Studio del comportamento meccanico di compositi ottenuti per SMC

I materiali compositi più diffusi sono quelli a matrice polimerica (PMC, Polymer Matrix Composites) con fibre di rinforzo, largamente utilizzati per la loro capacità di conciliare ottima resistenza meccanica con elevata leggerezza. Nel presente elaborato di tesi sono state studiate le caratteristiche meccaniche di materiali compositi a matrice resinosa, epossidica, rinforzati con fibre di carbonio chopped, ovvero fibre spezzate e disposte in modo del tutto casuale all’interno della matrice, mediante analisi microstrutturale e prove di trazione. Viene descritto il processo di produzione delle piastre di materiale composito ottenuto per SMC (Sheet Moulding Compound) da cui sono stati ricavati i provini. Lo studio a livello microstrutturale è stato possibile grazie all’inglobamento nella resina di alcune sezioni dei provini, le cui superfici sono state esaminate al microscopio acquisendo una quantità di immagini tale da permettere la ricostruzione della superficie stessa tramite software ed il calcolo percentuale delle porosità tramite SolidWorks. La caratterizzazione meccanica è stata eseguita utilizzando la macchina per le prove di trazione presente nell’hangar della sede di Forlì della Scuola di Ingegneria e Architettura dell’Università di Bologna: la preparazione dei provini è basata sull’applicazione di tabs di alluminio. I provini in materiale composito sono stati forniti in quattro differenti tipologie riguardanti la pressione a cui sono stati prodotti: 25, 50, 100 e 150 bar. Lo scopo dell’elaborato è stabilire la pressione ottimale di produzione dei provini, a cui il materiale composito mostra le migliori proprietà meccaniche, in particolare la più alta resistenza a carico di trazione. Le prove sono state condotte su provini a tre diverse lunghezze, per diversificare le modalità di stress meccanico. I risultati sono stati poi analizzati per stabilire quale valore di pressione di processo conferisce le migliori caratteristiche meccaniche al materiale.

Processing and Composition Effects on the Fracture Behavior of Spray-Formed 7XXX Series Al Alloys

The fracture properties of high-strength spray-formed Al alloys were investigated, with consideration of the effects of elemental additions such as zinc,manganese, and chromium and the influence of the addition of SiC particulate. Fracture resistance values between 13.6 and 25.6 MPa (m)1/2 were obtained for the monolithic alloys in the T6 and T7 conditions, respectively. The alloys with SiC particulate compared well and achieved fracture resistance values between 18.7 and 25.6 MPa (m)1/2. The spray-formed materials exhibited a loss in fracture resistance (KI) compared to ingot metallurgy 7075 alloys but had an improvedperformance compared to high-solute powder metallurgy alloys of similar composition. Characterization of the fracture surfaces indicated a predominantly intergranular decohesion, possibly facilitated by the presence of incoherent particles at the grain boundary regions and by the large strength differentialbetween the matrix and precipitate zone. It is believed that at the slip band-grain boundary intersection, particularly in the presence of large dispersoids and/or inclusions, microvoid nucleation would be significantly enhanced. Differences in fracture surfaces between the alloys in the T6 and T7 condition were observed and are attributed to inhomogeneous slip distribution, which results in strain localization at grain boundaries. The best overall combination of fracture resistance properties were obtained for alloys with minimum amounts of chromium and manganese additions.

High-temperature mechanical properties of aluminium alloys reinforced with titanium diboride (TiB2) particles

The physical and mechanical properties of metal matrix composites were improved by the addition of reinforcements. The mechanical properties of particulate-reinforced metal-matrix composites based on aluminium alloys (6061 and 7015) at high temperatures were studied. Titanium diboride (TiB2) particles were used as the reinforcement. All the composites were produced by hot extrusion. The tensile properties and fracture characteristics of these materials were investigated at room temperature and at high temperatures to determine their ultimate strength and strain to failure. The fracture surface was analysed by scanning electron microscopy. TiB2 particles provide high stability of the aluminium alloys (6061 and 7015) in the fabrication process. An improvement in the mechanical behaviour was achieved by adding TiB2 particles as reinforcement in both the aluminium alloys. Adding TiB2 particles reduces the ductility of the aluminium alloys but does not change the microscopic mode of failure, and the fracture surface exhibits a ductile appearance with dimples formed by coalescence.

