This SAE Aerospace Standard (AS) covers the requirements for thermocouple extension cable. Manufacturers of primary thermocouple wire in accordance with this specification must be qualified to the similar wire type specified in Table 1.

AE-8D Wire and Cable Committee

Cable, Thermocouple Extension, Shielded and Unshielded

AS5419B-TEST-REC (Historical)06/02/2020

AE-8D Wire and Cable Committee

Hybrid Forming - A Novel Manufacturing Technique for Metal-LFT Structural Parts

2020-01-023504/14/2020

Hybrid structural parts combining aluminum or steel sheets with long glass fiber reinforced thermoplastics (LFT) offer a great opportunity to reduce component weight for automotive applications. But due to high manufacturing cost, metal-LFT hybrid components are still scarcely used in automotive large-scale production. Thus in this work a novel cost- and time efficient manufacturing process for simultaneous metal sheet forming and compression molding of long fiber reinforced thermoplastics to manufacture automotive lightweight components is presented. In this manufacturing process, which is referred to as “Hybrid forming”, a fiber reinforced thermoplastic melt is used as a forming medium in the manner of well-known hydroforming processes. After forming the metal sheet by polymer melt in combination with the rigid die, the melt solidifies and forms a local reinforcement structure in the hybrid component. Since the metal sheet is pre-coated with a bonding agent prior to the forming

Heidrich, Daniel, Kloska, Tobias, Fang, Xiangfan

Experimental Study on Static and Fatigue Behavior of a Short Glass Fiber Reinforced Polypropylene

2020-01-019004/14/2020

One approach of reducing vehicle weight is using composite materials. Fiber reinforced polypropylene is one of the most popular composite materials. To improve accuracy in prediction of durability performance of structures made of this kind of composite material, static and fatigue properties of a 30% fiber reinforced polypropylene have been physically studied. This paper describes details of test coupon design, fabrication and test setup of both quasi static and fatigue tests. In this study, various fiber orientation (0, 20, 90 degrees & knit line), temperature (-40, 23 and 80 degree C), mean stress (R=-1.0, -0.5, -0.2, 0.1 and 0.4) have been considered and the result of the tests discussed.

Guo, Mingchao, Wang, Congyue, Tao, Jian, Joseph, Johnson, Bhandarkar, Ramchandra

Investigation of Mechanical Behavior of Chopped Carbon Fiber Reinforced Sheet Molding Compound (SMC) Composites

2020-01-130704/14/2020

As an alternative lightweight material, chopped carbon fiber reinforced Sheet Molding Compound (SMC) composites, formed by compression molding, provide a new material for automotive applications. In the present study, the monotonic and fatigue behavior of chopped carbon fiber reinforced SMC is investigated. Tensile tests were conducted on coupons with three different gauge length, and size effect was observed on the fracture strength. Since the fiber bundle is randomly distributed in the SMC plaques, a digital image correlation (DIC) system was used to obtain the local modulus distribution along the gauge section for each coupon. It was found that there is a relationship between the local modulus distribution and the final fracture location under tensile loading. The fatigue behavior under tension-tension (R=0.1) and tension-compression (R=-1) has also been evaluated. Damage evolution on the free edge of the samples under cyclic loading has been recorded using optical microscopy by

Sun, Xuze, Engler-Pinto, Carlos, Huang, Li, Huang, Shiyao, Tang, Haibin, Cui, Haitao, Su, Xuming

CAE Modeling Static and Fatigue Performance of Short Glass Fiber Reinforced Polypropylene Coupons and Components

2020-01-130904/14/2020

Fiber reinforced polypropylene (FRPP) is a typical anisotropic composite and its material properties highly depend on the fiber orientations within the material. To improve accuracy in prediction of durability performance of structures made of this kind of composite material, simulation of manufacturing process is necessary to obtain distribution of fibers and their orientations at every location of the structure. This paper describes a CAE modeling techniques to simulate 1) injection molding process, 2) static and fatigue performance of coupons and 3) static and fatigue performance of components made of 30% FRPP. Details of CAE model setup, analysis procedures and correlation between analysis and test results are presented. In this study, various fiber orientation (0, 20, 90 degrees & knit line), temperature (-40, 23 and 80 degree C) and mean stress (R=-1.0, -0.5, -0.2, 0.1 and 0.4) have been considered. To demonstrate correlation, battery trays made of this FRPP have been tested

Wang, Congyue, Guo, Mingchao, Shanmugam, Mohan, Bhandarkar, Ramchandra

Influence of Weld Lines on the Mechanical Properties of Talc Filled Polypropylene

