Composite materials are well-renown for their strength to weight ratios and are widely used in many industries where high strength and low weight is required. Although steel is the traditional material of choice in the mining industry, and particularly for conveyor support structures, the strength and weight advantages offered by composite materials has prompted this investigation into the feasibility of using composite materials in underground mining conveyor support structures. The first phase of the project centred on establishing and applying selection criteria for the materials and processes which could be used in such a structure. Key concerns include fire performance, electrical conductivity, cost, availability and manufacturability. Based on these considerations, the project identified a phenolic-glass laminate manufactured using the RTM method (for moulded components) or the pultrusion process (for tube sections) as a possible basis for a composite conveyor support structure. The second phase of the project developed a set of design criteria for the use of composite materials in conveyor support structures and a series of preliminary designs based on current conveyor configurations. After analysing each preliminary design against key design criteria, in particular cost, weight, assembly time, susceptibility to damage and torsional loading, the Linestand Suspended - Beam configuration was selected as the preferred option. The third phase of the project used the findings of the preliminary design analysis and the key design criteria to develop a prototype final design. The prototype design is based on a hybrid style of frame. The majority of the structure is constructed from a custom pultruded beam connected with a composite connection piece, while the interface between the rollers and the frame utilises a steel bracket to reduce the risk of damage to the composite frame. The final design is 12kg lighter than the current smaller steel design of similar function. The project has demonstrated the feasibility of using composite materials in conveyor support structures and the weight savings that may be achieved.

Composite materials have the potential to revolutionize life in the 21st century. They are contributing significantly to developments in aerospace, hydrogen fuel cells, electronics and space exploration today. While a number of composite material processing methods exist, resin transfer molding (RTM) has the potential of becoming the dominant low-cost process for the fabrication of large, high-performance products. RTM has many advantages over alternative processes, including the capability of producing complex 3D shapes with a good surface finish, the incorporation of cores and inserts, a tight control over fiber placement and resin volume fraction and the possibility of embedding sensors into manufactured components for structural health monitoring. Part of the reason RTM has not received widespread use is due to its drawbacks such as its relatively trial and error nature, race tracking, washout, high cycle time and void formation. The basic operation of the process involves loading a fiber reinforcement preform into a mold cavity, closing the mold, injecting resin into the mold and allowing the resin to cure. To study the resin transfer molding process and issues affecting it, a laboratory containing an experimental RTM apparatus has been established. The apparatus has a glass window to observe the mold filling process and can incorporate various mold shapes such as a quasi-2D panel, a 3-D rectangular section and a 3-D semicircular section. To characterize the flow through the molds a commercial CFD software has been used. This thesis describes the establishment of this laboratory and preliminary studies that have been conducted.

Submitted by Johnny Rodrigues (johnnyrodrigues@ufcg.edu.br) on 2018-04-24T16:54:35Z No. of bitstreams: 1 IRAN RODRIGUES DE OLIVEIRA - TESE PPGEP 2014..pdf: 8399659 bytes, checksum: a53ba70ec49d8f5448c637ec5198e35e (MD5) / Made available in DSpace on 2018-04-24T16:54:35Z (GMT). No. of bitstreams: 1 IRAN RODRIGUES DE OLIVEIRA - TESE PPGEP 2014..pdf: 8399659 bytes, checksum: a53ba70ec49d8f5448c637ec5198e35e (MD5) Previous issue date: 2014-08-22 / Este trabalho tem como objetivo realizar um estudo teórico e experimental do processo de moldagem por transferência de resina (RTM), com a adição de carbonato de cálcio (CaCO3), na manufatura de compósitos de matriz poliéster reforçados com fibras de vidro. Realizou-se experimentos em molde