scholarly journals Manufacturing and metallization of hybrid thermoplastic-thermoset matrix composites

2021 ◽  
Author(s):  
Hetal Parmar ◽  
Antonio Gambardella ◽  
Alessia Serena Perna ◽  
Antonio Viscusi ◽  
Roberta Della Gatta ◽  
...  
Keyword(s):  
Composite Laminates ◽  
Composite Laminate ◽  
Cold Spraying ◽  
Processing Parameters ◽  
Matrix Composites ◽  
Composite Manufacturing ◽  
Common Strategy ◽  
Hybrid Substrates ◽  
A New Technique ◽  
Temperature Exposure

Metallization is a common strategy employed to enhance the electrical and thermal conductivity of polymer matrix composite materials. Nevertheless, metallic deposition on polymer-based materials is challenging due to the inherent limitations related to high temperature exposure of the substrate. In this article, a new technique for the manufacturing of composite laminates and the subsequent metallization by cold spraying of metallic powder is presented. The composite manufacturing route is based on the production of thermoplastic-thermoset hybrid substrates and consisted of two main stages: in the first stage the partial impregnation of a reinforcement textile by a thermoplastic film was promoted by hot pressing compaction. Afterwards, the prepared lamina was vacuum bagged with other reinforcing layers and impregnated by the thermoset catalyzed resin by a vacuum infusion process. Finally, the thermoset and thermoplastic layers were co-cured to increase the adhesion of the substrate with the thermoplastic film. The metallization of composite laminate was obtained through the cold spraying technique, depositing powders on the thermoplastic surface layer. The effect of processing parameters on the coating deposition, quality and microstructure was reported and discussed.

scholarly journals Influence of cure parameters in polymer matrix composites using embedded optical fibers

2020 ◽  
Vol 54 (19) ◽  
pp. 2611-2621
Author(s):  
Daniel A Drake ◽  
Rani W Sullivan ◽  
Jonathan E Spowart ◽  
Katie Thorp
Keyword(s):  
Optical Fibers ◽  
Composite Laminates ◽  
Composite Structures ◽  
Polymer Matrix Composites ◽  
Processing Parameters ◽  
Internal Strain ◽  
Matrix Composites ◽  
Molding Process

The influence of cure processing parameters was investigated using strain distributions from embedded optical fibers. The determination of optimized cure parameters is often needed to achieve material properties which meet aerospace industry design requirements. Optical fibers were embedded near the midplane of thin (5 mm; [0/90/90/0]3s) composite laminates to monitor the internal strain during cure for two different cure cycles (manufacturer-recommended and an alternative two-step cure). Each laminate was fabricated using a vacuum-assisted resin transfer molding process. The internal strain with respect to the spatial position and time were monitored. During cure, greater variations in the strain near the vicinity of the laminate edges were observed. However, a two-step cure cycle revealed that the variation of strain near the laminate edges is reduced. The results demonstrate the capability of high-spatial resolution optical fibers to measure the in-situ cure and residual strain during the processing of composite structures.

CFD Simulation and Experimental Validation of Solidification of Metal Matrix Composites (MMC) in the Presence of Cooled Fibers

2004 ◽  
Author(s):  
R. S. Amano ◽  
J. Xie ◽  
E. K. Lee ◽  
P. K. Rohatgi
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cfd Simulation ◽  
Applied Pressure ◽  
Casting Process ◽  
Processing Parameters ◽  
Matrix Composites ◽  
Primary Alpha ◽  
Parametric Studies ◽  
Solidification Of Metal

A new experimental configuration for the casting of metal matrix composites (MMCs) using Al-4.5 wt pct Cu have been used to obtain finer microstructures around the fiber reinforcement. The new configuration allows the fibers to be extended out the mold and cooled by a heat sink. By doing so, the solidification can be made more rapid, and more primary alpha-aluminum phase can be formed on the surface of the fibers. It is believed that this can lead to improvement in the properties of the composite. CFD simulation of the solidification of Al-4.5 wt pct Cu in the casting process has been carried out by using commercial CFD code. Parametric studies on the effects of different processing parameters on solidification time have been simulated using the CFD code. These parameters include, but are not limited to, the pouring temperature of the liquid melt, sink temperature, fiber length extended out of the mold, the mold initial temperature, fiber conductivity, applied pressure, and fiber bundle diameter. Selected simulation results are compared with the available experimental data obtained from the UWM Center for Composites.

