[PPT] - Materials, Mechanical Characterization & Manufacturing Overview PowerPoint Presentation

SLIDE 1

Materials, Mechanical Characterization & Manufacturing

Materials, Mechanical Characterization & Manufacturing Overview

David R. Veazie, Ph.D. P.E., Professor and Director Southern Polytechnic State University Center for Advanced Materials Research and Education - SPSU Materials and Mechanical Testing Laboratories - CAU Test and Evaluation Research Opportunities Workshop July 26 -28, 2012

SLIDE 2

Outline



Material & Manufacturing Infrastructure



Nanotechnology & Functional Materials



Novel Nanoscale Characterization Equipment



Full-Field Deformation and Structural Characterization



AFOSR DURIP – Field Emission SEM



Energetic Materials



Advanced Material Development and Testing



Novel Structural Testing and Implementation



Advanced Power & Energy Generation



Computational & Multi-Scale Modeling

SLIDE 3

Equipment and Instrumentation

– Center of excellence in composite manufacturing – Field Emission Scanning Electron Microscope – Axial and axial-torsion servohydraulic test frames – Elevated temperature creep frames (composites) – Ultrasonic NDI and environmental chambers – Melt and capillary rheometry, extrusion and thermal imaging, compression molding, and thermoforming – RTM, VARTM, autoclave, walk-in oven, 30T press – Thermal analysis (TGA, DSC, TMA, DMA) – Chemical analysis (NMR, FT-IR, Raman, Wet Lab) – Microscopy (2 AFM's, TEM, X-Ray Diff) – Vibrational and florescence spectroscopy

Materials & Manufacturing Infrastructure

SLIDE 4

Materials & Manufacturing Infrastructure

Faculty, Staff and Students (Last 3 Years)

– 6 Faculty and 4 Full-Time Staff – 50 Supported Students (Engr. & Chemistry) – 18 Masters Graduates – 5 Ph.D. Graduates and 8 Ph.D. Candidates

Productivity (Last 6 Years)

– Over 100 Refereed Publications in Journals* – Over 250 Conference Proceedings and Presentations – 3/4 of Publications Co-Authored by Students – 5 National Publication Student Awards – Generated over $4 Million in External Research Funds – Over $2.5 Million in Equipment Purchased – Lab Maintains Upgrades & Calibrations

* Some Government and Industry research restricts open literature publications

SLIDE 5

(AFOSR DURIP) Thermal Field Emission SEM Veazie (FA9550-11-1-0323) - Southern Polytech

A JOEL JSF-7600F Field Emission SEM was installed in April 2012 at Southern Polytechnic State

University. This SEM currently supports several

projects including: Characterization of Nanoparticle Reinforced Resins for Readily Processable, High Temperature, Low Density Composites (DoD W911NF-12-1-0084) and Characterization of Copper Zinc Tin Sulfide (CZTS) for Photovoltaics (NSF 1125775).

Copper Zinc Tin Sulfide (CZTS) thin films were prepared by a non-vacuum liquid-based coating method enabling fabrication of high-efficiency, low cost and toxicity CZTS solar cell devices. A particle solution (slurry) was developed using the CZTS constituents, varying the range of composition ratios to achieve a stable stoichiometric kesterite CZTS crystal structure. SEM of separated graphene sheets with wrinkling SEM of 0.3 wt% graphite/PETI-298, clearly confirming the dispersed graphene.

