Instead, different fitting parameters must be used for different initial states and concentrations, which suggests that the orientation models do not accurately capture the underlying physics of fiber orientation in FRTs. / Ph. D. / In order to keep pace with government fuel economy legislation, the automotive and aerospace industries have adopted a strategy they call “lightweighting”. This refers to decreasing the overall weight of a car, truck, or plane by replacing dense materials with less-dense substitutes. For example, a steel engine bracket in a car could be replaced with a high-temperature plastic reinforced with carbon fiber. This composite material will be lighter in weight than the comparable steel component, but maintains its structural integrity. Thermoplastics reinforced with some kind of fiber, typically carbon or glass, have proven to be extremely useful in meeting the demands of lightweighting. Thermoplastics are materials that can be melted from a feedstock (typically pellets), reshaped in the melted state through use of a mold, and then cooled to a solid state, and some common commodity-grade thermoplastics include polypropylene (used for Ziploc bags) and polyamides (commonly called Nylon and used in clothing). Although these commodity applications are not known for their strength, the fiber reinforcement in the automotive applications significantly improves the structural integrity of the thermoplastics. The ability to melt and reshape thermoplastics make them incredibly useful for highthroughput processes such as injection molding. Injection molding takes the pellets and conveys them through a heated barrel using a rotating screw. The melted thermoplastic gathers at the tip of the barrel, and when a set volume is gathered, the screw is rammed forward to inject the thermoplastic into a closed mold of the desired shape. This process typically takes between 30-60 seconds per injection. This rate of production is crucial for the automotive industry, as manufacturers need to put out thousands of parts in a short period of time. The improvement to mechanical properties of the thermoplastics is strongly influenced by the orientation of the reinforcing fibers. Although design equations connecting the part’s mechanical properties to the orientation of the fibers do exist, they require knowledge of the orientation of the fibers throughout the part. Fibers in injection-molded parts have an extremely complicated orientation v state. Measuring the orientation state at each point would be too laborious, so empirical models tying the flow of the thermoplastic through the mold to the evolving orientation state of the fibers have been developed to predict the orientation state in the final part. These predictions can be used in lieu of direct measurements in the part design equations. However, the orientation models rely on empirical fitting parameters which must be obtained before injection molding simulations are performed. There is currently no standard test for obtaining these parameters, nor is there a standardized look-up table. The work presented in this dissertation continues efforts to establish such a test using simple flows in a laboratory setting, independent of injection molding. Previous work focused exclusively on using shearing flow (e.g. pressure-driven flow found in injection molding) to obtain these parameters. However, when these parameters were used in simulations of injection molding, the agreement between measured and predicted fiber orientation was mediocre. The work here demonstrates that another type of flow, namely extensional flow, must also be considered, as it has a non-negligible influence on fiber orientation. this is crucial to injection molding, as injection molding flows have elements of both shearing and extensional flow. The first major contribution from this dissertation demonstrates that extensional flow (e.g. stretching a film) has a much stronger influence than shearing flow, even at the same overall rate of deformation. The second major contribution used a combination shear/extensional flow to demonstrate that the empirical model parameters, thought to be characteristic of the composite, are actually strongly influenced by the type of flow experienced by the sample, and that no single set of model parameters can fit the full orientation state. The final major contribution extends the previous case to long-fiber reinforcement at multiple fiber concentrations which are of industrial interest. This finds the same results, that the model parameters are dependent on the type of flow experienced by the sample. The flow-dependence of the parameters is a crucial point to address in future work, as the flows found in injection molding contain both shearing and extensional flow. By further developing this flow-type dependence, future injection molding simulations should become more accurate, and this will make computer-aided injection-molded part design much more efficient.