Galvanic Corrosion of High-Temperature Low-Sag (HTLS) High Voltage Conductors: New Materials - New Challenges

High-Temperature Low-Sag (HTLS) high voltage overhead conductors offer higher operating temperatures, reduced resistance and less sag than conventional designs. With up to twice the current capacity for the same diameter conductor, they may help ease the power shortage in the constantly increasing electricity demand, but there might be some concerns about their corrosion resistance. These new conductors use materials relatively new to the power industry, such as advanced carbon fiber polymer matrix composites and unique metal matrix composites/nano-composites predominantly used in aerospace industries. This study has made an initial assessment of potential galvanic corrosion problems in three very different HTLS designs: ACCC (Aluminum Conductor Composite Core), ACCR (Aluminum Conductor Composite Reinforced) and ACSS (Aluminum Conductor Steel Supported). In particular the ACCC design was evaluated for its resistance to corrosion and compared to the other designs. The study concludes that all three designs can develop galvanic corrosion under certain circumstances. While the results are not sufficient to make service life predictions of any of the tested conductors, they point out the necessity of thorough corrosion testing of all new conductor designs.

Obtenção e caracterização de PLA reforçado com nanocelulose.

A celulose é o polímero natural renovável disponível em maior abundância atualmente. Por possuir estrutura semicristalina, é possível extrair seus domínios cristalinos através de procedimentos que ataquem sua fase amorfa, como a hidrólise ácida, obtendo-se assim partículas cristalinas chamadas nanopartículas de celulose (NCs). Estas nanopartículas têm atraído enorme interesse científico, uma vez que possuem propriedades mecânicas, como módulo de elasticidade e resistência à tração, semelhantes a várias cargas inorgânicas utilizadas na fabricação de compósitos. Além disso, possuem dimensões nanométricas, o que contribui para menor adição de carga à matriz polimérica, já que possuem maior área de superfície, quando comparadas às cargas micrométricas. Nanocompósitos formados pela adição destas cargas em matrizes poliméricas podem apresentar propriedades comerciais atraentes, como barreira a gases, melhores propriedades térmicas e baixa densidade, quando comparados aos compósitos tradicionais. Como se trata de uma carga com dimensões nanométricas, obtida de fontes renováveis, uma das principais áreas de interesse para aplicação deste reforço é em biopolímeros biodegradáveis. O poli(ácido lático) (PLA), é um exemplo de biopolímero com propriedades mecânicas, térmicas e de processamento superiores a de outros biopolímeros comerciais. No presente trabalho foram obtidas nanopartículas de celulose (NCs), por meio de hidrólise ácida, utilizando-se três métodos distintos, com o objetivo de estudar o método mais eficiente para a obtenção de NCs adequadas à aplicação em compósitos de PLA. Os Métodos I e II empregam extração das NCs por meio do H2SO4, diferenciando-se apenas pela neutralização, a qual envolve diálise ou neutralização com NaHCO3, respectivamente. No Método III a extração das NCs foi realizada com H3PO4. As NCs foram caracterizadas por diferentes técnicas, como difração de raios X (DRX), análise termogravimétrica (TG), espectroscopia vibracional de absorção no infravermelho (FTIR), microscopia eletrônica de transmissão (MET) e microscopia de força atômica (MFA). Os resultados de caracterização das NCs indicaram que, a partir de todos os métodos utilizados, há formação de nanocristais de celulose (NCCs), entretanto, apenas os NCCs obtidos pelos Métodos II e III apresentaram estabilidade térmica suficiente para serem empregados em compósitos preparados por adição da carga no polímero em estado fundido. A incorporação das NCs em matriz de PLA foi realizada em câmara de mistura, com posterior moldagem por prensagem a quente. Compósitos obtidos por adição de NCs obtidas pelo Método II foram caracterizados por calorimetria exploratória diferencial (DSC), análise termogravimétrica, microscopia óptica, análises reológicas e microscopia eletrônica de varredura (MEV). A adição de NCs, extraídas pelo Método II, em matriz de PLA afetou o processo de cristalização do polímero, o qual apresentou maior grau de cristalinidade. Além disso, a adição de 3% em massa de NCs no PLA foi suficiente para alterar seu comportamento reológico. Os resultados reológicos indicaram que a morfologia do compósito é, predominantemente, composta por uma dispersão homogênea e fina da carga na fase matriz. Micrografias obtidas por MEV corroboram os resultados reológicos, mostrando, predominantemente a presença de partículas de NC em escala nanométrica. Compósitos de PLA com NCs obtidas pelo Método III apresentaram aglomerados de partículas de NC em escala micro e milimétrica, ao longo da fase matriz, e não foram extensivamente caracterizados.

