Mechanical Engineering Commons^™

Carbon Fiber Recycling: Delamination System, Aaron Eastman

All Undergraduate Projects

The production of composite wings at Boeing causes carbon fiber waste and CWU Mechanical Engineering Technology students have been tasked in designing a carbon fiber recycling system. This project was brought forth and funded by the Joint Center for Aerospace Technology Innovation (JCATI). There are three subsystems that make up the carbon fiber recycling system, the delamination system, shredding system, and the oven. The purpose of this project was to increase the efficiency and effectiveness of the delamination system of the carbon fiber recycling system. The old system reached approximately 30-40 percent delamination with one pass through the system, and …

Multi-Mode Guided Wave Detection Of Various Composite Damage Types, Hanfei Mei, Robin James, Victor Giurgiutiu

Faculty Publications

This paper presents a new methodology for detecting various types of composite damage, such as delamination and impact damage, through the application of multimode guided waves. The basic idea is that various wave modes have different interactions with various types of composite damage. Using this method, selective excitations of pure-mode guided waves were achieved using adjustable angle beam transducers (ABTs). The tuning angles of various wave modes were calculated using Snell’s law applied to the theoretical dispersion curves of composite plates. Pitch–catch experiments were conducted on a 2-mm quasi-isotropic carbon fiber-reinforced polymer (CFRP) composite plate to validate the excitations of …

Jcati Composite Delaminator, Payden Coffman

All Undergraduate Projects

Improvements need to be made to the existing delaminator system designed to crush proprietary Boeing 777 composite material. The current design incorporates a hydraulic system to achieve the high loads needed to separate material layers. The new system will need to be able to apply the same loads while at the same time allowing for a constant feed of material through the system. To achieve this, a “gear-like” crushing system will be implemented that will apply a high enough radial load into the material that will achieve delamination equal or greater than the previous design while at the same time …

Hydrokinetic Turbine Composite Blades And Sandwich Structures: Damage Evaluation And Numerical Simulation, Mokhtar Fal

Doctoral Dissertations

“Composite materials are gaining interest due to their high strength to weight ratio. This study deals with both experimental and numerical approaches to cover the aspects of the failure of composite materials in hydrokinetic turbine applications. In Part I, the location and magnitude of failure in the horizontal axis water turbine carbon fiber-reinforced polymer (CFRP) composite blades with different laminate stacking sequences were investigated. Two lay-up orientations were adopted for this work ([0⁰]₄ and [0⁰/90⁰]_2s). A finite element analysis model was generated to examine the stresses along the blade. Five angles were introduced to study the effect …

Vibration-Based In-Situ Detection And Quantification Of Delamination In Composite Plates, Hanfei Mei, Asaad Migot, Mohammad Faisal Haider, Roshan Joseph, Md Yeasin Bhuiyan, Victor Giurgiutiu

Faculty Publications

This paper presents a new methodology for detecting and quantifying delamination in composite plates based on the high-frequency local vibration under the excitation of piezoelectric wafer active sensors. Finite-element-method-based numerical simulations and experimental measurements were performed to quantify the size, shape, and depth of the delaminations. Two composite plates with purpose-built delaminations of different sizes and depths were analyzed. In the experiments, ultrasonic C-scan was applied to visualize the simulated delaminations. In this methodology, piezoelectric wafer active sensors were used for the high-frequency excitation with a linear sine wave chirp from 1 to 500 kHz and a scanning laser Doppler …

Vibration-Based In-Situ Detection And Quantification Of Delamination In Composite Plates, Hanfei Mei, Asaad Migot, Mohammad Faisal Haider, Roshan Joseph, Md Yeasin Bhuiyan, Victor Giurgiutiu

Faculty Publications

This paper presents a new methodology for detecting and quantifying delamination in composite plates based on the high-frequency local vibration under the excitation of piezoelectric wafer active sensors. Finite-element-method-based numerical simulations and experimental measurements were performed to quantify the size, shape, and depth of the delaminations. Two composite plates with purpose-built delaminations of different sizes and depths were analyzed. In the experiments, ultrasonic C-scan was applied to visualize the simulated delaminations. In this methodology, piezoelectric wafer active sensors were used for the high-frequency excitation with a linear sine wave chirp from 1 to 500 kHz and a scanning laser Doppler …

Three-Dimensional Forming Of Multi-Layered Materials: Material Heat Response And Quality Aspects, Sami-Seppo Ovaska, Pavel Geydt, Ville Leminen, Johanna Lyytikäinen, Sami Matthews, Panu Tanninen, Malte Wallmeier, Marek Hauptmann, Kaj Backfolk