2020-01-130604/14/2020

Weld lines can significantly reduce ultimate tensile strength (UTS) and fracture strain of talc filled polypropylene (PP). In this paper, two different injection molding tests were completed. First, an injection mold with triangular inserts was built to study the influence of meeting angles on material properties at the weld line region. Tensile samples were cut at different locations along the weld line on the injection molded plaques. The test results showed that both UTS and fracture strain increase when the sample locations are away from the insert. This trend is attributed to different meeting angles. Second, standard ISO tensile bars with and without weld line were injection molded to identify the size of the weld line affected zone. A FEA model was built in ABAQUS, where the tensile sample was divided into two different regions, the solid region and the weld line affected region. Stress-strain relationships of the solid region were derived from tensile tests of solid bars, while

Huang, Shiyao, Tibbenham, Patti, Su, Lingxuan, Zeng, Danielle, Philbrick, Mayme, Zhou, Jin, Su, Xuming

Ruggedizing Coaxial and Fiber Optic Cable Assemblies from Mechanical Strain

TBMG-3661204/01/2020

From fiber optics to coaxial cables, common failure points in harsh environments call for various augmentations to enhance an interconnect’s operational lifetime. These modifications can range from the addition of armoring for crush/impact resistance to optimizing cable jacketing material for resistance to chemical/oil ingress. Mechanical strain is often a cause for premature failures of interconnects. Understanding the reasoning and methods behind ruggedizing commonly leveraged interconnects such as fiber optic and coaxial cables can be enlightening.

Ruggedizing Coaxial and Fiber Optic Cable Assemblies from Mechanical Strain

20AERP04_0204/01/2020

From fiber optics to coaxial cables, common failure points in harsh environments call for various augmentations to enhance an interconnect's operational lifetime. These modifications can range from the addition of armoring for crush/impact resistance to optimizing cable jacketing material for resistance to chemical/oil ingress. Mechanical strain is often a cause for premature failures of interconnects. Understanding the reasoning and methods behind ruggedizing commonly leveraged interconnects such as fiber optic and coaxial cables can be enlightening.

Effects of Helical Carbon Nanotubes on Mechanical Performance of Laminated Composites and Bonded Joints

2020-01-002903/10/2020

Most composite assemblies and structures generally fail due to weak interlaminar properties and poor performance of their bonded joints that are assembled together with an adhesive layer. Adhesive failure and cohesive failure are among the most commonly observed failure modes in composite bonded joint assemblies. These failure modes occur due to the lack of reinforcement within the adhesive layer in transverse direction. In addition, the laminated composites fail due to the same reason that is the lack of reinforcement through the thickness direction between the laminae. The overall performance of any composite structures and assemblies largely depends on the interlaminar properties and the performance of its bonded joints. Various techniques and processes were developed in recent years to improve mechanical performance of the composite structures and assemblies, one of which includes the use of nanoscale reinforcements in between the laminae and within the adhesive layer. However

Sritharan, Ramanan, Askari, Davood

Embedded Fiber Optic Sensors (EFOS)

TBMG-3569412/01/2019

Current laser interferometry pressure pulse detection techniques use the shock-induced change in index of refraction to track detonation and/or shock fronts in a single fiber optic by reflecting laser light off the boundary created between the unshocked material and the shocked material. This technique cannot be used in regimes where there isn't a strong enough shock front to reflect the laser light above the noise floor. Other embedded fiber techniques use a chirped fiber Bragg grating to track a shock position versus time by correlating a known spectrum of light to a calibrated position. These two systems use a single fiber and measure only time-of-arrival for a strong shock.

Sensing Applied Load and Damage Effects in Composites with Nondestructive Techniques

TBMG-3567212/01/2019

Composite materials are desirable for aeronautical and aerospace applications for many reasons including their high strength-to-weight ratios, fatigue and corrosion resistance, design adaptability, and performance capabilities in harsh environments. Because of these qualities, composites are useful in many applications such as in armor, helmets, and helicopters, and as structural components.

