• Composites Research
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• v.36 no.3
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• pp.154-161
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• 2023

This study explored the feasibility of replacing a metal link with a carbon fiber/epoxy composite link and assessed its capacity to withstand a given load condition using failure criteria. The micromechanics of failure (MMF) criterion was employed to predict the failure mode of the composite material, and mechanical tests were conducted to obtain reference strength parameters for MMF. The findings revealed that the stress distribution was concentrated near the hole, and weaknesses were found around the hole and at the end of the link under bending conditions. Based on the failure index, matrix tensile failure was predicted at the end of the link, and fiber compression failure occurred near the hole. The methods and results obtained from this study can provide valuable guidelines for assessing the safety of composite materials under specific load conditions when replacing metal parts with carbon fiber/epoxy composites to achieve weight reduction.

• Journal of the Korean institute of surface engineering
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• v.36 no.4
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• pp.347-355
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• 2003

Roughening of metal surfaces frequently enhances the adhesion strength of metals to polymers by mechanical interlocking. When a failure occurs at a roughened metal/polymer interface, the failure prone to be cohesive. In a previous work, an adhesion study on a roughened metal (oxidized copper-based leadframe)/polymer (Epoxy Molding Compound, EMC) interface was carried out, and the correlation between adhesion strength and failure path was investigated. In the present work, an attempt to interpret the failure path was made under the assumption that microvoids are formed in the EMC as well as near the roots of the CuO needles during compression-molding process. A simple adhesion model developed from the theory of fiber reinforcement of composite materials was introduced to explain the adhesion behavior of the oxidized copper-based leadframe/EMC interface and failure path. It is believed that this adhesion model can be used to explain the adhesion behavior of other similarly roughened metal/polymer interfaces.

• Journal of Aerospace System Engineering
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• v.1 no.2
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• pp.13-20
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• 2007

Structural qualification plan (SQP) for aerospace vehicle is based on material certification methodology, which must be approved by certification authority. It is internationally required to use of statistically based material allowables to design aerospace vehicles with aerospace materials. In order to comply with this regulation, it is necessary to establish relatively large amount of database, which increases test costs and time. Recently NASA/FAA develop the new methodology which results in cost, time, and risk reduction, and satisfies the regulation at the same time. This paper summarizes the certification methodology of materials system as a part of structural qualification plan (SQP) of aerospace vehicles and also thermal management of the vehicle system, like thermal protection materials system and thermally conductive material system. Materials design allowable was determined using this method for a carbon/epoxy composite material.

• Composites Research
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• v.29 no.6
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• pp.388-394
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• 2016

Fiber reinforced plastic (FRP) composites have drawn increasing attentions worldwide for decades due to its outstanding properties. Stress concentration factor (SCF) as an essential parameter in materials science are critically considered in structure design and application, strength assessment and failure prediction. However, investigation of stress concentration in FRP composites has been rarely reported so far. In this study, three resource-conserving analyses (Isotropic analysis, Orthotropic analysis and Finite element analysis) were introduced to plot the $K_T^A-d/W$ curve for E-glass/epoxy composite plate with the geometrical defect of circular hole placed centrally. The plates were loaded to uniaxial direction for simplification. Finite element analysis (FEA) was carried out via ACP (ANSYS composite prepost module). Based on the least squares method, a simple expression of fitting equation could be given based on the simulated results of a set of discrete points. Finally, all three achievable solutions were presented graphically for explicit comparison. In addition, the investigation into customized efficient SCFs has also been carried out for further reference.

• Korean Journal of Materials Research
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• v.9 no.10
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• pp.992-999
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• 1999

Due to the inherently poor adhesion strength of Cu-based leadframe/EMC(Epoxy Molding Compound) interface, popcorn-cracking phenomena of thin plastic packages frequently occur during the solder reflow process. In this study, in order to enhance the adhesion strength of Cu-based leadframe/EMC interface, brown-oxide layer was formed on the leadframe surface by immersing of leadframe sheets in hot alkaline solution, and the adhesion strength of leadframe/EMC interface was measured by using SDCB(Sandwiched Double Cantilever Beam) and SBN(Sandwiched Brazil-Nut) specimens. Results showed that brown oxide treatment of leadframe introduced fine acicular CuO crystals on the leadframe surface and improved the adhesion strength of leadframe/EMC interface. Enhancement of adhesion strength was directly related to the thickening kinetics of oxide layer. This might be due to the mechanical interlocking of fine acicular CuO crystals into EMC.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2000.04a
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• pp.149-153
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• 2000

