Nonmetallic Composite Materials Research Articles

Fabrication and Modeling of Matching System for Air-Coupled Transducer.

The tremendous acoustic impedance difference between the piezoelectric composite and air prevents the ultrasonic transition, resulting in low amplitude for the received signal for the composite defect detection using an air-coupled transducer. The matching system, which includes the matching layers and bonding layers attached to the piezoelectric composite, can reduce the acoustic impedance difference and benefit the acoustic transition. In this paper, the fabrication method and modeling for the matching layers are proposed to optimize the transducer performance. The effects of bonding layer material on the transducer performance are also discussed. Experiments were conducted for modeling validation. The proposed model can predict the matching layer acoustic properties with an error of less than 11%. The bonding layer using the same material as the first matching layer can help to increase the sensitivity by about 33% compared to the traditional epoxy bonding. The optimized air-coupled ultrasonic transducer, based on the results of this study, has a 1283 mV amplitude in the air, which is 56% higher than commercially available transducers, and can identify the defects in two typical non-metallic composite materials easily.

Planar Electrical Capacitance Tomography Dynamic Imaging for Non-Destructive Test

Planar electrical capacitance tomography (PECT) is sensitive to the dielectric changes in its proximity; therefore, has an attractive prospect in the non-destructive evaluation for the non-metallic composite materials. Currently, the planar ECT employs the static image method for the defect detection, which uses an individual frame of measurements for image reconstruction. The use of static image methods for defect detection depends greatly on the spatial resolution of image reconstruction algorithms. However, the ECT static images are usually of low spatial resolution, primarily due to the ill-posedness in solving its inverse problem. In this paper, a dynamic imaging method has been proposed, aiming to utilizing the information that buried in the consecutive frames. The Tikhonov regularization method is firstly employed for achieving the static image reconstructions. In addition, the level set method has been utilized for the image segmentation to distinguish between the defect and background materials. Subsequently, the dynamic imaging method that based on the frame difference methods has been used for calculating the contour of target defects. The numerical simulations and experiments showed that, the defect of different sizes and shapes could be figured out by using the dynamic imaging method. It also can be shown that, the dynamic imaging method offers more possibility and ways in detecting the defects.

Terahertz Shielding Properties of Carbon Black Based Polymer Nanocomposites.

The majority of industry using high-speed communication systems is shifting towards higher frequencies, namely the terahertz range, to meet demands of more effective data transfer. Due to the rising number of devices working in terahertz range, effective shielding of electromagnetic interference (EMI) is required, and thus the need for novel shielding materials to reduce the electromagnetic pollution. Here, we show a study on optical and electrical properties of a series of ethylene co-butyl acrylate/carbon black (EBA/CB) composites with various CB loading. We investigate the transmittance, reflectance, shielding efficiency, absorption coefficient, refractive index and complex dielectric permittivity of the fabricated composites. Finally, we report a material that exhibits superior shielding efficiency (SE)—80 dB at 0.9 THz (14.44 vol% CB loading, 1 mm thick)—which is one of the highest SE values among non-metallic composite materials reported in the literature thus far. Importantly, 99% of the incoming radiation is absorbed by the material, significantly increasing its applicability. The absorption coefficient (α) reaches ~100 cm−1 for the samples with highest CB loading. The EBA/CB composites can be used as lightweight and flexible shielding packaging materials for electronics, as passive terahertz absorbers or as radiation shields for stealth applications.

Characterization of Joints between Carbon Fiber Composite Parts Using a Microstrip Transmission Line Method.

The electromagnetic performance of aerial platforms, which are composed mostly of nonmetallic materials, is a subject of great interest at present time. The behavior of this type of composite structure against electromagnetic environmental effects (E3), such as lightning, is not well-studied as in the case of metalic structures. The purpose of this article is to characterize the joints present in aerial platforms constructed mainly of nonmetallic composite materials. The study of these joints is fundamental because electrical discontinuities or preferential routes can produce changes in the electromagnetic behavior of an aircraft. The proposed measurement system for the characterization of these joints is a microstrip line. The flexibility of the test setup allows for evaluation of different joints in carbon fiber composite (CFC) samples with a different number of plies. Additionally, approximated models of the behavior of the joints as well as the detection of possible defects in the joining process are reported.

