A numerical simulation model has been developed which describes the manufacture of composite laminates from fiber-reinforced polyimide (PMR-15) matrix prepreg materials. The simulation model is developed in two parts. The first part is the volatile formation model which simulates the production of volatiles and their transport through the composite microstructure during the imidization reaction. The volatile formation model can be used to predict the vapor pressure profile and volatile mass flux. The second part of the simulation model, the consolidation model, can be used to determine the degree of crosslinking, resin melt viscosity, temperature, and the resin pressure inside the composite during the consolidation process. Also, the model is used to predict the total resin flow, thickness change, and total process time. The simulation model was solved by a finite element analysis. Experiments were performed to obtain data for verification of the model. Composite laminates were fabricated from ICI Fiberite HMF2474/66C carbon fabric, PMR-15 prep reg and cured with different cure cycles. The results predicted by the model correlate well with experimental data for the weight loss, thickness, and fiber volume fraction changes of the composite. An optimum processing cycle for the fabrication of PMR-15 polyimide composites was developed by combining the model generated optimal imidization and consolidation cure cycles. The optimal cure cycle was used to manufacture PMR-15 composite laminates and the mechanical and physical properties of the laminates were measured. Results showed that fabrication of PMR-15 composite laminates with the optimal cure cycle results in improved mechanical properties and a significantly reduced the processing time compared with the manufacturer's suggested cure cycle. / Ph. D.

Experimental evaluations of impact damage resistance and residual compression strengths after impact are presented for nine laminated fiber reinforced composite material systems. The experiments employ a small scale specimen for assessing the impact damage resistance and impact damage tolerance of these materials. The damage area detected by C-scan is observed to develop linearly with the impact velocity for impact velocities higher than a threshold value. Brittle material systems have lower threshold velocities and higher damage area growth rates than toughened systems. The impact damage resistance of each material system can be characterized with threshold velocity V_c and damage area growth rate C. The residual compressive Strength after impact was observed to decrease linearly with the damage area equivalent diameter. The rate of compressive strength reduction, K_d, has been observed to be independent of the material properties. The impact damage can be simulated from quasi-static indentation test in which the damage due to these two loading conditions are quite similar. The residual compressive strength can also be simulated from specimens with similar damage size resulting from quasi-static indentation load. / Ph. D.

A stress model of the filament-winding fabrication process, previously implemented in a finite element program, was improved. Pre- and post-processing codes were developed to make the program easier and more efficient to use. A program which is used to design filament wound composite rocket motor cases was modified to write a model file for the fabrication stress code in the pre-processing stage. The same code was altered to provide post-processing output in the form of graphic displays. Also, a new code was written to provide additional post-processing capability for the fabrication stress model. Verification of the model of the filament-winding process was performed by comparing experimental pressure and strain data, for the fabrication of a filament wound bottle, with results of an analytical model. The final analytical results using consecutive models of the filament wound bottle show reasonable agreement with experimental pressure and hoop strain data. The maximum difference in the analytical and experimental values in the pressure data was about 25% for the final winding stage. The difference was smaller during the winding progression. These results also show that the accuracy of the model depends heavily on the assumptions made for input parameters during modelling. The stiffness of the segmented steel mandrel, simulated by an effective modulus (degraded by segmentation), and the instantaneous laydown tension loss parameters significantly affected the results of the model. Including the effective modulus for the segmented mandrel in the model reduced the difference in the experimental and analytical pressure results by about 150%. The inclusion of instantaneous laydown tension loss in the model reduced the analytical-experimental difference by roughly 225%. These two parameters reduced the largest difference in the predicted pressure values from about 400% for the first model to around 25% for the final model. The fabrication stress model was coupled with the thermo-kinetic cure model to provide more accurate fiber motion tension loss analysis capability. The stress model was modified to use the thermo-kinetic model as a subroutine to calculate fiber motion tension loss using a two-dimensional analysis. The results of the qualitative verification show that fiber motion tension loss is more important in the later stages of winding than in the beginning stages which indicates that it may provide the needed accuracy in the final winding stages. / Master of Science