Substituting composite structures for conventional metallic structures has many advantages because of higher specific stiffness and specific strength of composite materials. In this work, one-piece propeller shafts composed of carbonfepoxy and glass/epoxy composites were designed and manufactured for a rear wheel drive automobile satisfying three design specifications, such as static torque transmission capability, torsional buckling and the fundamental natural bending frequency. Single lap adhesively bonded joint was employed to join the composite shaft and the aluminum yoke. For the optimal adhesive joining of the composite propeller shaft to the aluminum yoke, the torque transmission capability of the adhesively bonded composite shaft was calculated with respect to bonding length and yoke thickness by finite element method and compared with the experimental result. Then an optimal design method was proposed based on the failure model which incorporated the nonlinear mechanical behavior of aluminum yoke and epoxy adhesive. From the experiments and FEM analyses, it was found that the static torque transmission capability of composite propeller shaft was maximum at the critical yoke thickness, and it saturated beyond the critical length. Also, it was found that the one-piece composite propeller shaft had 40% weight saving effect compared with a two-piece steel propeller shaft.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2005.04a
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• pp.5-8
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• 2005

In this paper, the electromechanical displacements of curved piezoelectric actuators composed of PZT ceramic and laminated composite materials are calculated based on high performance computing technology and the optimal configuration of composite curved actuator is examined. To accurately predict the local pre-stress in the device due to the mismatch in coefficients of thermal expansion, carbon-epoxy and glass-epoxy as well as PZT ceramic are numerically modeled by using hexahedral solid elements. Because the modeling of these thin layers increases the number of degrees of freedom, large-scale structural analyses are performed through the PEGASUS supercomputer, which is installed in our laboratory. In the first stage, the curved shape of the actuator and the internal stress in each layer are obtained by the cured curvature analysis. Subsequently, the displacement due to the piezoelectric force (which is resulted from applied voltage) is also calculated. The performance of composite curved actuator is investigated by comparing the displacements obtained by the variation of thickness and elastic modulus of laminated composite layers. In order to consider the finite deformation in the first analysis stage and include the pre-stress due to curing process in the second stage, nonlinear finite element analyses are carried out.

• Proceedings of the KSME Conference
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• 2000.04a
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• pp.148-152
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• 2000

The aluminum alloy 6061-T6 has been successfully used in structural applications especially the pressure vessel of the Advanced Neutron Source research reactor. And aluminum alloys, including 6061-T6, have a face-centered-cubic crystals structure. Under normal circumstances face-centered-cubic crystal structures do not exhibit cleavage fractures even at very lo9w temperatures. In aluminum-based structures, plates frequently find use as connecting links. Mechanical fasteners are often utilized in instances where ease of application, familiarity with fabrication processes, and severe dynamic loading are of concern. Plates frequently find use as connecting elements in structures built from aluminum alloys. Many structural elements employ mechanical fasteners. Twenty and twenty aluminum alloy 6061-T6 plates, representing four different bolt patterns, were mechanically deformed. And variable materials such as A1 6061-T6, Al 2024-T3, Carbon/Epoxy, Glass/Epoxy Composite and Woven fiber composite, are used as patch materials. From this experiment, it has been shown that the strength of patch-repaired specimens is different with the patch materials.

• Korean Chemical Engineering Research
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• v.46 no.5
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• pp.945-948
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• 2008

Nanocomposite materials provides efficient reinforcement, thermal endurance, and many other advantages depending on the additives used, with applications in the aerospace, automotive, and biomedical industries. Here, epoxy based nanocomposites were synthesized in the presence of Cloisite 15A and characterized with TEM, XRD, TGA, and DMA. To determine the effect of the clay d-spacing, Cloisite 20A was also used to synthesize the nanocompostes. In addition to the traditional hot plate method, an ultrasonicator was used to investigate the effect of different types of mixing on the properties of the nanocomposite; no significant effect was found. An examination of the nanocomposite morphology revealed that all the nanocomposites synthesized yielded an intercalated structure. When 5 wt% of Cloisite 15A was used with 20 min sonication time, the storage modulus increased 10% over the neat(no clay) nanocomposite. In general, the presence of Cloisite 15A produced a better storage modulus than Cloisite 20A.

• Journal of the Microelectronics and Packaging Society
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• v.7 no.2
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• pp.7-12
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• 2000

Copper-based leadframe sheets were oxidized in a black-oxide forming solution, and molded with epoxy molding compound (EMC) to form sandwiched double-cantilever beam (SDCB) specimens. The adhesion strength of leadframe/EMC interface was measured in terms of fracture toughness by using SDCB specimens and the fracture surfaces were analyzed by various equipments such as glancing-angle XRD, AFM, and SEM. Results showed that three types of failure paths, which were closely related to the surface condition of leadframes before molding.