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.

This research strived to examine the potential for carbon fibre to improve the strength characteristics of ceramic water filters (CWFs) to improve their length of use in the field while maintaining, or improving, existing flow and bacteria attenuation capabilities. Model-scale CWF discs were made exploring several configurations of carbon fibre reinforcement and were tested for flow through rates, E coli attenuation, and equi-biaxial flexural strength. It was determined that, while the particular carbon fibre configurations explored in this study did not increase the strength of the CWF discs, they did provide some benefit such as improving flow-through rates while minimally detracting from bacteria removal. This indicates that the reinforcement of CWFs has potential and further research should be conducted to determine an appropriate reinforcement configuration to improve both their strength characteristics. Given that CWFs are gaining more widespread use in many countries worldwide, extending their lifespan of use would have significant value.

Carbon fibre reinforced polymer, or CFRP composite materials, play an increasingly important role in modern manufacturing. They are widely used in aerospace, and their use is currently spreading to other industries where high strength-to-weight ratios are required. However, machining of composites is still a challenging task and often hampered by poor quality. Despite the extensive research that was conducted on the machining of composite materials over the last few years, mechanical drilling still suffers from delamination, fibre pull-out and poor surface finish, whereas laser cutting produces microstructured defects and a taper problem. This thesis reports on the drilling of CFRP composites by demonstrating the possibility of drilling small diameter holes (i.e. 8mm) into 25.4mm thick carbon fibre reinforced polymer composites (CFRPs) using mechanical drilling and laser drilling as stand-alone processes and as a sequential combination. The research involved four main phases of experimental testing. The first part of Phase 1 involved!preliminary experiments of drilling thick CFRP to identify the most suitable drilling strategy. Three mechanical drilling strategies conducted in the same parameter by using a 2-flute uncoated WC twist drill that was assessed with respect to feasibility of drilling thick CFRP. The results showed that the single-step strategy was the most feasible strategy to drill thick CFRP compared to 2- and 4-peck drilling strategies. The second part of Phase 1 concerned the influence of speed-feed combinations on hole quality by utilising three twist drills with different materials and geometries in both an uncoated and coated condition. The results indicated that a significant increase in peel-up delamination was found with increasing feed rate. In contrast, using a constant feed rate but increasing the spindle speed seemed to reduce peel-up delamination. Furthermore, the hole entry for 2-flute uncoated WC drill bits was an uncommon study finding because most of the previous researchers experienced more damages at the hole exit and their investigation focused on the hole exit only. Currently, implementation of laser technology in cutting and drilling composites is becoming popular as an alternative solution. Various experiments were conducted with the goal of identifying the effects of machining parameters on key output measures (i.e. heat affected zone (HAZ), hole depth and other damages) in drilling of 25.4 mm thick CFRP by using a fibre laser. Phase 2 involved a number of machining parameters selected to identify the potential of a fibre laser in drilling thick CFRP composites (i.e. laser power, scanning speed, focal point plane position (FPP), assisted-gas type and gas pressure). The results proved that a fibre laser could penetrate thick CFRP to a 22mm depth only. Moreover, the spiral trepanning strategy was able to penetrate 80% out of the total thickness of the CFRP in continuous wave (CW) mode, whereas the modulated laser beam (i.e. laser pulse mode) can penetrate 67% only. This result was a major recorded breakthrough because previous research attempts cut up to 5mm only. Laser power proved to be the most influential factor for hole depth in laser drilling of thick CFRP when the spiral trepanning strategy was applied. Machining trials were conducted in Phase 3 by using a 16kW fibre laser in modulated pulsed laser mode. In this phase, laser power of more than 1kW was attempted to cut the whole thickness of CFRP composites in CW mode, but it was unsuccessful. However, a new parameter was discovered (i.e. the cooling time between passes in modulated pulsed mode), which proved a considerable reduction of HAZ when the higher cooling time was imposed. Finally, phase 4 involved the experiments of sequential laser-mechanical drilling. A 1kW fibre laser was selected as a pre-drilling or initial step and followed by mechanical drilling as the final step. The sequential drilling method successfully reduced thrust force and torque for mechanical drilling by an overall average of 61%, resulting in high productivity and decreasing the thermal and mechanical stresses in the cutting tool and, in turn, promoting higher tool life. The highest delamination factor (Fda) ratio was experienced by the sequential laser 8mm – mechanical 8mm for both tools (i.e. 2- and 3-flute uncoated tungsten carbide) and laser pre-drilling strategies (i.e. single- and double-side). Thus, a novel laser-mechanical sequential drilling technique was developed, evaluated and tested in the drilling of thick CFRP composites; this is the first time ever in drilling thick CFRP (i.e. 25.4mm).

