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This thesis describes the manufacturing, structural analysis and testing of a composite cylinder for space application. This work includes the design and fabrication of a reusable multicomponent mandrel made of aluminum and steel and the manufacturing of a carbon fiber reinforced tube in an epoxy resin matrix. This structure intends to serve as the optical lens housing onboard a spacecraft. In addition, some future work needs to be done before this component is certified. The objective is to determine if the composite meets the stiffness and strength requirements for lens housing. The structural analysis is made by means of a finite element model simulating the true boundary conditions. The testing includes the design of a fixture to allow the composite cylinder to be mounted in one the testing machines at the Department of Aerospace Engineering at Texas A&M University and the preparation for the actual test. The response to the experimental analysis will be compared to the numerical simulation to verify the results.

Two topics, i.e., the scale effects and the geodesics of random heterogeneous materials will be discussed in this work. / When the separation of scales in random media does not hold, the representative volume element (RVE) of deterministic continuum mechanics does not exist in the conventional sense, and new concepts and approaches are needed. This subject is discussed here in the context of microstructures of two types - planar random chessboards, and planar random inclusion-matrix composites -- with microscale behavior being elastic-plastic-hardening (power-law). The microstructure is assumed to be spatially homogeneous and ergodic. Principal issues under consideration are those of yield and incipient plastic flow of statistical volume elements (SVE) on mesoscales, and the scaling trend of SVE to the RVE response on macroscale. Indeed, the SVE responses under uniform displacement (or traction) boundary conditions bound from above (respectively, below) the RVE response, and we show via extensive simulations in plane stress that the larger is the mesoscale, the tighter are both bounds. However, the mesoscale flows under both kinds of loading do not, in general, display normality. Also, with the limitation imposed by currently available computational resources, we do not recover normality (or even a trend towards it) when studying the largest possible SVE domains. / The second topic is the geodesic (i.e., shortest path) character of strain fields occurring in elasto-plastic response of planar inclusion-matrix composites. The composites' spatially random morphology is created by generating the disk centers through a sequential inhibition process based on a poisson point field in plane. Both phases (inclusions and matrix) are elastic-plastic-hardening with the matrix being more compliant and weaker than the inclusions, and perfect bonding everywhere. A quantitative comparison of a response pattern obtained by computational micromechanics with that found only by mathematical morphology indicates that (i) the regions of plastic flow are very close to geodesics, and (ii) a purely geometric, and orders of magnitude more rapid than by computational mechanics assessment of these regions is possible.

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Safety snap-hooks are a critical component of a fall-arrest system worn by individuals working at elevated heights. Current snap-hook technology has not evolved in many years, and as a result, the hooks are both heavy and conduct electricity. This project investigated the design and manufacture of a polymer-composite safety-snap-hook. The objective was to determine whether a light-weight, dielectric, composite hook can meet the safety requirements, while being manufactured at a competitive price. Several fibre arrangements were tested using current aluminium hook geometry. A research plan was designed and completed to maximize the hook strength by optimizing fibre architecture. These results were then used to design a composite hook that meets all the current CSA standards (static load, dynamic load, side and front load gate test). The design enables the hook to be completely non-conductive and lighter than the current pincer hook. Different manufacturing techniques were also considered and it was determined that both the net-shaped moulding and vacuum bag panel method were suitable techniques. It is recommended that further research be carried out to decrease the cost of the composite hook. Less expensive resin materials should be tested to determine how much strength is lost with lower grade resins. A standard test should also be developed so that hooks can be characterized for their electrical conductivity. In addition, research is required to find a process to cut the mats so that the cut-outs can be handled without falling apart, making the net-shape moulding process more suitable. Further design modifications are also needed to meet newly proposed gate regulatory standards. Research is required to determine whether increasing the thickness of the gate or embedding a metal reinforcement would provide the required gate strengths. / Thesis (Master, Mechanical and Materials Engineering) -- Queen's University, 2007-09-25 13:25:27.368

Composite polymer particles were made of two or more polymers. If these polymers are incompatible, the particles after polymer phase segregation exhibit complex morphologies which determine their properties and applications. Such particles may have applications in both academia and industry. In this work, polystyrene (PS)/ poly(2-cinnamoyloxyethyl methacrylate) (PCEMA) and poly(acetyloxyethyl methacrylate) (PAEMA)/PCEMA composite polymer particles are prepared by the evaporation of toluene from PS/PCEMA/toluene and PAEMA/PCEMA/toluene droplets dispersed in an aqueous solution containing surfactants. The surfactants used for the two systems are poly(glyceryl methacrylate)100-block-poly(2-cinnamoyloxyethyl methacrylate)15 (PGMA100-b-PCEMA15) and poly(glyceryl methacrylate)300-block-poly(2-cinnamoyloxyethyl methacrylate-ran-acetyloxyethyl methacrylate)37 (PGMA300-b-P(CEMA-ran-AEMA)37), respectively, for the PS/PCEMA and the PAEMA/PCEMA systems. The morphologies of the PS/PCEMA and PAEMA/PCEMA composite particles are analyzed by transmission electron microscopy (TEM), atomic force microscopy (AFM), and dynamic light scattering (DLS). The results indicate that the particles are polydisperse and of nanometer size. For the PAEMA/PCEMA particles, the preferred morphology is hemisphere, while for the PS/PCEMA system the morphology is a mixture of acorn and occluded core-shell. Based on Gibbs free energy theory, and knowing the corresponding surface tensions and interfacial tensions, the thermodynamic equilibrium morphologies for both kinds of composite particles were found. Due to the uncertainty during measurements and calculations, and the influence of kinetic factors, the theoretical predictions agreed only partially with the experimental observations. / Thesis (Master, Chemistry) -- Queen's University, 2008-08-27 12:16:37.142

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