Composite materials

In this investigation, polymer precursor of syntactic foam has been reinforced with SiC nanoparticles to enhance mechanical and fracture properties. Derakane 8084 vinyl ester resin was first dispersed with 1.0 wt% of SiC particles using a sonic cavitation technique. In the next step, 30.0 wt% of microspheres (3M hollow glass borosilicate, S-series) were mechanically mixed with the nanophased vinyl ester resin, and cast into rectangular molds. A small amount of styrene was used as dilutant to facilitate mixing of microspheres. The size of microspheres and SiC nanoparticles were 20-30 um and 30-50 nm, respectively. Tension, compression, and flexure tests were conducted following ASTM standards and a consistent improvement in strength and modulus within 20-35% range was observed. Fracture toughness parameters such as KIC and GIC were also determined using ASTM E-399. An improvement of about 11-15% was observed. Samples were also subjected to various environmental conditions and degradation in material properties is reported.

This study focused on the fracture and fatigue crack growth behavior in polyvinylchloride (PVC) and polyethersulfone (PES) foams. A new sandwich double cantilever beam (DCB) test specimen was implemented. Elastic foundation and finite element analysis and experimental testing confirmed that the DCB specimen is appropriate for static and cyclic crack propagation testing of soft polymer foams. A comprehensive experimental mechanical analysis was conducted on PVC foams of densities ranging from 45 to 100 kg/m3 and PES foams of densities ranging from 60 to 130 kg/m3. An in-situ scanning electron microscope study on miniature foam fracture specimens showed that crack propagation in the PVC foam was inter-cellular and in the PES foam, failure occurred predominately by extensional failure of vertical cell edges. Sandwich DCB specimens were loaded cyclically as well. For the PVC foams, the crack growth rates were substantially influenced by the density. For the PES foams, there was no clear indication about the influence of foam density on the crack growth rate.

Enhancement of mechanical, thermal and hygrothermal properties of carbon fiber/vinyl ester (CFVE) composites through nanoparticle reinforcement has been investigated. CFVE composites are becoming more and more attractive for marine applications due to two reasons : high specific strength and modulus of carbon fiber and low vulnerability of vinyl ester resin to sea water. However, the problem with this composite system is that the fiber matrix (F/M) interface is inherently weak. This leads to poor mechanical properties and fast ingress of water at the interface further deteriorating the properties. This investigation attempts to address these deficiencies by inclusion of nanoparticles in CFVE composites. Three routes of nanoparticle reinforcement have been considered : nanoparticle coating of the carbon fiber, dispersion of nanoparticles in the vinyl ester matrix, and nanoparticle modification of both the fiber and the matrix. Flexural, short beam shear and tensile testing was conducted after exposure to dry and wet environments. Differential scanning calorimetry and dynamic mechanical analysis were conducted as well. Mechanical and thermal tests show that single inclusion of nanoparticles on the fiber or in the matrix increases carbon/vinyl ester composite properties by 11-35%. However, when both fiber and matrix were modified with nanoparticles, there was a loss of properties.

SC-15 epoxy is used in many industrial applications and it is well known that the mechanical and viscoelastic properties of epoxy can be signicantly enhanced when reinforced with nanofillers. In this work, SC-15 epoxy is reinforced by loading with magnetically-active nanofillers and cured in a modest magnetic field. Because of the signicant magnetic response of the nanofillers, this is a low cost and relatively easy technique for imposing a strong magnetic anisotropy to the system without the need of a superconducting magnet. It is also found that this method is an effective way of enhancing the mechanical properties of epoxy. Three systems were prepared and studied. The first is a dilute system of various concentrations of Fe2O3 nanoparticles in SC-15 epoxy. The second system is a combination of Fe2O3 nanoparticles and chemically-functionalized single-walled carbon nanotubes (SWCNT(COOH)s) in SC-15 epoxy. The third is a dilute system of SWCNT(COOH)s decorated with Fe3O4 particles t hrough a sonochemical oxidation process in SC-15 epoxy. Samples have an initial cure of 6 hrs in a magnetic led of 10 kOe followed by an additional 24 hours of post curing at room temperature. These are compared to the control samples that do not have initial field curing. Tensile and compressive stress-strain analysis of the prepared systems shows that mechanical properties such as tensile strength, tensile modulus and compressive strength are enhanced with the inclusion of these nanofillers. It is also found that there is an anisotropic enhancement of these properties with respect to the imposed curing field. An interesting phenomenon is observed with the increase in modulus of toughness and fracture strain with nanotube inclusion.

An experimental investigation was undertaken to determine the effects of marine environmental exposure on the mechanical properties of vinylester resins (VE510A and VE8084) and carbon fiber/VE510A vinylester composites. The effect of carbon fiber sizing on the composite strengths was also examined. Neat resins were exposed to marine environments until moisture content reached a point of saturation after which they were tested in tension, compression and shear. Compared to the baseline dry specimens, specimens subjected to moisture showed overall increased ductility and a reduction in strength. Dry and moisture saturated composite specimens were tested in tension and compression in different orientations. Longitudinal specimens were tested in in-plane shear and interlaminar shear. Composites with F-sized carbon fibers displayed overall higher strength than those with G-sized fibers at both dry and moisture saturated conditions. An analysis of moisture absorption of the composites was performed which vii shows that the moisture up-take is dominated by the fiber/matrix region which absorbs up to 90% of the moisture. The composites experienced reduced strength after moisture absorption. The results revealed that the fiber sizing has stronger effect on the fiber/matrix interface dominated strengths than moisture up-take.

