Factors in fiber manufacturing procedures affect fiber¡¦s production, and the fiber quality will be affected accordingly. The residual stresses, in particular, have a significant influence on fiber quality, due to the mechanical strength and the refraction rate that has been changed. Mechanically, residual stresses may cause ruptures in the preform, reducing the intrinsic strength of the fiber and its durability; optically, it may also cause anisotropic distortions of the refractive index profiles. In the process of cooling under high temperature, fiber core and cladding will be compressed owing to the material difference and the residual stress will be in the fiber. Thermal conductance and thermal expansion coefficient contribute to the cracks on the interface and thus affect the refraction rate. Experiments have shown that quartz and Cr4+¡GYAG will rupture on the interface as a result of the huge thermal expansion coefficient. According to researches, stress in different directions will bring about fiber cracks or changes of the refraction rate. This paper mainly investigates the influence of material properties on the temperature field and thermal stress distribution in the cooling process of fiber and preform manufacturing by numerical simulations. The results show the preform temperature profile and the stress distribution in different directions. Also, through the stress distribution, the stress is known to be centered on the interface between core and cladding.

v Abstract This study was developed using fiber drawing tower to fabricate various types of capillary fiber and microstructured fiber. For example, different diameter sizes, different thickness, different internal diameter ratio of the capillary fiber and capillary tube, single ring and double ring hexagonal arrangement of the air-holes microstructured fiber. Trying different ways to create complex structures preform, we use the stack - drawing - cutting way, is now able to produce only simple pressure can be achieved by the complex structure of the preform, compared to drilling way, we can effectively reduce the production costs of 80%. Now successfully produced a single ring and double ring hexagonal air holes arranged in preform which has been drawn into standard fiber. Depending on the optical properties, we can use quartz tube with a row of self-developed method to produce most of the complex structure of the preform. However, each fiber is still not very uniform about the pores, which we need to improve in the manufacturing process of fiber drawing. Produce more diverse system and much homogeneous microstructured fiber as the goal. Application is to use the self-fabricated capillary tube, after processing, the production target into a low-loss device, then inject different materials within the devices, and do the different optical measurements for our devices.

In this investigation, a comprehensive Vacuum Assisted Resin Transfer Molding (VARTM) process simulation model was developed and verified. The model incorporates resin flow through the preform, compaction and relaxation of the preform, and viscosity and cure kinetics of the resin. The computer model can be used to analyze the resin flow details, track the thickness change of the preform, predict the total infiltration time and final fiber volume fraction of the parts, and determine whether the resin could completely infiltrate and uniformly wet out the preform. Flow of resin through the preform is modeled as flow through porous media. Darcy's law combined with the continuity equation for an incompressible Newtonian fluid forms the basis of the flow model. During the infiltration process, it is well accepted that the total pressure is shared by the resin pressure and the pressure supported by the fiber network. With the progression of the resin, the net pressure applied to the preform decreases as a result of increasing local resin pressure. This leads to the springback of the preform, and is called the springback mechanism. On the other side, the lubrication effect of the resin causes the rearrangement of the fiber network and an increase in the preform compaction. This is called the wetting compaction mechanism. The thickness change of the preform is determined by the relative magnitude of the springback and wetting deformation mechanisms. In the compaction model, the transverse equilibrium equation is used to calculate the net compaction pressure applied to the preform, and the compaction test results are fitted to give the compressive constitutive law of the preform. The Finite Element/Control Volume (FE/CV) method is adopted to find the flow front location and the fluid pressure. The code features the ability of simultaneous integration of 1-D, 2-D and 3-D element types in a single simulation, and thus enables efficient modeling of the flow in complex mold geometries. VARTM of two flat composite panels was conducted to verify the simulation model. The composite panels were fabricated using the SAERTEX multi-axial warp knit carbon fiber fabric and SI-ZG-5A epoxy resin. Panel 1 contained one stack of the carbon fabric, and Panel 2 contained four stacks of the fabric. The parameters verified included the flow front location and preform thickness change. For Panel 1, the flow front locations were accurately predicted while the predicted resin infiltration was much slower than measured for Panel 2. The disagreement is attributed to the permeability model used in the simulation, which failed to consider the interface flow in the unstitched preform containing more than one stack of the fabric under very low compaction force. The predicted transverse displacements agree well with the experimental measurement qualitatively, but not quantitatively. The reasons for the differences were discussed, and further investigations are recommended to develop a more accurate compaction model. The simulation code was also used to investigate the VARTM of a new form of sandwich structure with through-the-thickness reinforcements, which is being considered for use in primary aircraft structure. The infiltration of three foam core sandwich preforms with different stitch densities was studied. The objective of the study was to determine whether the preforms could be completely infiltrated and how the stitch density affects the infiltration process. The visualization experiments were conducted to verify the simulation. The model accurately predicted the resin infiltration patterns. The calculated filling times underpredicted experimental times by 4 to 14%. The model revealed the resin flow details and found that increasing the stitch spacing shortens the total filling time, but increases the nonuniformity of the flow front shape. Extreme nonuniformity of the flow front shape could result in the formation of the voids. / Ph. D.