Detection of Impurities in Nonmetallic Materials Based on Tilted Spoof Surface Plasmon Polaritons

This article proposes a novel sensor based on tilted spoof surface plasmon polaritons (SSPPs), which is used to detect impurities in nonmetallic composite materials. The SSPPs sensor can be bent and can be wrapped on the material under test (MUT). When the tilted SSPPs sensor detects impurities, the transmission coefficient of the SSPPs sensor at the cutoff frequency will change. By increasing the tilt angle of the SSPPs sensor unit structure and reducing the size of SSPPs sensor appropriately, the sensitivity and resolution of impurities detection can be improved without increasing the working frequency of the SSPPs sensor significantly. Taking Teflon as an example of MUT, the measurement frequency is 14.4 GHz; by simulation and experiment, it can be proved that the tilted SSPPs sensor can realize impurities detection with the size of $0.5\times 1\times0.5$ mm3 in nonmetallic composite materials. The tilted SSPPs sensor can distinguish impurities that have a spacing of 0.5 mm. Compared with previous work, the tilted SSPPs sensor can quickly determine whether the MUT has impurities or not by moving MUT in one direction.

Deposition of heat-resistant coatings based on the ZrSi2-MoSi2-ZrB2 system for protection of non-metallic composite materials in high-speed high-enthalpy gas flows

The work demonstrates possibility of formation of coatings based on the ZrSi2-MoSi2-ZrB2 system by the slip-firing method. During oxidation, the coatings form heterogeneous oxide film resistant to high-speed high-enthalpy gas flow due to generation of refractory ZrO2 framework filled with borosilicate glass doped with zirconium dissolved in it. The advantages and disadvantages of the coatings in the system under study are presented.

Contact element use peculiarities in the numerical model construction of the reinforcing bar force interaction with an anchoring field

The application experience of non-metallic composite materials is quite wide in foreign countries, as well as systematized and assembled into a single database. In Russia, since the necessary computing resources have become more relevant and accessible for design organizations, independent researchers, and graduate students of higher educational institutions, this question resurfaced only in the last decade. As well as benefits, non-metallic composite reinforcement has its disadvantages, which prevent it from wide usage in structures, including a relatively low elastic module, as well as the inability to bend during installation. To improve the reinforced structures with stressed reinforcement calculation and possible prestressing force loss prediction, the finite element model production has been discussed. This model would allow us to evaluate the damaging shear stresses in the reinforcement region. The bracing formation process in the scope of this model was presented in this article, with the purpose of simulation the contact layer stress-strain state between reinforcement and concrete. The calculation is performed in a linear setting. Model development of a T-section decking component reinforced with a composite reinforcement beam produced via LIRA SAPR software. Exert a force on shank ends that is equivalent to the clamping force when the prestressed reinforcement is released. The authors proposed a selection option of the junction stiffness by stem contact with the anchoring field. The stiffness is assumed to be constant along the entire length of the contact layer. Elastic coefficient variation of the contact layer was performed here. The contact layer is highlighted conditionally as a separate material. A model for three types of materials was discussed. The shear stresses patterns in the contact element region were obtained. The patterns of abutting end reinforcement bars motion are obtained. To create a span element with a pre-tensioned reinforcement, a full-scale experiment was performed, as well as reinforcement abatement. Upon abatement, the retraction was recorded. The retraction results of the shank ends were measured, the values of which are comparable to the numerical motion.

