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Browsing by Author "Broyles, Norman S."

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    Sizing and characterization of carbon fibers with aqueous water-dispersible polymeric interphases
    Broyles, Norman S. (Virginia Tech, 1996-02-05)
    Composite durability can be influenced by varying the properties of the fiber/matrix interphase region. One method to modifY the properties of this interphase is through the application of a sizing to the carbon fiber. Recent work at Virginia Tech has shown that polymer-modified interphases can lead to increases by as much as two orders of magnitude in notched fatigue lifetime. In the present work, an apparatus was constructed to uniformly coat carbon fiber tow with water-soluble and dispersible polymers. Few such devices have been developed for use in academic settings because of the processing complexities presented by the aqueous coating system. Due to the high surface tensions of the aqueous solutions, fiber clumping and heterogeneous sizing deposition were major bottlenecks. Our novel process utilizes high tensions, high spreading, and low line speeds to accomplish the sizing step. Each processing independent variable can be continuously monitored and controlled which allowed for statistical correlation to the sizing level and uniformity. The sizing process was shown to satisfy three criteria for quality. 1. The average sizing level or weight percent on the final fiber can be readily controlled to achieve typical target values. 2. Filament clumping as a result of cohesion between corresponding filaments is kept to a minimum. 3. The sizing process must produce fiber with a consistent level of polymer sizing. In addition, characterization techniques for the sized fiber were developed. Pyrolysis in a high temperature nitrogen furnace was developed as a precise technique to ascertain the quantitative sizing level on the carbon fiber. SEM and ESCA were utilized to determine fiber clumping and sizing homogeneity. The sizing process along with the statistical process model and the characterization techniques allow for the precise development of optimal interphase materials that are tailored to meet the performance requirements of the composite consumer.
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    Thermoplastic Sizings: Effects on Processing, Mechanical Performance, and Interphase Formation in Pultruded Carbon Fiber/Vinyl-Ester Composites
    Broyles, Norman S. (Virginia Tech, 1999-12-16)
    Sizings, a thin polymer coating applied to the surface of the carbon fiber before impregnation with the matrix, have been shown to affect the mechanical performance of the composite. These sizings affect the processability of the carbon fiber that translates into a composite with less fiber breakage and improved fiber/matrix adhesion. In addition, the interdiffusion of the sizing and the bulk matrix results in the formation of an interphase. This interphase can alter damage initiation and propagation that can ultimately affect composite performance. The overall objective of the work detailed in this thesis is to ascertain the effects that thermoplastic sizing agents have on composite performance and determine the phenomenological events associated with the effects. All of the thermoplastic sizings had improved processability over the traditional G' sizing. These improvements in processability translated into a composite with less fiber damage and improved surface quality. In addition, all of the thermoplastic sizings outperformed the industrial benchmark sizing G' by at least 25% in static tensile strength, 11% in longitudinal flexure strength, and 30% in short beam shear strength. All moduli were found to be unaffected by the addition of a sizing. The interphase formed in K-90 PVP sized carbon fiber composites was fundamentally predicted from the constitutive properties of K-90 PVP/Derakane™ interdiffusion and fundamental mass transport equations. The K-90 PVP sizing material interdiffusing with the Derakane™ matrix was found to be dissolution controlled. The dissolution diffusion coefficient had an exponential concentration dependence. Fundamental mass transport models were utilized to predict the interphase profile. The predicted K-90 PVP interphase concentration profile displayed steep gradients at the fiber/matrix interface but essentially no gradients at points distant from the fiber surface. The predicted mechanical property profile was essentially flat for the modulus but did show a steep gradient in the strain-to-failure and shrinkage properties. However, the K-90 PVP interphase compared to the unsized/pure Derakane™ interphase showed improvements in strength and strain-to-failure and a reduction in cure shrinkage without significantly affecting the interphase tensile or shear moduli.