Rapid composite tube manufacture utilizing the quickstep™ process

In this study, a novel method for manufacturing composite tubes utilizing the Quickstep^TM process has been developed. Tubes manufactured from `quick-cure' Toray G83C prepreg have demonstrated highly repeatable axial crush behavior with an average specific energy absorption (SEA) of 86 kJ/kg. The cure cycle is optimized by comparing the results from compression, dynamic mechanical thermal analysis (DMTA), differential scanning calorimetry (DSC), and porosity testing. The tube lay-up is optimized using compression and porosity test results. The effect of changes in fiber-orientation on SEA is also investigated. Process development has resulted in a robust manufacturing method capable of producing fully cured, high performance composite tubes with a cure cycle of 7 min. This corresponds to a 95% reduction in time compared to an equivalent autoclave cycle.

Investigation of failure mechanisms in aged aerospace composites

The effect of isothermal ageing on two high temperature, bismaleimide composite materials, a novel CSIRO CBR 320/328 composite and a commercial CIBA GEIGY Matrimid® 5292 composite, was examined at 204 and 250 °C. Delamination is a major cause of failure in composite materials, therefore, the Mode I interlaminar fracture toughness (GIC) of both materials was measured using the double cantilever beam (DCB) test. Chemical degradation of the matrix was monitored concurrently using Fourier transform infrared (FTIR) and Raman spectroscopy. Chemical changes at the core of both of these materials were found to occur concomitantly with the observed changes in interlaminar fracture toughness. FTIR analysis of both matrix materials revealed the predominant degradation mechanism to be the oxidation of the methylene group bridging two aromatic rings common to the structure of both resins, and was substantiated by the ingrowth of a broad peak centred at 1600 cm⁻¹ . In addition to this, the pyromellitic anhydride unit present only in the CBR 320/328 composites was found to be highly resistant to the effects of ageing, whereas the saturated imide, common to the cured structures of both materials, was observed to degrade. Raman spectroscopy indicated that the predominant degradation mechanism of the composites differed at the two ageing temperatures.

eBusiness and information systems : academic programs in Australia and New Zealand in the e-Age

Universities are increasingly turning to ‘fashionable’ education programs to attract bright, high-quality students to both under-graduate and post-graduate degree programs. Traditional offerings in technology areas, such as Information Systems and Information Technology are being augmented by newer, more marketable degrees in areas such as eCommerce/eBusiness. This paper analyses the eCommerce/eBusiness and Information Systems (IS) / Information Technology (IT) academic programs in Australian and New Zealand universities on the basis of Kotler and Fox's service offering model of educational institutions; and considers what differences exist between these two apparently similar areas of academic endeavour. Finally we look at the trends of academic program delivery in the e-age and question whether universities need to take a more consumer-product approach to the issue of attracting appropriate students.

Manufacturing influence on the delamination fracture behavior of the T800H/3900-2 carbon fiber reinforced polymer composites

'Torayca' T800H/3900-2 is the first material qualified on Boeing Material Specification (BMS 8-276) which utilizes the thermoplastic-particulate interlayer toughening technology. Two manufacturing processes, the autoclave process and the fast heating rated Quickstep™ process, were employed to cure this material. The Quickstep process is a unique composite production technology which utilizes the fast heat transfer rate of fluid to heat and cure polymer composite components. The manufacturing influence on the mode I delamination fracture toughness of laminates was investigated by performing double cantilever beam tests. The composite specimens fabricated by two processes exhibited dissimilar delamination resistance curves (R-curves) under mode I loading. The initial value of fracture toughness GIC-INIT was 564 J/m2 for the autoclave specimens and 527 J/m2 for the Quickstep specimens. However, the average propagation fracture toughness GIC-PROP was 783 J/m2 for the Quickstep specimens, which was 2.6 times of that for the autoclave specimens. The mechanism of fracture occurred during delamination was studied under scanning electron microscope (SEM). Three types of fracture were observed: the interlayer fracture, the interface fracture, and the intralaminar fracture. These three types of fracture played different roles in affecting the delamination resistance curves during the crack growth. More fiber bridging was found in the process of delamination for the Quickstep specimens. Better fiber/matrix adhesion was found in the Quickstep specimens by conducting indentation-debond tests.