This thesis contributes towards understanding of mechanical response of 3D composites and ceramics. Composite materials have widespread applications ranging from aerospace, civil sectors to sports and drones. One important application is in composite armours where composites and ceramic layers are used together. Therefore, it is important to study the mechanical response of these components to develop better armour systems. The first part of this thesis concerns with dynamic penetration response of confined ceramic targets. In the second part, mechanics of a novel 3D composite consisting of orthogonal carbon fibre tows is studied. The dynamic penetration of ceramic target by a long-rod projectile is studied using a mechanism based ceramic constitutive model. This is to capture and explain the essential physics observed during penetration of a ceramic target such as dwell and structural size effect. Dwell is captured using the constitutive model and the related physics is studied along with identification of causes of dwell. Origins of structural size effect in ceramics are identified and their influences are studied. In the second part of the thesis a novel 3D composite consisting of three mutually perpendicular orthogonal tows is studied under compression, indentation and three-point bending. Under compression along low fibre volume fraction direction (Z), the 3D composite forms stable and multiple kinks in the Z tows resulting in 10% ductility. This contrasts with traditional UD or 2D composites which fail catastrophically at 2% strain. The stability in the case of the 3D composite is due to the constraint imposed by the surrounding material. Under indentation, the 3D composite has a near isotropic and ductile response. In contrast, traditional cross-ply composites show highly anisotropic response where indentation results in brittle failure along in-plane direction. Under three-point bending, the response was ductile in Z-direction and brittle in other two directions. Overall, the 3D composite studied in this thesis shows improvement over traditional CFRPs in ductility and energy absorption capability. The 3D composite has been demonstrated to have smooth load-displacement curves reminiscent to indentation of metal in all three directions achieved at densities significantly lower than structural metals that display equivalent ductility. Thus, these 3D composites are strong candidates for applications where loading direction is unknown a-priori, and where high energy absorption is required along with reusability of the material.

This Thesis investigates the damage sensing capabilities of the electrical potential measurement technique in carbon fibre reinforced polymer composites. Impact damage was introduced in multidirectional laminates and its effect on potential distribution studied. It was found that delaminations and fibre breakages within the laminate can be detected and located by measuring potential changes on the external composite surface. The extent and size of potential changes were significantly affected by the position of the current electrodes in relation to the potential measurement probes. A numerical model was developed investigating the effect of different size delaminations, located in various positions within the lamina, on electrical potential distributions on the external ply, and a quantitative analysis of the numerical results is presented. The numerical simulations demonstrated that the measured potential changes on the external ply were in proportion to the delamination size. The numerical and experimental results were compared and the optimum configuration of current electrodes and potential probes for damage detection selected. The response of electrical potential to mechanical strain, in unidirectional and multidirectional samples was also investigated. It was found that the conductive medium, used for introducing the current, defines the piezo-resistance performance of the composite. A finite element model was developed able to predict the effect of inhomogeneous current introduction in unidirectional specimens on electrical potential and piezo-resistance. The effects of temperature and water absorption on potential measurements were also presented.

