Faculty of Engineering and Built Environment
Permanent URI for this communityhttp://ir-dev.dut.ac.za/handle/10321/9
Browse
7 results
Search Results
Item Hybrid syntactic foam core cased natural-glass fibre sandwich composite(2023-05) Afolabi, Olusegun Adigun; Kanny, Krishnan; Mohan, Turup PanduranganComposite materials comprised of two separates with different properties to form a single material that reflect the properties of the combined materials. Syntactic foam composites (SFC) are made from the combination of hollow glass microspheres and epoxy resin. They are lightweight and used as a core in the hybrid sandwich composite. Hollow glass microspheres (HGM) are high strength microballoons that provide closed cell porosity and help to reduce material weight. SFCs made of HGM, and resin matrix are used as the core in sandwich composite material and reinforced with natural or synthetic fiber materials. The sandwich syntactic foam composite (SSFC) has a wide range of applications in the marine, aerospace, structural, and automobile industry. Therefore, it is important to investigate their physical, mechanical, thermal, and morphological properties to achieve high strength and low density. Most of the previous work in literature employed the use of different fillers and core materials in sandwich composite but are limited in strength because of their high density. In this study, a single HGM filler was employed as heterogeneous and homogenous by varying into four different particle sizes to investigate the effect of these particle sizes on the mechanical and physio-mechanical properties of the SFC used as the core in the SSFC. The effect of wall thickness and radius ratio of the HGM on the microstructural properties of SFC was also determined. The heterogeneous and homogeneous SFC was fabricated by degassing method mixing the epoxy matrix with HGM filler, the filler was varied into five-volume fractions of 5, 10, 15, 20, and 25%. The functional group of the HGM filler and the neat epoxy was determined and compared with that of the SFCs fabricated using Fourier Transform Infrared Spectroscopy (FTIR). The results showed that the filler contain various functional groups such as hydroxyl group, phenol-OH, aldehyde C-H group, aromatic proton, epoxy group, which enhanced the bonding process. It was determined that the intensity of the SFCs for all the volume fractions increased more than the neat epoxy due to the shifts in the peaks representing the filler and the matrix groups. The physical (density, water absorption, buoyancy) properties and the mechanical (hardness, tensile, flexural, and impact) properties of the SFCs improved significantly compared with the neat epoxy. The Scanning Electron Microscopy (SEM), Dynamic Mechanical Analysis (DMA), and Thermo-gravimetric Analysis (TGA) were also used to determine the morphological structure, the viscoelastic properties, and degradation temperature of the HGM and the neat epoxy and compared with the fabricated SFCs. The surface of the HGM showed the microballoons in their different sizes before separation. The surface of the SFCs showed the epoxy matrix, matrix porosity, microballoons porosity, and microballoons structure in their mixed state. It was an indication of good interaction between the epoxy matrix and the HGM filler using degassing processing method. The DMA showed improved storage and loss modulus values by 9% and above 100% respectively compared to the neat epoxy and the TGA showed better glass transition Tg values of 4.5% and 2.7% at 20% and 55% weight loss respectively compared to the neat epoxy. This indicated that good interaction and interfacial bonding existed between HGM and the epoxy matrix and because of lower density and void content. The SFC was used as the core to fabricate a lightweight sandwich syntactic foam composite (SSFC). The SSFC was made into four different orientations (kenaf-SFC-kenaf, as KK; glass –SFCglass, as GG; glass/kenaf – SFC – kenaf/glass, as GK; and kenaf/glass –SFC- glass/kenaf, as KG) using kenaf and glass fibers as reinforcement. The physical properties (density, water absorption capacity, and buoyancy), mechanical properties (hardness, tensile, compression, and flexural), morphological properties (SEM), and acoustic properties were determined. The porosity of KK increased by 21.6% because the kenaf fiber is less dense and more porous in terms of water absorption which makes it require higher buoyancy force to stay afloat. The mechanical properties results showed that GK and KG have the highest hardness, flexural and compressive strength of 70.2%, 74.4%, and 42.7% respectively, while GG has improved tensile strength of 210.96% increase than KK. The acoustic properties results showed that GG improved in sound level (P) dB by 24.1% compared to KK, while the sound pressure (Lp) dB does not show a significant difference in the SSFC. In conclusion, the degassing processing method