Circular air-coupled ultrasonic testing (ACUT) setup for the inspection of commercial carbon-carbon composite aircraft brake disks was developed in Intelligent Measurement and Evaluation Laboratory (IMEL) at Southern Illinois University Carbondale (SIUC). The developed test setup utilizes Airstar single channel air-coupled equipment and has only manual A-scan and B-scan capability. The developed ACUT technique is unique compared to the commercial C-scan ultrasonic systems and is proficient, fast, economically feasible, and easy to implement method particularly for the inspection of carbon-carbon (C/C) composites aircraft brake disks. Prior to conducting air-coupled measurements, wobble analysis was carried out. This was important because significant wobbling in the test setup can lead to the interference of the reflected and the incident beam which would result to inaccurate ultrasonic measurements. The measured deviation due to wobbling, surface profile of the disk, design, and experimental error were relatively small. Therefore, these errors were neglected while performing ACUT measurements. For ACUT measurements, several through-transmitted amplitude signals were recorded within the C/C brake disks manually. The images were then reconstructed using Matlab based on the through-transmitted amplitude signals. Finally, a comparison was drawn between the reconstructed images and the C-scan images of the C/C brake disks obtained from the commercial Airstar C-scan ACUT system. Like commercial C-scan ACUT image results, reconstructed images were also able to detect all defects in the commercial C/C brake disks which served for the system verification and validation. In addition, defect, non-defect, and suspected areas within the C/C brake disks were quantified with air-coupled measurement. For this, light microscopy was conducted for every sample made from each C/C brake disks at lower magnification of 10X. It was concluded that it is very difficult to assess the crack or delamination situation based on a 2D micrograph of one depth. Also, it was concluded that an internal porosity and micro-cracks may not be only factors that can be related to defects. Finally, an intelligent systems approach, specifically, fuzzy logic and artificial neural network (ANN) methodologies were implemented for the automatic defect detection in commercial C/C aircraft brake disks by using air-coupled ultrasonic results. For this, a multi-layer perceptron (MLP) with two hidden layers and a scaled conjugate gradient back-propagation (BP) learning algorithm was used for the ANN training. The network training process was performed in an off-line mode using the ANN toolbox in Matlab. The network training was repeated until a steady state was reached, where there was no further change in the synaptic weights. The ANN provided plausible results in detecting the defect areas for different C/C brake disks. It was also demonstrated that the system was able to learn the rules without knowing any algorithm for automatic defect detection.

Cette thèse avait pour objectif d’étudier les relations existant entre la microstructure de réfractaires alumine-carbone utilisés en coulée continue dans l’industrie sidérurgique et leurs propriétés thermomécaniques. Le travail réalisé ici s’inscrit dans une logique composite, en déterminant les propriétés thermomécaniques des constituants séparément et en analysant ensuite les propriétés des matériaux multiphasiques. Différents systèmes de matériaux modèles ont été étudiés en s’intéressant à deux échelles : agrégats et matrice. Ces matériaux sont constitués d’une part, d’un squelette de graphite et d’agrégats d’alumine et d’autre part d’une matrice carbonée chargée en petits grains d’alumine. La liaison carbone de ces matériaux résultant de la pyrolyse d’une résine phénolique, les propriétés thermomécaniques des matériaux modèles élaborés ont été analysées à la fois pendant et après le traitement thermique de pyrolyse. L’évolution des propriétés au cours de la pyrolyse des échantillons réticulés a mis en évidence l’apparition d’un léger endommagement en fin de montée en température, et un endommagement plus prononcé lors du refroidissement. Cet endommagement résulte d’un différentiel de dilatation thermique entre les grains d'alumine et la liaison carbone. L'influence de ces effets microstructuraux sur le comportement mécanique des matériaux pyrolysés a été étudiée grâce à des essais de traction, mettant en évidence un comportement non-linéaire assez marqué. Des relations entre la fraction volumique et les propriétés physiques clés des matériaux ont pu être établies. Par ailleurs, les résultats obtenus ont montré qu’un changement de composition relativement peu important peut modifier radicalement les propriétés thermomécaniques de ces matériaux. Cette étude sur des matériaux modèles a permis de dégager des pistes pour une amélioration des compositions industrielles. / The present thesis aimed at investigating the relationships existing between the microstructure of alumina-carbon refractories used in steel continuous casting and their thermomechanical properties. The work realized here fall within a composite approach, by determining thermomechanical properties of the single constituents of the materials and analyzing then the properties of the heterogeneous composites. Different systems of double scale model materials, constituted of graphite and alumina aggregates in one hand, and of carbon matrix loaded with fine alumina grains on the other hand were studied here. The carbon bond of these materials resulting from pyrolysis of phenolic resin, the thermomechanical properties of the elaborated model materials were analyzed both during and after the pyrolysis heating treatment. The properties evolutions of the cured samples during the pyrolysis highlighted a slight damage during the end of heating and important damage during cooling, due to a thermal expansion mismatch between the alumina grains and the resin/carbon bond. The influence of the thermal damage has been investigated thanks to tensile tests on the pyrolyzed materials, which exhibit a rather strong non-linear behavior. Relationships between volume fraction and physical key-properties of the materials have been established. Besides, the obtained results highlighted that a small change in composition can drastically change the thermomechanical properties of these materials. This overall study on model materials allowed to develop some ideas in order to improve industrial compositions.

