SOCIETY FOR THE ADVANCEMENT OF

MATERIAL AND PROCESS ENGINEERING

46th International SAMPE Symposiumand Exhibition

VOLUME 46

Book 1 of 2 Books

2001:

A MATERIALS AND PROCESSES ODYSSEY

Edited byUnas Repecka

Frederick F Saremi

Long Beach Convention Center

Long Beach, California

May 6-10,2001

Contents

Bookl

Preface xxxi

ADHESIVES BONDING TECHNOLOGY

Chairman: David Uhl, Loctite Corporation

Fatigue Strength ofAdhesives and Their Energies ofCohesive Failure 1

GEORGE E. MANN

Influence of Substrate-Adhesive Resin Compatibility onthe Fracture Properties of Composite Bonds 8MATTHEW S. TILLMAN, BRIAN S. HAYES and JAMES C. SEFERIS

Sensor to Detect Moisture/Degradation of Composites and

Adhesive Bonds 20

G. D. DAVIS, L. A. KREBS and C. M. DACRES

Structural Bonding Applications for the Automotive Industry 30FRANCESCO ROSSELLI and PETER CARBUTT

Development of Hysol EA 9296, a Two-Part Low VOC Waterborne

Primer for the 121C (250F) Aerospace Metal Bond Market 39

THOMAS W. REGULSKI and MYRNA R SERRANO

Study on the Thermal and Hygrothermal Behaviors of Epoxyand Polyimide Adhesives 51YANG ZHONG and PAUL 0. BINEY

7

The Strength in the Weakness .F KADIOGLU, A OZEL and R D. ADAMS

61

3D Spline Variational Analysis of a CompositeDouble-Lap Shear Joint 72GREGORY A SCHOEPPNER, DAVID H. MOLLENHAUER and ENDEL IARVE

PMC THERMOSETS AND THERMOPLASTICS

Chairman: Prof. Xiao-Su Yi, Beijing Institute ofAeronautical Materials

Matrix Resin Improvement for Aerospace PolymerMatrix Composites 84XIAO-SU YI

Mechanical Properties of Graphite Fiber-ReinforcedPhthalonitrile Composites 94DAWN D DOMINGUEZ, HARRY N JONES, P P TRZASKOMA-PAULETTE and

TEDDY M KELLER

Application and Characterization of High Modulus-Graphite/Epoxy(HM-Gr/Ep) for High Stiffness Aircraft Structural ComponentsThe Benefits and Shortcomings 107JOSEPH W. BRUNO

HexMCComposites in 3D (a New High Performance

Molding Compound) 121JACK FUDGE

Synthesis and Properties of New Processable

Type Polyarylacetylenes 134PIERRICK BUVAT, FRANCK JOUSSE, LAURENT DELNAUD and CHRISTIAN LEVASSORT

Surface Preparation of Aluminum for Adhesive Bonding of a

Liquid Crystal Thermoset 145BEN DIETSCH, CHRYSA THEODORE, DON KLOSTERMAN, TATTONG,RICHARD CHARTOFF and PATRICK HOOD

RECYCLING OF ADVANCED MATERIALS

Chairman: Dr. Ronald E. Allred, Adherent Technologies, Inc.

Environmental Benefits of Flame Retarded High ImpactPolystyrene Based on Ethane 1,2 Bis(Pentabromophenyl) 158RAYMOND B DAWSON and SUSAN D. LANDRY

vi

Novel Binder Systems Derived from Polyethylene terephthalate)PET Waste for Solventless Magnetic Tape Manufacturing.I. Investigation of the Mechanical Properties of theAcrylated Oligomers 172MEDHAT S FARAHAT and DAVID E NIKLES

Recycling Process for Carbon/Epoxy Composites 179RONALD E ALLRED, JAN M GOSAU and JOHN M SHOEMAKER

Production of Phenolic Resins from Oils Produced by RecyclingThermoset Composites 193STEPHEN S KELLEY, XIANG-M1NG WANG, NOSHENA KHAN, RONALD E ALLREDand JAN-MICHAEL GOSAU

