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The aerospace industry is steadily increasing its use of polymer-matrix composites (PMCs) in airframe structures as it seeks to benefit from the high specific in-plane strength of laminated structural PMCs. However, PMC laminates suffer from low interlaminar shear strength due to their weaker polymer-matrix. Minimising risks of delamination is of paramount importance towards improving the safety of PMC structures. Multi-scale composites that are reinforced by both continuous fibres and nano-particles were identified as a potential solution for improving toughness and reducing risks of delamination in PMCs. An important challenge in the fabrication of multi-scale PMCs is to ensure that nano-particles are dispersed uniformly within the matrix. This is only achieved through minimal filtration of nano-particles during processing. The short resin flow lengths enabled by the resin film infusion (RFI) process make this process a prime candidate for the fabrication of multi-scale PMCs. The main objective of this thesis is to validate the possibility of using out-of-autoclave RFI for fabricating multi-scale carbon fibre composites featuring epoxy resins modified with carbon nanotubes (CNTs). The work is accomplished in 5 phases. In phase 1, preliminary work investigates the fabrication of PMCs with and without CNTs, using out-of-autoclave RFI. Results show that the types of reinforcement and matrix have strong effects on the porosity and interlaminar strength of PMCs. These results ushered the need for more thorough investigation and understanding of the RFI process, beyond what is available in the literature. Phases 2 to 4 focus on understanding how the choices of materials and types of stacking configuration can affect parts made using RFI. Phase 2, the in-situ characterisation of resin saturation during RFI is performed. Results enable a detailed analysis of the way in which resin flows around and inside yarns. Phase 3 consists in the characterisation of void formation during RFI. Two types of voids are observed: flow-induced voids resulting from either the merging of resin flow fronts or the drainage from capillary action; and gas-induced voids resulting from resin volatiles going out of solution and remaining in the resin matrix. In this work, the greatest source of porosity was caused by volatiles. In phase 4, the distribution and filtration of CNTs during RFI processing is characterised. Results show that processing choices can limit filtration and that clustering of CNTs prevents a uniform dispersion of CNTs in PMCs. Finally, the possibility of using RFI for making a multi-scale PMC demonstrator part is investigated. The work culminated with the successful fabrication of a delta-stringer panel. This thesis makes several important contributions to the knowledge pertaining to multi-scale PMC processing and performance, and to RFI. Firstly, it provides a robust description of RFI processing beyond was it available in literature, through in-situ observations of resin flow and void formation. Secondly, it assesses the viability of RFI for producing multi-scale PMCs featuring CNTs. In-situ observations of RFI processing enabled the identification of mechanisms leading to a loss of CNT dispersion during processing, partly explaining the minimal improvements in the interlaminar properties of composites observed when adding CNTs to the matrix. Thirdly, the fabrication of a delta-stringer panel made of a multi-scale PMC was successful, making it the first validation of the scalability of out-of-autoclave RFI processing for manufacturing multi-scale PMCs. The work presented herein contributed to the dissemination of knowledge; one conference paper was presented at ICCM20 (20th International Conference on Composite Materials), and another was presented at CANCOM2017 (10th Canadian-International Conference on Composites), and one journal article written in collaboration with project partners was submitted to Composites Science and Technology.

Alumina particles filled Ultra-high Molecular Weight Polyethylene (UHMWPE), with Al2O3 contents 0, 1, and 2.5 wt% were milled for up to 10 hours by the mechanical alloying (MA) process performed at room temperature to produce composite powders. Compression molding was utilized to produce sheets out of the milled powders. A partial phase transformation from orthorhombic and amorphous phases to monoclinic phase was observed to occur for both the un-reinforced and reinforced UHMWPE in the solid state, which disappeared after using compression molding to produce composite sheets. The volume fraction of the monoclinic phase increased with milling time, mostly at the expense of the amorphous phase. The melting temperature decreased as a function of milling time as a result of modifications in the UHMWPE molecular structure caused by the milling. At the same time, for a given alumina composition the activation energy of melting increased with milling time. Generally, the crystallinity of the molded sheets increased with milling time, and this caused the yield strength and elastic modulus to increase with milling time for a given alumina composition. However, the tensile strength and ductility remained about the same. / Master of Science

The aim of this study was to develop a new single-part healing system for self-healing composites. The self-healing approach to composite repair has been developed in the last two decades and means that a damaged area can be repaired by material already housed within the structure. The background and development of self-healing has been reviewed. The two main self-healing mechanisms are discussed. To date only two part self healing systems have been examined. These require diffusion of the separate constituents to a single location in order to effect cure and restore strength. Single part adhesives do not have this disadvantage and are therefore very attractive. Several candidate single-part adhesive or resin systems were considered and discussed according to the critical requirements of a self-healing system. A series of experiments was undertaken to evaluate the possibility of candidate adhesive systems being effective for self-healing by focusing on the determination of storage stability and bonding efficiency. The results of storage stability testing showed that the stability of cyanoacrylate and polyurethane adhesives was poor. However silane and polystyrene cements showed good storage stability. Very low bonding efficiency was achieved with polystyrene cement but a 22% strength recovery was obtained with the silane 3-[tris(trimethylsiloxy)silyl]-propylamine. Suggestions for further research into single-part healing systems are also given.