Fiber-yielding plants is an area of increased interest due to the potential use in a variety of green-based materials. These biocomposites can be incorporated into multiple uses; for example, to replace building materials and interior vehicular paneling. The research here aims to focus in on the crop Hibiscus cannabinus for utilization into these functions. H. cannabinus is economically attractive due to the entire process being able to be accomplished here in the United States. The plant can be grown in a relatively short growth period (120-180 days), and then processed and incorporated in a biocomposite. The plant fiber must first be broken down into a useable medium. This is accomplished by the retting process, which occurs when microbial constituents breakdown the heteropolysaccharides releasing the fiber. The research aims to bridge the gap between the primitive process of retting and current techniques in molecular and microbiology. Utilizing a classical microbiological approach, which entailed enrichment and isolation of pectinase-producing bacteria for downstream use in augmented microbial retting experiments. The tracking of the bacteria was accomplished by using the 16S rRNA which acts as “barcodes” for bacteria. Next-generation sequencing can then provide data from each environment telling the composition and microbial diversity of each tested variable. The main environments tested are: a natural environment, organisms contributed by the plant material solely, and an augmented version in which pectinase-producing bacteria are added. In addition, a time-course experiment was performed on the augmented environment providing data of the shift to an anaerobic environment. Lastly, a drop-in set was performed using each isolate separately to determine which contributes to the shift in microbial organization. This research provided a much needed modernization of the retting technique. Previous studies have been subject to simple clone libraries and growth plate assays and next-generation sequencing will bring the understanding of microbial retting into the 21st century.

Thesis (D.Tech.: Mechanical Engineering)-Dept. of Mechanical Engineering, Durban University of Technology, 2007 xxx, 190 leaves, Annexures A-D / A composite material comprises two or more materials with properties that are superior to those of the individual constituents. Composites have become important engineering materials, especially in the fields of chemical plant, automotive, aerospace and marine engineering. The development of more advanced materials and manufacturing techniques in composites has grown from humble beginnings in the 1930s to a recognized and well-respected engineering discipline, providing solutions to conventional and challenging applications. At present, fibre-reinforced composites (FRCs) are amongst the most common types of composites used. They are produced in various forms with different structural properties, and designers, specifiers and end-users can choose from an almost endless list of these materials, providing design flexibility as well as low manufacturing and maintenance cost. Many suggest that composites have revolutionised the chemical and petro-chemical industries. Examples of applications include tanks and chemical reactor vessels that contains many hundreds of litres of hazardous chemicals, reinforced pipes measuring up to several meters in diameter conveying dangerous gases and so on. The South Africa Coal, Oil and Gas Corporation Limited (SASOL) was established in September 1950. From a small start-up, the company has grown to be a world leader in the commercial production of liquid fuels and chemicals from coal and crude oil. Sasol manufactures more than 200 fuel and chemical products at its main plants in Sasolburg and Secunda in South Africa as well as at several other plants abroad. Its products are exported to more than 90 countries around the world. The use of composites in general, and fibre reinforced composites in particular has received little support in Sasol through the years. Some sporadic use of these materials in the construction of process equipment, e.g. tanks, vessels and piping has taken place with varying degrees of success. While the use of equipment fabricated with fibre-reinforced composites has proven extremely successful in the chlorine producing facility in Sasolburg, catastrophic failures have taken place in Secunda in critical fire water systems made of these materials. The history of correct use and application of fibre-reinforced equipment has shown that the cost of ownership of such equipment is significantly lower than similar metallic equipment, therefore reducing costs and safety risks. However, even though this technology brings a company like Sasol closer to the realisation of the vast number of advantages and solutions offered by these materials, the reality is that most engineering personnel are still applying traditional (viz. steel and wood) technology as used by our predecessors. The work presented here attempts to indicate the relevance of fibre-reinforced composites for Sasol, and to detail efforts aimed at the raising of awareness amongst appropriate personnel at Sasol to increase the use of these materials in major capital projects and day-to-day maintenance contracts, therefore taking advantage of the superior performance of fibre-reinforced composites in demanding applications. In support of this drive, part of the work presented indicates the status as well as progress of the composites industry in the last few years. This project was therefore aimed at identifying the level of utilization of fibre-reinforced composites at Sasol, and the possible improvement in benefits of using these technologies. A methodology was developed, using engineering as well as marketing principles, to reach the engineering personnel in various divisions and seniority levels of Sasol to increase the awareness of the capabilities of composites materials, specifically regarding fibre-reinforced composites. Questionnaires were used to gauge the level of awareness while various methods, e.g. one-on-one meetings, seminars, conferences, electronic media, etc were used to upgrade the target groups’ knowledge. The results of the initial survey to determine the status of various dimensions in the company are indicated as well as the outcomes at the end of the research period. In support of the process in Sasol, the development, interaction and cross-pollination of international and national role-players in the fibre-reinforcement industry with respect to chemical containment and Sasol are indicated. The importance of this two-legged process is demonstrated: it ensures a professional national support framework for companies like Sasol. Results are indicated, compared and discussed to give future direction in this ongoing process. As important to this process was the development of appropriate technical resources (like design standards and codes) to enable their use within the group. It was recognised early on that raising the level of awareness of the target groups was not enough and that these resources had to be in-place down the line so that those who chose to could start to implement these material technologies with the aid of the resources. The development of the necessary resources is also discussed. Finally, it will be shown that significant growth has taken place regarding the awareness within the group over the course of implementation of this project. Specifically, about 20% of the target groups have moved from a stage of no knowledge to higher levels of confidence. In terms of use of these materials, significant growth has also taken place judging by the number of plant requests, activity on major capital projects and so on. In fact, from almost nothing in 1999, over the last 5 years in excess of R137 Million has been spent on capital equipment manufactured from composite materials, with the majority in the last 2 years.

