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Thesis (Ph. D.)--Polymer, Textile and Fiber Engineering, Georgia Institute of Technology, 2008. / Committee Chair: Karl I. Jacob; Committee Member: Anselm C. Griffin; Committee Member: C. P. Wong; Committee Member: Rina Tannenbaum; Committee Member: William J. Koros; Committee Member: Yonathan S. Thio.

A shape memory alloy (SMA) is an intermetallic compound able to recover, in a continuous and reversible way, a predetermined shape during a thermal cycle while generating mechanical work. In this thesis, its use in developing an actuator for a machining process is investigated. The actuator is to drive the tool cross feed into an aluminium workpiece in a finishing lathe operation. The actuator structure was designed with an output shaft to transfer the movement and force of the SMA wire outside the device. The actuator was fabricated and the experimental setup was assembled which also included a power supply control circuit, displacement sensor, temperature sensor and current sensor for feedback, and data collection and monitoring within software. PID control was implemented within the software that regulated the power supplied to the SMA, thereby providing the position control. This study covers the mechatronics system design and development of the actuator, the experiments carried out to determine performance and the results. Open loop tests were conducted to determine the maximum stroke, the effect of cooling and response to radial forces. These tests revealed the expected non-linearity of the SMA. The actuator achieved the rated maximum stroke of 3-4 percent. The forced cooling test showed a general improvement of approximately 65 percent with fans. The radial force tests showed the value of the maximum stroke remained unaffected by force. The results from the closed loop tests responses with a tuned PID controller produced a stable system for various displacement setpoints. The actuator had a feed rate of 0.25 mm/s and an accuracy of 0.0153mm, which was within the acceptable accuracy for turning operations. The system was deemed accurate for a conventional lathe machine cross feed.

A systematic study was conducted to examine the influence of fiber surface treatment and sizing on the formation of fiber-matrix interphase and its effects n the mechanical properties of composite laminates. Three material systems having the same Apollo graphite fibers and HC 9106-3 toughened epoxy matrix, but with different fiber surface treatments and sizings were used in this study. The fibers used in the 810A and 820 A systems received 100% and 200% industry standard surface treatments respectively and were sized with Bisphenol-A unreacted epoxy material. The 810 O system was manufactured with 100% surface treated fibers that were sized with pvp (polyvinylpyrrolidone), a thermoplastic material. The presence of different interphase in these materials was confirmed using a permanganic etching technique. Results indicate that the interphase is discontinuous and made of linear chain polymeric material in the 810 A system. The interphase in the 810 O system has a gradient morphology while the 820 A system does not possess a well defined interphase. Mechanical test results indicate that the 810 O system significantly greater longitudinal tensile strength and failure strain compared to the 810 A system. The 810 A and 820 A systems have similar longitudinal tensile properties. Transverse tensile test results indicate that the 820 A system has the highest strength while the 810 O system has the lowest strength. The (0,90₃), cross-ply laminates from the three material systems exhibit different damage mechanisms and failure modes under monotonic tensile loading. Fatigue test results indicate that the 810 O laminates have longer fatigue lives at higher load levels and shorter fatigue lives at lower load levels compared to the 810 A laminates. The 820 A laminates have longer life compared to the other two materials systems, at all three load levels. The 810 O material exhibits greater damage and stiffness reduction than the other two materials. The 810 A and 820 A systems exhibit a brittle stress concentration controlled failure, while the pvp sized 810 O system exhibits a global strain conuolled failure. A micromechanics model was developed to investigate the role of the interphase on the tensile strength of unidirectional laminates. A new parameter called the ‘efficiency of the interface’, is introduced in the model. A simple scheme that uses the experimentally determined tensile modulus of unidirectional laminates in a concentric cylinders model, is described to estimate the interfacial efficiency. The tensile fatigue performance of cross-ply laminates is predicted using this micromechanics model in a cumulative damage scheme. The predicted fatigue lives and failure modes agree well with experimental results. / Ph. D.

The static and dynamic flexural properties of a wood fiber matrix internally reinforced with continuous glass fibers were investigated. When modelled as a sandwich composite, the static flexural modulus of elasticity (MOE) of glass fiber reinforced hardboard could be successfully predicted from the static flexural MOE of the wood fiber matrix, and the tensile MOE and effective volume fraction of the glass fiber reinforcement. Under the same assumption, the composite modulus of rupture (MOR) is a function of the reinforcement tensile MOE and effective volume fraction, and the matrix stress at failure. The composite MOR was predicted on this basis with limited success. The static flexural modulus of elasticity, dynamic modulus of elasticity, and modulus of rupture of glass fiber reinforced hardboard increased with increasing effective reinforcement volume fraction. The logarithmic decrement of the composite decreased with increasing effective reinforcement volume fraction. Excellent linear correlation found among flexural properties determined in destructive static tests and nondestructive dynamic tests demonstrated the usefulness of dynamic test methods for flexural property evaluation. The short-term flexural creep behavior of glass fiber reinforced hardboard was accurately described by a 4-element linear viscoelastic model. Excellent agreement existed between predicted and observed creep deflections based on nonlinear regression estimates of model parameters. / Ph. D.

A process for fabricating particulate reinforced composites from dry powder-powder blends was developed. The process was designed to exploit the nature of fine powder constituent materials, such that the energy input during the molding process could be reduced. Polymer and reinforcement materials were chosen, characterized, and molded into composite plaques. These composites were characterized in terms of mechanical and thermo-mechanical properties. Stiffness, coefficient of thermal expansion, and overall dimensional stability were found to improve; and strength, strain-to-failure, and toughness were found to decrease to varying degrees. The results of these predictions were compared with simple micromechanics models to gain a better understanding of their physical behavior. / M.S.