of SFCs improved its physical and mechanical properties by reducing the density using particle distribution analysis (PSA) and particle variation analysis (PVA) with the aid of a gas pycnometer, and porosity values thereby making it a suitable core material for the sandwich composite. A novel sandwich syntactic foam composite (SSFC) material was fabricated by hybridizing the face-sheets in different layering pattens. The SSFC physical and mechanical properties improved significantly with the use of hybrid fibers. Hence, this study has demonstrated that for structural and marine purposes, hybrid fibers can perform better as reinforcement in the sandwich composite than using a single fiber.Item Advances in sintering of titanium aluminide : a review(Springer Science and Business Media LLC, 2022) Mphahlele, Mahlatse R.; Olubambi, Peter Apata; Olevsky, Eugene A.Item Structural characterization and nanoindentation studies on mechanical properties of spark plasma sintered duplex stainless steel nanocomposite(Elsevier BV, 2020-11) Oke, Samuel Ranti; Mphahlele, Mahlatse R.; Ige, Oladeji Oluremi; Falodun, Oluwasegun Eso; Okoro, Avwerosuoghene Moses; Olubambi, Peter ApataNano-sized titanium nitride (TiN) powders were used as reinforcements for the fabrication of duplex stainless steel (SAF 2205) via spark plasma sintering (SPS) route. Optimized parameters of 1150 C temperature, 100 C/min heating rate, 50 MPa pressure and 15 min holding time were utilized for sintering of the SAF 2205-TiN composite. SEM equipped with an EBSD and TKD detectors were used to gain insight into sintered composite microstructures and grain boundary character. XRD was used to study crystallinity and phase transformation. The discrete mechanical properties of ferrite/austenite grains and grain boundaries were studied using nanoindentation technique. The addition of TiN nanoparticles resulted in decrease of the a-Fe peaks with principal planes shifting from a-Fe (110) to g-Fe (111). The EBSD confirmed that the addition of TiN nanoparticles to duplex stainless steel could initiate and advance ferrite to austenite phase reverse transformation. The TKD confirmed that nanosized nitrides are concentrated at the ferrite/austenite interface. The nanoindentation studies showed that the nanohardness (H), elastic modulus (E), plasticity index (J), and anti-wear properties were improved with the TiN nanoparticle addition from 0 to 8 wt%.Item An improved finite element model for vibration and control simulation of smart composite structures with embedded piezoelectric sensor and actuator(2001) Kekana, Marino; Tabakov, Pavel Y.This thesis details a study conducted to investigate the dynamic stability of an existing active control model (ACFl) of a composite structure embedded with a piezoelectric sensor and actuator for the purpose of vibration measurement and control. Criteria for stability are established based on the second method of Lyapunov which considers the energy of the system. Results show that ACFl is asymptotically stable although piezoelectric control effects persist when the feedback gain is set to zero. Meanwhile, it is required that there should be no control effects occurring through the piezoelectric actuator when the gain is set to zero. In this study, a new active control model (ACF2) is developed to satisfy the stability criteria, which satisfies the requirement of no piezoelectric control effects when the gain is set to zero. In ACF2 - as well as ACFl - the displacement and potential fields are discretised using the finite element method. In light of the locking phenomena associated with discrete displacements - which is expected to be pronounced in the case of discrete potentials due to their element geometry, ACF2-mixed is developed. ACF2 and ACF2-mixed control methodologies are similar except that in ACF2 both the displacement and potential field are discretised whereas in ACF2-mixed, only the displacement field is discretised and the potential field is continuous. Consequent to ACF2 and ACF2-mixed, stability analysis of the resulting time integration scheme is investigated as well. The results show that the damping forces due to the piezoelectric effect do not add energy to the structure. Hence, asymptotic stability is achieved. The time integration scheme yielded a small error, consistent with the literature. Numerical results revealed that ACFl exhibits a high degree of locking which is relaxed in ACF2 whereas ACF2-mixed exhibits envisaged results when compared with the other two models. Therefore, the ACF2 and ACF2-mixed will provide engineers with an alternative simulation model to solve actively controlled vibration problems hitherto.Item Development of prototype UCAV airframe components using advanced composite materials(2004) Jordan, Kenneth Gary; Jonson, Jon DavidThe study presented here addresses the design of the composite wing and canard structures for an -un-inh-ab-it-ed-combat