Journal of Applied Packaging Research

The micro- and macrostructural changes occurring in multi-layered substrates during three-dimensional forming were studied by atomic force microscopy (AFM), scanning electron microscopy (SEM) and optical analyses. Particular attention was paid to heat-induced deformations at the interface between of polymeric coating layer and the paperboard. With excessive heat transfer, occasional delamination of polyethylene terephthalate (PET) coating from the paperboard was observed. The mechanism behind delamination was studied in detail in-situ with an AFM at temperatures relevant to the converting process. Based on the analysis, the delamination could partially be linked to the widening of the initially-existing nano-scale cracks at the coating-paperboard …

Finite Element Modeling Of Delamination Damage In Carbon Fiber Laminates Subject To Low-Velocity Impact And Comparison With Experimental Impact Tests Using Nondestructive Vibrothermography Evaluation, George Rodriguez Iv

Master's Theses

Carbon fiber reinforced composites are utilized in many design applications where high strength, low weight, and/or high stiffness are required. While composite materials can provide high strength and stiffness-to-weight ratios, they are also more complicated to analyze due to their inhomogeneous nature. One important failure mode of composite structures is delamination. This failure mode is common when composite laminates are subject to impact loading.

Various finite element methods for analyzing delamination exist. In this research, a modeling strategy based on contact tiebreak definitions in LS-DYNA^®was used. A finite element model of a low-velocity impact event was created to …

Fracture Mechanics-Based Simulation Of Pv Module Delamination, Dominic I. Jarecki, Johanna B. Palsdottir, Peter Bermel, Marisol Koslowski

The Summer Undergraduate Research Fellowship (SURF) Symposium

Photovoltaic (PV) cells are rapidly growing as a renewable alternative to fossil fuels like coal, oil, and natural gas. However, greater adoption has also reduced government subsidies, placing the onus of making solar panels economically competitive on innovative research. While multiple methods have been considered for reducing costs, with each reduction in cost comes the associated peril of reduction in quality and useful lifetime. Several problems considered solved have now resurfaced as potential failure mechanisms with the introduction of cheaper PV cell technologies. However, to remain economically viable, PV modules will not only have to become cheaper, they will have …

Validation Of Delamination Reduction Trend For Stitched Composites Using Quasi-Static Indentation Test, Kwek Tze Tan, N. Watanabe, A. Yoshimura, Y. Iwahori

Dr. Kwek-Tze Tan

A novel empirical-based Delamination Reduction Trend (DRT) for stitched composites has been recently proposed. The DRT is capable of predicting the effective reduction in impact induced delamination area due to the influence of stitching. DRT simply relates two parameters: normalized delamination area and stitch fibre volume fraction, to characterize the effectiveness of stitching in impact damage suppression. This paper seeks to validate the DRT by using quasi-static indentation (QSI) test, which is considered analogous to low velocity impact test, due to similar structural response. Results from QSI test show good agreement with DRT. Furthermore, limitations in DRT have been established.

Progressive Damage In Stitched Composites Under Impact Loading, Kwek Tze Tan, N. Watanabe, A. Yoshimura, Y. Iwahori, T. Ishikawa

Dr. Kwek-Tze Tan

Damage in carbon fibre reinforced plastics (CFRP) due to impact loading is an extremely complex phenomenon that comprises of multiple failure mechanisms like intra-laminar matrix cracks, interlaminar delamination, fibre pull-out and fibre fracture. In stitched composites, impact damage behavior is further complicated by the presence of through-thickness stitching [1, 2], which not only favorably increases mode I/II interlaminar strength [3, 4], but also inevitably creates geometrical defects like weak resin-rich pockets around stitch threads and misalignment of in-plane fibres. Computational modeling has been used to simulate progressive damage effectively [5]. However, the complexity of impact damage progression in stitched composites …

Effects Of Temperature Change On Interfacial Delamination In Thermal Barrier Coatings, Hossein Ebrahimi, Soheil Nakhodchi

Hossein Ebrahimi

No abstract provided.