Sensing Applied Load and Damage Effects in Composites with Nondestructive Techniques

19AERP12_0812/01/2019

Comparing and correlating piezoelectrically induced guided waves, acoustic emission, thermography, and X-ray imaging to determine the effects of applied load on a composite structure. Army Research Laboratory, Aberdeen Proving Ground, Maryland Composite materials are desirable for aeronautical and aerospace applications for many reasons including their high strength-to-weight ratios, fatigue and corrosion resistance, design adaptability, and performance capabilities in harsh environments. Because of these qualities, composites are useful in many applications such as in armor, helmets, and helicopters, and as structural components. However, when in-service, composite materials experience very different damage mechanics than metals. Performance and quality of composite materials can suffer from fatigue, environmental conditions, and external damage just as metals can, but due to their inherent complexity and the difficulty of detecting damage in composites with traditional inspection

Experimental Investigation on Mechanical Properties and Vibration Damping Frequency Factor of Kenaf Fiber Reinforced Epoxy Composite

2019-28-016710/11/2019

Kenaf Fiber regarded as industrial crop for different applications. It is one of the most important plants cultivated for natural fibers globally. Natural fibers such as kenaf fibers are getting attention of researchers and industries to utilize it in different composites due to its biodegradable nature. In this present investigation mechanical properties, vibration damping frequency factor and thermogravimetric analysis of kenaf fiber reinforced epoxy composite (KFREC) have been evaluated and reported. The tests were conducted with different weight categories of kenaf fiber such as 20%, 25%, 30% and 35%. The effects of fiber content on tensile, flexural, impact strengths, hardness and thermal decomposition properties of the composite were determined. The failure mechanism and damage features of the KFREC were categorized using Scanning Electron Microscope (SEM). The results indicate that the increase in the fiber content decreases the damping vibration factor (ζ) correspondingly. The

Rajamanickam, Sathish Kumar, Ravichandran, Vishnuvardhan, Sattanathan, Sivakumar, Ganapathy, Deenadayalan, Arockia Dhanraj, Joshuva

Analogy of Thermal Properties of Polyamide 6 Reinforced with Glass Fiber and Glass Beads through FDM Process

2019-28-013710/11/2019

The essential target of this examination is to compare the morphological and thermal properties of two different polyamide composite blends with inventive thermal properties. The polyamide-6 (PA6) reinforced with 10, 20 and 30 wt. % glass fiber (GF) and PA6 reinforced with 10, 20 and 30 wt. % glass beads (GB) are the two different polyamide composite blends extruded in form of wire by twin screw extrusion process. The experimental study illustrates to print the specimens by means of Fusion Deposition Modeling (FDM) based Three-Dimensional (3D) printer. The responses like morphology, Thermal Conductivity (TC) and Heat Distortion Temperature (HDT) of composites were observed. From the scanning electron microscope (SEM) analysis equal distribution of higher 30wt% GF and GB in the PA6 matrix was observed. The results compare the increasing thermal properties of the 3D printed specimen like TC and HDT with the enhancement of beads content during the investigation. The GB are crystalline

Ranganathan, Soundararajan, Rangasamy Suguna Thangaraj, Hari Nishok, Vasudevan, Aravind Kumar, Shanmugan, Dharshan Karthick

Design of Lightweight Composites for Vehicle Front End Energy Management of Bumper Beam

2019-28-008510/11/2019

Application of advance composites in place of the various conventional materials such as steel can give significant weight and performance advantages. The application of composites is now finding it’s way in the automotive industry due to the growing requirement of the lightweight solutions and high strength to weight ratio. However, their low mechanical properties have limited their application in automotive structural components. The study presented here is focused on the explicit dynamic analysis of a bumper beam and advance composites are used for the study. Different configurations and designs of the bumper are considered to be able to make a comparative study of the stress and deformation levels. The analysis was done in coherence to the Euro NCAP tests and the offset frontal impact analysis was done. The boundary conditions were aligned with the real time impact conditions for proper prediction of the results. Based on stress, deformation, specific strength and weight, the

Kumar, Praveen, Akella, Sarma Sr, Chakraborty, Ayan, Muthiah, Balasubramanian, Ramachandran, Velmurugan, M Venugopal, Shankar

Development and Investigation of Jute/Linen Fibre Reinforced Polymer Composite

2019-28-017110/11/2019

In recent automotive era, natural fibre reinforced with thermoset polymer composites have been incorporated by automotive industries especially for interiors, car body panels, dashboards, headliners etc. Natural fibres offer many affirmative qualities such as less weight and cost, especially in reduction of carbon di-oxide which is a major threat to the planet from the automotive sectors. The current work deals with the study of the potential usage of mineral powder (industrial by-product) in polymer. In this paper, hybrid composites with natural fabrics reinforcements and mineral powder as filler to matrix material are developed. The mineral powder used as filler is silica fumes which is a by-product of industries. The hand lay-up methodology is employed to fabricate the composite. The composites with and without mineral filler material are developed. The mechanical properties of the composites are assessed. The mechanical properties of composites with and without mineral filler are