air vehicle. The desian philosophy is based on a ~- combination of finite element analysis and mathematical programming. The wings and canards were manufactured using advanced composite materials. the manufacturing methodology was based on a rapid protoryping approach using 3D computer models and eNe machining. The theory of composite materials is covered in detail, attention IS given to the properties of the separate constituents, composite material properties and manufacturing methods that are relevant to the project. The finite element method and sequential linear programming are discussed in the context of structural analysis and optimisation. An overview of the methodology and how it is implemented is presented. Numerical optimisation techniques are discussed with particular emphasis being placed on sequential linear programming. The optimisation problem formulation is presented in detail with attention paid to elements and their formulation as well as design variables, constraints and sensitivity analysis. Two design concepts were considered for the wing and canard structures, the first being a conventional configuration and the second being a novel radial design. The development and evaluation of these structural concepts are presented in detail. The optimisation study done on the canard is also presented as well as the manufacture thereof. Details regarding the manufacturing methodology used in the construction of the canard for the uninhabited combat air vehicle are presented in detail with particularItem Increasing the use of fibre-reinforced composites in the Sasol group of companies : a case study(2007) Mouton, JacquesA composite material comprises two or more materials with properties that are superior to those of the individual constituents. Composites have become important engineering materials, especially in the fields of chemical plant, automotive, aerospace and marine engineering. The development of more advanced materials and manufacturing techniques in composites has grown from humble beginnings in the 1930s to a recognized and well-respected engineering discipline, providing solutions to conventional and challenging applications. At present, fibre-reinforced composites (FRCs) are amongst the most common types of composites used. They are produced in various forms with different structural properties, and designers, specifiers and end-users can choose from an almost endless list of these materials, providing design flexibility as well as low manufacturing and maintenance cost. Many suggest that composites have revolutionised the chemical and petro-chemical industries. Examples of applications include tanks and chemical reactor vessels that contains many hundreds of litres of hazardous chemicals, reinforced pipes measuring up to several meters in diameter conveying dangerous gases and so on. The South Africa Coal, Oil and Gas Corporation Limited (SASOL) was established in September 1950. From a small start-up, the company has grown to be a world leader in the commercial production of liquid fuels and chemicals from coal and crude oil. Sasol manufactures more than 200 fuel and chemical products at its main plants in Sasolburg and Secunda in South Africa as well as at several other plants abroad. Its products are exported to more than 90 countries around the world. The use of composites in general, and fibre reinforced composites in particular has received little support in Sasol through the years. Some sporadic use of these materials in the construction of process equipment, e.g. tanks, vessels and piping has taken place with varying degrees of success. While the use of equipment fabricated with fibre-reinforced composites has proven extremely successful in the chlorine producing facility in Sasolburg, catastrophic failures have taken place in Secunda in critical fire water systems made of these materials. The history of correct use and application of fibre-reinforced equipment has shown that the cost of ownership of such equipment is significantly lower than similar metallic equipment, therefore reducing costs and safety risks. However, even though this technology brings a company like Sasol closer to the realisation of the vast number of advantages and solutions offered by these materials, the reality is that most engineering personnel are still applying traditional (viz. steel and wood) technology as used by our predecessors. The work presented here attempts to indicate the relevance of fibre-reinforced composites for Sasol, and to detail efforts aimed at the raising of awareness amongst appropriate personnel at Sasol to increase the use of these materials in major capital projects and day-to-day maintenance contracts, therefore taking advantage of the superior performance of fibre-reinforced composites in demanding applications. In support of this drive, part of the work presented indicates the status as well as progress of the composites