Verkehr und Mobilität gehören in unserer Gesellschaft zu den wichtigsten Schlüsselthemen der Gegenwart und Zukunft. Um im Bereich von Spitzentechnologien auch im heute weltweit stattfindenden Wettbewerb mithalten zu können ist die Bearbeitung von Innovationsfeldern eine entscheidende Voraussetzung. Dazu zählt im Besonderen auch die Verkehrstechnik. Mobilität ist aus unserer modernen Gesellschaft nicht mehr wegzudenken. Das Verkehrswachstum wächst nach wie vor unaufhaltsam und scheinbar unbegrenzt auch in wirtschaftlich schwierigen Zeiten. Besonders dort, wo aufgrund von Massereduzierung, Energieeinsparung, Gewichtskraftverringerung oder Geschwindigkeitserhöhung bei bewegten Massen erzielt werden kann, werden immer neue Einsatzgebiete erschlossen. So ist es nicht verwunderlich, dass sich gerade die TUC und herausragende Industriepartner der Region wie die Firma Lätzsch GmbH auf der Basis eines Verbundprojektes mit der Themenstellung „Entwicklung von Herstellungstechnologien für belastungsgerechte Strukturgelege und deren Anwendung in Bauteilen der Verkehrstechnik“ befasst. Dieses Thema wurde im Rahmen des InnoRegio- Programms als Forschungsthema 10/2002 begonnen und 12/2005 zum Abschluss gebracht. Als Themenschwerpunkt in der Entwicklungstätigkeit wurden Massenverkehrsmittel wie Reisebusse und Schienenfahrzeuge im Besonderen betrachtet. Strukturkonzepte unter Einsatz von Glas- und Kohlenstofffasern haben während der Themenbearbeitung hochinteressante Einsatzfelder ergeben. So haben die in der Baugruppe verbleibenden Bauteile mehrere, multiple Aufgaben. Das Spektrum der Veränderlichkeit ist dabei recht breit gefächert und reicht von der Schwerpunktverlagerung bis zu Änderungen der Eigenfrequenz.

Significant proportion of composite industry is currently produced using prepregs, cured in autoclave which is very expensive and time consuming process. Dry textile preforms in conjunction with liquid molding techniques can lead to significant reductions in material costs, manufacturing costs and cycle times. These dry preforms are typically 2D woven or braided fabrics which also required lay-up and have low interlaminar properties. Through thickness reinforcement provides solution for this problem as it gives better interlaminar properties as well as near net shape performing. Various 3D performing methods are discussed and reviewed in this research where 3D weaving comes out as ideal process to develop near net shape preforms with more efficiency and better material performance. This research highlights the advantages and limitations of conventional 3D weaving processes. A number of approaches for improving the flexibility of 3D weaving process have been presented including changing fiber architecture in different sections of the preform, tapering in the width and thickness directions and finally to change the fiber orientation. It is concluded that multi step and taper fabrics can be produced on conventional weaving by some modifications. Furthermore, a novel 3D weaving machine is designed and developed after reviewing various patents and weaving methods to overcome limitations of conventional weaving machine. Key criterions from limitations of conventional weaving processes are considered and modified such as multiple weft insertion, limited warp stuffer movement, linear take-up to develop 3D weaving machine. In order to achieve isotropic material, two textile technologies are combined to get final requirements. 3D weaving can provide us fibres in 0° and 90° direction with through thickness reinforcement, whereas braiding can satisfy the requirement of bias direction fibres. Near net shape preforms such as taper and multistep are produced and laminated. Preliminary testing is performed on these laminates to evaluate fibre architectures. Further work is required in terms of machine modification which can provide weave design flexibility to explore various multilayer weave architectures. Thorough testing is required to evaluate and define structure performance and effect of fibre damage during weaving process.