Polymer matrix composites reinforced by metal fibers are observed to present an onset of the insulator-to-conductor transition through previous experimental studies. Analytical studies revealed that the percolation threshold occurs when fiber volume fraction reaches the critical value. The numerical study based on Monte Carlo simulations are performed to investigate such a relation. In this work, the conductive fillers are modeled as a three dimensional (3D) network of identical units randomly distributed in the polymer matrix. For the simplest case, straight fibers are used in the simulation. The effects of the aspect ratio and fiber length on the critical volume fraction are also studied. Linearization is made to the logarithm of simulation results. Next, in order to study the effects of emulsion particles and the emulsion particle sizes on the percolation behavior, cubic particles are aligned in the sample model. The gap width to particle size ratio is fixed at 1/10. The calculated critical volume fraction is used in the power-law function to predict the electrical conductivity of the polymer composites. Due to the insensitivity of the thermal conductivity to the percolation threshold, a combination of two empirical equations is used to predict the range of overall thermal conductivity.

The aim of this study was to develop a new single-part healing system for self-healing composites. The self-healing approach to composite repair has been developed in the last two decades and means that a damaged area can be repaired by material already housed within the structure. The background and development of self-healing has been reviewed. The two main self-healing mechanisms are discussed. To date only two part self healing systems have been examined. These require diffusion of the separate constituents to a single location in order to effect cure and restore strength. Single part adhesives do not have this disadvantage and are therefore very attractive. Several candidate single-part adhesive or resin systems were considered and discussed according to the critical requirements of a self-healing system. A series of experiments was undertaken to evaluate the possibility of candidate adhesive systems being effective for self-healing by focusing on the determination of storage stability and bonding efficiency. The results of storage stability testing showed that the stability of cyanoacrylate and polyurethane adhesives was poor. However silane and polystyrene cements showed good storage stability. Very low bonding efficiency was achieved with polystyrene cement but a 22% strength recovery was obtained with the silane 3-[tris(trimethylsiloxy)silyl]-propylamine. Suggestions for further research into single-part healing systems are also given.

Bio-based flax fiber polymer composites (FFPC) have the potential to replace metals and synthetic fibers in certain applications due to their unique mechanical properties. However, the long term reliability of FFPC needs to be better understood. In this study, the fatigue limit was evaluated using mathematical, thermographic, and energy-based approaches. Each approach determined fatigue limits around 45% load of ultimate tensile strength at a loading frequency of 5 Hz. Thermographic and energy-based approaches were also implemented at different loading frequencies (5, 7, 10, and 15 Hz) to define the effect of loading frequency on the fatigue life. Fatigue limit was found to decrease slowly with increasing loading frequency. Moreover, two forms of damage energy (thermal and micro-mechanical) during cyclic loading was separated using an experimental approach to pinpoint the main responsible damage energy for decreasing fatigue limit with increasing loading frequency.

A design of experiments methodology was used to investigate the effect of vaporgrown carbon nanofiber (VGCNF) weight fraction, high-shear mixing time, and ultrasonication time on the Izod impact strength of vinyl ester (VE) based nanocomposites. A response surface model (RSM) was developed for predicting impact strengths using a regression analysis approach. The RSM predicts a maximum increase in impact strength of 18% at a VGCNF weight fraction of 0.17 parts per hundred parts resin (phr) (a volume percent of ~0.1) and 100 min high-shear mixing when compared to that of neat VE. The impact strength predictions show an initial increase for low VGCNF weight fractions and extended high-shear mixing. However, a marked decrease in impact strength occurred as the VGCNF weight fraction increased above 0.45 phr. Scanning electron micrographs of the fracture surface of several specimens suggest that the impact strength of VGCNF/VE nanocomposites is directly related to nanofiber dispersion.

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In order for future space transportation vehicles to be considered economically viable, the extensive use of lightweight materials is critical. For spacecraft with liquid fueled rocket engines, one area identified as a potential source for significant weight reduction is the replacement of traditional metallic cryogenic fuel tanks with newer designs based on polymer matrix composites. For long-term applications such as those dictated by manned, reusable launch vehicles, an efficient cryo-tank design must ensure a safe and reliable operating environment. To execute this design, extensive experimental data must be collected on the lifetime durability of PMC's subjected to realistic thermal and mechanical environments. However, since polymer matrix composites (PMC's) have seen limited use as structural materials in the extreme environment of cryogenic tanks, the available literature provides few sources of experimental data on the strength, stiffness, and durability of PMC's operating at cryogenic temperatures. It is recognized that a broad spectrum of factors influence the mechanical properties of PMC's including material selection, composite fabrication and handling, aging or preconditioning, specimen preparation, laminate ply lay-up, and test procedures. It is the intent of this thesis to investigate and report performance of PMC's in cryogenic environments by providing analysis of results from experimental data developed from a series of thermal/mechanical tests. The selected test conditions represented a range of exposure times, loads and temperatures similar to those experienced during the lifetime of a cryogenic, hydrogen fuel tank. Fundamental, lamina-level material properties along with properties of typical design laminates were measured, analyzed, and correlated against test environments. Material stiffness, strength, and damage, will be given as a function of both cryogenic test temperatures and pre-test cryogenic aging conditions. This study focused on test temperature, preconditioning methods, and laminate configuration as the primary test variables. The material used in the study, (IM7/PETI-5), is an advanced carbon fiber, thermoplastic polyimide composite. / Master of Science