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Vapor grown carbon fiber (VGCF) is a new class of highly graphitic carbon nanofiber and offers advantages of economy and simpler processing over continuous-fiber composites. VGCF used in this work (Pyrograf® III) is grown by means of gas phase catalyst synthesis. The diameter of this fiber ranges from 60 and 200 nanometers and the length varies from 50 to 100 micrometers. There are several issues that must be resolved before VGCF can be a suitable reinforcement. The VGCF must be dispersed in the polymer matrix, a good interface with matrix must be obtained, and the VGCF must be aligned in a specific direction. The object of this study is the extrusion of VGCF/nylon composites. To produce the composite, VGCF and nylon 6 were premixed, and then extruded by twin-screw extruder. An annular converging die was used to produce different volume fractions of VGCF/nylon 6 composite in the form of a continuous strand. SEM analysis and X-ray diffraction results showed that VGCF is well dispersed, wetted, and aligned in the nylon 6 matrix. The tensile strength and modulus for extruded VGCF/nylon 6 composites increased as VGCF volume fraction increased, whereas the ductility decreased. For composite strands subjected to additional extension by drawing, it was seen that both the tensile strength and modulus of composites were increased as draw ratio increased. The theoretical strength prediction performed in this study is a combination of a strength prediction model based on fiber alignment, a model for fiber rotation in the polymer melt, and POLYFLOW simulation, which are sequentially correlated. The theoretical prediction was comparable with experimental results when fiber orientation was evaluated by x-ray diffraction; but the theory overestimated composite strength when fiber rotation was incorporated with the model.

This study is an investigation into methods of developing ergonomic guidelines for automotive assembly tasks involving insertion of small parts. The study was conducted in four major parts: 1) a method of determining and evaluating subjective exertion limits was modified and tested, 2) a large dataset was collected from an industrial population in 10 simulated assembly line tasks, 3) a smaller dataset was collected from a student population to assess hand dominance effects, and 4) strength data obtained was compared with a strength prediction model to determine if the model could predict manual insertion forces. The traditional method of psychophysical data collection requires participants to extrapolate sensations from a relativity short session to judge if the task could be done for a much longer period. Maximum acceptable limits (MALs) are typically derived from having participants adjust a weight, resistance, or frequency to an acceptable level. The present study evaluated a relatively new method of collecting MAL data for simple, single-digit exertions where participants were asked to determine an MAL by self-adjusting and then regulating to maintain the exertion level. Results showed that MAL values obtained from a series of self-regulated exertions were independent of both analysis method and duration (5 minutes vs. 25 minutes) used for evaluation, and that the method was repeatable both within and between sessions. Ergonomic guidelines are often obtained from the strength capacity for a certain task, as it is important to ensure that workers possess sufficient strength to accomplish a task. As task demands increase, however, a larger percentage of a worker's strength capability in required, and other factors, such as performance and worker comfort, tend to be compromised. In this work, both strength capacity and subjective limits were obtained for a variety of simulated tasks to facilitate development of guidelines for the specific tasks. The relationship between these two measures (maximum force, acceptable force) was determined, and acceptable limits were found to be approximately 55% of population strength capacity, with correlations (R2) ranging from 0.40 to 0.60 depending on the task, suggesting the subjective limits and strength capacity are related in these tasks. Hand dominance was found to have a small (5%), but significant (p = 0.006) effect on strength capability, and no significant effect on subjective limit. Biomechanical strength prediction models can be used to assess loads placed on the human performing various tasks. One of the more popular models, Three-Dimensional Static Strength Prediction Program, is often used for heavy material handling tasks, such as lifting or pushing. The tasks studied presently, however, are manual insertions, requiring localized force application rather than whole body exertion. The prediction capabilities of this strength prediction model were compared with strength values obtained from the simulated assembly tasks. Results indicated that the model was not successful when predicting localized force, accounting for only 40% of the observed variance in strength (R2 = 0.4)

Modern durability and damage tolerance predictions for composite material systems rely on accurate estimates of the local stress and material states for each of the constituents, as well as the manner in which the constituents interact. In this work, an number of approaches to estimating the stress states and interactions are developed. First, an elasticity solution is presented for the problem of a penny-shaped crack in an N-phase composite material system opened by a prescribed normal pressure. The stress state around such a crack is then used to estimate the stress concentrations due to adjacent fiber fractures in a composite materials. The resulting stress concentrations are then used to estimate the tensile strength of the composite. The predicted results are compared with experimental values. In addition, a cumulative damage model for fatigue is presented. Modifications to the model are made to include the effects of variable amplitude loading. These modifications are based upon the use of remaining strength as a damage metric and the definition of an equivalent generalized time. The model is initially validated using results from the literature. Also, experimental data from APC-2 laminates and IM7/K3B laminates are used in the model. The use of such data for notched laminates requires the use of an effective hole size, which is calculated based upon strain distribution measurements. Measured remaining strengths after fatigue loading are compared with the predicted values for specimens fatigued at room temperature and 350°F (177°C).

To achieve satisfactory levels of strength, fracture toughness, and reliability for man-rated systems such as jet engines, fiber reinforced ceramic matrix composites are needed. An elevated temperature axial testing system is developed to investigate and characterize fatigue behavior of Nicalon fiber reinforced enhanced silicon carbide matrix. composites at 1800 of under fully reversed cyclic loading. Notch effect on quasi-static tensile response is also considered. Quasi-static and fatigue damage mechanisms and failure modes are examined using various specimen geometries, load levels, fatigue ratios, and laminates stacking sequences by employing a number of NDE techniques. Issues such as damage tolerance and durability are addressed by conducting interrupted fatigue tests at various stages of life for different load levels. Results are compared to the predictions of remaining strength and life, obtained using a performance simulation code. Initial results indicate existence of a threshold stress value which limits the use of the material system.