This work was performed under a cooporative research effort sponsored by the National Aeronautics and Space Administration (NASA) in conjunction with the aerospace industry and acedemia. One of the primary goals of NASA is to improve the safety and affordability of commercial air flight. Part of this goal includes research to reduce fuel consumption by developing lightweight carbon fiber, polymer matrix composites to replace existing metallic airframe structure. In the Twenty-first Aircraft Technology Program (TCAT) efforts were focused on developing novel processing methods to fabricate tailored composite airframe structure. The Vacuum Assisted Resin Transfer Molding (VARTM) processing technique offers a safer, more affordable alternative to manufacture large scale composite fuselages and wing structures. Vacuum assisted resin transfer molding is an infusion process originally developed for manufacturing of composites in the marine industry. The process is a variation of Resin Transfer Molding (RTM), where the rigid matched metal tooling is replaced on one side with a flexible vacuum bag. The entire process, including infusion and consolidation of the part, occurs at atmospheric pressure (101.5 kPa). High-performance composites with fiber volumes in the range of 45% to 50% can be achieved without the use of an autoclave. The main focus of the VARTM process development effort was to determine the feasibility of manufacturing aerospace quality composites with fiber volume fractions approaching 60%. A science-based approach was taken, utilizing finite element process models to characterize and develop a full understanding of the VARTM infusion process as well as the interaction of the constituent materials. Achieving aerospace quality composites requires further development not only of the VARTM process, but also of the matrix resins and fiber preforms. The present work includes an investigation of recently developed epoxy matrix resins, including the characterization of the resin cure kinetics and flow behaviors. Two different fiber preform architectures were characterized to determine the response to compaction under VARTM conditions including a study to determine the effect of thickness on maximum achievable fiber volume fraction. Experiments were also conducted to determine the permeabilities of these preforms under VARTM flow conditions. Both the compaction response and the permeabilities of the preforms were fit to empirical models which can be used as input for future work to simulate VARTM infusion using process models. Actual infusion experiments of these two types preforms were conducted using instrumented tools to determine the pressures and displacements that occur during VARTM infiltration. Flow experiments on glass tooling determined the fill-times and flow front evolution of preform specimens of various thicknesses. The results of these experiments can be used as validation of process model infusion simulations and to verify the compaction and permeability empirical models. Panels were infused with newly developed epoxy resins, cured and sectioned to determine final fiber volume fractions and part quality in an effort to verify both the infusion and compaction experimental data. The preforms characterized were found to have both elastic and inelastic compression response. The maximum fiber volume fraction of the knitted fabrics was dependent on the amount of stacks in the preform specimen. This relationship was found in the determination of the Darcy permeabilities of the preforms. The results of the characterization of the two epoxy resin systems the show that the two resins have similar minimum viscosities but significantly different curing behaviors. Characterization of the VARTM process resulted in different infusion responses in the two preform specimens investigated. The response of the saturated preform to a recompaction after infusion indicated that a significant portion of the fiber volume lost during infusion could be recovered. Fiber volume and void-content analysis of flat composite panels fabricated in VARTM using the characterized resins and preforms resulted in void-free parts with fiber volumes over 58%. Results in the idealized compaction tests indicated fiber volumes as high as 60% were achievable with the knitted fabric. The work over the presented here has led to a more complete understanding of the VARTM process but also led to more questions concerning its feasibility as an aerospace composite manufacturing technique. / Master of Science

3D textile performs offer a high potential to increase mechanical properties of composites and they can reduce the production steps and costs as well. The variety of woven structures is enormous. The algorithms based on the conventional weaving notation can only represent the possible woven structures in a limited way. Within the scope of this dissertation, a new weaving notation was developed in order to analyze the multilayer woven structures analytically. Technological solutions were developed in order to guarantee a reproducible preform production with commingled hybrid yarns. Terry weaving technique can be utilized to create vertical connections on carrier fabrics, which makes it suitable for the development of complex profiles. A double rapier weaving machine was modified with electronically controlled terry weaving and pneumatic warp yarn pull-back systems. Various spacer fabrics and 3D profiles were developed. A linear take-up system is developed to assure reproducible preform production with a minimum material damage. Integrated cutting and laying mechanisms on the take-up system provides a high level of automation.

3D textile performs offer a high potential to increase mechanical properties of composites and they can reduce the production steps and costs as well. The variety of woven structures is enormous. The algorithms based on the conventional weaving notation can only represent the possible woven structures in a limited way. Within the scope of this dissertation, a new weaving notation was developed in order to analyze the multilayer woven structures analytically. Technological solutions were developed in order to guarantee a reproducible preform production with commingled hybrid yarns. Terry weaving technique can be utilized to create vertical connections on carrier fabrics, which makes it suitable for the development of complex profiles. A double rapier weaving machine was modified with electronically controlled terry weaving and pneumatic warp yarn pull-back systems. Various spacer fabrics and 3D profiles were developed. A linear take-up system is developed to assure reproducible preform production with a minimum material damage. Integrated cutting and laying mechanisms on the take-up system provides a high level of automation.