com dimensões da cavidade de 320 x 150 x 3,6 mm, temperatura ambiente, pressão de injeção máxima de 0,25, 0,50 e 0,75 bar, volumes de fibras de 19, 24 e 30% e teores de CaCO3 (0, 10, 20, 30 e 40%), e simulou-se a infiltração retilínea de resina no molde via software comercial PAM-RTM. Resultados da posição da frente de fluxo e tempo de preenchimento do molde são apresentados, analisados e comparados com os resultados obtidos via software a fim de se investigar o comportamento do escoamento e estimar a permeabilidade do meio usando o método do erro mínimo quadrático. Conclui-se que o uso de CaCO3 na resina poliéster, dificulta o preenchimento do meio fibroso durante processo de moldagem do RTM, e afeta a permeabilidade, mobilidade e viscosidade da resina, e o tempo de preenchimento do molde. Observou-se também que as distribuições granulométricas ficaram próximas, enquanto que, na análise microscópica ver-se somente área sem fibras e sem CaCO3. Os resultados numéricos obtidos com o simulador apresentaram boa concordância com os dados experimentais em termos de posição da frente de fluxo, tempo de preenchimento e pressão de injeção. / This paper aims to conduct a theoretical and experimental study of the process of resin transfer molding (RTM), with the addition of calcium carbonate (CaCO3) in the resin, in the manufacture of polyester matrix composites reinforced with glass fibers. Experiments were carried out in a mold with cavity dimensions 320 x 150 x 3.6 mm, at room temperature, maximum injection pressure of 0.25, 0.50 and 0.75 bar, fiber volume fraction of 19, 24 and 30% and CaCO3 concentrations (0, 10, 20, 30 and 40%) and simulated in rectilinear infiltration of resin in the mold via software commercial PAM-RTM. Results of the flow front position and mold filling time are presented, analyzed and compared with results obtained via software in order to investigate the behavior of the flow and to estimate the permeability of the medium using the method of least squares error. It is concluded that the CaCO3 used in the polyester resin hinders the filling of the fibrous medium for the RTM molding process and affects permeability, resin mobility and viscosity, and the filling time of the mold. It was also observed that the granulometric size distributions were next, while that, in the microscopic analysis seen only fiber area and without CaCO3. The numerical results obtained with the simulator showed good agreement with experimental data in terms of the position of the flow front, filling time and injection pressure.

Submitted by Emanuel Varela Cardoso (emanuel.varela@ufcg.edu.br) on 2018-08-17T18:37:47Z No. of bitstreams: 1 RUDÁ ARANHA – DISSERTAÇÃO (PPGEM) 2017.pdf: 11257254 bytes, checksum: 2d827010d52a9ce6d3f05b9ddf1bf617 (MD5) / Made available in DSpace on 2018-08-17T18:37:47Z (GMT). No. of bitstreams: 1 RUDÁ ARANHA – DISSERTAÇÃO (PPGEM) 2017.pdf: 11257254 bytes, checksum: 2d827010d52a9ce6d3f05b9ddf1bf617 (MD5) Previous issue date: 2017-11-30 / Os materiais compósitos são sinônimos de boas propriedades mecânicas associadas a baixo peso estrutural com vasta aplicação na área da engenharia. A partir dos avanços tecnológicos e da necessidade de desenvolvimento de novos materiais, torná-los multifuncionais surge como interesse imediato. O método mais simples para conferir multifuncionalidade a um compósito é através da introdução de inserts nos compósitos antes de sua fabricação, conferindo-os as mais variadas características, sendo importante entender as consequências geradas a partir do uso dos inserts no processamento das placas. O estudo experimental do escoamento de resina através da pré-forma e os efeitos recorrentes devido à adição dos inserts impermeáveis aos compósitos durante o processo de Moldagem por Transferência de Resina (RTM) são os objetivos deste trabalho. Neste trabalho, foram utilizados reforço de tecido de fi bra de vidro e matriz de resina poliéster na composição de placas de material compósito com dimensões de 250x250x14 mm3 com 1 e 9 inserts impermeáveis de polietileno com dimensões de 50x50x4 mm3, processadas pelos métodos de RTM Light e VARTM para futura aplicação estrutural e/ou balística. Como esperado, a introdução de inserts na pré-forma causou distúrbio no escoamento da resina durante os processamentos, sendo evidenciadas regiões super ciais em algumas das placas, acima dos inserts, onde as bras não foram molhadas. Ao fim dos processamentos foram observadas variações nas espessura das placas, sendo esta uma consequência da compactação