SOCIETY FOR THE ADVANCEMENT OF MATERIAL AND PROCESS ENGINEERING 39th International SAMPE Symposium and Exhibition VOLUME 39 Book 2 of 2 Books MOVING FORWARD WITH 50 YEARS OF LEADERSHIP IN ADVANCED MATERIALS Edited by Ken Drake Jerry Bauer Tito Serafini Paul Cheng Anaheim Convention Center Anaheim, California April 11-14, 1994
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SOCIETY FOR THE ADVANCEMENT OF
MATERIAL AND PROCESS ENGINEERING
39th International SAMPE Symposiumand Exhibition
VOLUME 39
Book 2 of 2 Books
MOVING FORWARD WITH 50 YEARS
OF LEADERSHIP IN ADVANCED MATERIALS
Edited by
Ken Drake
Jerry Bauer
Tito Serafini
Paul Cheng
Anaheim Convention Center
Anaheim, California
April 11-14, 1994
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
PageNonautoclave Processing I
Co-Chairman: David Lewis, IBM/TJ Watson Research Centei
Co-Chairman: Jim Methven, Manchester Umveistty
Microwave Processing of Polymers and Composites 1
David A Lewis
Microwave Processing of Isocyanate/Epoxy Composites 13M T DeMcuse, F Parodi, R Gerbelli and A C Johnson
A Comparison of Various Microwave Applicators for the
Continuous Manufacture of Thermoset Composites 25
J M Methven
A Mechanism for Observed Reaction Rate Enhancement in a
Microwave Applicator Based on the Concept of a Non-EquilibratedTemperature Reaction (NETR) 34
S F Bush and J M Methven
Microwave Processing of Polymers and Composites 45
Jianghua Wei and Martin C Hawley
Reactive Poly(Arylene Ether) Toughening of Cyanate Ester Networks
Via Thermal and Microwave Curing 60
SA Snnivasan, S S Joaidar, DB PnddyJi.TC WaidandJE McGrath
Microwave Properties of Organically Based Materials 72
L Olmedo, C Deleuze, J L Foiveille, P Hourquebie and F Jousse
Resin Transfer Molding
Chairman: Steve Hackett, 3M Company
Tackifier/Resin Compatibility is Essential for AerospaceGrade Resin Transfer Molding 83
JeffL Kittelson and Steven C Hackett
Characterization of RTM Panels with Woven Preforms 97
Eileen Aimstiong Cairoll and Roland Cochran
Void Formation and Transport in the RTM Process 108
T Staffan Lundstrom
Void Flow Behavior in Structural Resin Transfer Molding with
Twin Injection System 120
Hiroyuki Hamada, Naoto Ikegawa and Zemchuo Maekawa
A New Toughened Epoxy Resin for Resin Tranfer Molding Applications 133
Shaw Ming Lee, Tony Golato, Mark Thiede-Smet, Henri Girardy and
Gerard Chekherdemian
Production of Fibre Reinforced Components with High Surface
Traditional and Non-Traditional Machining of Fiber Reinforced
Plastic Composites 1073
M Ramulu and D Arola
Analysis of a Composite Laminate Having a Naturally-Derived,
Unsymmetric Ply Orientation 1088
Stephen L Gunderson and James M Whitney
xlviu
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
PageMinimization and Replacement ofHazardous Substances
Co-Chairman: John Lamb, TRWCo-Chairman: Katy Wolf, IRTA
Impact of the Clean Air Act Amendments on the Aerospace Industry 1100Jerry P Bauer, Leigh Ann Carroll and Edward N Ruddy
National Program for Supercritical Fluids Cleaning 1109Dennis Hjeresen, Laura Silva, Dale Spall, Ronald Stephenson,Scott Butner and Robert Purtell
Evaluation of a New Pre-Bond Surface Treatment and WaterborneAdhesive Primer 1116Francis L Keohan, Alan J Mitchell, Joseph B Adelstein and
Anthony C Arvamtes
Process Parameters for the APK-2000 Adhesive Pretreatment System 1130Francis L Keohan, Joseph B Adelstein and Anthony C Aivamtes
Aircraft Depainting: Impact of New Federal Regulations 1143
Virginia Morns
Investigation ofthe Cleaning Effectiveness of Alternative Solvents/Cleaners for Adhesive Bonding and Sealing 1156David C Goeders, Donald W Bridges and Morns R Boyaner
Environmentally Conscious Manufacturing of Composite Structures 1171Paul B Hauwiller
Offgassing Techniques for Composite Systems 1183Dale A Scheei
Avoid Exomthermic Reactions While Processing Prepregs 1193C D Bowland, B Robinson and G R Almen
Fracture and Failure Analysis