Future of Nonmetallic Composite Materials in Downhole Applications

This article, written by JPT Technology Editor Judy Feder, contains highlights of paper SPE 198572, “The Future of Nonmetallic Composite Materials in Upstream Applications,” by Wael Badeghaish, SPE, Mohamed Noui-Mehidi, SPE, and Oscar Salazar, Saudi Aramco, prepared for the 2019 SPE Gas and Oil Technology Showcase and Conference, Dubai, 21-23 October. The paper has not been peer reviewed. Nonmetallic (NM) composite-based materials offer distinct advantages in overcoming the effects of corrosion, scale, and friction on carbon steel to minimize frequent workovers and extend the life cycle of critical downhole products. However, high initial cost and technical-skills limitations pose challenges to more-widespread development and deployment of these materials downhole, particularly in extended-reach drilling and other challenging wells. The complete paper highlights examples of nonmetallic materials selection and qualification for upstream water-injection and producer and hydrocarbon wells and presents suggestions for future progress. Introduction Carbon steel (CS) is the material of choice for downhole applications because of its advantages over other materials in terms of cost, temperature and pressure ratings, and field-construction-support services. The downsides of CS include corrosion, scale, and friction that can result in high repair and workover costs and limitations of equipment life. Corrosive fluids are handled generally by chemically inhibited CS and corrosion-resistant alloys (CRAs). However, CRAs can increase project cost and complexity significantly. NM composite materials have been introduced for drilling and completions in high-risk, corrosive environments to minimize the effect of corrosion, scale, and friction in CS tubulars and extend the well life cycle. The new proposed materials are lightweight, high-strength, and offer superior fatigue and corrosion resistance. Economic analysis shows that using NM tubulars and internal linings will yield substantial life-cycle cost savings per well, mainly from the elimination of workover operations. However, composite materials pose several challenges. In downhole environments, the materials are subjected to a more-complex set of dynamic stress conditions under variable multiphase fluids and temperatures. Forces such as burst, collapse, tension, and axial compression play a significant role in NM downhole tubular performance. In deep-well operations, service tools are required to perform at high pressures and temperatures. Currently, the industry has explored the opportunity to deploy NM materials in standard applications while pursuing research and development (R&D) to expand the operating envelope to target high-pressure/high- temperature applications.

Study of the process of tool forming made of high-strength materials

The work covers the problems of forming tools cutting elements equipped with high-strength tool materials as exemplified by hard alloy tools for machining of non-metallic composite materials. The reasons for the formation of various defects, such as chips, cracks, breaks, burns, unwanted interphase structural transformations in the surface layers and the formation of high residual stresses in the wedge in areas where the grinding wheel contacted with the element being sharpened are indicated. The need for a comprehensive assessment of the quality of cutting blade shaping is noted. The need of technological system modeling of an abrasive tool - machined high-strength material is substantiated, since conducting of a comparative analysis of forming cutting elements methods from high-strength materials empirically is a rather long, laborious and economically inefficient process. At the same time, a detailed study of the regularities of stress-strain state formation in the elements of the cutting tool from difficult-to-work tool materials during grinding is required. The initial data are determined and restrictions are imposed on the system under study. The accepted assumptions do not limit the processes study, but allow us to estimate the contact processes occurring in the cutting zone. A method for the tool forming modeling process equipped with high-strength, difficult-to-work materials is given. The constructed model will allow: 1) to determine the rational ranges of technological machining modes, which will ensure the formation of a high-quality cutting edge during the sharpening process; 2) to carry out a comparative analysis of the methods of grinding tools equipped with cutting elements of high-strength materials, with the aim to choose the most favorable method for sharpening at the preliminary stages of technological preparation of tool-making facilities; 3) reduce the amount of empirical research, which in its turn will reduce the time spent on research, material consumption and improve the economic efficiency of research, due to reduced number of the experiments series.

Design and Analysis of Centrifugal Pump Using Computational Fluid Dynamics

Centrifugal pumps are used to transport drinks / fluids with rotational kinetic power conversion to hydro energy dynamics of fluid glide. The rotational electricity is normally derived from the engine or electric motor or turbine. In the simplest case is typical, the liquid enters the pump impeller along or close to the rotating axis and is accelerated through the impeller, flowing radially outward into a diffuser or volute chamber (casing), from in which he came. Contemporary blade impellers in centrifugal pumps used in commercial applications include aluminum or metallic. It is proposed to layout a centrifugal pump, using Computer Aided Design (CAD) software with a variety of metallic alloys and non-metallic composite materials, examine the electricity and deformation using simulation software program. In order to evaluate the effectiveness of Metal Alloys and non-steel composites. The purpose of this observe is to trade the fabric and perform unique analyzes which includes Static, dynamic, evaluation to find the first-rate substances to reduce weight and enhance efficiency the usage of SOLID WORKS software program (Premium Version 2014). It also involves a technique of manufacturing methods to recognise Blower use Non-metal composite fabric. Keywords: centrifugal pumps, Computer Aided Design (CAD), Metal Alloys, NonMetallic Composite Materials, SOLIDWORKS, Simulation Analysis