Pandian, Arvinda, Jailani, Siddhi

Banana Stem Based Activated Carbon as Filler in Polymer Composites for Automobile Applications

2019-28-009310/11/2019

Activated carbon was produced from a new part of banana plant namely true stem in this current research and used as fillers in polymer composites for automobile application. True stems of banana plants are the main wastes in banana or fruit markets which refer to the remains after banana fruits are removed from the supporting stems. Conversion of raw material into activated carbon particles is done by chemical and heat activation. The raw material used here were dried samples of banana plant’s true stem. This material was heated in a crucible at 400°C and then powdered. These crushed samples were activated using hydrochloric acid at 120°C for 5 hours and finally in a furnace for thermal activation at 700oC for 1 hour. These particles were incorporated as fillers in composites at Proportions of 15%, 25%, 35% and 45%. The activated carbon samples have been characterized by determining its fixed carbon content and bulk density. Scanning electron microscopy was done to analyze the

Ayyaswamy, John Presin Kumar, Sattanathan, Sivakumar, Ramachandran, Balaji, Nadarajan, Mukesh

Clamp Material, Injection Molded

AIR1397B (Current)09/26/2019

This report presents the material properties and test requirements for an injection molded thermoplastic compound utilized for fabrication of AS1396 clamp block assembly.

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies

A step-change in the cost of CFRP

19AUTP05_0305/01/2019

Williams Advanced Engineering reveals secrets behind its innovations aim to move carbon fiber into the mobility mainstream. A joke in the auto industry about CFRP (carbon fiber reinforced polymer) is that the “C” stands for “costly.” So, any manufacturing process that solves this significant drawback of the ultra-lightweight material's use outside of Formula One racing and exotic supercars, could change the vehicle-production game. Engineers at Williams Advanced Engineering in the U.K. are confident they have developed two complementary solutions to the cost hurdle. Revealing details of both, the company stated these solutions could be applied to high-volume production by 2021.

Birch, Stuart

Investigating Collaborative Robot Gripper Configurations for Simple Fabric Pick and Place Tasks

2019-01-069904/02/2019

Fiber composite materials are widely used in many industrial applications - specially in automotive, aviation and consumer goods. Introducing light-weighting material solutions to reduce vehicle mass is driving innovative materials research activities as polymer composites offer high specific stiffness and strength compared to contemporary engineering materials. However, there are issues related to high production volume, automation strategies and handling methods. The state of the art for the production of these light-weight flexible textile or composite fiber products is setting up multi-stage manual operations for hand layups. Material handling of flexible textile/fiber components is a process bottleneck. Consequently, the long term research goal is to develop semi-automated pick and place processes for flexible materials utilizing collaborative robots within the process. Collaborative robots allow for interactive human-machine tasks to be conducted. The immediate research is to

Alebooyeh, Morteza, Wang, Bowen, Urbanic, Ruth Jill, Djuric, Ana, Kalami, Hamed

Characterization of Carbon Fiber and Glass Fiber’s Micro and Nanostructure Using Electron Microscopy, Raman Spectroscopy and XRD Analysis

2019-01-144103/25/2019

Nowadays, most manufacturers are looking for the improvement of lightweight parts and other components in the automobile field. Carbon fiber and glass fiber are the most effective materials for their requirement to reduce the weight in vehicles due to their light weight and high tensile strength. The diameter of carbon fiber is 6 μm while glass fiber diameter is 17 μm. The mechanical tensile force of carbon fiber and glass fiber are 430 N and 290 N respectively on fiber alone without matrix. Carbon fibers are gradually smaller in each filament due to tensile force. Approximately 5 mm are elongated for both carbon fiber and glass fiber in tensile test report. In current research, characteristic and tensile force of carbon fiber and glass fiber were investigated by using electron microscopy, Raman spectroscopy and XRD.