CARBON TECHNOLOGYAND NANOTUBES

Chairman: Dr. Moe K. Soleiman, Boeing Materials Technology

Designing with Wavy Composites 203WILLIAM F PRATT, MATTHEWS ALLEN and C GREG JENSEN

Testing and Characterization of Wavy Composites 216WILLIAM F PRATT, MATTHEWS ALLEN and SCOTT D SOMMERFELDT

Modeling and Stress Analysis of Open-Cell Carbon Foam 230SANGWOOK SIHN and AJIT K ROY

CERAMICS/CERAMIC MATRIX COMPOSITES

Chairman: Prof. Thomas T. Meek, University of Tennessee/

Materials Science and Engineering

DC Plasma Sprayed Coatings Modified via Application ofUltrasonic Power 243T. T MEEK

Processing and Growth of Refractory Single Crystals 249RALPH H ZEE, ZHIGANG XIAO and JUN LIU

The Effect ofAdhesive Properties on Ballistic

Performance of Hybrid Systems of Fiber Compositeswith Ceramic Front Plates 259

J. W SONG, I SWAN and B L LEE

vn

RTM/VARTMI

Chairman: Gerald Sutton, Intellitec

Process Development forRTM Fabrication of Unitized Structure. . . 273

SLADE GARDNER and LEE McKAGUE

Use of a Design and Control Methodology to Manufacture

Complex Composite Parts by Manipulating Flow duringResin Transfer Molding Process 286JEFFREY M. LAWRENCE, KUANG-TING HSIAO, RODERIC C, DON and

SURESH G. ADVANI

Process Control ofResin Transfer Molding (RTM) by Ultrasonics ... 300JOCHEN TOPKER and WALTER M1CHAELI

A Method to Find Optimal Auxiliary Injection Gate Locations

for Successful Mold Filling in Resin Transfer Molding Process .... 310ALI GOKCE, KUANG-TING HSIAO and SURESH ADVANI

Modular Tooling for Affordable RTM 326DAN DAVENPORT

Isothermal RTM Simulation of GFRP Parts for

Automotive Applications 335MARKUS HENNE, CHRISTIAN H. LEPPIN and CHARLIE GOTSCHI

The True Value of RTMPart Consolidation 348

JOSEPH R, DE CILLIS

NANOCOMPOSITES/ELASTOMERIC MATERIALS

Chairmen: Prof. Steven R. Nutt, University ofSouthern California/Materials Science

Dr. Wolfgang Schuett, Wacker Silicones Corporation

Carbon Fiber Composites Prepared from

Organoclay-Aerospace Epoxy Nanocomposites 355BRIAN R RICE, CHENGGANG CHEN, LARRY CLOOS and DAVID CURLISS

Organoclay-Aerospace Epoxy Nanocomposites 362CHENGGANG CHEN and DAVID CURLISS

RTV-2 Silicone Foams: Diverse Material

for Diverse Applications 375BERNDT STADELMANN and TOBY VICK

viii

JOINT DESIGN AND ANALYSIS

Chairman: Prof. RikardB. Heslehurst, University ofNew South Wales/

Aerospace and Mechanical Engineering

Estimating Adhesive Shear Stress/Strain Properties 380R B HESLEHURST

Environmental Influences on GLARE

Riveted Joints 389THOMAS BEUMLER AD VLOT ORIO KIEBOOM and

BOB BORGONJE

The Design of Adhesively-Bonded Lap Joints:

Modelling Considerations 402R D ADAMS

Improvement of Bearing Strength ofMechanically Fastened

Composite Joints Using Fiber Steering 415D KELLY, R LI, R WILLGOSSandA CROSKY

INFRASTRUCTURE APPLICATIONS

Chairmen: Jerry Bauer, The Aerospace CorporationDr. Srinivasa Iyer, Stress Steel Company

The Development of a New Structural Core Material

for Composites in Civil EngineeringConstituentInfluences on Stiffness Behaviour 427

STEPHEN R AYERS and GERARD M VAN ERP

Microwave-Based NDE of FRP-JacketedConcrete Structures 439

YOO JIN KIM, FRANCO DE FLAVIIS, LUIS JOFRE and

MARIA Q FENG

A Fast Method for Field Evaluation of Concrete/FRP

Adhesive Bonding in Extreme Temperatures 451P K DUTTA, A MOSALLAM, J VARGAS and D MIKHAEL