The increased demand in stringent requirements on engineered surfaces in the aerospace and manufacturing industries drove the need for developing advanced surface engineering techniques such as chemical etching, plasma etching, corona discharge and laser surface texturing in order to alter material surface physical and chemical properties. Among these techniques, laser surface texturing has been identified as one of the most efficient and effective surface treatment/ texturing techniques which utilizes laser ablation to meet the demand of practical engineering requirements. This thesis details three practical engineering challenges in the field of paint adhesion, dust adhesion and tribology performance of SPF sheet forming dies in which case the problems and motivation for development came from projects by industrial partner collaborations with BAe Systems, Rolls-Royce and Dyson Ltd. The proposed solutions to these challenges are formulated around laser surface texturing techniques using excimer and femtosecond lasers on three engineering materials which are CFRP, ABS polymer and HR4 nickel alloy. As ablation is the main mechanism used in laser surface texturing techniques in achieving surface property changes, the understanding of laser beam interaction with materials is crucial. The fundamental understanding of laser beam interaction with different materials has been researched since the use of lasers in practical engineering applications by which laser material interaction parameters such as ablation threshold, incubation coefficient and optical penetration depth are of primary interest in addition to the ablation rate. Currently the published literatures are either material specific or laser specific with minimal or zero comparison between different types of lasers and materials as such which limits the understanding of laser beam interaction with materials. In addition, laser beam interaction with polymers has always been done using ultraviolet wavelength lasers. In this thesis, the interaction between two types of lasers and three types of materials which includes metals and polymers are presented through comparison and discussion between different interactions. It has been discovered that the ablation threshold value is lower for ABSinteraction with excimer laser as compared to the interaction with femtosecond laser due to the difference in the ablation mechanism. The optical penetration depth value is higher for ABS interaction with the excimer laser as compared to the interaction with the femtosecond laser due to differences in the photon energy of the laser beam of different wavelength. Two ablation rate curves were identified on ABS interaction with infrared wavelength femtosecond laser beams which has not been reported before. Chemical composition of the laser treated layer changes through chain scission process, creating free radical carbons that reacted with oxygen, nitrogen and water vapour in air creating oxygen and nitrogen rich functional groups which increased with increasing laser fluence and number of pulses. Laser ablation is known for its capability of altering surface morphology and surface chemistry of materials through excitation of electrons causing bond scission or melt where materials are vaporised, ejected or undergo chemical compositional changes. In the case of polymers, addition of oxygen and nitrogen rich functional groups are identified whereas in the case of metals, changes in crystallographic, orientation and oxidation states are identified. Such changes are deemed ideal for applications such as adhesion where it is mainly used for bonding and joining of similar or dissimilar materials. In this research, excimer laser surface treatment showed improvement in CFRP paint adhesion where a better adhesion is achieved than sand-papered surfaces. Paint adhesion of CFRP surfaces is affected by surface contaminants, surface chemical composition and surface roughness where the degree of inuence is in the respective order. In addition, excimer and femtosecond laser surface treated ABS also improved dust adhesion. The main factors that affect the ABS surface dust adhesion performance are surface roughness and surface chemical composition. The increase in surface roughness increases the surface area available for dust to adhere to. In addition, it also increases the drag coefficient of the air flow results in a higher removal force exerted by the air flow onto the dust particles through changes in the localised aerodynamic flow. The increase in polar functional groups increases the adhesion of the dust particles onto the surface due to an induced dipole moment by the charged dust particles. Laser micro-dimpled surfaces have been reported to be effective in reducing friction coefficient and wear rate of surfaces under oil lubricated conformal contact conditions where the dimples act as reservoirs to store lubricant and wear particles. But such surfaces have not been extensively researched under non-conformal contact conditions for different lubricated environments. In addition, there are contradictory results found between published literatures which observe under similar wear environments and conditions but with different dimple geometry. Hence a detailed investigation on dimpled surfaces under non-conformal contact conditions is being carried out. Laser surface texturing of 100 μm size dimples shows a reduction in nickel alloy wear rate under dry and oil lubricated environments. A higher dimple area ratio reduces the wear rate under dry condition with abrasive wear as the main wear mechanism. Under oil lubricated environments, the friction coefficient is dependent on the surface contact pressure, sliding speed and the viscosity of the lubricant and the wear rate is dependent on the film thickness which correlates to the friction coefficient. The wear rate of a dimpled surface is dependent on three factors which are the dimple diameter to contact area diameter ratio, depth of the dimple produced and the density of the dimples. Positive results are obtained in all three engineering applications indicating the feasibility of laser surface texturing techniques in providing suitable material surface properties for these applications.

