Metallic robotic arms, or manipulators, currently dominate automated industrial operations, but due to their intrinsic weight, have limited usefulness for large-scale applications in terms of precision, speed, and repeatability. This thesis focuses on exploring the feasibility of using polymeric composite materials for the construction of long-reach robotic arms. Different manipulator layouts were investigated and an ideal design was selected for a robotic arm that has a 5 [m] reach, 50 [kg] payload, and is intended to operate on large objects with complex curvature. The cross-sectional geometry of the links of the arm were analyzed for optimal stiffness- and strength-to-weight ratios that are capable of preserving high precision and repeatability under time-dependent external excitations. The results lead to a novel multi-segment link design and method of production. A proof-of-concept prototype of a two degrees-of-freedom (2-DOF) robotic arm with a reach of 1.75 [m] was developed. Both static and repeatability testing were performed for verification. The results indicated that the prototype robot main-arm constructed of carbon fiber-epoxy composite material provides good stiffness-to-weight and strength-to-weight ratios. Finite element analysis (FEA) was performed on a 3-D computer model of the arm. Successful verification led to the use of the 3-D model to define the dimensions of an industrial-sized robotic arm. The results obtained indicate high stiffness and minimal deflection while achieving a significant weight reduction when compared to commercial arms of the same size and capability.

This work is devoted to the computational modeling of a lightning strike electric arc discharge induced air plasma and the material response under the lightning strike impact. The simulation of the lightning arc plasma has been performed with Finite element analysis in COMSOL Multiphysics. The plasma is regarded as a continuous medium of a thermally and electrically conductive fluid. The electrode mediums, namely the cathode and anode, have also been included in the simulation in a unified manner, meaning that the plasma and electrode domains are simulated concurrently in one numerical model. The aim is to predict the lightning current density, and the heat flux impinged into the anode's material surface, as well as the lightning arc expansion and pressure and velocity of the plasma flow. Our predictions have been validated by the existing experimental data and other numerical predictions reported by former authors.

Unidirectional carbon fiber and fiberglass epoxy composite elements consolidated with aramid sleeves were radially impacted at 5 J (3.7 ft-lbs) and 10 J (7.4 ft-lbs), tested under compression, and compared to undamaged control specimens. These structural elements represent local members of open three-dimensional composite lattice structures (e.g., based on isogrid or IsoTruss® technologies). Advanced three-dimensional braiding techniques were used to continuously fabricate these specimens. The unidirectional core specimens, 8 mm (5/16 in) in diameter, were manufactured with various sleeve patterns. Bi-directional braided sleeves and unidirectional spiral sleeves ranged from a nominal full to half coverage. These specimens were tested for compression strength after impact. This research used an unsupported length of 50.8 mm (2.0 in) specimens to ensure a strength-controlled compression failure. Compression strength of undamaged unidirectional carbon fiber and fiberglass epoxy composites is virtually unaffected by sleeve type and sleeve coverage. Fiberglass/epoxy configurations exhibited approximately 1/2 and 2/3 reduction in compression strength relative to undamaged configurations after impact with 5 J (3.7 ft-lbs) and 10 J (7.4 ft-lbs), respectively. Increasing aramid sleeve coverage and/or increasing the interweaving of an aramid sleeve (i.e., braid vs. spiral) increases the damage tolerance of fiberglass/epoxy composite elements. Damaged carbon/epoxy composites exhibited an approximate decrease in strength of 70% and 75% after 5 J and 10 J of impact, respectively, relative to undamaged configurations. The results verify that an aramid sleeve, regardless of type (braid or spiral), facilitates consolidation of the carbon fiber and fiberglass epoxy core. Not surprisingly, full coverage configurations exhibit greater compression strength after impact than half coverage configurations.