Surface growth for molten silicon infiltration into carbon millimeter-sized channels: Lattice–Boltzmann simulations, experiments and models

The process of liquid silicon infiltration is investigated for channels with radii from 0.25 to 0.75 [mm] drilled in compact carbon preforms. The advantage of this setup is that the study of the phenomenon results to be simplified. For comparison purposes, attempts are made in order to work out a framework for evaluating the accuracy of simulations. The approach relies on dimensionless numbers involving the properties of the surface reaction. It turns out that complex hydrodynamic behavior derived from second Newton law can be made consistent with Lattice-Boltzmann simulations. The experiments give clear evidence that the growth of silicon carbide proceeds in two different stages and basic mechanisms are highlighted. Lattice-Boltzmann simulations prove to be an effective tool for the description of the growing phase. Namely, essential experimental constraints can be implemented. As a result, the existing models are useful to gain more insight on the process of reactive infiltration into porous media in the first stage of penetration, i.e. up to pore closure because of surface growth. A way allowing to implement the resistance from chemical reaction in Darcy law is also proposed.

Strength-ductility behaviour of Al-Si-Cu-Mg casting alloys in T6 temper

A comparative study of the mechanical properties of 20 experimental alloys has been carried out. The effect of different contents of Si, Cu, Mg, Fe and Mn, as well as solidification rate, has been assessed using a strength-ductility chart and a quality index-strength chart developed for the alloys. The charts show that the strength generally increases and the ductility decreases with an increasing content of Cu and Mg. Increased Fe (at Fe/Mn ratio 0.5) dramatically lowers the ductility and strength of low Si alloys. Increased Si content generally increases the strength and the ductility. The increase in ductility with increased Si is particularly significant when the Fe content is high. The charts are used to show that the cracking of second phase particles imposes a limit to the maximum achievable strength by limiting the ductility of strong alloys. The (Cu + Mg) content (at.%), which determines the precipitation strengthening and the volume fraction of Cu-rich and Mg-rich intermetallics, can be used to select the alloys for given strength and ductility, provided the Fe content stays below the Si-dependent critical level for the formation of pre-eutectic alpha-phase particles or beta-phase plates.

Catalytic effects of subsurface carbon in the chemisorption of hydrogen on a Mg(0001) surface: an ab-initio study

Ab initio density functional theory (DFT) calculations are performed to explore possible catalytic effects on the dissociative chemisorption of hydrogen on a Mg(0001) surface when carbon is incorporated into Mg materials. The computational results imply that a C atom located initially on a Mg(0001) surface can migrate into the subsurface and occupy an fcc interstitial site, with charge transfer to the C atom from neighboring Mg atoms. The effect of subsurface C on the dissociation of H-2 on the Mg(0001) surface is found to be relatively marginal: a perfect sublayer of interstitial C is calculated to lower the barrier by 0.16 eV compared with that on a pure Mg(0001) surface. Further calculations reveal, however, that sublayer C may have a significant effect in enhancing the diffusion of atomic hydrogen into the sublayers through fcc channels. This contributes new physical understanding toward rationalizing the experimentally observed improvement in absorption kinetics of H2 when graphite or single walled carbon nanotubes (SWCNT) are introduced into the Mg powder during ball milling.