Characterization of melded carbon fibre/epoxy laminates

‘Melding’ is a novel in situ method for joining thermosetting composite structures, without the need of adhesives. Laminate joining is achieved using uncrosslinked resin matrix of the pre-preg. This study used Hexply914C pre-preg material to characterize melded CFRP structures produced using the melding method. A designated area of a laminate was maintained at temperatures below 40 °C retaining uncured (B-staged) material, while the remainder of the laminate was cured at 175 °C. After a 2.5 h cure cycle, the cured region showed a high degree of cure (0.88) and glass transition temperature (176 °C). The uncured area of the same laminate was cured in a second stage, simulating an in situ melded joint. By controlling the temperature and duration of the intermediate dwell and affecting minimum viscosity values prior to final cure, low values of porosity (<0.5%) were achieved. The mechanical properties of the resulting joint were consistent throughout the melded laminate. Flexural strength (1600 MPa), flexural modulus (100–105 MPa) and short beam strength (105–115 MPa) values observed where equivalent or greater than those found in the recommended autoclave cured control specimens. After the entire laminate was post cured, glass transition temperatures of 230 °C (peak tan δ) were observed in all areas of the laminate.

Investigation of processing conditions of melded parts to determine process boundaries

Melding, a novel method for producing seamless joints in thermosetting composites utilising the Quickstep™ process, is explored in this paper. The effect of processing conditions on the quality of melded joins is examined and a set of processing boundaries defined so that the strength of melded joints is optimized. HexPly® 914c pre-preg material was exposed to a range of processing temperatures prior to joining via the melding process. Differential Scanning Calorimetry analysis was carried out to investigate the degree of cure of material prior to final joining, and it was found that minimal cure occurs at temperatures below 120°C. After consolidation and cure of the melded parts, short beam shear testing was conducted to evaluate the strength of the melded interface. Exposure temperatures between 65°C and 120°C were found to optimize short beam shear join strength. Mode I double cantilever beam and mode II end notched flexural tests showed no detrimental effect of elevated exposure temperatures prior to joining.

Strain rate effects on the energy absorption of rapidly manufactured composite tubes

As a result of recent increases in fuel prices and the growing number of accident fatalities, the two major concerns of the automotive industry and their customers are now occupant safety and fuel economy {1, 2]. Increasing the amount of energy and optimizing the manner in which energy is absorbed within vehicle crush zones can improve occupant survivability in the event of a crash, while fuel economy is improved through a reduction in weight.  Axial crush tests were conducted on tubular specimens of Carbon/Epoxy (Toray T700/G83C) and Glass/Polypropylene (Twintex). This paper presents results from the tests conducted at quasi-static rates at Deakin Unniversity, Victoria Australia, and intermediate rate tests performed at the Oak Ridge National Laboratory, Tennessee  USA.   The quasi-static tests were conducted at 10mm/min (1.67x10-4m/s) using 5 different forms of initiation. Tests at intermediate rates were performed at speeds of 0.25m/s, 0.5m/s, 0.75m/s 1m/s, 2m/s and 4m/s. Quasi-static tests of tubular specimens showed high specific energy absorption (SEA) values with 86 kJ/kg for Carbon/Epoxy specimens. The SEA of the Glass/Polypropylene specimens was measured to be 29 kJ/kg. Results from the intermediate test rates showed that SEA values did not fall below 55kJ/kg for carbon specimens or 35kJ/kg for the Glass/Polypropylene specimens. When compared with typical steel and aluminium, SEA values of 15 kJ/kg and 30kJ/kg respectively, the benefits of using composite materials in crash structures is apparent.                                                                     

The effect of cure cycle heating rate on the fibre/matrix interface

Development of civil aerospace composites is key to future “greener” aircraft. Aircraft manufacturers must improve efficiency of their product and manufacturing processes to remain viable. The aerospace industry is undergoing a materials revolution in the design and manufacture of composite airframes. The Airbus A350 and Boeing 787 (both due to enter service in the latter part of this decade) will push utilisation levels of  composite materials beyond 50% of the total airframe by weight. This  change requires massive investment in materials technology, manufacturing capability and skills development. The Quickstep process provides the ability to rapidly cure aerospace standard composite materials whilst providing enhanced mechanical properties. Utilising fluid to transfer heat to the   composite component during the curing process allows far higher heat rates than with conventional cure techniques. The rapid heat-up rates reduce the viscosity of the resin system greatly to provide a longer processing window introducing greater flexibility and removing the need for high pressure during cure. Interlaminar fracture toughness (Mode I) and Interfacial Shear Strength of aerospace standard materials cured using Quickstep have been    compared to autoclave cured laminates. Results suggest an improvement in fibre-matrix adhesion.