A l'heure actuelle le stockage de l'hydrogène sous forme gazeuse, comprimée à haute pression, apparaît comme la solution le plus mature présentant le meilleur compromis en termes de masse, de pression de service mais aussi de volume des réservoirs. Cependant pour un développement plus large et sécurisé, l'amélioration des performances et la réduction des coûts des réservoirs restent des enjeux prioritaires. C'est dans ce contexte que nous avons étudié le stockage de l'hydrogène dans des réservoirs de type IV, en composites fibres de carbone/époxy. Ce travail a eu pour objectif d'accroitre la fiabilité du dimensionnement. Dans un premier temps, une étude expérimentale de caractérisation des matériaux constitutifs du réservoir a été réalisée. Pour améliorer la fiabilité des calculs, un modèle probabiliste a été proposé pour décrire le comportement de la partie composite du réservoir, principalement la rupture des fibres. Des calculs multiéchelles ont été mis en place basés sur les propriétés mécaniques et physiques des fibres. Les autres modes de dégradations, décollement entre plis, liaison embase-liner ont aussi été pris en compte dans les calculs de comportement du réservoir jusqu'à son éclatement. Enfin des recommandations de dimensionnement du réservoir ont été proposées afin d'améliorer les performances tout en minimisant la masse de composite dans un objectif de réduction des coûts. / Presently, the compressed hydrogen storage under high pressure appears to be the most sophisticated solution regarding to a compromise of mass, service pressure and also volume of pressure vessels. However, the challenges of pressure vessels nowadays are their performance improvement as well as their cost reduction. In this context, we studied the type IV hydrogen storage pressure vessel in carbon fibre/epoxy composites. This work aims to obtain a reliable pressure vessel design. Firstly, an experimental study of associated materials and pressure vessel characterisation has been carried out. Then, we proposed a probabilistic model for a composite which is dedicated in particular to fibre breakage using multi-scale simulations in accordance with its mechanical and physical properties. Once this model joined with damage criteria dedicated separately to the others damage mechanisms are integrated into the pressure vessel simulations. Finally, recommendations on composite pressure vessels have been proposed in order to improve their performances and to decrease the mass of composite directly corresponding to the reduction of composite pressure vessels cost.

Compression tests were performed on damaged and undamaged rods and tubes made from unidirectional carbon/epoxy composite and lightweight core materials. Tested samples represent local members in an open, three-dimensional, composite lattice structure. Testing was performed in order to establish effective core materials to use in order to increase the buckling length of local IsoTruss® members while maintaining low weight. Members were formed from T700SC-12K-50C carbon fiber with UF6639-100 resin. Core materials consisted of 3/8-inch (0.953 cm) outside diameter Teflon® rods, Teflon® tubes, nylon rods, nylon tubes, Ertalyte® rods, and Duratron® rods. All 3/8-inch (0.953-cm) cores were each surrounded by 50 tows of carbon/epoxy prepreg. Control samples were also created with 50 carbon/epoxy prepreg tows. Half-inch (1.27 cm) outside diameter copper tubes were used as core materials for tubes consisting of 100 carbon/epoxy prepreg tows. Control samples to compare against samples with copper cores were also created with 100 tows of carbon/epoxy prepreg. Impact damage was inflicted using a cylindrical tup with 20 ft-lb impact energy.In undamaged specimens, nylon tube showed the highest structural efficiency. Nylon showed structural efficiencies much higher than other materials when comparing undamaged samples. In damaged specimens Ertalyte® rods showed the highest structural efficiency. Core stiffness appeared to control the level of absorbed impact energy with stiffer cores absorbing and dissipating more energy than softer equivalents during impact.

Compression strength after impact tests were conducted on unidirectional composite rods with sleeves. These elements represent local members of open three-dimensional composite lattice structures (e.g., based on isogrid or IsoTruss® technologies). The unidirectional cores composed of carbon, glass, or basalt fiber/epoxy composites were co-cured in aramid sleeves. Sleeve patterns included both bi-directional (unsymmetric) braids and unidirectional spiral wraps with sleeve coverage ranging from nominally half to full. The diameters were nominally 8 and 11 mm (5/16 and 7/16 in). The larger diameter had nominally twice the cross-sectional area, to quantify the effects of scaling. The specimens were long enough to encourage local buckling failure as expected in members of typical composite lattice structures. The unsupported lengths varied from 127 mm (5.0 in) to 160 mm (6.3 in). Specimens were radially impacted at mid-length with energy levels ranging from 0 to 20 J (0 to 14.8 ft-lbs) and tested in longitudinal compression to quantify the effects of local impact damage on the buckling strength. In undamaged specimens, sleeve type and sleeve coverage have no effect on the ultimate compression strength of carbon, glass, or basalt composites (7% or less standard deviation for each material). When impacted, the influence of sleeve type and sleeve coverage varies with the type of fiber in the unidirectional core. Sleeve type and coverage did not affect the compression strength after impact for fiberglass composites. On the other hand, both carbon and basalt composites exhibited improved performance with braided (vs. spiral) sleeves (up to 34% stronger) and full (vs. half) coverage (up to 38% stronger). The compression strength of carbon configurations decreases with increasing impact energy regardless of sleeve type or coverage. The higher flexibility of glass and basalt composites, however, allowed some configurations to maintain the same compression strength after impact as their undamaged counterparts, at lower impact energy levels. Doubling cross-sectional area of basalt composites significantly improves the stiffness and compression strength after impact, more than doubling the impact energy required to achieve the same compression strength.