SELF-HEALING OF WOVEN COMPOSITE LAMINATES VIA IN SITU THERMAL REMENDING

2021 ◽  
Author(s):  
ALEXANDER D. SNYDER ◽  
ZACHARY J. PHILLIPS ◽  
JASON F. PATRICK
Keyword(s):  
Composite Laminates ◽  
Composite Laminate ◽  
Laminated Composites ◽  
Reaction Times ◽  
Carbon Fiber Composites ◽  
Self Healing ◽  
Damage Mode ◽  
Woven Composite ◽  
Internal Damage

Fiber-reinforced polymer composites are attractive structural materials due to their high specific strength/stiffness and excellent corrosion resistance. However, the lack of through-thickness reinforcement in laminated composites creates inherent susceptibility to fiber-matrix debonding, i.e., interlaminar delamination. This internal damage mode has proven difficult to detect and nearly impossible to repair via conventional methods, and therefore, remains a significant factor limiting the reliability of composite laminates in lightweight structures. Thus, novel approaches for mitigation (e.g., self-healing) of this incessant damage mode are of tremendous interest. Self-healing strategies involving sequestration of reactive liquids, i.e. microcapsule and microvascular systems, show promise for the extending service- life of laminated composites. However, limited heal cycles, long reaction times (hours/days), and variable stability of chemical agents under changing environmental conditions remain formidable research challenges. Intrinsic self- healing approaches that utilize reversible bonds in the host material circumvent many of these limitations and offer the potential for unlimited heal cycles. Here we detail the development of an intrinsic self-healing woven composite laminate based on thermally-induced dynamic bond re-association of 3D-printed polymer interlayers. In contrast to prior work, self-repair of the laminate occurs in situ and below the glass-transition temperature of the epoxy matrix, and maintains >85% of the elastic modulus during healing. This new platform has been deployed in both glass and carbon-fiber composites, demonstrating application versatility. Remarkably, up to 20 rapid (minute-scale) self-healing cycles have been achieved with healing efficiencies hovering 100% of the interlayer toughened (4-5x) composite laminate. This latest self-healing advancement exhibits unprecedented potential for perpetual in-service repair along with material multi-functionality (e.g., deicing ability) to meet modern application demands.

Damage Control in Composite Laminates

2001 ◽  
Author(s):  
Alexander P. Suvorov ◽  
George J. Dvorak
Keyword(s):  
Composite Laminates ◽  
Composite Laminate ◽  
Damage Control ◽  
Thermomechanical Loading ◽  
Interlaminar Stresses ◽  
Damage Resistance ◽  
Viscoelastic Composite ◽  
Mechanical Loads ◽  
Composite Damage ◽  
The Matrix

Abstract Several effects that fiber prestress may have on stress redistribution in the plies of composite laminates and in the phases of individual plies are illustrated. These include improvement of composite damage resistance under tensile mechanical loads, reduction/cancelation of interlaminar stresses at free edges of composite laminate subjected to thermomechanical loading, and stress relaxation in the matrix phase of viscoelastic composite laminates. Specific results are found for quasi-isotropic and cross-ply symmetric S-glass/epoxy and carbon/epoxy AS4/EPON 828 laminates.