das fi bras devido à presença dos inserts. Também foi identi cada a movimentação dos inserts quando os pontos de entrada e saída foram posicionados em planos diferentes no molde. Tal movimentação foi evitada a partir da fixação dos inserts em uma tela antes do processamento. Com o corte das placas, regiões ricas em resina próximas às laterais dos inserts foram observadas, sendo esta uma consequência do mecanismo de afastamento das fibras devido à presença dos inserts. Assim, 4 zonas foram identifi cadas nos compósitos com inserts impermeáveis embebidos. Por fim,nos ensaios de flexão em 3 pontos, falhas de delaminação por cisalhamento tipo II foram identi cadas nos corpos de prova. / Composite materials are synonymous with good mechanical properties associated with low structural weight and have a great variety of applications in the engineering area. Taking into account technological advances and the necessity to develop new materials, make them multifunctional appears as immediate interest. The simplest method to confer multifunctionality to a composite is through the introduction of inserts into the composites, giving them the most varied characteristics. It is important to understand how these inserts will a ect the fabrication process and the structural characterization of the material. The experimental analysis of the ow through the preform and the effects due to the addition of the impermeable inserts to the composite during the process of Resin Transfer Molding (RTM) are the objectives of this work. In this work, reinforcement of glass ber fabric and polyester resin matrix was used in the composition of 250x250x14 mm3 composite materials sheets with 1 and 9 polyethylene impermeable inserts with dimensions of 50x50x4 mm3, processed by the RTM Light and VARTM methods for future structural and/or ballistic application. As expected, introduction of inserts into the preform caused disturbances in resinow during processing, with surface regions in some of the plates above the inserts where the bers were not wetted. At the end of the processing, variations in the thickness of the plates were observed, being this a consequence of the bercompaction due to the presence of the inserts. The movement of the inserts was also identi ed when the resininlet and outlet were positioned on di erent planes in the mold. the inserts movimentation was prevented from attaching the inserts to a mesh before the processing.With the cutting of the plates, resin-rich regions close to the sides of the inserts were observed, which is a consequence of the mechanism of ber spacing due to the presence of the inserts. Thus, 4 zones were identi ed in the composites with embedded impermeable inserts. Finally, in the 3-point bending tests, delamination failures for shear mode II were identi ed in the specimens.

Submitted by FRANCISCO MACIEL MONTICELI null (francisco_monticelli@hotmail.com) on 2017-08-15T16:18:26Z No. of bitstreams: 1 Dissertação Francisco_M_Monticeli.pdf: 22030385 bytes, checksum: 6b57793ae92e8109811a1ce2e8318122 (MD5) / Approved for entry into archive by Monique Sasaki (sayumi_sasaki@hotmail.com) on 2017-08-22T17:27:29Z (GMT) No. of bitstreams: 1 monticeli_fm_me_guara.pdf: 22030385 bytes, checksum: 6b57793ae92e8109811a1ce2e8318122 (MD5) / Made available in DSpace on 2017-08-22T17:27:29Z (GMT). No. of bitstreams: 1 monticeli_fm_me_guara.pdf: 22030385 bytes, checksum: 6b57793ae92e8109811a1ce2e8318122 (MD5) Previous issue date: 2017-07-04 / Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP) / O compósito híbrido surgiu com o objetivo de reduzir a quantidade de materiais de elevado custo e, ao mesmo tempo, manter as elevadas propriedades mecânicas. Além disso, viu-se a possibilidade de, em se usando reforços diferentes, obter um novo material que evidenciasse as vantagens dos reforços e diminuísse as desvantagens simultaneamente. Um importante fator durante o processamento de compósitos poliméricos para aplicação estrutural é o controle da formação de vazios, pois estes atuam como concentradores de tensão. O objetivo deste trabalho foi produzir compósitos híbridos utilizando diferentes disposições de tecidos de fibra de vidro e carbono, sem perda significativa de propriedades mecânicas. Para a produção do compósito, a pré-forma foi inicialmente caracterizada quanto à impregnação, sendo, para isto desenvolvido um modelo analítico geral que determina o parâmetro de permeabilidade dos compósitos híbridos. O modelo foi validado através de teste de permeabilidade e a qualidade dos laminados (híbridos, e não híbridos) foi certificada pelo processamento dos compósitos e pela quantificação da fração volumétrica de vazios. Este projeto propôs, ainda, a melhoria da análise de vazios pela técnica de porosimetria de Hg com auxílio do planejamento de experimentos. Assim foi possível determinar a fração volumétrica de poros abertos e fechados, a distribuição do diâmetro dos poros e a distância entre os poros dos compósitos, em uma análise conjunta com as técnicas de digestão ácida e microscopia óptica. A pré-forma de carbono apresentou elevada taxa de resistência ao fluxo; por outro lado, observou-se um comportamento oposto para a pré-forma de vidro. Contudo, as pré-formas híbridas apresentaram um efeito híbrido positivo, resultado de uma sinergia que proporcionou um maior valor de permeabilidade. Consequentemente, pode-se conseguir uma otimização do tempo de injeção, considerando uma combinação de tecidos de vidro e carbono equilibrados. O modelo analítico foi capaz de prever o comportamento da frente de fluxo mostrando um valor superestimado de 10%. A técnica de porosimetria de Hg foi validada para análise de poro em compósito avançados com valores próximos obtidos pelas técnicas de digestão ácida e de microscopia óptica. Em função dos resultados obtidos dos valores de diâmetro dos poros, que foi semelhante para todos os compósitos, concluí-se que este ocorre em função do tipo de processo e da resina. Do mesmo modo, a distância e a fração de poros abertos dependem diretamente da quantidade de poros presente no material. Os resultados encontrados indicaram que os compósitos híbridos estudados neste trabalho são materiais promissores para a aplicação aeronáutica, combinando as excelentes propriedades mecânicas da fibra de carbono com a viabilidade do ciclo de injeção da fibra de vidro. Com isso, o laminado híbrido 2 foi o compósito ideal para um processamento com fração de vazios próximo ao uso aeronáutico, resultando em uma redução de custo de matéria prima e tempo de processamento. / Hybrid composite arose with the aim of reducing high cost materials and, at the same time, maintaining mechanical properties suitable for use. In addition, using different reinforcements, a new material could be obtained which would evidence the advantages of the reinforcements and decrease the disadvantages simultaneously. An important factor, during the processing of polymeric composites for structural application, is the voids formation control, since they act as stress concentrators. The aim of this work was to produce hybrid composites using different stacking of glass and carbon fabrics without significant loss of mechanical properties. For the composite manuftacturing, the preform was initially characterized as the impregnation, for which a general analytical model was developed that determines the permeability parameter of the hybrid composites. In addition, the model was validated by conducting permeability test and the quality of several laminates (hybrid, and non-hybrid) was certified by processing them, and voids were quantified thereof. This project also proposed the improvement of voids analysis by the Hg porosimetry technique with the support of design of experimental. Therefore, it was possible to determine the volumetric fraction of open and closed voids, pore diameter distribution and the distance between voids, in an ensemble analysis with acid digestion and optical microscopy. Carbon preform presented high flow resistance; on the other hand, an opposite behavior was observed for the glass preform. The hybrid architecture presented a positive hybrid effect, which means a synergy that provided a higher permeability value. Therefore, optimization in injection time can be achieved, considering a combination of balanced glass and carbon fabrics. The analytical model was enabled to predict the flow front behavior by showing an overestimated value of 10%. The Hg porosimetry technique was validated for advanced composite voids analysis with similar results obtained by acid digestion techniques and optical microscopy. Based on the results obtained from pore diameter values, which were similar for all composites, it was concluded that this occurs as a function of the type of process and the resin. Although, the distance and the open pores fraction depend directly on the amount of pores along the laminate. Hybrid composites have proven to be a promising material in which it combines the excellent mechanical properties of carbon fiber with the viability of the fiberglass injection cycle. With that, hybrid 2 laminate is the ideal composite for a processing with voids fraction close to the aeronautical use requirement with reduction of high-cost material and processing time. / FAPESP: 2015/19967-4

