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<div>The use of carbon-fiber reinforced composite materials is not novel in the field of motorsports industry. Their use in collapsible structures for crashworthiness is however not fully understood and predicted. Due to the complex failure mechanisms occurring within the material, the energy absorbing capacity cannot be easily predicted. The need to understand their contributions in crashworthy structures is thus of great importance. Furthermore, failure of carbon-fiber composites is highly dependent on the geometry of structure. Problems arise in both experimental and numerical modelling of these structures. Although many explicit FEA codes exist, they often include experimental parameters that need to be calibrated through either coupon tests or actual crash tests. As composite structures become more commonly used in automotive industry, it is necessary to set some guidelines to successfully model and simulate composite crashworthy structures. </div><div><br></div><div>The numerical modelling was done in LS-DYNA Enhanced composite damage MAT54. The material properties were configured using experimental coupon tests. The tests were conducted on square composite tubes. The Specific Energy Absorption (SEA) of the tubes were calculated through several coupons. As SEA is a function of geometry, it was necessary to conduct tests with similar geometry as seen in nosecone. MAT54 was chosen to simulate both crush and crash simulations due to its capability to simulate element level crushing. Furthermore, various modifications within the material model, improve its accuracy to determine composite failure. </div><div><br></div><div>The research utilizes the characterization of material inputs in MAT54 by conducting quasi-static compression tests on simpler but similar geometry. By utilizing inputs, a zonal optimization was conducted on the nosecone geometry. The number of layers, layer orientations and ply thicknesses were varied to vary the energy absorbed per zone. The deceleration of the vehicle can thus be controlled, and the weight of the structure could be reduced.</div>

The demand for materials with high mechanical performances such as Carbon Fiber Reinforced Plastics (CFRP) is increasing. However, there are major challenges in machining CFRP as it involves delamination, fiber pullouts, and extreme cutting tool wear. Analysis of chip formation mechanisms and prediction of associated cutting forces in CFRP machining enables one to address these challenges. This study proposes a mechanistic cutting force model for milling operations of the CFRP workpiece, considering its non-homogeneity and anisotropy, by taking into account variations of fiber cutting angle during machining. A mechanistic model of cutting force constants is obtained from a number of experimentally measured unidirectional CFRP milling forces. The obtained mechanistic force model predictions are verified against experimentally measured milling forces with arbitrary tool path indicating the accuracy of the proposed mechanistic model in predicting cutting forces. The proposed mechanistic cutting force model is capable of being integrated into the manufacturing process to allow optimized machining of quality certified CFRP work-pieces. / Graduate

Electrical and thermal behavior of the carbon fiber polymer matrix composites subjected to time-varying and steady electric currents is studied. A fully automated experimental setup for real time measurements of the electric current, resistance, voltage, and temperature in carbon fiber polymer matrix composites has been developed. A series of electrical characterization tests on IM7/977-3 unidirectional and symmetric cross-ply composite laminates have been performed and the effects of electric current magnitude and duration, electrical resistance, and associated thermal effects have been investigated. It is determined that voltage-current relationship stays ohmic for up to 50 A steady currents, electrical resistance exhibits time-dependent behavior. It is also found that application of an electric current leads to a significant temperature rise in the composites that is a result of the intense Joule heat produced in the electrically conductive carbon fibers as well as in the composite-electrode contact.