This research investigates composite tubes developed with hybrid preform manufacturing techniques of braiding and filament winding (FW). A quadriaxial braid-wound (QBW) preform [(±45°/0°/90°)2/(±45°/0°)] and a triaxial braided (TB60) preform [(±60°/0°)3] were developed. Quasi-isotropic (QI) fibre orientations were selected for both the lay-ups for comparison of mechanical properties. The large diameter of the tubes led to incomplete surface coverage with (±45°/0°)3 braided preforms (TB45). Circumferential distribution of multiple layers improved the coverage by reducing through the thickness resin pockets. Also addition of hoop winding improved the coverage and consolidated the braided preform. The use of braiding together with FW resulted in an improved fibre volume fraction. Also predicting surface coverage was a fundamental interest for a triaxial braided preform. An equation was proposed for cover factor estimation and was verified by using image analysis. Resin infusion of the preforms was carried out and composite tubes were fabricated. During resin infusion of braided preforms wrinkles were formed. A brief study on wrinkle formation was carried out and the reasons of wrinkle formation for braided tubes were identified based on existing literature. Longitudinal tensioning in conjunction with optimization of fibre amount in a layup and over-winding on braid was established to minimize wrinkle formation. This was primarily due to compaction of braided layers with hoop winding. Hence braid-winding has the additional advantage of manufacturing wrinkle free composite tubes. Finally composite tubes were tested under tension and torsion loads. One of the major findings was the effect of hoop winding on transverse deformation of the braid-wound tubes. As axial fibre percentage for QBW tube was less than that of TB45, the tensile strength was compromised. However presence of hoop winding resulted in lower transverse strain contributing to higher tensile modulus of QBW tubes along with lower Poisson's ratio. Although shear modulus of TB60 tube was exceptionally high for its fibre orientation, for QBW tubes, shear modulus was not significantly higher than that of other tubes. An aluminium tube was also tested for comparing the elastic properties of the QI tubes with those of an isotropic material. QBW tubes specific modulus was higher than that of the aluminium. The shear modulus of the QI and aluminium tubes was estimated by applying the theory for isotropic materials. In comparison to aluminium, for QBW tube the differences between estimated and actual shear modulus was higher. However QBW tube properties were in closer relation to those of the aluminium tube than TB60 tubes. Hence a QBW hybrid layup technique has the potential for manufacturing composite tubes without losing comparative composite material properties.

Made available in DSpace on 2014-12-17T14:57:51Z (GMT). No. of bitstreams: 1 VladimirAMC_capa_ate_cap2pdf.pdf: 1064881 bytes, checksum: ad3fb45b35e0f929ffd17f2ade8f17c2 (MD5) Previous issue date: 2008-08-15 / In the manufacture of composite, textile materials are being used as reinforcement. Generally, the combination of the matrix with the textile material in the form of fibres or yarns is used depending on their distribution in the web. In the present work, in place of fibres or yarns, a knitted structure in the form of the final product which is defined as preform. The preform is weft knit manufactured with polyester filaments. In the manufacture of composite, polyester resin was used as matrix. The physical and mechanical properties as well as the formability of the weft knit were analysed. The physical and mechanical properties as well as the formability of the knitted structure were analysed. The results obtained on the analysis show that the courses and wales of the weft knit structure and the tensile properties help the formability of the structure and the impregnation of the resin. It could be clearly observed that composite structure in the direction of the courses support more tension than in the direction of the wales. In relation to the three points flexural tests it was possible to note that there was more flexion in the direction of wales, what was expected. It was also possible to note that there are other advantages such as reduction in the loss of materials used, homogeneity in the distribution of the knitted structure in the mould, reduction in the preparation time and also in the reduction in the cost of manufacture / Na fabrica??o de comp?sitos, resultados da jun??o da resina como matriz e o material t?xtil como refor?o, o material t?xtil usualmente utilizado como refor?o, est? no formato de filamentos ou fibras soltas, que s?o aplicados diretamente sobre um molde, essa distribui??o aleat?ria do material pode ocasionar pontos fracos na estrutura j? que n?o garante uma distribui??o homogenia. No presente trabalho, em vez de fios ou fibras, foi utilizada uma malha t?xtil, fabricada na forma do produto final, que defini-se como pr?-forma, melhorando a distribui??o do material sobre o molde,. Esta pr?-forma foi fabricada em malha de trama (malha Jersey) com filamento de poli?ster e a resina de poli?ster foi utilizada como matriz na fabrica??o desse comp?sito. As propriedades f?sicas, mec?nicas e formabilidade das la?adas foram analisadas. Os resultados das propriedades da malha Jersey estudadas mostram que as la?adas da malha e as propriedades tensil ajudam a formabilidade da estrutura e a facilitam a impregna??o da resina. Claramente pode-se observar que a estrutura de comp?sito na dire??o de coluna suporta maior tens?o em compara??o com a estrutura na dire??o da carreira. Com rela??o ao teste de flex?o de tr?s pontos, foi poss?vel verificar maior flex?o no sentido da carreira, o que foi esperado. Foi poss?vel pontuar tamb?m outras vantagens como a redu??o de perdas de materiais, homogeneidade na distribui??o da estrutura de malha no molde, redu??o do tempo de produ??o e barateamento nos custos produtivos