An enhanced demand for lightweight materials in automotive applications has resulted in the growth of the use of injection molded discontinuous fiber-reinforced thermoplastics. During the intensive injection molding process, severe fiber breakage arises in the plasticating stage leading to a broad fiber length distribution. Fiber orientation distribution (FOD) is another highly anisotropic feature of the final injection molded parts induced by the mold filling process. The mechanical and other properties can be highly dependent on the fiber length distribution and fiber orientation distribution. The residual fiber length in the final part is of great significance determining the mechanical performances of injection molded discontinuous fiber reinforced thermoplastic composites. One goal of this research is to develop a fiber length characterization method with reproducible sampling procedure in a timely manner is described. In this work is also proposed an automatic fiber length measurement algorithm supported by Matlab®. The accuracy of this automatic algorithm is evaluated by comparing the measured results using this in-house developed tool with the manual measurement and good agreement between the two methods is observed. Accurate predictions of fiber orientation are also important for the improvement of mold design and processing parameters to optimize mechanical performances of fiber-reinforced thermoplastics. In various fiber orientation models, a strain reduction factor is usually applied to match the slower fiber orientation evolution observed experimentally. In this research, a variable strain reduction factor is determined locally by the corresponding local flow-type and used in fiber orientation simulation. The application of the variable strain reduction factor in fiber orientation simulations for both non-lubricated squeeze flow and injection molded center-gated disk, allows the simulated fiber re-orient rate to be dependent on the local flow-type. This empirical variable strain reduction factor might help to improve the fiber orientation predictions especially in complex flow, because it can reflect the different rates at which fibers orient during different flow conditions. Finally, the stiffness of injection-molded long-fiber thermoplastics is investigated by micro-mechanical methods: the Halpin-Tsai (HT) model and the Mori-Tanaka model based on Eshelby's equivalent inclusion (EMT). We proposed an empirical model to evaluate the effective fibers aspect ratio in the computation for the fiber bundles under high fiber content in the as-formed fiber composites. After the correction, the analytical predictions had good agreement with the experimental stiffness values from tensile tests on the composites. Our analysis shows that it is essential to incorporate the effect of the presence of fiber bundles to accurately predict the composite properties. / PHD / An enhanced demand for lightweight materials in automotive applications has resulted in the growth of the use of injection molded discontinuous fiber-reinforced thermoplastics. The injection molding process results in fiber length and fiber orientation distributions in the final parts. The mechanical and other properties can be highly dependent on the fiber length distribution and fiber orientation distribution. This work focuses on the process-structure-property relationship of fiber-thermoplastic composites. A novel fiber length measurement procedure and an automatic fiber length measurement tool were developed to improve the accuracy of fiber length measurement. The existing fiber orientation models have been improved by integration of the flow-type dependent fiber orientation kinetics. To improve the stiffness predictions, an empirical model has been developed to include the effects of fiber clumping on the elastic properties of injection molded fiber composites.

Yes / We have performed shrinkage restraint force measurements on three shape memory polymers of polyethylene terephthalate (PET), polymethyl methacrylate (PMMA) and a blend of the two at a range of temperatures. Observations are made of the change in stress during temperature rise, hold and cooling. All materials show an increase in stress during rise and hold, but on cooling the three materials behave differently; the PET shows a drop in stress, the PMMA a rise and the blend a much smaller rise. This behaviour correlates with the reversible thermal dimensional change at below the shrinkage threshold temperature; the expansion coefficients are negative for PET, positive for PMMA and positive at a lower order of magnitude for the blend. We model the behaviour by supposing that the shrinkage forces are created by prestressed strains effective at long range within a matrix of shorter chains effective at short range. The total stress is the sum of the shrinkage stress and the thermal stress in the matrix. The drops in stress on cooling are modelled using an elastic analysis based on measured elastic moduli and thermal expansion coefficients. For the blend, downward jumps in temperature produce small transient increases in the total stress, leaving it effectively unchanged. This phenomenon and the results of the elastic model for the stress drops imply that the shrinkage stress from the long-range chain network is largely unaffected by the temperature change, and so is not entropic.