M.S.

No description available.

The adhesion of carbon fibers to several high performance polymers, including a phosphorus-containing bismaleimide, a cyanate ester resin, and a pyridine-containing thermoplastic, was evaluated using the microbond single fiber pull-out test. The objective was to determine the chemical and mechanical properties of the fiber and the polymer which affect the fiber/polymer adhesion in a given composite system. Fiber/matrix adhesion is of interest since the degree of adhesion and the nature of the fiber/matrix interphase has a major influence on the mechanical properties of a composite. The surface chemical composition, topography, tensile strength, and surface energy of untreated AU-4 and commercially surface treated AS-4 carbon fibers were evaluated using x-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), single fiber tensile tests, and dynamic contact angle analysis. The commercial surface treatment which converted the AU-4 to the AS-4 fiber oxidized the carbon fiber surface. The surface of the AS-4 carbon fiber was further modified using air, oxygen, ammonia, and ethylene plasmas. The AS-4 fiber tow was also characterized following exposure to the aqueous poly(amic acid) solution used to disperse the matrix powder during aqueous suspension prepregging of thermoplastic matrix composites. The air and oxygen plasma treatments significantly oxidized and roughened the surface of the AS-4 carbon fibers. In addition, the air and oxygen plasma increased the the polar component of the AS-4 fiber surface energy. The ammonia plasma increased the concentration of nitrogen on the fiber surface, without significantly altering the fiber topography (at a nlagnification of 50,000X). The atomic oxygen present in the air and oxygen plasma treatments is capable of reacting with both the edge and basal planes in the carbon fiber structure. As a result, the oxygen-containing plasmas progressively ablated the organic material in the carbon fiber surface. Energetic species in the ammonia plasma cleaned the fiber surface and reacted with the carbon fiber surface, increasing the concentration of amine groups in the fiber surface. The ethylene plasma deposited a layer of plasma polymerized polymer on the carbon fiber surface. The AS-4 carbon fibers were coated with poly(amic acid) when the tow was wet with the aqueous suspension prepregging solution. The carbon fiber adhesion of bis(3-maleimido phenoxy) triphenylphosphine oxide was compared to that of Ciba-Geigy's Matrimid 5292 A/B bismaleimide system. With both bismaleimides, the carbon fiber adhesion increased significantly when the fiber received an oxidative commercial surface treatment or was exposed to an air or ammonia plasma prior to bonding. In contrast, the poly(pyridine-bis A) microbond pull-out test results showed that the carbon fiber adhesion of poly(pyridine-bis A) was not affected by the fiber surface chemical composition, fiber surface energy, or topography. / Ph. D.

The coupling resulting from the mutual influence of material thermal and mechanical parameters is examined in the thermal stress analysis of a long, hollow, multilayered, isotropic composite cylinder subjected to sudden axisymmetric external and internal temperature. The method of complex frequency response functions together with the Fourier transform technique is utilized. Because coupling parameters for some composite materials, such as carbon-carbon, are very small, the effect of coupling is neglected in the orthotropic thermal stress analysis. The stress distributions in long, hollow, multilayered orthotropic cylinders subjected to sudden axisymmetric temperature loading combined with dynamic pressure as well as asymmetric temperature loading are also obtained. The method of Fourier series together with Laplace transform is utilized in solving the heat conduction equation and thermal stress analysis. The inertial term is considered and the perturbation technique is applied to cylinders subjected to dynamic pressure loading. For brittle materials, like carbon-carbon composite, the strength variability is represented by two or three parameter Weibull distributions. The “weakest link" principle which takes into consideration both the applied stresses and the effected volume of material is used in the reliability analyses for both the isotropic and orthotropic carbon-carbon composite cylinders. The complex frequency response analysis is performed on a long hollow multilayed orthotropic cylinder under asymmetrical thermal load. Both deterministic and random thermal stress and reliability analyses can be based on the results of this frequency response analysis. The stress and displacement distributions and reliability of rocket motors under static or dynamic line loads are analyzed by an elasticity approach. Rocket motors are modeled as long hollow multilayered cylinders with an air core, a thick isotropic propellant inner layer and a thin orthotropic kevlar-epoxy case. The case is treated as a single orthotropic layer or a ten layered orthotropic structure. Five material properties and the load are treated as random variables with normal distributions when the reliability of the rocket motor is analyzed by the first-order, second-moment method (FOSM). / Ph. D. / incomplete_metadata