Co-Chairman: 5 R Lin, The Aewspace CorporationCo-Chairman: Fu-Kuo Chang Stanford Univei sity/Aewnautical and
Asti onautical Department
The Influence of Carbon Fiber Surface Treatment on the Mechanical
Properties and Fracture Behaviors of Bi-Directional Carbon/Carbon
Composites 1203
Chen-Chi M Ma, Nyan-Hwa Tai, Wen-Chi Chang, Chin-Kun Fang and
Huai-Te Chao
In-Situ Bondline Strength Verification by Load Test 1215
Bruce A Goldstone and Frederick M Payne
Delamination of Woven E-Glass Fabric Composites 1224
M L Dunn, E D Reedy Jr and T R Guess
Predication of Delamination Onset Characteristics in Laminated Composites 1237
S Subiamanian, KL Reifsnidei and WW Stinchcomb
The Effect of Preloading on Fatigue Damage in Composite Structures 1250
Jeffrey L Timmer and H Thomas Hahn
xllx
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Constrained Blister Peel Testing on Elastomer Bondlines 1264
Craig L Horn, Robert Giaham and Russell Crook
The Evolution of Matrix Failure in the Composite Laminate with
a Circular Hole 1275
C S Hong and YW Kim
Failure of Composite Laminates Containing a Center Elliptical Hole 1284
B D Harrington and C T Sun
Strength Envelope of Bolted Composite Joints 1297
Chang-Li Hung and Fu-Kuo Chang
Application-Driven Non Destructive Evaluation II
Co-Chairman: Phil Hodgetts, Quality Material InspectionCo-Chairman: Wdlem Grandia, Quality Material Inspection
Advances in Nondestructive Testing Noncontact Ultrasonic
Inspection of Composites 1308
Willem A Grandia
Composite Material Property Nondestructive Characterization Using
Obliquely Insonified Ultrasonic Waves 1316
Yoseph Bar-Cohen, Ajit K Mai and Shyh-Shiuh Lih
Damage and Repair Evaluation of Composite Structures 1330
D Hagemaier, N Shah and J Petty
Development of Real Time Low Cost High Performance Scanning Systemsfor Advanced Ultrasonic Imaging 1344
George Bennett, Todd Wing, Rani Sullivan and Knshnan Balasubramamam
Estimation of Creep Damage in GFRP Laminates Under Corrosive
Environments Using Acoustic Emission 1356
F Fuju, S Ramaknshna, H Hamada, Z Maekawa, A Murakami and T Yoshiki
Assessing Matrix Degradation in Fibre Reinforced Plastics 1368
RB Heslehurst.JP Baird and H M Williamson
Large Area Composite Inspection System (LACIS) - Automation of
Traditional Inspection Techniques 1375
Nancy Wood
Quality Management in Integrated Product Development
Co-Chairman: Mamsh Mehta Environmental Research Institute ofMichiganCo-Chairman: Lew Blad, Composites Automation Consortium
Integrated Quality Management: Managing for 2000 and Beyond 1391
Leigh Reid
Requirements Discovery and Analysis 1406
William J Pardee
Quality Function Deployment in Integrated Development of Composites
Manufacturing Automation Systems 1418
Mamsh Mehta
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
TQM in Practice at Vought Aircraft Company: Improvements in the
Titanium to Aluminum Core Bonding Process 1434
David Wayne and Jennifer Andrew
Supporting Total Quality with Concurrent Engineering in IntegratedProduct Development 1447
Roger L Turner
Total Quality Management in Composites Technology Transfer 1454
Michael J Martin
Thermoplastics I
Co-Chairman: Charles Browning, Air Force Materials Directorate
Co-Chairman: Tia Benson Tolle, Air Force Materials Directorate
Microcracking in Radel 8320 Laminates and Its Influence on
Mechanical Properties 1463
Allan S Crasto, Ran Y Kim and Tia Benson Tolle
Fatigue Behavior of [±45]4S Laminate of Carbon Fiber Reinforced
Peek Composites (II) Residual Strength and Fatigue Life Prediction 1477
CCM Ma,NH Tai, S H Wu, S S Lm,JF Wu,CL Ong,I C Wu and M F Sheu
Creep Properties of [±45]4S Laminate of Carbon Fiber Reinforced
Peek Composites 1489
CCM Ma, N H Tai, S H Wu, S S Lin, J F Wu, C L Ong,YC WuandMF Sheu
On-Line Consolidation of Thermoplastic Matrix Composite Tape
Using Ultrasonic Heating 1500
Daniel E Bullock and Joseph Boyce
Impregnation and Mechanical Properties of Carbon Fiber Reinforced
Thermoplastic Composites with Commingled Spun Yarn 1507