The mechanical and wear behaviour of B(SiC) fibre-reinforced composite materials

The mechanical properties and wear behaviour of B(SiC) fibre-reinforced metal matrix composites (MMCs) and aluminium alloy (2014) produced by metal infiltration technique were determined. Tensile tests were peliormed at different conditions on both the alloy matrix and its composite, and the tensile fracture surfaces were also examined by Scanning Electron Microscopy (SEM). Dry wear of the composite materials sliding on hardened steel was studied using a pin-on-disc type machine. The effect of fibre orientation on wear rate was studied to provide wear resistance engineering data on the MMCs. Tests were carried out with the wear surface sliding direction set normal, parallel and anti-parallel to the fibre axis. Experiments were perfonned for sliding speeds of 0.6, 1.0 and 1.6 m/s for a load range from 12 N to 60 N. A number of sensitive techniques were used to examine worn surface and debris, i.e: Scanning Electron Microscopy (SEM), Backscattered Electron Microscopy (BSEM) and X-ray Photoelectron Spectroscopy (XPS). Finally, the effect of fibre orientation on the wear rate of the Borsic-reinforced plastic matrix composites (PMCs) produced by hot pressing technique was also investigated under identical test conditions. It was found that the composite had a markedly increased tensile strength compared with the matrix. The wear results also showed that the composite exhibited extremely low wear rates compared to the matrix material and the wear rate increased with increasing sliding speed and normal load. The effect of fibre orientation was marked, the lowest wear rates were obtained by arranging the fibre perpendicular to the sliding surface, while the highest wear was obtained for the parallel orientation. The coefficient of friction was found to be lowest in the parallel orientation than the others. Wear of PMCs were influenced to the greatest extent by these test parameters although similar findings were obtained for both composites. Based on the results of analyses using SEM, BSED and XPS, possible wear mechanisms are suggested to explain the wear of these materials.

Failure in composite materials

The economic and efficient exploitation of composite materials in critical load bearing applications relies on the ability to predict safe operational lives without excessive conservatism. Developing life prediction and monitoring techniques in these complex, inhomogeneous materials requires an understanding of the various failure mechanisms which can take place. This article describes a range of damage mechanisms which are observed in polymer, metal and ceramic matrix composites.

Predicting residual stiffness of cracked composite laminates subjected to multi-axial in-plane loading

Peer reviewed

Predicting residual stiffness of cracked composite laminates subjected to multi-axial in-plane loading

Peer reviewed

Modelling of stiffness degradation due to cracking in laminates subjected to multi-axial loading

Funding Financial support of this research by the Engineering and Physical Sciences Research Council (EPSRC/GR/L51348) and the British Ministry of Defence is gratefully acknowledged.

Caracterização de atapulgita visando aplicação para reforço de materiais poloméricos

The clay mineral attapulgite is a group of hormitas, which has its structures formed by microchannels, which give superior technological properties classified the industrial clays, clays of this group has a very versatile range of applications, ranging from the drilling fluid for wells oil has applications in the pharmaceutical industry. Such properties can be improved by activating acid and / or thermal activation. The attapulgite when activated can improve by up to 5-8 times some of its properties. The clay was characterized by X-ray diffraction, fluorescence, thermogravimetric analysis, differential thermal analysis, scanning electron microscopy and transmission electron microscopy before and after chemical activation. It can be seen through the results the efficiency of chemical treatment, which modified the clay without damaging its structure, as well as production of polymer matrix composites with particles dispersed atapugita

Comportamento magnético de compósitos de matriz polimérica com adição de ferritas

Polymer matrix composites offer advantages for many applications due their combination of properties, which includes low density, high specific strength and modulus of elasticity and corrosion resistance. However, the application of non-destructive techniques using magnetic sensors for the evaluation these materials is not possible since the materials are non-magnetizable. Ferrites are materials with excellent magnetic properties, chemical stability and corrosion resistance. Due to these properties, these materials are promising for the development of polymer composites with magnetic properties. In this work, glass fiber / epoxy circular plates were produced with 10 wt% of cobalt or barium ferrite particles. The cobalt ferrite was synthesized by the Pechini method. The commercial barium ferrite was subjected to a milling process to study the effect of particle size on the magnetic properties of the material. The characterization of the ferrites was carried out by x-ray diffraction (XRD), field emission gun scanning electron microscopy (FEG-SEM) and vibrating sample magnetometry (VSM). Circular notches of 1, 5 and 10 mm diameter were introduced in the composite plates using a drill bit for the non-destructive evaluation by the technique of magnetic flux leakage (MFL). The results indicated that the magnetic signals measured in plates with barium ferrite without milling and cobalt ferrite showed good correlation with the presence of notches. The milling process for 12 h and 20 h did not contribute to improve the identification of smaller size notches (1 mm). However, the smaller particle size produced smoother magnetic curves, with fewer discontinuities and improved signal-to-noise ratio. In summary, the results suggest that the proposed approach has great potential for the detection of damage in polymer composites structures