L’utilisation des thermoplastiques renforcés de fibres de verre courtes pour la fabrication de pièces de structure dans l’industrie des transports est croissante pour des applications structurelles en environnements chauds. La conception de telles pièces nécessite le développement d’un outil de dimensionnement en fatigue à hautes températures. La prise en compte de la distribution d’orientation des fibres (DOF), dû au procédé d’injection, hétérogène est essentielle.Ces travaux de thèse, cofinancés par la Direction Générale de l’Armement et la région Poitou-Charentes, proposent une approche complétement intégrée de la simulation du procédé d’injection à la prédiction de durée de vie en fatigue, dans un cadre viscoélastique, de pièces injectées en thermoplastiques renforcés, à 110°C.Différentes étapes jalonnent la structure de l’outil numérique qualifié de « Through Process Modelling » (TPM). A partir de la connaissance de la DOF au sein d’une pièce obtenue par simulation du procédé d’injection, les propriétés effectives anisotropes locales sont estimées par homogénéisation viscoélastique. Les champs mécaniques hétérogènes, associés à différents types/niveaux de chargement et obtenus par simulation éléments finis, sont post-traités pour extraire la grandeur mécanique équivalente en entrée d’un critère de fatigue énergétique fournissant la durée de vie de la pièce pour chacune de ces conditions de chargement.L’identification des paramètres du critère de fatigue, puis la validation de l’ensemble de la méthodologie, s’appuient sur des essais de fatigue en traction uniaxiale à 110°C. Ces essais sont réalisés, en enceinte climatique, sur éprouvettes découpées dans des plaques injectées de PA66GF30 selon différentes orientations par rapport à la direction d’injection, pour 2 rapports de charge (R = 0,1 et R = -1) et à 2Hz.Les prédictions de durées de vie sont très satisfaisantes. L’influence de la qualité de prédiction de la DOF en entrée de la chaîne de calcul sur les résultats est aussi discutée. / The employment of short glass fibres reinforced thermoplastics is increasing in the automotive industry for hot environment applications. The design of components in such conditions and with this type of materials under fatigue loading must be optimized using a fatigue life assessment methodology. The heterogeneous fibres orientation distribution (FOD), due to the injection process should be considered.This work, funded by the Direction Générale de l’Armement et Région Poitou-Charentes, suggests an integrated approach from the injection process simulation to the assessment of the fatigue life at 110°C of injected components in a viscoelastic framework.The methodology here advanced is called “Through Process Modelling” (TPM). From the FOD in the component given by the injection simulation, the anisotropic effective local properties are estimated using viscoelastic homogenisation. The heterogeneous mechanical fields obtained by finite element simulations, for different types/levels of loading, are post-processed in order to get the input equivalent mechanical quantity of an energetic fatigue criterion giving the fatigue life of the component in each of these loading conditions.The identification of the fatigue criterion parameters and the validation of the whole methodology rely on an experimental fatigue database for a PA66GF30. Uniaxial tensile fatigue tests are carried out at 110°C in a climatic chamber, for 2 stress ratios (R = 0,1 and R = -1) and at 2Hz. They are performed for specimens cut out from injected plates with different orientations with respect to the flow direction.The methodology leads to very good predictions. The influence of the prediction of the FOD, input of the calculation chain, on the results is discussed.

The impact of swirl (i.e., flow with axial and azimuthal velocity components) on the turbulent flow in a pipe is studied using two-component laser-Doppler velocimetry (LDV). There are practical motivations for the flow geometry. For example, previous studies demonstrate that introducing swirl in the tube bank of a paper machine headbox can significantly increase mixing, and hence increase fiber dispersion and orientation isotropy in the finished paper product. The flow characteristics in a pipe downstream of a single straight tapered fin, a single fin with 180??ist but otherwise identical geometry, and four twisted fins were therefore studied at a pipe-based Reynolds number of 80,000. Radial profiles of the mean and rms fluctuations of the streamwise and azimuthal velocity components are measured; results for the straight and twisted single fin are compared to determine the effects of fin geometry and swirl on the turbulent wake downstream of the fin. From a practical viewpoint, it is also desirable to have adjustable swirl, where swirl can either be turned on or off depending upon the type of paper product being produced. The next generation swirler concept consists of fins fabricated from two-way shape memory alloys. Using the two-way memory effect, the fins will be in their straight configuration when cold and twisted configuration (hence acting as a swirler) when hot. This study is the initial phase in developing new active control mechanisms, known as the Vortigen concept, for increasing productivity, and hence reducing wasted raw material and energy, in the pulp and paper industry.