This research project is partnership project involving industrial, university and government collaborators. The overall objective is to develop and enhance tools for use in Resin Transfer Moulding (RTM) design technology in order to re-design existing metallic parts using composite materials. / The specific objective of this work is to present preliminary research findings of the development of an optimized design of a leading edge slat (horizontal stabilizer component) from the Bell Model 407 Helicopter. The results presented here focus on the static stress analysis and the structure design aspects. The findings will serve as a basis for future design optimization as well as further developments in the use of RTM technology in re-designing metallic aeronautic components and can be considered to be "semi-optimized". / This research is based on extensive finite element analysis (FEA) of several composite material configurations, with a comparison made with the original metallic design. Different key criteria of the part design such as ply lay-up, bracket geometry, angle and configuration are tested using FEA technology with the objective of selecting the design which is minimizing stress concentrations. The influence of the modification of model-related parameters was also studied. / Preliminary comparative studies show that the slat configuration with half brackets opened towards the inside with an angle of 70 degrees (angle between the top of the airfoil and the side of the bracket) is the best option according to minimum stress concentration and structural flexibility. This choice is confirmed by other factors such as material savings and ease of processing.

Laminated carbon/epoxy composite structures are increasingly used in the aerospace industries. Low weight, elastic tailoring, and high durability make the composite materials well suited for replacement of conventional metallic structures. However the difficulty to capture structural failure phenomena is a significant barrier to more extensive use of laminated composites. Predictions are challenging because matrix (resin) dominated failure mechanisms such as delaminations and matrix cracking contribute to the structural failure in addition to fiber-dominated failures. A key to rigorous failure predictions for composites is availability of measurements to quantify structural model parameters including matrix-dominated stress-strain relations and failure criteria. Novel techniques for measurement of nonlinear interlaminar constitutive properties in tape composites have been recently developed at Georgia Institute of Technology. Development of methods for accurate predictions of failure in carbon/epoxy tape laminate configurations with complex lay-ups is the main focus of this work. Failures through delamination and matrix cracking are considered. The first objective of this effort is to implement nonlinear interlaminar shear stress-strain relations for IM7/8552 carbon/epoxy tape in ABAQUS finite element models and validate structural delamination failure predictions with tests. Test data for composite configurations with wavy fibers confirm that nonlinear interlaminar shear stress-strain response enables accurate failure prediction. The problem of the presence of porosity and its influence on failure was noted. The second objective is to assess the ability to simulate initiation and propagation of matrix-ply cracking. Failure models for IM7/8552 carbon/epoxy tape open-hole tensile coupons are built and validated.

No description available.

Thesis (M. Tech.) -- Central University of Technology, Free State, 2010 / The aim of this study is to produce more cost effective carbon fibre (CF) parts. To achieve this there must be a saving on materials, labour and time. Thus, a production process to produce cost effective CF moulds while saving time and money is required. This procedure must be suited for the incorporation in the small to medium production ranges. The composite industry is one of the fastest growing industries in the world. Therefore, the faster a mould can be produced, the faster the end product will reach the market. This research project investigates the possibility to sinter CF moulds on the Electro Optical Systems (EOS) Laser Sintering (LS) machine cheaper and faster than the conventional method using computer numerically controlled (CNC) machining. The surface finish produced on the LS machine is not of the same quality as a CNC machined mould, but there are ways to enhance the surface quality of a LS part to the point that it is compatible to the surface quality of a CNC machined mould. The CF moulding process uses many different types of moulding processes. However, it is not possible to use LS parts for all of the available processes to produce CF parts. In this study only one CF moulding process will be investigated, namely compression moulding. The moulds will be designed to be manufactured as cheaply and as quickly as possible. Different methods of mould adapting have been studied to find the cheapest most suitable method of mould design for the LS process.