RTM6 has for more than 20 years been the main commercial epoxy system for infusion processing qualified by the aerospace industry. In common with other aerospace-grade epoxy systems RTM6 is mechanically strong but brittle, producing carbon-fibre (CF) composites with relatively low impact resistance and damage tolerance. This thesis reports an approach to toughening epoxy-CF composites without modification of the resin. Thus, a T300 carbon fabric (ES-fabric) coated with 20 weight % of a poly (aryl ether ketone) (PAEK) was used to toughen the composite. The initial stage of the study was the manufacturing process. DSC and oscillatory-shear rheology were used to determine flow times and cure conditions, and to produce laminates with fibre volume fractions ≥55% a hybrid resin infusion/hot-press process was developed. Dynamic mechanical thermal analysis also showed that the PAEK coating produced relatively little plasticization of the epoxy matrix, with values of the matrix glass transition temperature shifting from 186±4.4 to 181± 1.4 ºC when using the ES-fabric. The main body of the study focussed on the toughening effect afforded by the PAEK coating relative to an uncoated fabric system as a reference. Mode I and Mode II interlaminar fracture toughness behaviour were studied using dual cantilever beam (DCB) and four-point end-notch flexure (4ENF) tests, respectively. The measured mode-I fracture energy, GIC, increased three-fold, from 216 ± 7.2 Jm-2 to 751 ± 105 Jm-2, due to the toughening effect of the PAEK coating; whereas the mode-II fracture energy, GIIC, increased almost four-fold from 857 ± 99 Jm-2 to 3316 ± 372 Jm-2. Damage resistance was studied using low-velocity impact testing and damage tolerance using a miniature compression-after-impact (CAI). A comparative study of damage tolerance was performed using open-hole compression (OHC) testing. The impact damage resistance significantly improved with the use of the PAEK-coated ES-fabric as well as the CAI and OHC behaviour. Impact testing showed the PAEK -toughened system exhibited higher energy abortion than the untoughened system, larger damage area was created in the T300/RTM6-2 after impacted with same energy. The CAI results indicated that the normalized CAI strength is major related that damage width rather than other factor. OHC results are predicted by using W-N criteria, for ES/RTM6-2: ASC a0 = 9.35 mm and PSC d0 = 2.72mm; whereas for T300/RTM6-2: ASC a0 = 7.95 mm and PSC d0 =2.43 mm, indicates that the compressive strength of T300/RTM6-2 is more sensitive to the size of the hole, thus ES/RTM6-2 perform better damage tolerance. The results from mechanical testing indicate that the PAEK coating toughened the composite system and significantly improved damage tolerance. Scanning electron microscopy indicated that these improvements in fracture behaviour were due to morphological changes induced by the PAEK coating in the matrix-CF interfacial region, where such changes can provide the maximum benefit. Small particles of RTM (approximately 1 µm in diameter) were observed imbedded within a continuous PAEK phase. Thus, during testing crack propagation was deflected (or bifurcated) by the RTM6 particles or stopped by shearing of the continuous PAEK phase of this multiphase region. This morphology is proposed to have formed in the interfacial region during processing by dissolution of the PAEK coating within the matrix resin system, followed by reaction-induced phase separation and then phase-inversion as the matrix cures.

This thesis reports a study of the effects on processing and properties of incorporating nano-scale reinforcements (multiwall carbon nanotubes, MWCNTs) in the matrix of epoxy- carbon fibre (CF) laminate composites to produce multi-scale composites (M-SC). The main aim of this research was to study the effects of MWCNTs on matrix toughening and the through-thickness properties of M-SCs based on a commonly used aerospace grade epoxy resin — triglycidyl-p-aminophenol (TGPAP) cured with diaminodiphenyl sulphone (DDS). In order to improve resin processing, diglycidyl ether of bisphenol F (DGEBF) was added into the TGPAP/DDS system as a reactive diluent. Factorial experimental design (FED) was used to optimize the composition of this tri-component system to obtain high Tg and low resin viscosity, which gave a TGPAP/DGEBF/DDS system with 30.56 wt.% of DGEBF and a chemical stoichiometry of 0.5. Three types of MWCNTs were used; as-received (AR-), base-washed (BW-) and amine functionalized (NH2-). These were shear-mixed with both the bi- and tri-component systems using a 3-roll mill to produce nanocomposite matrices (NCM). The curing behaviour, dispersion state of MWCNTs in the resin and processability of NCMs were studied to decide upon the preparation method for the final M-SC. The fracture toughness (KIC) and the flexural properties of NCM were affected by both MWCNTs and the matrix type; thus KIC increased by up to 8 % in TGPAP/DDS NCM but decreased by 23% in TGPAP/DGEBF/DDS NCM with 0.5 wt.% AR-CNTs. The addition of both non-functionalized and functionalized MWCNTs increased the flexural modulus. The failure mechanism of NCMs was found to be dominated by the size and distribution of CNT aggregates and the behaviour of MWCNTs, both those dispersed in the matrix and in aggregates. The addition of functionalized MWCNTs increased the interfacial bonding between MWCNT and epoxy resin and thus improved the mechanical properties. All the NCM systems were taken forward to manufacture M-SC using a hybrid resin film infusion (RFI)/hot press process. The fibre volume fraction and the void content could be controlled at 43 ± 5 % for M-SC with TGPAP/DDS NCM and 60 ± 6 % for M-SC with TGPAP/DGEBF/DDS NCM. M-SCs were characterised using a range of tests, including flexural, interlaminar shear strength (ILSS), mode-II interlaminar fracture toughness (GIIC), low velocity impact and compression after impact (CAI). The most obvious improvement occurred for the M-SC with tri-component system with 0.5 wt.% CNTs, whereILSS increased by 16 % upon adding NH2-CNTs and GIIC increased significantly on addition of 0.5 wt.% AR-CNTs and NH2-CNTs, by 85% and 184% respectively. However the effect of MWCNTs on other properties was at best marginal. For example, for the M-SC with TGPAP/DDS, the flexural modulus and ILSS only increased by 4.1 % and 2.3 % with 0.5 wt.% AR-CNT.