The influence of turbulence on the orientation state of a dilute suspension of stiff fibers at high Reynolds number in a planar contraction is investigated. High speed imaging and LDV techniques are used to quantify fiber orientation distribution and turbulent characteristics. A nearly homogenous, isotropic grid generated turbulent flow is introduced at the contraction inlet. Flow Reynolds number and inlet turbulent characteristics are varied in order to determine their effects on orientation distribution. The orientation anisotropy is shown to be accurately modelled by a Fokker-Planck type equation. Results show that rotational diffusion is highly influenced by inlet turbulent characteristics and decays exponentially with convergence ratio. Furthermore, the effect of turbulent energy production in the contraction is shown to be negligible. Also, the results show that the flow Reynolds number has negligible effect on the development of orientation anisotropy, and the influence of turbulence on fiber rotation is negligible for $mathrm{Pe_r}>$ 10. It was concluded that inertia induced fiber motion played a negligible role in the experiments.

This study focuses on developing novel modeling techniques for fiber-reinforced composites with polymer and ceramic matrix based on Peridynamic approach. To capture the anisotropic material behaviors of composites under quasi-static and dynamic loading conditions, a new peridynamic model for composite laminate and a modified peridynamic approach for non-uniform discretization are proposed in this study. In order to achieve the numerical implementation of the proposed model and approach, a mixed implicit-explicit solver based on GPU parallel computing is developed as well. The new peridynamic model for composite laminates does not have any limitation in fiber orientation, material properties and stacking sequence. It can capture the expected orthotropic material properties and coupling behaviors in laminates with symmetric and asymmetric layups. Unlike the previous models, the new model enables the evaluation of stress and strain fields in each ply of the laminate. Therefore, it permits the use of existing stress- or strain-based failure criteria for damage prediction. The computation of strain energy stored at material points allows the energy-based failure criteria required for delamination propagation and fatigue crack growth. The capability of this approach is verified against benchmark solutions, and validated by comparison with the available experimental results for three laminate layups with an open hole under tension and compression. The modified peridynamic approach for non-uniform discretization enables computational efficiency and removes the effect of geometric truncations in the simulation. This approach is a modification to the original peridynamic theory by splitting the strain energy associated with an interaction between two material points according to the volumetric ratio arising from the presence of non-uniform discretization and variable horizon. It also removes the requirement for correction of peridynamic material parameters due to surface effects. The accuracy of this approach is verified against the benchmark solutions, and demonstrated by considering cracking in nuclear fuel pellet subjected to a thermal load with non-uniform discretizations. Unlike the previous peridynamic simulations which primarily employs explicit algorithm, this study introduces implicit algorithm to achieve peridynamic simulation under quasi-static loading condition. The Preconditioned Conjugate Gradient (PCG) and Generalized Minimal Residual (GMRES) algorithms are implemented with GPU parallel computing technology. Circulant preconditioner provides significant acceleration in the convergence of peridynamic analyses. To predict damage evolution, the simulation is continued with standard explicit algorithms. The validity and performance of this mixed implicit-explicit solver is established and demonstrated with benchmark tests.

Several active methods, which requires external control systems and moving parts, have been developed to control the fiber orientation during 3D printing. Active mechanisms like rotating nozzle, impeller, and magnetic field have been integrated to realize complex internal fiber structures. In this study, instead of using active methods, I investigate a passive method for controlling the fiber orientation without any moving parts or additional mechatronics added in the printing process. Composites of polydimethylsiloxane (PDMS) and glass fibers (GF) are 3D printed. Channels, such as helicoid, are designed and integrated to guide the ink flow and passively result in different pre-alignment of fibers before the ink flow into narrow nozzle space. While passing through the designed channels, the fibers orient due to the shear between channel walls and the ink. The effect of helicoids with different pitch sizes are investigated via mechanical experiments, microstructural analysis, and numerical simulations. The results show that both surface to volume ratio and helix angle of the channel affect pre-alignment of fiber orientation at the entry of nozzle. The internal fiber structures lead to enhanced and tunable mechanical properties of printed composites. Pitch size 7-9 mm (helix angle of 7.92- 10.15o) is found to be optimal for the 3D printed PDMS-GF composites. Stiffness and strength can be tuned up to 77.6% and 47.8%, respectively, compared with the case without helicoid channel. Channels of parallel holes, parallel holes with taper end and gradually changing pitch helicoids are experimentally tested, showing further enhancement in mechanical properties.