A Low-Cost and Compact Three-Dimensional Microwave Holographic Imaging System

With the significant growth in the use of non-metallic composite materials, the demands for new and robust non-destructive testing methodologies is high. Microwave imaging has attracted a lot of attention recently for such applications. This is in addition to the biomedical imaging applications of microwave that are also being pursued actively. Among these efforts, in this paper, we propose a compact and cost-effective three-dimensional microwave imaging system based on a fast and robust holographic technique. For this purpose, we employ narrow-band microwave data, instead of wideband data used in previous three-dimensional cylindrical holographic imaging systems. Three-dimensional imaging is accomplished by using an array of receiver antennas surrounding the object and scanning that along with a transmitter antenna over a cylindrical aperture. To achieve low cost and compact size, we employ off-the-shelf components to build a data acquisition system replacing the costly and bulky vector network analyzers. The simulation and experimental results demonstrate the satisfactory performance of the proposed imaging system. We also show the effect of number of frequencies and size of the objects on the quality of reconstructed images.

Ferromagnetic particles as magnetic resonance imaging temperature sensors.

Magnetic resonance imaging is an important technique for identifying different types of tissues in a body or spatial information about composite materials. Because temperature is a fundamental parameter reflecting the biological status of the body and individual tissues, it would be helpful to have temperature maps superimposed on spatial maps. Here we show that small ferromagnetic particles with a strong temperature-dependent magnetization, can be used to produce temperature-dependent images in magnetic resonance imaging with an accuracy of about 1 °C. This technique, when further developed, could be used to identify inflammation or tumours, or to obtain spatial maps of temperature in various medical interventional procedures such as hyperthermia and thermal ablation. This method could also be used to determine temperature profiles inside nonmetallic composite materials.

НАПРЯЖЕННО-ДЕФОРМИРОВАННОЕ СОСТОЯНИЕ ТВЕРДОСПЛАВНЫХ РЕЖУЩИХ ЭЛЕМЕНТОВ ПРИ АЛМАЗНОМ ЗАТАЧИВАНИИ

The paper shows the influence of the technology forming the cutting surfaces and blades of the tools on the cutting process and tool wear during operation, and the quality of the processed products. The importance of this problem is emphasized for sharpening tools made of composite materials when a brittle fracture of the tool material occurs under the influence of cutting forces. The authors communicate the necessity a detailed study of deflected mode of the cutting edge and surfaces near it during formation (sharpening) of a tool with a geometry specific for the processing of non-metallic composite materials. The paper considers the questions of shaping the quality cutting blade of a tool made of high-strength materials in diamond machining. Initial and boundary conditions for research are presented as well as methodology for creation of a computational model of deflected mode in the sharpened plate. To research the formation of the deflected mode in the sharpened plate made of hard alloy, there has been used a computational model developed with account for mechanics of the damaged environment. The computational model has been implemented on the example of carbide cutting elements of the brand VK6 (WC + Co) having a specific geometry typical for a tool used for processing the items made of non-metallic composite materials. Evaluation of the test parameters in various combinations of cutting force, velocity and temperature has been performed. Sharpening parameters and terms that ensure a satisfactory condition of the cutting tools blade with carbide cutting elements are determined. Such requirements can be met by combined methods of electro-diamond machining: diamond grinding with continuous electrochemical dressing of the diamond wheel surface; electrochemical diamond grinding; a mixed method which combines electrochemical diamond grinding with simultaneous electrochemical dressing of the diamond wheel surface.

Haemocompatibility and cytotoxic studies of non-metallic composite materials modified with magnetic nano and microparticles.

Preventing the formation of blood clots on the surface of biomaterials and investigation of the reasons of their formation are the leading topics of the research and development of biomaterials for implants placed into the bloodstream. Biocompatibility and stability of a material in body fluids and direct effect on blood cell counts components are related both to the structure and physico-chemical state of an implant surface. The aim of this study was to determine haemocompatibility and cytotoxicity of polysulfone-based samples containing nano and micro particles of magnetite (Fe3O4). The polysulfone-based samples modified with nanometric and micrometric magnetite particles were examined. Physicochemical properties of the composites were determined by testing their wettability and surface roughness. The action of haemolytic, activation of coagulation system and cytotoxicity of composites was evaluated. Wettability and roughness of materials were correlated with nanoparticles and microparticles content. In the tests of plasma coagulation system shortening of activated partial thromboplastin time for polysulfone with nano magnetite and with micro magnetite particles was observed in comparison with pure polysulfone. Prothrombine time and thrombine time values as well as fibrinogen concentration were unchanged. Haemolysis values were normal. Morphology and viability of cells were normal. Composites made from polysulfone modified with nanoparticles and microparticles of magnetite cause neither haemolytic nor cytotoxic reaction. These composites evoke plasma endogenous system activation.