Dr. David Veazie

SEM of stoichiometric CZTS confirming the formation of a tetragonal crystal lattice structure. Deidra Hodges

Dr. Eric Mintz

SLIDE 6

Novel Materials & Characterization

Multiple programs investigating the

processing and properties of nano- composites

Self Healing Composites
Develop and characterize advanced

composites which exhibit self-repairing properties

Thermal and mechanical analysis of

nano-structured thermoset polymers

RTM composite process trials
Georgia Research Alliance Innovation

Grants

Develop and deploy technologies that

lead to growing state’s economy

LM Aero, AFRL and NASA sponsored

developments

Programs to Support Materials Research for Aerospace Industry

SLIDE 7

Nanotechnology & Functional Materials

Objective

Multiple programs

investigating the processing and properties of nano- composites

1 10 100 1000 10000 100000 1000000 10000000 500 1000 1500 2000 2500 3000 Time (s) Property eta* (P) G' (Pa) G'' (Pa)

SLIDE 8

Novel Nanoscale Characterization Equipment

Micro-Nano Test Frame (Patent-Pending)

Exchangeable Load Cell XY translation Stage Sample Micro-translator AFM Supporting Plate

Better load cell resolution (0.001 N at full scale) with ultra-fine load stepping (1/1028 revolution)
More accurate gripping of thin structures (No sample twisting)
Micro/Nanoscale strain measurement with AFM (Atomic Force Microscope)
Scan length: 100mm for use with microfabricated reference marks for nano-scale strain measurement
In-situ image monitoring of microstructure (characterize changes due to mechanical and thermal loading such as surface

morphology, crack propagation, etc.

m m

SLIDE 9

Advanced Material Development and Testing

Metal Polymer Gap Filler Development

Successes on boot extrusion leads to study of innovative gap filler concept
Developed low cost, flexible and lightweight gap filler to replace conductive caulk
Highly successful IRAD sponsored program transitioned to production qualification
F/A-22 Door Edge Protection potential production supplier

SLIDE 10

Young's Modulus

40% Al(5 mm) 10% Ni(44 mm)

E (GPa)

4 5 6 7 8 9 10 11 DMA Data DMA Friction Model Compression Data 40% Al(5 mm) 40% Al(50 mm) 10% Ni(44 mm) 40% Al(50 mm) 20% Al(5 mm) 10% Ni(44 mm) 20% Al(50 mm) 10% Ni(44 mm) 20% Al(5 mm) 20% Al(50 mm)

Decreasing Volume Fraction



 

V Friction DMA

dV U U E   2 2 1

DMA Measured Strain

m m mm) mm) m mm) m m mm) m mm) mm)

Decreasing Volume Fraction

Strain (%)

0.042 0.044 0.046 0.048 0.050 0.052

DMA Measured Strain Stress  (Pa)

2.0e+6 2.5e+6 3.0e+6 3.5e+6 4.0e+6 4.5e+6 5.0e+6

DMA Measured Stress

m m ) m m ) m m ) m m ) m m ) m m ) m m ) m m ) m m ) m m ) m m ) m m )

Decreasing Volume Fraction

Strain Energy Strain Energy





V

dV U E

2

2 1 

Rearranging Rearranging Including Including Interparticle Interparticle Friction Energy Loss Friction Energy Loss

  

  

V V V

dV E U

r

dV E dV U

2 2

2 1 2 1 2 1   





V DMA

dV U  2 1



 

V Friction DMA

dV U U E   2 2 1

U U DMA

DMA

Particle Friction Energy

40% Al(5 mm) 10% Ni(44 mm)

Friction Energy (N-m)

0.0 5.0e-7 1.0e-6 1.5e-6 2.0e-6 2.5e-6 3.0e-6 40% Al(5 mm) 40% Al(50 mm) 10% Ni(44 mm) 40% Al(50 mm) 20% Al(5 mm) 10% Ni(44 mm) 20% Al(50 mm) 10% Ni(44 mm) 20% Al(5 mm) 20% Al(50 mm)

Decreasing Volume Fraction

    



V

F V Damping Particle Friction

dF Particles Tan Energy Friction U * * 

U U Friction

Friction

Tangential Stiffness Td (Pa)

3.0e+5 4.0e+5 5.0e+5 6.0e+5 7.0e+5

Average DMA Measured Tangential Compliance-1

4 % A l

( 5 m m )

1 % N i

( 4 4 m m )

4 % A l

( 5 m m )

