Effect of the manufacturing process on the interlaminar fracture toughness of 2/2 twill weave fabric carbon/epoxy composites

A 2/2 twill weave fabric carbon fibre reinforced epoxy matrix composite MTM56/CF0300 was used to investigate the effect of different manufacturing processes on the interlaminar fracture toughness. Double cantilever beam tests were performed on composites manufactured by hot press, autoclave and 'Quickstep' processes. The 'Quickstep' process was recently developed in Perth, Western Australia for the manufacture of advanced composite components. The values of the mode I critical strain energy release rate (G1d were compared and the results showed that the composite specimens manufactured by the autoclave and the 'Quickstep' process had much higher interlaminar fracture toughness than the specimen produced by the hot press. When compared to specimens manufactured by the hot press, the interlaminar fracture toughness values of the Quickstep and autoclave samples were 38% and 49% higher respectively. The 'Quickstep' process produced composite specimens that had comparable interlaminar fracture toughness to autoclave manufactured composites. Scanning electron microscopy (SEM) was employed to study the topography of the mode I interlaminar fracture surface and dynamic mechanical analysis (DMA) was performed to investigate the fibre/matrix interphase. SEM micrography and DMA spectra indicated that autoclave and 'Quickstep' produced composites with stronger fibre/matrix adhesion than hot press.

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.

Development of an evaluation approach for excellence in the Australian manufacturing industry

An approach to study best practice manufacturing with particular relevance to the Australian context. Sections include the development and analysis of results from a World Class Manufacturing survey, a literature review of best practice manufacturing from Japan/USA/UK, and case studies from its application at two major business units within a large Australian manufacturing company.

Examination of the relationship between advanced manufacturing technologies (AMTs) and workforce development activities : implications for organisational performance

This study examines the relationship among organisational performance, advanced manufacturing technologies and workforce development activities. A model of this relationship is proposed with the workplace needs acting as a mediator between technology and workforce development activities. This survey examined the technology and developmental practices of manufacturing companies in Hong Kong.

Data with abnormal systematic pattern in a manufacturing process

The data represents a systematic pattern in process variable presented in a control chart due to measurement gauge rotation and power fluctuations in manufacturing processes.

A manufacturing process using the infrared ray local heating method for seat cross members

Recent studies have shown that the infrared (IR) local heating method drastically reduces springback of advanced high-strength steels (AHSSs). Though the IR local heating method saves heating energy because it utilizes focused IR rays to heat only the plastic deformation zone, there has yet to be an attempt to show that the heating method can be applied to industrial manufacturing processes. In this work, the IR local heating method is used to manufacture a seat cross member. Seat cross members require high strength because they are responsible for protecting passengers from broadside collisions. Although AHSS is preferred in seat cross members, the large amount of springback of AHSS makes a problem in the accuracy of the shape. This work verifies that the IR local heating method is able to make the seat cross member with the target shape in the manufacturing process. A thermo-mechanical analysis was also conducted with the finite element method to discuss the springback results.

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.

Current developments and future challenges for the creation of aortic heart valve

The concept of tissue-engineered heart valves offers an alternative to current heart valve replacements that is capable of addressing shortcomings such as life-long administration of anticoagulants, inadequate durability, and inability to grow. Since tissue engineering is a multifaceted area, studies conducted have focused on different aspects such as hemodynamics, cellular interactions and mechanisms, scaffold designs, and mechanical characteristics in the form of both in vitro and in vivo investigations. This review concentrates on the advancements of scaffold materials and manufacturing processes, and on cell–scaffold interactions. Aside from the commonly used materials, polyglycolic acid and polylactic acid, novel polymers such as hydrogels and trimethylene carbonate-based polymers are being developed to simulate the natural mechanical characteristics of heart valves. Electrospinning has been examined as a new manufacturing technique that has the potential to facilitate tissue formation via increased surface area. The type of cells utilized for seeding onto the scaffolds is another factor to take into consideration; currently, stem cells are of great interest because of their potential to differentiate into various types of cells. Although extensive studies have been conducted, the creation of a fully functional heart valve that is clinically applicable still requires further investigation due to the complexity and intricacies of the heart valve.

The ultimate sustainable home

The introduction of assembly line techniques to vehicle manufacturing by Henry Ford in the early 1900s dramatically reduced production costs, improved quality and made cars affordable to all. As a consequence people’s lives, cities and society were transformed.
Many attempts have been made to apply vehicle mass production techniques to domestic housing manufacturing, but the success has been limited largely due to underdeveloped manufacturing processes, incomplete integration of building services and limited consideration of environmental performance.
This paper describes an approach that promises to revolutionize the building market in Australia by providing architect designed attractive high quality comfortable modular housing system that incorporates state-of-the-art services and controls. Costs, GHG emissions and material wastage are all substantially less than timber framed housing construction commonly used in Australia.

Bamboo : a distinctive green fibre

This article reports the preliminary findings on the morphology, chemical structure, antimicrobial and UV-screening properties of bamboo fibres. Bamboo fibres provide a very promising alternative to other natural fibres by virtue of their distinctive characteristics such as eco-friendly farming, inherent antimicrobial, UV-protective and highly· breathable properties. However, these novel properties are moslly claimed by fibre manufacturers, with little scientific evidence.  Moreover, those properties may largely depend on the manufacturing process, which is not widely disclosed by the manufacturers, Common manufacturing processes may require the use of a large amount of chemicals which would not make the product truly eco-friendly. Therefore, there is a strong need for unbiased laboratory experiments being conducted in a rigorous manner to elucidate the origin of those unique properties of bamboo fibres and to develop new processing methods to effectively utilise the properties in the final products. This research is aimed to prove the unique characteristics of bamboo fibres scientifically and to develop an efficient manufacturing process, in order to establish the place of bamboo fibres as a novel green material.