Wood pulp fibers are a unique reinforcing material as they are non-hazardous, renewable, and readily available at relatively low cost compared to other commercially available fibers. Today, pulp fiber-cement composites can be found in products such as extruded non-pressure pipes and non-structural building materials, mainly thin-sheet products. Although natural fibers have been used historically to reinforce various building materials, little scientific effort has been devoted to the examination of natural fibers to reinforce engineering materials until recently. The need for this type of fundamental research has been emphasized by widespread awareness of moisture-related failures of some engineered materials; these failures have led to the filing of national- and state-level class action lawsuits against several manufacturers. Thus, if pulp fiber-cement composites are to be used for exterior structural applications, the effects of cyclical wet/dry (rain/heat) exposure on performance must be known. Pulp fiber-cement composites have been tested in flexure to examine the progression of strength and toughness degradation. Based on scanning electron microscopy (SEM), environmental scanning electron microscopy (ESEM), energy dispersive spectroscopy (EDS), a three-part model describing the mechanisms of progressive degradation has been proposed: (1) initial fiber-cement/fiber interlayer debonding, (2) reprecipitation of crystalline and amorphous ettringite within the void space at the former fiber-cement interface, and (3) fiber embrittlement due to reprecipitation of calcium hydroxide filling the spaces within the fiber cell wall structure. Finally, as a means to mitigate kraft pulp fiber-cement composite degradation, the effects of partial portland cement replacement with various supplementary cementitious materials (SCMs) has been investigated for their effect on mitigating kraft pulp fiber-cement composite mechanical property degradation (i.e., strength and toughness losses) during wet/dry cycling. SCMs have been found to be effective in mitigating composite degradation through several processes, including a reduction in the calcium hydroxide content, stabilization of monosulfate by maintaining pore solution pH, and a decrease in ettringite reprecipitation accomplished by increased binding of aluminum in calcium aluminate phases and calcium in the calcium silicate hydrate (C-S-H) phase.

M. Tech. Polymer Technology / Determines the mechanical and thermal properties of polypropylene-based (PP) composites containing locally produced Sisal and Kenaf fibres.