L'objectif de ces recherches est l'amélioration du procédé de placement de fibre par dépose laser, appliqué à des composites Poly(EtherKetoneKetone) / fibre carbone continue. L'optimisation des paramètres de dépose implique l'étude de la stabilité de la matrice, ainsi que l'analyse du comportement thermique des composites. La conductivité et diffusivité thermiques, ainsi que l'émissivité sont les paramètres clés pour comprendre le comportement des transferts volumiques et surfacique dans ces matériaux. Des composites PEKK/particules de carbone ont été élaborés afin d'étudier l'effet de la morphologie du carbone sur les paramètres thermiques. L'émissivité des composites PEKK / fibres continues a été mesurée en comparant les radiations émises par le matériau et celle émises par un corps noir à la même température. La conductivité et la diffusivité thermiques, qui sont des paramètres intrinsèques au composite, augmentent avec le taux de charge et la température. Ces deux paramètres ont été étudiés en fonction de la Température, dans le cas de composite PEKK / fibre carbone continue et PEKK / particules de carbone pour plusieurs taux de charge. / : The aim of this research is the improvement of the laser depositing fiber placement process, applied to Poly (EtherKetoneKetone) / continuous carbon fiber composites. The optimization of deposit parameters implies the investigation of the stability of the matrix and of the thermal behavior of composites. Thermal conductivity, diffusivity, and optical emissivity, are the key parameters for understanding the behavior of volume and surface conduction of composites. PEKK / carbon particle composites have been processed to study the effect of carbon morphology on thermal parameters. The emissivity of the PEKK / continuous fiber composites was measured by comparing the radiation emitted by the material with the one emitted by a black body at the same temperature. Thermal conductivity and diffusivity, which are intrinsic parameters of the composite, increase with the rate of charge and the temperature. These two parameters have been studied as a function of temperature, in the case of PEEK / continuous fibers composites and PEKK / carbon particles composites for various charge rates.

In this work the conditions for which a (0,90,90,0,0,90)s BMI-carbon fiber laminate will initiate transverse microcracking are determined for the fabrication of a cryogenic fuel tank for use in a Reusable Launch Vehicle (RLV). This is accomplished using a quadratic interaction criterion failure analysis on the total stress state at possible launch conditions. There are three major sources of stress, that is, thermal residual stress, internal pressure stress, and applied load stress, that are evaluated at the launch stage to determine the total stress state. To assess the accuracy of the analysis the well known X-33 cryogenic fuel tank failure was analyzed as an example. The results of the X-33 example show that the analysis accurately portrays the failure of the X-33 and provides evidence that the analysis can be used to provide reliable conditions for the initiation of microcracking. The final result of this study is a range of launch conditions that can be used without the initiation of microcracking and a limiting range of conditions that cause complete microcracking throughout the laminate.

The exploitation of sandwich structures as a means toachieve high specific strength and stiffness is relatively new.Therefore, the knowledge of its damage tolerance is limitedcompared to other structural concepts such as truss bars andmonocoque plate solutions. Several aspects of the damage tolerance of sandwichstructures are investigated. The influence of impact velocityonresidual strength is investigated. Sandwich panels withfaces of glass fiber reinforced vinylester are impacted bothwith very high velocity and quasi static. The residual strengthafter impact is found to be similar for both cases of impactvelocity. Curved sandwich beams subjected to opening bending momentare studied. Faceñcore debonds of varying size areintroduced between the compressively loaded face sheet and thecore. Finite element analysis in combination with a pointstress criterion is utilized to predict the residual strengthof the beams. It is shown that it is possible to predict thefailure load of the beams with face-core debond. Using fractography the governing mode of failure ofcompressively NCF-carbon is characterized. Sandwich panelssubjected to compression after impact are shown to fail byplastic micro buckling. The residual compressive strength after impact of sandwichpanels is investigated. Sandwich panels with face sheets ofnon-crimp fabric (NCF) carbon are subjected to different typesof impact damages. Predictions of residual strength are madeusing the Budiansky, Soutis, Fleck (BSF) model. The residualstrength is tested, and the results are compared topredictions. Predictions and tests correlate well, and indicatethat the residual strength is dependent on damage size and notthe size of the damaged panel. A study of the properties of a selection of fiberreinforcements commonly used in sandwich panels is conducted.The reinforcements are combined with two types of core materialand three types of matrix. Also the influence of laminatethickness is tested. Each combination materials is tested inuni-axial compression, compressive strength after impact andenergy absorption during quasi static indentation. Thespecimens which are tested for residual strength are eithersubjected to quasi-static or dynamic impact of comparableenergy level. Prediction of the residual strength is made andcorrelates reasonably whith the test results. The tests showthat if weight is taken into account the preferred choice offiber reinforcement is carbon.