Face Sheet/Core Debonding In Sandwich Composites Under Static And Fatigue Loading, Manjinder Singh Warriach

Wayne State University Dissertations

Delamination growth due to face sheet/core debonding is a major concern due to its inherent weakness in sandwich composites which can be exacerbated due to the presence of flaws. In this research work The primary objective of this research was to characterize the delamination crack growth behavior in E-glass face sheet/polyurethane foam core sandwich composite with pre-existing initial delamination crack at a face sheet/core interface under static and fatigue for mode I and mixed mode loading. For mode I static loading two types of delamination experiments, namely T-peel test and wedge test were implemented to evaluate fracture toughness in polyurethane …

Micro Modeling Study Of Cathode/Electrolyte Interfacial Stresses For Solid Oxide Fuel Cells, Xinfang Jin, Xingjian Xue

Faculty Publications

Delamination of the cathode/electrolyte interface is an important degradation phenomenon in solid oxide fuel cells (SOFCs). While the thermal stress has been widely recognized as one of the major reasons for such delamination failures, the role of chemical stress does not receive too much attention. In this paper, a micro-model is developed to study the cathode/electrolyte interfacial stresses, coupling oxygen ion transport process with structural mechanics. Results indicate that the distributions of chemical stress are very complicated at the cathode/electrolyte interface and show different patterns from those of thermal stress. The maximum principal stresses take place at the cathode/electrolyte interface …

An Investigation Of Damage Arrestment Devices On Carbon Fiber Sandwich Specimens Under Dynamic Loading, Gabriel Sabino Sanchez

Master's Theses

This research studies the effects of a damage arrestment device embedded between a carbon fiber facesheet and foam core to find whether there is an increase in the structural integrity of the sandwich composites. Experimental and theoretical finite element analyses are implemented for two different composite sandwich geometries; plates and beams. Each structure consisted of the same loading criteria and was restricted to the same vibration fixture during the experiment. An accelerometer was placed on the composite plate to record the amplitude and the natural frequencies of the composite structure. Each composite specimen is then fixed to the surface of …

Validation Of Delamination Reduction Trend For Stitched Composites Using Quasi-Static Indentation Test, Kwek Tze Tan, N. Watanabe, A. Yoshimura, Y. Iwahori

Mechanical Engineering Faculty Research

A novel empirical-based Delamination Reduction Trend (DRT) for stitched composites has been recently proposed. The DRT is capable of predicting the effective reduction in impact induced delamination area due to the influence of stitching. DRT simply relates two parameters: normalized delamination area and stitch fibre volume fraction, to characterize the effectiveness of stitching in impact damage suppression. This paper seeks to validate the DRT by using quasi-static indentation (QSI) test, which is considered analogous to low velocity impact test, due to similar structural response. Results from QSI test show good agreement with DRT. Furthermore, limitations in DRT have been established.

Progressive Damage In Stitched Composites Under Impact Loading, Kwek Tze Tan, N. Watanabe, A. Yoshimura, Y. Iwahori, T. Ishikawa

Mechanical Engineering Faculty Research

Damage in carbon fibre reinforced plastics (CFRP) due to impact loading is an extremely complex phenomenon that comprises of multiple failure mechanisms like intra-laminar matrix cracks, interlaminar delamination, fibre pull-out and fibre fracture. In stitched composites, impact damage behavior is further complicated by the presence of through-thickness stitching [1, 2], which not only favorably increases mode I/II interlaminar strength [3, 4], but also inevitably creates geometrical defects like weak resin-rich pockets around stitch threads and misalignment of in-plane fibres. Computational modeling has been used to simulate progressive damage effectively [5]. However, the complexity of impact damage progression in stitched composites …

Interface Engineered Diamond Coatings For Dry Machining Applications, Humberto Arturo Gomez Vega

USF Tampa Graduate Theses and Dissertations

Several studies have been propose to improve the adhesion of diamond films on cemented carbide tool materials, however a systematic study in identifying the role of the factors that affect the final diamond adhesion and the resulting machining performance of the tool under real manufacturing conditions is still unexplored. CVD diamond film's extraordinary qualities bring little benefit if the film fails to adhere sufficiently to the substrate. Inadequate adhesion undermines tool performance and longevity, causing unpredictable behavior under load and possibly leading to unexpected failure of the tool in the production line. This dissertation investigates the effects of different surface …

Embedded Piezoelectric Fiber Composite Sensors For Applications In Composite Structures, Hari Prasad Konka

LSU Doctoral Dissertations

Health monitoring of the composite structures is an important issue that must be addressed. Embedded sensors could be an effective way to monitor the health of composite structures continuously and which could also avoid the catastrophic failures of composite structures. Piezoelectric-fiber-composite sensors (PFCS) made from micro-sized Lead Zirconate Titanate (PZT) fibers have great advantages over the traditional bulk PZT sensors for embedded sensor applications. PFCS as an embedded sensor will be an ideal choice to continuously monitor the stress/strain levels and health conditions of composites. This work presents a critical study on using PFCS as an effective embedded sensor within …

