An evaluation of the performance of advanced melded composite joints

Melding is an efficient three step composite joining process that involves the selective cure of composite adherends before the final adhesive joint is created using the adherends own resin system. Melding does not require many of the processes and compromises associated with conventional techniques like adhesive bonding and mechanical fastening.

The Taguchi design of experiments technique was used to optimise three melded joint factors for a unidirectional epoxy prepreg material. The performance of the joint was evaluated using tensile and flexural strength as well as flexural modulus. It was found that not having a step for every ply in the joint was the most influential factor affecting joint performance. This was due to the differing failure modes induced by this factors various levels, which varied the amount of fibre breakage at failure.

Structural and material properties of a rapidly cured thermoplastic-toughened epoxy system

Thermoplastic-toughened epoxy resins are widely used as matrices in modern composite prepreg systems. Rapid curing of thermoplastic-toughened epoxy matrix composites results in different mechanical properties. To investigate the structure–property relationship, we investigated a poly(ether sulfone)-modified triglycidylaminophenol/ 4,4'-diamino diphenyl sulfone system that was cured at different heating rates. An intermediate dwell was also applied during the rapid heating of the thermoplasticmodified epoxy system. We found that a higher heating rate led to a larger domain size of the phase-separated macrostructure and also facilitated more complete phase separation. The intermediate dwell helped phase separation to proceed even further, leading to an even larger domain size of the macrostructure. A carbon-fiber-reinforced polymer matrix composite prepreg based on the poly(ether sulfone)-modified multifunctional epoxy system was cured with the same schedule. The rapidly heated composite laminates exhibited higher mode I delamination fracture toughness than the slowly heated material.

Inspection of drop-weight impact damage in woven CFRP laminates fabricated by different processes

The influence of manufacturing process on the drop-weight impact damage in woven carbon/epoxy laminates was inspected by visual observation, dyepenetrant X-ray technique, and optical microscopy observation. The MTM56/ CF0300 woven quasi-isotropic laminates were fabricated by two processes: the autoclave and the Quickstep processes. Quickstep^TM is a novel composite manufacturing process, which was designed for the out-of-autoclave production of high-quality composite parts at lower cost. It utilizes higher heat conduction of fluid other than gas to transfer heat to components, which results in much shorter cure cycles. The laminates cured by this fast heating process showed different impact failure modes from those cured by the conventional autoclave process. The residual indentation in the top side of the Quickstep-cured laminates had a bigger diameter, but a smaller depth at the same impact energy level. Dye-penetrant X-ray revealed more intense and connected impact damage regions in the autoclave-cured laminates. Optical micrography as a supplementary method showed less severe matrix damage in the quickstep-cured laminates indicating a more ductile property of the resin matrix cured at a faster heating rate.

Surface analysis of carbon fibre epoxy composites

This thesis investigated the surface finish of rapidly cured composites for automotive body panels. Findings showed that curing composites with rapid heating rates increased surface roughness, although it improved paint adhesion to the substrate. This thesis also highlighted the need for surface barriers to reduce fibre print through during aging.

Determination of resin acids in pulp mill effluent and receiving waters by high performance liquid chromatography

Resin acids are reported to be of major toxicological importance in pulp mill effluents for Rainbow Trout. Their determination, using a high performance liquid chromatographic method, is described.

Characterisation of an out-of-autoclave resin film infusion process for textile composites

A new method to manufacture damage tolerant textile composites, which combines Resin Film Infusion with a fast and cost·efficient curing technology QuickstepTM, was investigated. The effect of process parameters on resin flow through carbon fibre preforms was analysed and model-based parameter optimisation resulted in considerable improvement of resin flow properties.

Improving the dispersion and mechanical properties of epoxy/carbon nanotube composites

The incorporation and uniform dispersion of carbon nanotubes (CNTs) in polymer matrix could facilitate engineers to create high performance nanocomposites that potentially compete with most advanced materials in nature. The unique combination of outstanding mechanical, thermal, and electrical properties of CNTs makes them excellent nanofillers for the fabrication of advanced materials. Successful enhancement in mechanical properties via reinforcement is expected only when the nanofillers are well dispersed in the polymer matrix. Moreover, the orientation as well as the CNT/matrix interfacial strength also determines the effective physical properties of the nanocomposites. However, CNTs typically assemble to give bundles, which are heavily entangled to each other with a high aspect ratio and a large π-electronic surface. In this work, we outline some preliminary results in preparing high performance epoxy composites. Composites with fine dispersion and superior mechanical properties were prepared using epoxy and multiwalled carbon nanotubes (MWCNTs). The fine dispersion of the nanocomposites can be identified in the high resolution SEM image shown in Figure 1. This method can provide an alternative route for the preparation of new structural and functional nanocomposites.