THE EFFECT OF LAMINATION SCHEME AND ANGLE VARIATIONS TO THE DISPLACEMENTS AND FAILURE BEHAVIOUR OF COMPOSITE LAMINATE

2015 ◽  
Vol 76 (11) ◽  
Author(s):  
Azizul Hakim Samsudin ◽  
Jamaluddin Mahmud
Keyword(s):  
Fiber Orientation ◽  
Composite Laminates ◽  
Finite Element Modelling ◽  
Composite Laminate ◽  
Maximum Stress ◽  
Failure Load ◽  
Failure Criteria ◽  
Stress Theory ◽  
Failure Behaviour ◽  
Failure Index

This paper aims to investigate the effect of lamination scheme and angle variations to the displacements and failure behaviour of composite laminate. Finite element modelling and analysis of symmetric, anti-symmetric and angle-ply Graphite/ Epoxy laminate with various angles of fiber orientation subjected to uniaxial tension are performed. Maximum Stress Theory and Tsai-Wu Failure Criteria are employed to determine the failure load (failure index = 1). Prior to that, convergence analysis and numerical validation are carried out. Displacements and failure behaviour of the composite laminates (symmetric, anti-symmetric and angle ply) are analysed. The failure curves (FPF and LPF) for both theories (Maximum Stress Theory and Tsai-Wu) are plotted and found to be very close to each other. Therefore, it can be concluded that the current study is useful and significant to the displacements and failure behaviour of composite laminate.

Interply Behavior Exhibited in Compliant Filamentary Composite Laminates

1982 ◽  
Vol 55 (4) ◽  
pp. 1078-1094 ◽  
Author(s):  
J. L. Turner ◽  
J. L. Ford
Keyword(s):  
Shear Strain ◽  
Composite Laminates ◽  
Matrix Material ◽  
Matrix Composites ◽  
Efficient Manner ◽  
Strain Behavior ◽  
The Matrix ◽  
Order Of Magnitude ◽  
Extensional Strain ◽  
Interlaminar Shear

Abstract Cord-rubber composite systems allow a visualization of interply shear strain effects because of the compliant nature of the matrix material. A technique termed the pin test was developed to aid this visualization of interply shear strain. The pin test performed on both flat pads and radial tires shows that interlaminar shear strain behavior in both types of specimens is similar, most of the shear strain being confined to a region approximately 10 interly rubber thicknesses from the edge. The observed shear strain is approximately an order of magnitude greater than the applied extensional strain. A simplified mathematical model, called the Kelsey strip, for describing such behavior for a two-ply (±θ) cord-rubber strip has been formulated and demonstrated to be qualitatively correct. Furthermore, this model is capable of predicting trends in both compliant and rigid matrix composites and allows for simplified idealizations. A finite-element code for dealing with such interply effects in a simple but efficient manner predicts qualitatively correct results.

Determination of the Residual Stresses in Composite Laminate Using the Compliance Method

2005 ◽  
Vol 490-491 ◽  
pp. 533-538 ◽  
Author(s):  
Guillaume Montay ◽  
Olivier Sicot ◽  
X.L. Gong ◽  
Abel Cherouat ◽  
Jian Lu
Keyword(s):  
Experimental Data ◽  
Residual Stresses ◽  
Composite Laminates ◽  
Composite Laminate ◽  
Constant Width ◽  
Strain Gages ◽  
New Methods ◽  
Structure Surface ◽  
Finite Elements Simulation

Residual stresses play an important role on the mechanical behavior of composite laminate. The development of new methods to determine the residual stresses gradient within the laminates is necessary. This article presents the adaptation of the compliance method in the case of composite laminates carbon/epoxy [02/902]s. The incremental drilling of a constant width groove allows for each increment to measure the strains (using strain gages) and displacements (using an optical device) of particularly points of the structure surface. These experimental data are compared with results given by a finite elements simulation. This comparison allows to raise the residual stresses in the composite laminate.