Coke Drum Support Design 463JAAN TAAGEPERA and JESA KREINER

Behavior of Unreinforced Masonry Walls (URM)

Strengthened with FRP Composite Materials 473TAREKH ALMUSALLAM.YOUSEFA AL-SALLOUM,

SALEH H ALSAYED and AYMAN S MOSALLAM

ix

Effect of Aggressive Environments on Strength ofRC Beams Strengthened with Composite Laminates 485YOUSEF A AL-SALLOUM, SALEH H ALSAYED, TAREK H ALMUSALLAM

andAYMANS MOSALLAM

HIGH PERFORMANCE POLYMERS AND COMPOSITES

Chairmen: Dr. Paul M. Hergenrother, NASA Langley Research Center

Prof. James McGrath, Virginia Tech

PMR Polyimides with Enhanced Melt Flow for High

Temperature Applications 497MICHAELA MEADOR, MARY ANN B MEADOR, JENNIFER PETKOVSEK, THOMAS

OLIVER, DANIEL A SCHEIMAN, CHRISTOPHER GARIEPY, BAOCHAU NGUYEN

and RONALD K EBY

High Temperature Transfer Molding ResinsII 510J G SMITH, JR, J W CONNELL, PM HERGENROTHER and J M CRISS

Phenylethynyl Containing Arlyene Ether Oxadiazolesand Triazoles for High Performance Applications 522C M THOMPSON and P M HERGENROTHER

Novel High Performance Matrix Systems 533YEFIM BLYAKHMAN, ANTONIOS TONTISAKIS, JAMES SENGER and ASH CHAUDHARI

Nylon 6/PoIyimide Nanocomposites 546FRANK W HARRIS and YOULEE PAE

Melt Stable Aromatic Polyphosphonates 561H K SHOBHA, H JOHNSON, M SANKARARANDIAN, P RANGARAJANand J E McGRATH

Coatings for High Temperature Polymer Composites 572MARY ANN B MEADOR, JAMES K SUTTER, GEORGE LEISSLER,E EUGENE SHIN and LINDA McCORKLE

METALS/METAL MATRIX COMPOSITES

Chairman: Prof. Paul Fussell, Arizona State University/Mechanical Engineering

Hybrid Metallic and Composite Structures 586ERIC GAVELDA

Fracture Toughness Determination Using MaterialStatic Properties 598BOB FARAHMAND and FRANK ABDI

x

Alotech Precision Sand Casting ofAluminum Alloys,a New Technology for Cost Efficient, Extremely HighQuality Cast Components for Aerospace andAutomotive Applications 611G W KUHLMAN, J R GRASSI and J CAMPBELL

MATERIALS FOR RECREATION INDUSTRY

Chairman: Prof Brian Hayes, University ofWashington/Polymeric Composites

Effects of Metal Particle Concentration on Prepreg InterlayerToughened Composites 626ERIC N GILBERT BRIAN S HAYES and JAMES C SEFERIS

Improved Flexural Properties of Composite Circular Cylinderfor Sporting Goods 636SHINICHITAKEMURA, HIDEYUKI OHNO and ALBERT S KOBAYASHI

CARBON-CARBON

Chairmen: Dr. Keith Bowman and Dr. Benji Maruyama, Air ForceResearch Laboratory/MLBC

Influence of Carbon Nanofiber Surface Characteristics

on Composite Properties 647DAVID J BURTON, D GERALD GLASGOW, MAX L LAKE, CHOONGYONG KWAGandJOANAC FINEGAN

Joint Attachment of Carbon-Carbon Aircraft HX Core 658ROLAND WATTS, JOHN PRICE, DAN DANIELS, DAN VRABLE and ED KLOSTERMAN

Low-Cost Oxidation Resistant C-C Composites 671W KOWBEL, C BRUCE, J R PATEL and J C WITHERS

Effect of Oxidation-Induced Weight Loss on

Mechanical Properties of Two-Dimensiona