4 % A l

( 5 m m )

1 % N i

( 4 4 m m )

4 % A l

( 5 m m )

2 % A l

( 5 m m )

1 % N i

( 4 4 m m )

2 % A l

( 5 m m )

1 % N i

( 4 4 m m )

2 % A l

( 5 m m )

2 % A l

( 5 m m )

Decreasing Volume Fraction (Averaged over Particle Volume Fractions, Vf)

3 1

1 4



          N T a dT d m    

                                       

3 2 1 1 3 5 1 2

1 1 6 5 1 1 10 9 P T P T P T a P E m m m  m 

Energetic Materials - AFRL

Stiff particles in soft matrix

Stiff particles in soft matrix

Different particle types

Different particle types

Particle contact

Particle contact

Particle chains

Particle chains

Particle clustering

Particle clustering

Adapted from slide by B. White TMS 2010

Test Preference Order Material Volume (mm3) Test Method to Measure Elastic Modulus 1 *49.1 Miniature SHPB 2 *175.9 SHPB 3 190.0 Ultrasonic and Vibratory 4 520.2 Dynamic Mechanical Analysis 5 *2782.9 Impact and Taylor Rod 6 3217.6 Compression 7 3242.9 Hardness 8 4129.0 Flexure 9 7258.1 Miniature Tension 10 18097.5 Tension

SLIDE 11

Advanced Power & Energy Generation

Micro-Gas Turbine Engine Power MEMS Technology

SLIDE 12

Polymer Chemistry Composite Structural Mechanics

Multi-Scale Model

Computational Chemistry Meso-scale Randomness Stochastic Response Computational Structural Mechanics

Experimental Parameters Micro-Level Modeling

Objective

Develop multi-scale technology

to link molecular scale to structural scale

Computational & Multi-Scale Modeling

SLIDE 13

(a) (b)

Impact Surface Shape for (a) Front and (b) Back Surfaces

Full-Field Structural Characterization

Full-Field Deformation Measurement with Digital Correlations Software (Optical Strain)

Support 0.2” 0.4” (10.2 mm) (a) Short Beam Shear Test Setup (b) Axial Strain Contour Plot (d) Shear Strain Contour Plot (c) Transverse Normal Strain Contour Plot Delamination about to initiate Support (a) Wrinkle Coupon Test Setup (b) Axial Strain Contour Plot (d) Shear Strain Contour Plot (c) Transverse Normal Strain Contour Plot

Stereo Camera Set for Capturing 3D Surface Shape and Full-Field Deformation
Optical Strain from Digital Correlations Software

SLIDE 14

Novel Structural Testing and Implementation

Structural validation testing of high speed machined monolithic door design
Static and fatigue pressure testing conducted in Mechanical Test Lab
Developed test set-up, strain monitoring and data acquisition system
FAA Certified (C-130J implementing new design)

C-130J Emergency Exit Door Structural Qualification Tests

SLIDE 15

F/A-22 Material Screening

Ultimate Bearing Strength , FBTu

130000 140000 150000 160000 170000 180000 190000 200000 RTM 6 Loctite NBR77 Cycom RS50 VR 6 5250-4 Material psi Room Temperature

65 F

220 F 220 F Wet

Screen 6 commercially available RTM epoxies

for F/A-22 qualification

Industry standards for damage tolerance, OHC,

bearing and T-elements

Scope of effort
Build flat and element tooling
Fabricate 28 flat panels
Fabricate 14 T-elements
Coupon/element machining
Moisture conditioning
Mechanical Test
NDI
Dynamic mechanical analysis
Photomicroscopy
Program completed in 7 months

Aerospace Materials – Lockheed-Martin

SLIDE 16

High Temperature Polyimides

VARTM of NASA PETI resins
Process temperatures up to 700°F using high

temperature injector

Scope of effort
Resin rheology
6 glass and carbon panels
NDI
Developed process which achieved 4% void

contents (typical of VARTM)