Thesis (D.Tech.: Mechanical Engineering)-Dept. of Mechanical Engineering, Durban University of Technology, 2007 xxx, 190 leaves, Annexures A-D / A composite material comprises two or more materials with properties that are superior to those of the individual constituents. Composites have become important engineering materials, especially in the fields of chemical plant, automotive, aerospace and marine engineering. The development of more advanced materials and manufacturing techniques in composites has grown from humble beginnings in the 1930s to a recognized and well-respected engineering discipline, providing solutions to conventional and challenging applications. At present, fibre-reinforced composites (FRCs) are amongst the most common types of composites used. They are produced in various forms with different structural properties, and designers, specifiers and end-users can choose from an almost endless list of these materials, providing design flexibility as well as low manufacturing and maintenance cost. Many suggest that composites have revolutionised the chemical and petro-chemical industries. Examples of applications include tanks and chemical reactor vessels that contains many hundreds of litres of hazardous chemicals, reinforced pipes measuring up to several meters in diameter conveying dangerous gases and so on. The South Africa Coal, Oil and Gas Corporation Limited (SASOL) was established in September 1950. From a small start-up, the company has grown to be a world leader in the commercial production of liquid fuels and chemicals from coal and crude oil. Sasol manufactures more than 200 fuel and chemical products at its main plants in Sasolburg and Secunda in South Africa as well as at several other plants abroad. Its products are exported to more than 90 countries around the world. The use of composites in general, and fibre reinforced composites in particular has received little support in Sasol through the years. Some sporadic use of these materials in the construction of process equipment, e.g. tanks, vessels and piping has taken place with varying degrees of success. While the use of equipment fabricated with fibre-reinforced composites has proven extremely successful in the chlorine producing facility in Sasolburg, catastrophic failures have taken place in Secunda in critical fire water systems made of these materials. The history of correct use and application of fibre-reinforced equipment has shown that the cost of ownership of such equipment is significantly lower than similar metallic equipment, therefore reducing costs and safety risks. However, even though this technology brings a company like Sasol closer to the realisation of the vast number of advantages and solutions offered by these materials, the reality is that most engineering personnel are still applying traditional (viz. steel and wood) technology as used by our predecessors. The work presented here attempts to indicate the relevance of fibre-reinforced composites for Sasol, and to detail efforts aimed at the raising of awareness amongst appropriate personnel at Sasol to increase the use of these materials in major capital projects and day-to-day maintenance contracts, therefore taking advantage of the superior performance of fibre-reinforced composites in demanding applications. In support of this drive, part of the work presented indicates the status as well as progress of the composites industry in the last few years. This project was therefore aimed at identifying the level of utilization of fibre-reinforced composites at Sasol, and the possible improvement in benefits of using these technologies. A methodology was developed, using engineering as well as marketing principles, to reach the engineering personnel in various divisions and seniority levels of Sasol to increase the awareness of the capabilities of composites materials, specifically regarding fibre-reinforced composites. Questionnaires were used to gauge the level of awareness while various methods, e.g. one-on-one meetings, seminars, conferences, electronic media, etc were used to upgrade the target groups’ knowledge. The results of the initial survey to determine the status of various dimensions in the company are indicated as well as the outcomes at the end of the research period. In support of the process in Sasol, the development, interaction and cross-pollination of international and national role-players in the fibre-reinforcement industry with respect to chemical containment and Sasol are indicated. The importance of this two-legged process is demonstrated: it ensures a professional national support framework for companies like Sasol. Results are indicated, compared and discussed to give future direction in this ongoing process. As important to this process was the development of appropriate technical resources (like design standards and codes) to enable their use within the group. It was recognised early on that raising the level of awareness of the target groups was not enough and that these resources had to be in-place down the line so that those who chose to could start to implement these material technologies with the aid of the resources. The development of the necessary resources is also discussed. Finally, it will be shown that significant growth has taken place regarding the awareness within the group over the course of implementation of this project. Specifically, about 20% of the target groups have moved from a stage of no knowledge to higher levels of confidence. In terms of use of these materials, significant growth has also taken place judging by the number of plant requests, activity on major capital projects and so on. In fact, from almost nothing in 1999, over the last 5 years in excess of R137 Million has been spent on capital equipment manufactured from composite materials, with the majority in the last 2 years.

Terahertz radiation or T-rays or THz radiation refers to the region of the electromagnetic spectrum between approximately 100 GHz and 30 THz. This spectral region is often referred to as the THz gap as these frequencies fall between electronic (measurement of field with antennas) and optical (measurement of power with optical detectors) means of generation. THz measurements may yield useful information about the structural and chemical nature of the material inspected. Examples include detection of voids in materials and protein binding in biomolecules. This report provides an overview of THz measurements of defects in fiber composites. We find that it efficiently detects defects such as voids and delamination in glass fiber composites better than ultrasound, which was widely used for defect characterization in glass fiber earlier. Comparison of the existing methods with THz is presented in the report for characterization of defects.

This thesis addresses the results of an experimental and analytical investigation aimed at examining the static load-displacement response of braced plane frame structures composed of fiber reinforced polymeric (FRP) composite material structural members manufactured by the pultrusion process. In the experimental part of this investigation, eighteen full-scale lateral loading tests for FRP composite frames with different brace configurations and beam column connection types were performed. The load-displacement responses of such frames were measured and are reported herein. In the analytical part of this investigation, a frame analysis method that accounts for the anisotropic nature of FRP composite material structural members was investigated. The results from the experimental work are compared with the results from the analytical procedures. The effects of various structural parameters of the frame such as (1) effective mechanical material properties of members, (2) beam-column connection types, and (3) the influence of diagonal structural members on the lateral load-displacement response of the braced plane frames are also investigated. The numerical load-displacement results from the proposed FRP composite frames analysis procedure provided good agreement with the results from the full-scale laboratory tests.