Les composites à matrice organiques (CMO) et fibre de carbone sont de plus en plus employés dans la réalisation de structures « tièdes » (aubes de fan, nacelles …) ; ces pièces peuvent être soumises, en service, à la fatigue mécanique, au cyclage thermique et à la fatigue thermo-mécanique. Bien qu’il existe une littérature consistante sur le comportement en fatigue des composites tissés, l'interaction entre fatigue et la dégradation liée à l'environnement à haute température n’a pas été encore bien exploitée. Le couplage entre les effets de la thermo-oxydation, le comportement mécanique (viscoélastique, viscoplastique) de la matrice organique à températures élevées et la dégradation par fatigue peut être néfaste pour le composite.Le but de ce travail est de caractériser et de modéliser - pour les composites tissés C/matrice organique - le comportement thermomécanique, l'apparition et le développement de l’endommagement liés aux mécanismes mécaniques cycliques (fatigue) sous environnement contrôlé (température et gaz).Une étude préliminaire sur un composite stratifiée [02/902]s a été menée pour pouvoir analyser les effets de l’environnement sur une architecture simple. La corrélation d’image numérique (CIN) et des scans μ-tomographiques (μCT) ont été employés pour le suivi et la caractérisation de l’endommagement de fatigue de composites tissés 2D à architecture complexe pour applications aéronautiques. Les effets de l’environnement sur la dégradation par fatigue ont été également explorés.L'objectif à long terme de cette étude est de fournir des outils expérimentaux et numériques pour renforcer la compréhension et la modélisation du couplage mécanique/endommagement/environnement pour la prédiction de la durée de vie et pour la proposition de protocoles d’essais accélérés réalistes de pièces « tièdes » en CMO. / In the next future, the employment of organic matrix/carbon fibre composites (OMC) is foreseen for the realization of “hot” structures: these parts may be subjected, in service, to mechanical fatigue (e.g. fan blades turbo-engines), thermal cycling and thermo-mechanical fatigue (e.g. aircraft structural parts). Though there is a consistent literature concerning the fatigue behaviour of woven composites, the interaction between fatigue and environmental degradation at high temperature has been poorly explored. Coupling between thermo-oxidation effects, mechanical (viscoelastic, viscoplastic) behaviour of the polymer matrix at high temperatures and degradation due to fatigue may be highly detrimental for the material. This work aims at characterizing and modelling - for carbon fibre/organic matrix (polyimide) textile composites – the thermomechanical behaviour, the onset and the development of damage related to cyclic mechanical mechanisms (fatigue) under controlled (temperature and gas) environment.A preliminary study on a cross-ply laminate [02/902]s has been carried out in order to analyse the environmental effect on a model sample. Digital Image Correlation (DIC) and μ-Computed Tomography (μCT) have been used to monitor and characterize the fatigue damage of 2D woven composites for aeronautical applications. The environmental effect on fatigue degradation have been also explored.The long-term aim of the study is to provide experimental and numerical tools to strengthen the understanding and the modelling of mechanics/damage/environment coupling for durability prediction.

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.