Demonstrated comparable high

temperature properties between VARTM and RTM

Related programs with engine and

spacecraft contractors

Aerospace Materials – Lockheed-Martin

SLIDE 17

F/A-22 Door Edge Protection

Replacing labor intensive injection

molding of “boots” with extrusion

Continuous extrusion of boot and sheet

permits fabrication of entire production lots in hours (vs. weeks)

Efforts conducted using Haake R&D

extruder

Scope of Aero efforts
Screening nylons and urethanes
Optimize filler loading fractions
Extrusion tooling
Thermal analysis/physical testing
Highly successful IRAD sponsored

program transitioned to production qualification

Baseline Loading A Loadings B,C, D Baseline Loading A Loadings B,C, D

Aerospace Materials – Lockheed-Martin

SLIDE 18

P-3 Orion Fairing Fabrication

Develop, build, and certify low cost

composite components for P-3 aircraft

Replaces corrosion sensitive components
n aging aircraft platform with VARTM

composites

First effort within LM Aero to build

flight worthy hardware for manned A/C

Selected component – Aft lower wing

fillet panel

Scope of effort
Full scale tooling
Design property testing
Sub and full scale fabrication
Program completed in 12 months

Aerospace Materials – Lockheed-Martin

SLIDE 19

P-3 Orion Test Article Fabrication

Fabrication efforts performed in new composites

laboratory

Efforts performed
Built 9 design property panels
Built 8 subcomponent articles
Built 2 full scale articles
Coupon machining
Moisture conditioning
Mechanical testing
NDI
Laminate physical testing
Dynamic mechanical analysis
Photomicroscopy
Very successful part replacement study

performed from “cradle to grave”

Aerospace Materials – Lockheed-Martin

SLIDE 20

Reusable Launch Vehicle (RLV) Program

Objective

Verify LaRC polyimide foam materials reliability

for vehicle lifetime

Standards for Thermal Protection System,

Support Structure and Cryogenic fuel tanks Scope of effort

Test and characterize mechanical/thermal

material properties

Develop predictive methods and processing

parameters

Fabricate and characterize sandwich composites

Accomplishments

Novel fabrication methods characterized
Cost reduction in foams
Fabricate flame resistant panels

Flatwise Tensile Strength Foam Material

0.5 pcf 2 pcf 5 pcf 8 pcf

Tensile Strength (Psi)

100 200 300 400 500 RTA 300 F

65 F

Aerospace Materials – NASA LaRC

SLIDE 21

Novel Polyimide Foams Processing and Characterization

Standards for Thermal Protection System, Support Structure and Cryogenic fuel tanks
Develop predictive fabrication methods and processing parameters
Novel fabrication methods characterized and cost reduction in foams
Fabricate flame resistant panels and sandwich composites
157°C

(-250°F)

253°C

(-423°F) 232°C (450°F)

TPS Launch Re-entry

316°C (600°F)

157°C

(-250°F)

253°C

(-423°F) 232°C (450°F)

TPS Launch Re-entry

316°C (600°F)

TPS: SA/HC (LaRC Metallic tile) Support Structure: Gr-Poly lattice Cryogenic insulation: LaRC TEEK™ foam panels E-Beam cured adhesive Tank wall: Externally stiffened Gr-Poly Liquid Crystal Polymer (LCP) coating

RLV Focused Airframe Systems RLV Focused Airframe Systems

Aerospace Materials – NASA LaRC

SLIDE 22

Joint Strike Fighter Structures

Small Business Collaborations

Develop low cost resin transfer molding

concepts

Composites Affordability Initiative – industry

consortium funding

Scope of CAU/M&P Technologies and

SPSU/Chattahoochee S.C. effort

Screening tests on BMI cure cycle
Investigate low cost fabric options
Conduct process limits task
Fabrication of over 25 RTM test panels
Coupon/element machining
Moisture conditioning
Mechanical test
NDI
Dynamic mechanical analysis
Photomicroscopy