There are several disadvantages in conventional unipolar/bipolar plates such as cost expensive, weight heavy and volume large. Therefore, it is difficult in making use conventional unipolar/bipolar plates to portable fuel cells. With a new heterogeneous carbon fiber bipolar plate, pumpless and air-breathing design and in cooperating with a special MEA, portable fuel cell stacks developed in our lab have made portable applications to be possible. The structure of the DMFC stack made with the new carbon fiber bipolar plate is much more simple and weight-light than the other designs. A two-layer 16-Cell DMFC Stack had been designed and made by using the heterogeneous carbon fiber monopolar plates developed in our fuel cell laboratory. With this design, the methanol solution can be directly stored in the anode chamber which can store fuel 17 ml and does not need any auxiliary equipment, so it easy to apply to the portable power source. Not including fuel, total weight of stack is only 50g and the volume is 75 cm3. The 16 cell stack includes two pieces of 117 membrane, 16 anode electrodes loading Pt/Ru 5 mg/cm2 and 16 cathode Pt loading 5 mg/cm2. Each single cell electrode area is about 3.5 cm&#x00B2;, so the total electrode area of the 16-cell stack is 56cm2. With methanol concentration 3 M, pumpless, air-breathing, and room temperature, the largest output power density of the fuel cell can reach 10.3 mW/cm&#x00B2;, and the total power can reach 578 mW in this stage. The performance of the stack will be further improved in the next stage.

The problem of the performance decay and the factors affecting on the DMFC performance for long-term operation are studied in this thesis. First, the influence of the initial treatments of MEA and the exposure of MEA in the atmosphere on the water content are measured. In addition, the effects of the pressure of the MEA hot press conditions, the treatments and preservation of MEA, and the operative conditions on the performance are also examined. Eventually, we expect that the best way to increase the DMFC performance and avoid the performance can be found. These can provide for references when a portable DMFC need to be designed and manufactured in future. In order to solve the problem of methanol crossover leading to the cathode poisoned, cells are operated only under the proper methanol concentration and discharged thoroughly before finishing the whole experiment. It is also necessary to maintain MEAs in proper wetness so that the performance of stack will not decay too quickly. In the initial treatment, firstly, a MEA is immersed in 3M MeOH and then boiled with 80oC DI water for an hour, respectively. The experimental conditions of this passive single-cell DMFC are pumpless in anode chamber, air-breathing, and room temperature. The power density of this DMFC with these test conditions can reach a value about 33mW/cm2. This value is about 106% higher than that of the untreated MEA. If MEA boiled with 0.5M H2SO4 for an hour and then boiled with 80oC DI water for an hour, its power density is about 75% higher than that of the untreated MEA.

In this thesis, a long-term operation direct methanol fuel cell (DMFC) stack with no performance decay is developed and improved. In a traditional passive portable DMFC, the Methanol solution is storage at anode Reaction chamber. The performance will drop after a short period due to the concentration of Methanol solution becoming lower (about 1.5M). Although High concentration of Methanol solution could increase the operation time, but it will couse crossover to poison the cathode Pt particle, and it is unable to keep long-term operation stably either. In order to achieve long-term operation stably, to maintain the concentration of methanol solution in the anode chamber will be very important. In our fuel supply stack, there are two chambers in the stack to storage methanol and water, and we could control the supplying rate by adjusting the diffusion area to control the diffusion rate of methanol and water. And the methanol solution deliver to anode reaction chamber by cotton tube. If the anode reaction chamber is filled with 1.3¢W, 2M methanol solution and without any fuel supply, operating on the 185mA constant current (82.2mA/cm2 ). The results shows that the performance begin decay about after 15minutes. If the appropriate amount of methanol and water is supplied, the performance can be steady in a long-term operation. But if supply too much methanol solution, the concentration in the anode reaction chamber will rise up, and the high concentration will cause crossover poised the cathode catalyst, and the performance will decay. If supply rate not enough, the concentration in the anode reaction chamber will become lower, and the performance will decay after long-term operation. In this study, based on operate current and the rate of evaporation of methanol solution, to supply appropriate supplying rate and concentration of methanol solution to anode reaction chamber, could keep the performance in a steady output.