Failure Analysis Of Retrieved Uhmwpe Tibial Insert In Total Knee Replacement

A.S. Md Abdul Haseeb

This study involves the failure analysis of an ultra high molecular polyethylene (UHMWPE) tibial insert from Apollo® Total Knee System, which was removed after 10. years of service from 70. years old female patient. The tibial insert was investigated by using a stereoscope, scanning electron microscope (SEM), infinite focus microscope (IFM) and energy disperse spectroscopy (EDS) to characterize the morphology and composition of the bearing surface. Differential scanning calorimetry (DSC) and Fourier transform spectroscopy (FTIR) were employed to characterize the degradation and crystallinity of the component. Gel-permeation chromatography (GPC) was used to measure the polyethylene tibial insert molecular weight. Results …

An Investigation Of Initially Delaminated Composite Sandwich With Delamination Arrest Mechanism Under Buckling Loading, Tony D. Tran

Master's Theses

This thesis involves the development of a fiberglass-foam composite sandwich structure with the introduction of delamination arrestment keys; therefore, a study of an initially delaminated composite sandwich structure was the experimental analysis on multiple configurations in how the arrestment keys are placed.

The first part of this thesis research was to the experimental design and manufacturing of the composite sandwich plates. These plates were later cut down to the specific test dimensions and manufacturing processes for the composite sandwich plates and test specimens were created. The composite sandwich plates were manufactured using a vacuum resin infusion process. The dimensions of …

Finite Element Simulation Of Repair Of Delaminated Composite Structures Using Piezoelectric Layers, Kunal Navale

Electronic Theses and Dissertations

Damage in composite material fabricated aerospace, aeronautical, mechanical, civil and offshore structures often results from factors such as fatigue, corrosion and accidents. Such damage when left unattended can grow at an alarming rate due to the singularity of the stress and strain in the vicinity of the damage. It can lead to increase in the vibration level, reduction in the load carrying capacity, deterioration in the normal performance of the component and even catastrophic failure. In most conditions, the service life of damaged components is extended with repair instead of immediate replacement. Effective repair of structural damage is therefore an …

Response Of Ti-6al-4v And Ti-24al-11nb Alloys To Dry Sliding Wear Against Hardened Steel

A.S. Md Abdul Haseeb

Titanium alloys have been of great interest in recent years because of their very attractive combination of high strength, low density and corrosion resistance. Application of these alloys in areas where wear resistance is also of importance calls for thorough investigations of their tribological properties. In this work, Ti-6Al-4V and Ti-24Al-11Nb alloys were subjected to dry sliding wear against hardened-steel counter bodies and their tribological response was investigated. A pin-on-disc type apparatus was used with a normal load of 15-45N and sliding speed of 1.88 ms -1. In the steady state, it was demonstrated that Ti-24Al-11Nb had a substantially higher …

A Comparative Wear Study On Heat-Treated Aluminium-Lithium Alloy And Pure Aluminium

A.S. Md Abdul Haseeb

Wear behaviour of solution-treated and aged aluminium-lithium alloy (2.5% Li, 2% Cu, 1% Mg and 0.15% Zr) was compared with that of pure aluminium. Wear tests were carried out in ambient air in a pin-on-disc type apparatus under dry sliding conditions using hardened steel disc as the counterbody. A normal load of 10 N and a linear speed of 0.98 m s-1 were used during the tests. Microscopic investigation, microhardness measurement on the subsurface of wear scars on pins, X-ray diffraction study and morphological examination of wear debris were done to elucidate wear mechanism. It has been found that the …

Study Of The Wear Behaviour Of Al-4.5% Cu-3.4% Fe In Situ Composite: Effect Of Thermal And Mechanical Processing

A.S. Md Abdul Haseeb

Wear behaviour of as-cast and heat-treated spheroidal graphite (SG) cast iron has been studied under dry sliding conditions using a pin-on-disc type apparatus. Wear tests were carried out at a linear sliding speed of 0.88 m s -1, under a constant load of 1.5 kg. All tests were performed in ambient air at room temperature. Extent of wear damage and wear mechanisms were investigated by means of weight loss measurement, optical microscopy, microhardness measurement and X-ray diffractometry on wear debris. The wear rate measured after 9500 m of sliding is found to be about three times higher in the as-cast …

Machining Of Composite Materials. Part I: Traditional Methods, Serge Abrate, D. A. Walton

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Composite materials are more difficult to machine than metals mainly because they are anisotropic, non-homogeneous and their reinforcing fibers are very abrasive. During machining, defects are introduced into the workpiece, and tools wear rapidly. Traditional machining techniques such as drilling or sawing can be used with proper tool design and operating conditions. A review of traditional machining methods applied to organic and metal matrix composites is presented in this article. The use of non-traditional machining methods such as waterjet, laser and ultrasonic machining will be discussed in the second part. © 1992.