Donald A. Sandusky, Joseph M. Marchello, Norman J. Johnstonand Robert M. Baucom
Cut and Refeed Mechanics for Thermoplastic Tape Placement 2627
Karl V Steiner, Eric Faude, Roderic C. Don and John W. Gillespie Jr
The Tepex System: Cost-Effective High Volume Production ofParts andProfiles for Recreation, Protection and Transportation Markets 2637M. Effing, M.W. Hopkins and E.P. Beyeler
Damage Tolerance
Co-Chairman: Roland Cochran, NavalAir Warfare Center
Co-Chairman: Tom Donnellan, Grumman Aircraft Systems
Impact-Fatigue in Graphite/Epoxy Laminates 2655Rachid Boukhili, Chakib Bojji and Raymond Gauvin
The Effects ofAssembly Induced Delaminations at Fastener Holes on
the Mechanical Behavior of Advanced Composite Materials 2665
C.A. Fracchia and R.E. Bohlmann
Bolt Bearing Strength of Pan-Based and Pitch-Based Carbon Fiber Composites 2679
Hironori Maikuma and Kenji Kubomura
Mechanical and Interlaminar Fracture Properties of Woven Fabric
Reinforced Composites 2693
Youjiang Wang and Dongming Zhao
Dissipated Energy Density Characterization of Composites 2706
Phillip W. Mast, John G. Michopoulos, Lee W. Gause and Robert Badaliance
Adhesives and Adhesion Promotion I
Co-Chairman: Cynthia L. T. Lambing, ALCOACo-Chairman: J.W. Gillespie Jr., University ofDelaware/Centerfor Composite Materials
Joining Dissimilar Materials Through Adhesive Bonding 2715
S.F. McCleary and C.L.T. Lambing
Improved 121°C (250°F) Curing Epoxy Film Adhesive for CompositeBonding Applications: FM® 300-2 Adhesive System 2731
Dalip K. Kohli
lix
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
An Analysis ofan Attachment Method for Fiber Reinforced Composite
Isogrid Panels 2745
Chffoid F Shaeffer, James L Koury, Thomas D Kim and James A Harvey
Silane Adhesion Promoter Improves Robustness of Steel/Epoxy Bonds
with Inherent Process Contamination 2752
M Reed Haddock and Gregory L Anderson
Durability Evaluation of Non-Chromate Based Aluminum Surface
Treatments for Bonding with Polypropylene 2760
Steven H McKmght, John W Gillespie Jr and C L T Lambing
Influence of Chemical Etching Prior to Sulfuric Boric Acid Anodizingand Adhesive Bonding 2771
Jason Mnich
The Thickness of Phosphoric Acid Anodizing Oxide Film on Aluminum Alloy 2780
IIou Ping
Development of Low Temperature Curing Epoxy Based Repair Adhesive:
FM®235M 2786
Richard T Mayhew and Dahp K Kohh
The Versatility of Epoxy Adhesives for Structural Fabrication and
Repair of Composite Materials 2792
Don C Wells and Winn Cannon
Structural Analysis
Chairman: C C Chamis, NASA Lewis Research Center
Integrated Probabilistic Composite Design-A Proposed New Approach 2806
CC Chamis and MC Shiao
Long Term Behavior of Polymer Matrix Composites 2820
C C Chamis, D G Liaw and S N Singhal
A New Approach for the Dimensioning of Thick Laminates UsingPhysically Based Strength Criteria 2829
W Michaeh and D Huybrechts
An Integrated Approach to the Geometrical and Mechanical Modelingof Textile Reinforced Composites 2841
Yassei A Gowayed, Christopher M Pastore and CaiI S Howailh
Delamination Buckling Analysis for Unsymmetric Composite Laminates 2855
Hsin-Piao Chen and Wei-Chin Chang
Calculation of the Shrinkage and Warpage Behaviour of Fibre
Reinforced Parts 2868
W Michaeh and M Heber
Optimization of Fiber Orientations for Laminated Plates Under
Uniformly Distributed Lateral Load 2875
Shaher A Kassaimih, Abdel-Aziz M Mohamed and Faysal A Kolkailah
Effects of Interaction Component of the Generalized Yeh-Stratton Criterion 2882
Hsien Yang Yeh and Chang H Kim
lx
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
PageTesting
Chairman: Michael W. Holl, Wright Research Development Center
Characterization of Bundle-Level Residual Strains in Woven CompositesUsing Moire Interferometry 2894David H. Mollenhauer and Michael W. Holl
Sapphire Fiber Strain Gage for Static and Fatigue Measurements 2905T. Tran, J. Greene, M. Alcock, K. Murphy, R. May, A. Wang, G. Wang,R. Claus and Jack E. Coate