industry in the last few years. This project was therefore aimed at identifying the level of utilization of fibre-reinforced composites at Sasol, and the possible improvement in benefits of using these technologies. A methodology was developed, using engineering as well as marketing principles, to reach the engineering personnel in various divisions and seniority levels of Sasol to increase the awareness of the capabilities of composites materials, specifically regarding fibre-reinforced composites. Questionnaires were used to gauge the level of awareness while various methods, e.g. one-on-one meetings, seminars, conferences, electronic media, etc were used to upgrade the target groups’ knowledge. The results of the initial survey to determine the status of various dimensions in the company are indicated as well as the outcomes at the end of the research period. In support of the process in Sasol, the development, interaction and cross-pollination of international and national role-players in the fibre-reinforcement industry with respect to chemical containment and Sasol are indicated. The importance of this two-legged process is demonstrated: it ensures a professional national support framework for companies like Sasol. Results are indicated, compared and discussed to give future direction in this ongoing process. As important to this process was the development of appropriate technical resources (like design standards and codes) to enable their use within the group. It was recognised early on that raising the level of awareness of the target groups was not enough and that these resources had to be in-place down the line so that those who chose to could start to implement these material technologies with the aid of the resources. The development of the necessary resources is also discussed. Finally, it will be shown that significant growth has taken place regarding the awareness within the group over the course of implementation of this project. Specifically, about 20% of the target groups have moved from a stage of no knowledge to higher levels of confidence. In terms of use of these materials, significant growth has also taken place judging by the number of plant requests, activity on major capital projects and so on. In fact, from almost nothing in 1999, over the last 5 years in excess of R137 Million has been spent on capital equipment manufactured from composite materials, with the majority in the last 2 years.Item The synthesis, structure and properties of polypropylene nanocomposites(2007) Moodley, Vishnu KribagaranPolymer nanocomposites may be defined as structures that are formed by infusing layered-silicate clay into a thermosetting orthermoplastic polymer matrix. The nanocomposites are normally particle-filled polymers for which at least one dimension of the dispersed particles is in nanoscale. These clay-polymer nanocomposites have thus attracted great interest in industry and academia due to their exhibition of remarkable enhancements in material properties when compared to the virgin polymer or conventional micro and macro-composites. The present work describes the synthesis, mechanical properties and morphology of nano-phased polypropylene structures. The structures were manufactured by melt- blending low weight percentages of montmorillonite (MMT) nanoclays (0.5, 1, 2, 3, 5 wt. %) and polypropylene (PP) thermoplastic. Both virgin and infused polypropylene structures were then subjected to quasi-static tensile tests, flexural tests, micro-hardness tests, impact testing, compression testing, fracture toughness analysis, dynamic mechanical analysis, tribological testing. Scanning electron microscopy studies were then conducted to analyse the fracture surfaces of pristine PP and PP nanocomposite. X-ray diffraction studies were performed on closite 15A clay and polypropylene composites containing 0.5, 1, 2, 3 and 5 wt. % closite 15A nanoclay to confirm the formation of nanocomposites on the addition of organo clays. Transmission electron miscopy studies were then performed on the PP nanocomposites to determine the formation of intercalated, exfoliated or agglomerated nanoclay structures. Analysis of test data show that the mechanical properties increase with an increase in nanoclay loading up to a threshold of 2 wt. %, thereafter the material properties degrade. At low weight nanoclay loadings the enhancement of properties is attributed to the lower percolation points created by the high aspect ratio nanoclays. The increase in properties may also be attributed to the formation of intercalated and exfoliated nanocomposite structures formed at these loadings of clay. At higher weight loading, degradation in mechanical properties may be attributed to the formation of agglomerated clay tactoids. Results of XRD, transmission electron microscopy studies and scanning electron microscopy studies of the fractured surface of tensile specimens verify these hypotheses.