The Actual State and Prospects of a High Power Electron Beam Technology for Metallic and Non-Metallic Compositions Used in Electric Contacts and Electrodes

In the paper the actual state and prospects of applicability of a high power electron beam technology for manufacturing metallic as well as nonmetallic composite materials mostly for electric contacts and electrodes are presented and discussed

Shielding Effectiveness of Carbon–Fiber Composite Aircraft Using Large Cavity Theory

This paper extends reverberation chamber theory to include chambers constructed out of non-metallic composite materials. This extension allows reverberation chamber theory to predict the shielding effectiveness (SE) of modern aluminum and composite aircraft. Existing theory is based on a power balance approach for aperture-excited cavities, and this paper extends it to include leakage through the cavity walls. Cavity excitation and power dissipation mechanisms are examined in detail, and the cavity SE is related to cavity energy loss in terms of the “quality factor.” SE measurements were made on a partially assembled Uncrewed Aerial System constructed with a carbon-fiber composite skin. The test-analysis agreement shows a high degree of correlation.

The influence of service solutions on the longitudinal and circumferential tensile properties of glass-polyester composite pipes

In numerous cases, metals and alloys traditionally used as structural materials in the process equipment can now be successfully replaced by nonmetallic composite materials. We study the influence of service solutions on the state of stress and tensile properties of glass-polyester pipes in the longitudinal and circumferential directions. These analyses are of great importance for the use of examined pipes in chemical industry. The pipes were produced by “Poliester” Corporation (Priboj). The influence of two solutions, methanol and ammonia, was studied. The samples were treated in solutions for three, seven and ten days. After this, the samples were subjected to tensile testing by the standard procedure. The stresses and strengths were determined both in the longitudinal direction (testing on flat test specimens) and in the circumferential direction (ring tests). The analysis of test results, according to the type of solution and the period of holding, was realized in comparison with the results obtained by testing intact pipes (not subjected to the influence of the solution). The micromechanical analysis of broken samples helped to determine the influence of the solution on the structure of composite pipes and determine the models and mechanisms responsible for the decrease in strength.

Strength and Plasticity of Metal and Nonmetallic Composites for Cryogenic and Aerospace Purposes

We present results of studying mechanical properties of four groups of metallic and nonmetallic composite materials in a temperature range of 300–4.2 K. Types of glass-reinforced and carbon-reinforced plastics with the best low-temperature strength and elastic characteristics have been specified. A deterioration of the strength characteristics of boron-fiber-reinforced aluminum alloy after temperature cycling in the temperature range 20–443 K has been detected. It has been shown that superconducting composites with ultra-fine filaments, fabricated by hydrostatic extrusion without intermediate annealings, possess optimal combination of mechanical and electrical characteristics.

Dynamic experimental investigations of composites

Investigation of non-metallic and polymeric composite materials (FRP - fiber reinforced plastics) response to impact loading is now one of the most actual problems of experimental mechanics. This paper describes current results in the field of dynamic investigations, when magnitude of inertial force becomes near equal to resistance force of the test sample. Time of loading up to rupture becomes very small under high strain rates. These two factors mainly define peculiarities of material dynamic testing. For composites these problems become more complicated because of high anisotropy of material elastic and strength properties. The paper contains basic classification of composite test methods according to strain rate and time of loading. To make this classification correctly it is necessary to take into account the specimen length, wave velocity and time factor. Among all kinds of dynamic experiments only experimental investigations devoted to impact toughness are standardized now. The rest types of experimental methods have not yet normalized because of lack of metrological founded demands to the methodic of testing. Present results of investigations in the field of dynamic loading of composites can be considered as definite basic step to the State Standard appearance. Some types of damage mechanics models are proposed and discussed.

On the practice of strength estimation for nonmetallic fibrous composite materials at high temperatures

We present experimental data on the effect of temperature on tensile, compression, bending, and shear strength characteristics of a carbon-reinforced plastic. It is shown that experimental shear strength values differ for various bending loading schemes.