Absolute Strain Measurement in Polymer Matrix Composites 2913R.O. Claus, V. Bhatia, M.F. Gunther, K.A. Murphy, T.A. Tran and J.A. Greene
Some Observations Concerning the Iosipescu Shear Test for
Composite Materials 2923
J.M. Whitney
Hygrothermal Effects on the Onset of Free-Edge Delamination in Composites 2935Ran Y. Kim and Allan S. Crasto
Processing of Carbon-Carbons
Co-Chairman: Bert Syms, Rockwell International/Space SystemsCo-Chairman: Julius Jortner, Jortner Research and Engineering
Microstructure and Properties of Protective Coatings on Carbon
Processed by Fused Slurry Method 2948A. Joshi and J.S. Lee
Phenolic/Carbon Pyrolysis Reaction Mechanism for IntelligentProcessing of Carbon/Carbon 2956
Kimberly A. Trick, Tony E. Saliba and Paula A. Meese
Low Fire, Smoke and Toxicity Materials
Chairman: Mel Kantz, M.R. Kantz Engineering
Determination of Materials Volatilized During the Preparation and
Cure of Phenolic Prepregs 2967
Robert J. Boudreau
Low Smoke and Low Heat Release Structural Phenolic Foam 2975
Martin I. Cohen
Multifunctional Cyanated Esters and Their Fire Retardant Properties 2983
Sajal Das
Mechanical and Flammability Characteristics of Phenolic Compositesfor Naval Applications 2991
U. Sorathia, H. Telegadas and M. Bergen
Flammability: An Attempt to Understand it by Computational
Thermochemistry 3003
Jeffrey J. Cai, Dingdu Shi and W.V. Chang
lxi
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
High Volume Low Cost Manufacturing
Co-Chairman: Jurgen Koster, Mobik GmbH
Co-Chairman: Saad Taha, American Fiber Industries
Scale Economies in Volume Processing of Advanced Composite Components:
Manufacturing Cost Cut by Half? 3018
Jurgen Koster
Feasibility Study on Mass-Production Forming of ThermoplasticSandwich Structure with Foam Core 3030
Ryoji Chikugo, Yuji Ashibe and Akihiko Yoshii
Hybridized Textile Structures for the Continuous Manufacture of
Consolidated Sheet-Technologies and Approaches Compared 3036
R. Kaldenhoff, B. Wulfhorst, G. Franzke, O. Diestel, P. Offermann and E. Mader
Technology and Large Scale Economies of Consolidated Sheet
Manufacturing Using a Double Belt Press 3051
Adel Tadros
Draping of Fabric Reinforced Plastics: Theory and Experience from
the Computer to the Tool 3057
O.K. Bergsma and W.D. Brouwer
The Automation of the Diaphragm Forming Process for Continuous
Fiber Reinforced Thermoplastic Composites 3068
S. Dclaloye and G. Ziegmann
Composite Health Monitorability
Co-Chairman: H. Thomas Hahn, University ofCalifornia/Mechanical, Aerospace and
Nuclear EngineeringCo-Chairman: Greg P. Carman, University ofCalifornia/Mechanical, Aerospace and
Nuclear Engineering
Monitoring the Fatigue Behavior of Composite Materials with
Fiber Optic Sensors 3078
Milan Milrovic and Greg P. Carman
A Mathematical Model for an On-Line, In Situ, Fiber Optic Void Sensor 3091
Donald A. Klosterman and Tony E. Saliba
Using Carbon Fiber Rovings as Sensors for the Loading of GFRP-Parts 3103
W. Michaeli and M. Goedel
Probabilistic Design of Smart Composite Structures 3112
Michael C. Shiao and Christos C. Chamis
Health Monitoring Systems with Active Control Capabilities 3127
Greg P. Carman, Donny Wang and Yoseph Bar-Cohen
Adhesives and Adhesion Promotion II
Chairman: Sylvester Hill, Boeing Company
Durability in Automotive Adhesive Bonding 3143
John G. Dillard and Ionel M. Spinu
lxii
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Environmentally Compliant Adhesive Bonding Primers 3156James M Browne, Renee D Cullen, Stanley L Lehmann and
Andrew F Teschendorf
Aerospace Structural Adhesive for Bonding Graphite Epoxy Laminates
and Glass Reinforced Phenolic Honeycomb Structures 3171
Les A Fox and Carl D Weber
New Repair Adhesive for Model 777 Metalbond Structure 3185
Robert Clark
Ultrapek - A Thermoplastic Super Adhesive 3193
Deva Devanathan, Dale Swarts and Richard King
LARC-IA Polyetherimide Adhesive 3206
Terry L St Clair, Donald J Progar, Emilie J Siochi and Dennis C Working