Banca: Herman Jacobus Cornelis Voorwald / Banca: Maysa Furlan / Banca: Sergio Frascino Muller de Almeida / Banca: Durval Rodrigues Junior / Banca: Paulo Roberto Mel / Resumo: Com o objetivo de ganhar competitividade no mercado internacional e contribuir para o desenvolvimento tecnológico no país, o presente trabalho apresenta a técnica de processamento de moldagem por transferência de resina (RTM), utilizada na fabricação de materiais compósitos estruturais e ainda pouco estudada no Brasil. Os compósitos processados por essa técnica apresentam maior fração volumétrica de fibras, melhor acabamento superficial e pouca ou nenhuma necessidade de acabamento do componente produzido. Este trabalho compreende a caracterização de compósitos produzidos com resina epóxi monocomponente RTM6 e o tecido não dobrável de fibra de carbono. Os compósitos produzidos pela Hexcel Composites foram analisados pela técnica de ultrassom C-Scan e os resultados mostraram que os laminados processados estão homogêneos quanto à impregnação. Ensaios mecânicos mostram que os laminados com tecido apresentam características comparáveis à dos compósitos produzidos em autoclave com maiores porcentagens de reforço. Em fadiga, os laminados apresentaram um alto e curto intervalo, com tensões próximas à de tração. Quanto ao comportamento térmico observou-se melhora nas propriedades com a adição do reforço de fibras de carbono, que promoveram o aumento da temperatura de transição vítrea (Tg). Quanto ao comportamento viscoelástico, foi observado a influencia da temperatura e freqüência no material. Considerando as propriedades mecânicas e térmicas, ambos os compósitos foram classificados como adequados à aplicação proposta. / Abstract: Aiming at gaining competitiveness on international market and contribute with technological development in the country, this work presents a processing technique of resin transfer molding (RTM), used to manufacture structural composites that Brazilian researches have yet few background. Composites processed by this method have a higher volume fraction of fibers, better surface finish, and requires little or none surface finish of the final component. This work includes the characterization of composites made with RTM6 monocomponent epoxy resin and carbon non-crimp fabric (NCF). Composites produced by Hexcel Composites were analyzed by C-scan ultrasound technique, which showed a homogeneous impregnation of the processed panels. Mechanical tests showed that RTM composites properties are comparable to those of autoclaving composites with higher fiber volume fraction. In fatigue, composites showed high and short interval, close to ultimate tensile strength (UTS), with an interval between 60-75% of UTS. Regarding the thermal behavior, it was observed an improvement in properties with the addition of carbon fiber reinforcement, which caused an increase in Tg. In regard to the viscoelastic behavior, it was observed the temperature and frequency influence on the material. Considering these mechanical and thermal properties, both composites are considered suitable for the application proposal.

Conferencia realizado del 12 al 14 de setiembre en Lima, Peru del 2012 en el marco del 15º Simposio Internacional de Tesis y Disertaciones Electrónicas (ETD 2012). Evento aupiciado por la Universidad Nacional Mayor de San Marcos (UNMSM) y la Universidad Peruana de Ciencias Aplicadas (UPC). / In the age of Information Technology it is very important to keep a pace with the rapid changes that has been taking place all over the world. Institutional repository play a vital role in dissemination of intellectual output of the organization hence it is essential to all the organization to develop and digitize their collection and scholarly communication. Keeping in view the technological changes and importance of creating digital repository of electronic theses, the proposal has been prepared for creation of institutional repository of electronic theses of social-sciences of Rashtrasant Tukadoji Maharaj Nagpur University , Nagpur . This proposal is submitted to Indian Council of Social-Science Research, (ICSSR) New Delhi and has been approved recently, now it is in execution stage. The proposal, constraints and measures for Institutional Repository have been also discussed in detail.