Man, Tial Cuai, Karin, Preechar, Ohtake, Naoto, Aakasaka, Hiroki, Larpsuriyakul, Patcharee, Rojsatean, Jareenuch, Prakymoramas, Natcha, Thanomjitr, Dumrong, Kaewket, Sanya

Theoretical Modeling of the Mechanical Degradation of Polymer Composites due to Moisture/Water Absorption and Damage Progression

2019-01-137603/19/2019

The moisture/water absorption and microvoids/cracks progression are two well-understood mechanisms that have significant degradation effects on the mechanical properties/behaviors of the polymer-based composites. To theoretically investigate the effects of above two mechanisms, we develop a simple fiber reinforced polymer composites model by employing the internal state variable (ISV) theory. The water content and the anisotropically distributed damage of the composites are considered as two ISVs (the water content is described by a scalar variable and the damage is defined as a second order tensor) whose histories are governed by two specific physically-based evolution equations. The proposed model can be easily cast into a general theoretical framework to capture more polymer composites behaviors such as viscoelasticity, viscoplasticity and the thermal effect. The results predicted by current model are in good agreement with the experimental data, which allows us to implement the

He, Ge, Liu, Yucheng

Numerical and Experimental Investigations on Flexural Fatigue Behaviour of Glass/Epoxy Composite and SAE 1040 Steel Tubes for Automotive Applications

2019-26-031701/09/2019

Fatigue life of automotive structures depends on static strength, the range of stress, mode of cycling, load histories, and environmental conditions. i.e., temperature, humidity, moisture, etc. This paper presents results on the flexural fatigue life and damage accumulation of SAE 1040 steel and Glass/Epoxy composite automotive material tubes at room temperature in the dry condition. The correlation between their structure, geometry and fatigue behavior is a subject area that needs to be understood and investigated in the automotive applications like anti-roll bars and tubes. For comparative durability studies, the flexural static and fatigue tests were carried out on test specimens under constant amplitude with a sinusoidal waveform for a frequency of 3 Hz. Flexural fatigue loading conditions were analyzed at different load levels from 30% to 87% of the material ultimate flexural strength. Fatigue tests were stopped after 1 million cycles even if fracture or damage were not observed

Bhanage, Amol, Krishnan, Padmanabhan

Evaluation of Peel Ply Surface Preparation of Composite Surfaces for Secondary Bonding

TBMG-3336712/01/2018

Lightweight composite structures offer significant long-term cost-saving opportunities for the U.S. Army as replacements for traditional metal structures. However, high-strength economical bonding processes must be developed to join composites in order for them to be viable replacements. The Army is exploring approaches, also under evaluation in the commercial aerospace industry, to reduce the process steps associated with composite bonding.

Environmental Degradation of Composite Materials

ARP6287 (Current)10/18/2018

In accordance with § 4.11 of AS36100, materials used in the construction of pallets, nets, and containers shall take into account the effects of environmental conditions, such as temperature, humidity, and UV degradation, expected in service. In accordance with (E)TSO-C90, the applicant shall consider environmental degradation due to aging, ultra-violet (UV) exposure, weathering, etc., for any materials used in the construction of pallets, nets, and containers. The purpose of this Aerospace Recommended Practice (ARP) is to provide guidelines for the basic requirements to be considered regarding environmental degradation effects when qualifying composite materials in the design to fulfill the (E)TSO-C90 Minimum Performance Standard. Material qualification is the verifying of a materials attributes and characterizations, which are typically determined through testing. Material variances related to raw materials and manufacturing processes are not part of this Aerospace Recommended

AGE-2 Air Cargo

Modeling Articulated Brake Component Wear to Assist with Routing Decisions

2018-01-189010/05/2018

Very few activities the brake engineer engages in can induce as much vexation as trying to find a satisfying routing for the flexible brake components such as hoses, wheel speed sensors, and electric parking brake cables. Ever increasing wheel end content, ever decreasing space, more complex suspensions, and bulkier (but lighter weight) suspension components provide quite the morass through which the components must be routed through. When routing is finalized - and free of any major issues - there frequently remains some combinations of articulation position and component tolerances that allow a light “friendly” touch between components (such as a sensor wire and a surface of a bracket or strut tube), or near misses where clearance exists but raises “what if” questions around what would happen if the tolerances would stack up slightly differently on another vehicle. These conditions are usually evaluated painstakingly by experienced engineers, and either corrected with design changes

Antanaitis, David B.

Variable-Camber Compliant Wing

TBMG-3247008/01/2018

In the early years of manned flight, wing warping was used for lateral control of an aircraft. This technique consisted of a system of pulleys and cables used to twist the trailing edges of the wings in opposite directions. Because most wing warping designs involved flexing of structural members, they were difficult to control, and the risk of structural failure was high. As aircraft further developed, wing warping was replaced by multiple, independent, rigid flight control surfaces — such as ailerons, leading edge slats, and flaps — and while this approach is still in use, it is not without problems.

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