An Experimental Determination of Optimum Processing Parameters for Al∕SiC Metal Matrix Composites Made Using Ultrasonic Consolidation

2007 ◽  
Vol 129 (4) ◽  
pp. 538-549 ◽  
Author(s):  
Y. Yang ◽  
G. D. Janaki Ram ◽  
B. E. Stucker
Keyword(s):  
Bond Strength ◽  
Metal Matrix Composites ◽  
Process Parameters ◽  
Metal Matrix ◽  
Oscillation Amplitude ◽  
Processing Parameters ◽  
Optimum Combination ◽  
Matrix Composites ◽  
Ultrasonic Consolidation ◽  
Push Out

Ultrasonic consolidation, an emerging additive manufacturing technology, is one of the most recent technologies considered for fabrication of metal matrix composites (MMCs). This study was performed to identify the optimum combination of processing parameters, including oscillation amplitude, welding speed, normal force, operating temperature, and fiber orientation, for manufacture of long-fiber-reinforced MMCs. A design of experiments approach (Taguchi L25 orthogonal array) was adopted to statistically determine the influences of individual process parameters. SiC fibers of 0.1mm diameter were successfully embedded into an Al 3003 metal matrix. Push-out testing was employed to evaluate the bond strength between the fiber and the matrix. Data from push-out tests and microstructural studies were analyzed and an optimum combination of parameters was achieved. The effects of process parameters on bond formation and fiber/matrix bond strength are discussed.

Effect of Processing Parameters on Mechanical Properties of Al7175/Boron Carbide (B4C) Composite Fabricated by Powder Metallurgy Techniques

2021 ◽  
Vol 105 ◽  
pp. 8-16
Author(s):  
Guttikonda Manohar ◽  
Krishna Murari Pandey ◽  
Saikat Ranjan Maity
Keyword(s):  
Mechanical Properties ◽  
Composite Material ◽  
Powder Metallurgy ◽  
Sintering Temperature ◽  
Processing Parameters ◽  
Matrix Composites ◽  
Composite Powders ◽  
Porosity Level ◽  
Milling Operations ◽  
Boron Carbide B4c

Metal matrix composites attain a significant position in Industrial, defense, structural and automobile applications. To amplify that strategy there is a need to find out the conditional behavior of the composites and enhancing the properties will be mandatory. The present work mainly investigates on the effect of processing parameters like densification rates, sintering temperature, reinforcement content on the microstructure, mechanical properties of the Al7175/B4C composite material fabricated by mechanical milling and powder metallurgy techniques. Results show there is a grain size reduction and refinement in the composite material through ball milling operations and along with that increasing B4C content in the composite powders make milling conditions very effective. Increasing the sintering temperature results in a consistent grain growth along with that porosity level decreases up to a limit and then attain a steady state, the strength of the composites increases with compaction pressures but reinforcements content effects the strength of the material by losing its ductility making it brittle.

Continuous Manufacture of Submicron Thick Ceramic Green Tapes and Coatings Demonstrated for TCO Nano Particles

2011 ◽  
Vol 2011 (CICMT) ◽  
pp. 000078-000083
Author(s):  
Nadja Straue ◽  
Andreas Roosen
Keyword(s):  
Indium Tin Oxide ◽  
Low Cost ◽  
Tape Casting ◽  
Casting Process ◽  
Processing Parameters ◽  
Nano Particles ◽  
Electrical Measurements ◽  
Particulate Suspensions ◽  
Continuous Manufacture ◽  
A New Technique

This presentation introduces a new technique to manufacture continuously submicron thick ceramic green tapes and coatings from nano particulate suspensions. A profiled steel rod is used to coat large areas with a very low film thickness of down to 250 nm. This technique can easily be scaled up and is therefore suitable for mass production at high throughput and low cost. The profile rod technique could be a method to overcome the limit of the tape casting process and therefore this technique exhibits an enormous economical potential. The technique is demonstrated at the example of nano particulate indium tin oxide (ITO) and zinc oxide (ZnO) particles, which are both transparent conductive oxides (TCOs) and therefore interesting materials for printed displays etc. Nano particles from Evonik Degussa GmbH were first dispersed and stabilized in organic solvents. Subsequently, dispersions as well as slurries were prepared. Their rheological and wetting behavior were studied and the effect on the microstructure of the resulting layer was evaluated. Furthermore, the influence of the processing parameters during coating on the layer quality was analyzed. Finally, the functionality of the printed layers was proven by electrical measurements as well as the assembly of electron devices.

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