Le développement d'une nouvelle voie de synthèse de poly(éther cétone cétone),polymères thermostables, a été étudiée pour des matériaux composites à matrice thermoplastique obtenus par le procédé de moulage par injection de résine RTM. Pour cela,nous nous sommes orientés vers une polymérisation par couplage réactif entre des monomères difonctionnels et des agents de couplage. Neuf monomères X-EKKE-X avec différentes extrémités réactives ont été synthétisés par acylation de Friedel-Crafts ou substitution nucléophile aromatique puis caractérisés structurellement et thermiquement.Des essais de couplage à partir de monomères à extrémités COOH sur des bisoxazoline sont permis la synthèse en masse de quatre polymères, semi-cristallins ou amorphes, de faibles masses molaires. A travers l'étude du comportement thermique de molécules modèles, une fragilité thermique à partir de 250°C a été mise en évidence pour ces polymères et attribuée au pont ester-amide entre deux unités EKKE. / A new synthetic route to poly(ether ketone ketone), thermostable and semi-crystalline polymers, has been studied towards composite materials with a thermoplastic matrix obtained by a resin transfer molding process (RTM). This original synthesis was conducted by coupling reactions between difunctionals monomers and coupling agents. Nine X-EKKE-X monomers with different reactive extremities have been synthesized by Friedel-Crafts acylation or nucleophilic aromatic substitution. Thermal and structural properties were thoroughly investigated. Four polymers with semi-crystalline or amorphous morphologies and low molecular weights were obtained by coupling reactions between monomers with COOH functional extremities and bisoxazolines. Through the study of the thermal behavior of models molecules, a thermal fragility was highlighted for these polymers from 250°C and assigned to the amide-ester bridge between two EKKE units.

The increasing demand for polymer matrix composites (PMCs) from the airframe industry raises the issues of productivity, cost and reproducibility of manufactured PMC components. Performance reproducibility is closely related to the manufacturing technique. Resin transfer moulding (RTM) offers the advantage of flexible manufacturing of net-shape PMC components with superior repeatability starting from ready-to-impregnate dry reinforcements. An RTM apparatus was developed for manufacturing PMC plates and demonstrator components representative of actual, PMC components and PMC moulds made and used in the airframe industry. The RTM process developed in this work involved making net-shape dry carbon fibre preforms and impregnating them an epoxy resin, targeting mould applications. Thermal repeatability of different net-shape PMC components manufactured using the RTM apparatus developed in-house was investigated. Effects of bonding an outer copper plate onto the PMC material, targeting mould applications known as integrally heated copper tooling (IHCT), were explored. Heat conduction through the PMC components was studied using simulation models validated by experimental data obtained primarily by thermography. Manufactured PMC components showed good repeatability, particularly in terms of thermal behaviour. The IHCT technique was found to be well suited for mould applications. Expected advantages of thermography were materialised. Finally, the simulation models developed were in good agreement with experimental data.

Producing composite parts using low-cost processes such as resin transfer moulding (RTM) has received much interest in the aerospace industry. RTM manufactured components require near net shape preforms which closely fit mould cavities. To reduce labour costs associated with composite production, automated preforming processes must be utilized. However, obtaining reproducible high quality preforms is required for manufacturing consistent high quality parts. Stitched multilayer 3D non crimp fabric preforms are well suited for automation and an investigation into quality and performance of components manufactured from these preforms is required. This thesis provides an initial evaluation of quality and mechanical properties of components made from stitched multilayer 3D non crimp fabric preforms using RTM. Similar sized flat plates of varying fibre volume fractions were manufactured to evaluate flexural modulus and strength, short beam shear strength and drop weight impact resistance of the material. Also, integral reinforced panels (IRPs) featuring a reinforcing section joined to a flat plate of varying laminating sequences were manufactured to evaluate debonding strength between sections. Optical microscopy was performed on component samples to determine quality based on void content and was found to be within acceptable limits for production composites. Flexural moduli were found to be comparable with theoretical expected values, however flexural strength was limited by the presence of transverse stitches. Short beam shear strength results showed high consistency between specimens, however were lower than comparable values found in literature. Impact specimens showed consistency among specimens, with greater damage resistance than comparable values found in literature. Determining debonding strength proved difficult as different failure modes were observed between IRPs, however, initial baseline values were acquired.