The study presents a reliability-based fatigue life prediction model for the ocean current turbine rotor blades. The numerically simulated bending moment ranges based on the measured current velocities off the Southeast coast line of Florida over a one month period are used to reflect the short-term distribution of the bending moment ranges for an idealized marine current turbine rotor blade. The 2-parameter Weibull distribution is used to fit the short-term distribution and then used to obtain the long-term distribution over the design life. The long-term distribution is then used to determine the number of cycles for any given bending moment range. The published laboratory test data in the form of an ε-N curve is used in conjunction with the long-term distribution of the bending moment ranges in the prediction of the fatigue failure of the rotor blade using Miner's rule. The first-order reliability method is used in order to determine the reliability index for a given section modulus over a given design life. The results of reliability analysis are then used to calibrate the partial safety factors for load and resistance.

A dual inclusion strategy for textile polymers has been investigated to increase elastic energy storage capacity of fibers used in high velocity impact applications. Commercial fibers such as Spectra and Dyneema are made from ultra high molecular weight polyethylene (UHMWPE). Dynamic elastic energy of these fibers is still low therefore limiting their wholesale application without a secondary metallic or ceramic component. The idea in this investigation is to develop methodologies so that the elastic energy of polyethylene based fibers can be increased by several folds. This would allow manufacturing of an all-fabric system for high impact applications. The dual inclusion consists of a polymer phase and a nanoscale inorganic phase to polyethylene. The polymer phase was nylon-6 and the inorganic phase was carbon nanotubes (CNTs). Nylon-6 was blended as a minor phase into UHMWPE and was chosen because of its large fracture strain - almost one order higher than that of UHMWPE. On the other hand, CNTs with their very high strength, modulus, and aspect ratio, contributed to sharing of load and sliding of polymer interfaces as they aligned during extrusion and strain hardening processes. A solution spinning process was developed to produce UHMWPE filaments reinforced with CNTs and nylon-6. The procedure involved dispersing of CNTs into paraffin oil through sonication followed by dissolving polymers into paraffin-CNT solution using a homogenizer. The admixture was fed into a single screw extruder for melt mixing and extrusion through an orifice. The extrudate was rinsed via a hexane bath, stabilized through a heater, and then drawn into a filament winder with controlled stretching. In the next step, the as produced filaments were strain-hardened through repeated loading unloading cycles under tension.

The success of harnessing energy from ocean current will require a reliable structural design of turbine blade that is used for energy extraction. In this study we are particularly focusing on the fatigue life of a 3m length ocean current turbine blade. The blade consists of sandwich construction having polymeric foam as core, and carbon/epoxy as face sheet. Repetitive loads (Fatigue) on the blade have been formulated from the randomness of the ocean current associated with turbulence and also from velocity shear. These varying forces will cause a cyclic variation of bending and shear stresses subjecting to the blade to fatigue. Rainflow Counting algorithm has been used to count the number of cycles within a specific mean and amplitude that will act on the blade from random loading data. Finite Element code ANSYS has been used to develop an S-N diagram with a frequency of 1 Hz and loading ratio 0.1 Number of specific load cycles from Rainflow Counting in conjunction with S-N diagram from ANSYS has been utilized to calculate fatigue damage up to 30 years by Palmgren-Miner's linear hypothesis.

Degradation of the Carbon Fiber/Vinylester (CF/VE) polymer matrix composites due to different electrochemical interactions when exposed to seawater or at high temperature had been experimentally investigated. Water uptake behavior of composite specimen was examined based on weight gain measurement. Three point bending test was performed to quantify the mechanical degradation of composite immersed in seawater with different environmental and electrochemical interactions. Finally, Electrochemical Impedance Spectroscopy (EIS) was used to better understanding of the degradation process in CF/VE composite produced by interactions between electrochemical and different environmental conditions. A detailed equivalent circuit analysis by using EIS spectra is also presented in an attempt to elucidate the degradation phenomenon in composites.

Durability of the composite materials in marine environments has been investigated experimentally and with analytical and numerical methods. The main focus of this study is on the integrity of the fiber/matrix interface under seawater exposure. A single-fiber compression test specimen called the Outwater-Murphy (OM) test has been analyzed using mechanics of materials principles and linear elastic fracture mechanics. Sizing of the OM specimen was conducted so that debonding of the fiber from the interface should be achieved prior to yielding of the matrix and global instability failure. Stress analysis of the OM specimen has been conducted from theory of elasticity and finite element analysis. A superelement technique was developed for detailed analysis of the stress state at the fiber/matrix interface. The interface stress state at the debond site in the OM specimen, i.e. at the hole edge, was identified as biaxial tension at the fiber/matrix interface. Characterization of cure and post-cure of 8084 and 510A vinlyester resins has been performed using cure shrinkage tests based on dynamic mechanical analysis and coated beam experiments. In addition, moisture absorption, swelling and the influence of moisture on the mechanical properties of the resins were determined. Testing of OM specimens consisting of a single carbon or glass fiber embedded in vinylester resin at dry conditions and after seawater exposure revealed that the debond toughness was substantially reduced after exposure of the OM specimen to seawater. C(F) did not debond. Macroscopic carbon/vinylester woven composites where the fibers were sized with F sizing were tested in shear at dry conditions and after four weeks of seawater exposure. The shear strength was very little affected after the short immersion time.