Internship report

(13-06-2012 to 09-07-2012)

Report Submitted By,

Khurram Suleman
Reg. # 2009-NUST-BE-Mech-228
Degree 31
Mechanical Engineering Department
NUST College of EME

Table of Contents
1. Ultrasonic C-Scan .......................................................................................... 3
Introduction: ............................................................................................................................................. 3
Test performance:..................................................................................................................................... 3

2. Scanning Electron Microscopy (SEM)............................................................. 4

Introduction: ............................................................................................................................................. 4
Test performance:..................................................................................................................................... 5

3. Volume fraction/Density measurement ........................................................ 6

Introduction: ............................................................................................................................................. 6
Test performance:..................................................................................................................................... 6

4. Drop weight impact and compression after impact tests .............................. 7

Introduction: ............................................................................................................................................. 7
Test performance:..................................................................................................................................... 7

5. Composite lay-up and fibre placements ........................................................ 8

Introduction: ............................................................................................................................................. 8
Pre-form Making: ...................................................................................................................................... 9
Vacuum Bagging:....................................................................................................................................... 9

6. Laser Processing .......................................................................................... 10

Laser metal deposition:........................................................................................................................... 10
Laser drilling: ........................................................................................................................................... 10

References ........................................................................................................ 11

1. Ultrasonic C-Scan
Test performed by:

Dr. Rizwan Saeed Choudhry

Sample:

Glass with Epoxy

Introduction:
Ultrasonic C-Scan is a non destructive testing method in which 2 transducers are used to
generate and sense ultrasonic signals passed through specimen. This scan is used to find out spatial
position, depth and size of defects in composite plates. The main specifications of this equipment are as
follows [1]:
Equipment

Type

Fixed/Portable

Midas Water Jet

C-Scan

Through
Transmission
Ultrasonic

Fixed

Maximum Size or
Weight of Sample
2m x 2m flat or
slightly curved panels

Main Uses
Spatial position, depth and
size of defects in composite
plates

It uses two water jets to act as a medium for the propagation of ultrasonic signals. Using the
variation of speed of sound with density of medium, the defected portion of material can be found.

Test performance:
Before the start of test it is required to align the two water jets so that signal will not distort.
The probes used for the test ranges from 0.5 to 15 MHz. For that particular test probe was of 5 MHz.
now to start the test, jets were turned on, the orientation and flow rate of water was adjusted manually.
After adjusting the water jets the sample was fixed in fixtures as shown in following figure.

The position of water jets at bottom left and top right position was then set. The scanner has two
reference axis of translation. The horizontal axis is named to be x-axis and vertical axis is named to be z-

axis. The speed in x direction was set to be 100 mm/s and index (z step) was set to be 200 m. The top
right and bottom left positions of the probe in terms of x and z coordinates are as follows:
Digitize bottom left
1126.2
-171.10

x
z

Digitize top right

1417.3
135.5

After setting all the options and controls, the scan was started. The scan initiated from bottom
left corner and moves towards right, covered 200 m upward and completed the scan. The following left
figure is during the scan and its output is shown in the right one. The green area in the right figure shows
absence of any material (i-e only air).

2. Scanning Electron Microscopy (SEM)

Mentor:

Erdem Selver

Research topic:

Damage tolerance in textile composites

Sample:

E-Glass/Polypropylene + epoxy (90-0)

Glass + Epoxy

Introduction:
Scanning electron microscope is a type of electron microscope that capture
images with electron beam by moving line by line (raster scan) of
specimen. The equipment used was S-3000 N Hitachi SEM as shown in
adjacent figure. The sample used for SEM is a hybrid material in which
reinforcement is composed of E-Glass and Polypropylene and matrix was
epoxy. The other sample was E-Glass with epoxy. The SEM is conducted for
impacted sample as shown below at left (white is Glass with Epoxy having

20 Joule impact, black is glass/PP with epoxy). To prepare the specimen for test the sample is cut at the
middle of impact and then surrounded by resin that act as a permanent holder for specimen as show in
right figure. This specimen is polished and cleaned before inserting it into SEM.

Test performance:
The specimen is inserted into its position as shown in
adjacent figure and the door is the closed. Vacuum button is then
pushed to evacuate internally. Now after some time the images
appeared at interface. The adjustment of this SEM was manually
operated for position as well as magnification. The magnification can
go up to thousands and 50 is the least. The figure below is showing
the image at 50x magnification. It shows both the warp and weft
direction of yarns. Black are the polypropylene and white are of glass.
The rest black portion is epoxy resin forming the matrix.

3. Volume fraction/Density measurement

Mentor:

Erdem Selver

Introduction:
The volume fraction of sample was found by first measuring its density and then by finding out
the weights before and after burning of sample in furnace. The apparatus used for density and weighing,
uses principal of buoyancy in water and then calculates the density
by the formula:
=

Where in the above equation is the density of sample, is the

weight of sample in air, is the weight of sample in water and
is the density of distilled water which is known.
There were 3 samples of commingled yarns of E-glass and
polypropylene as shown in adjacent figure.

Test performance:
As shown in above formula for density, the sample was weighed in
air and then in water (shown in adjacent figures). The software then
calculates density and output the calculation in set units. The samples
were then placed in furnace up to 600 C for one and half hour to burn
polypropylene yarns. It was then weighed again to find out weight of
polypropylene fiber yarns and hence to calculate volume fraction. The
individual densities of E-glass and polypropylene are known. Few
measurements done are tabulated below:

Sample
No.

Density
g/cm3

1
2

2.098
2.143

Weight
of
Sample
g
236.19
176.07

Weight
of PP
g
29.64
17.85

Mass
fraction
EPP
Glass
0.875 0.125
0.899 0.101

Volume
fraction
EPP
Glass
0.716 0.291
0.752 0.241

In the above calculations densities of E-Glass and polypropylene was taken

to be 2.56 g/cm3 and 0.9 g/cm3 respectively.

4. Drop weight impact and compression after impact tests

Mentor:

Erdem Selver/Dwi

Introduction:
To find out damage tolerance of hybrid composite, drop weight impact testing is done. The equipment
used for the test has following main specifications [2].
Equipment
Name

Instron
CEAST
9350

Maximum
Gravity
Mode
Velocity
(m/s)
0.77

Maximum
Spring
Assisted
Velocity
(m/s)
24

Simulated
Drop Height
Range (m)

Weight
Range
(kg)

Impact
Energy
Range
(J)

Relevant Standards

Projectile

0.03 - 29.4

2.0 - 70

0.59
1800

- ISO 3127, 6603, 7765,

11343, 8256 - DIN 53373PR EN 6038- ASTM
D2444, D3763, D5268,
D7136, D7192- Boeing
BSS
7260

Airbus
AITM1.0010,1-0057SACMA SRM 2R-94

16mm
hemispherical
tup insert

This equipment has closed chamber by which controlled environmental

conditions can be applied. Impact is made by dropping known weight
through height. A metal cylinder, with hemispherical shaped top carries the
weight and produces impact on specimen fixed in a fixture.
After the impact at the centre of samples, these samples were tested in
compression test. The equipment used for compression test is shown in
adjacent figure.

Test performance:
For impact the samples were fixed firmly in a fixture and then placed inside the chamber of impact
testing machine. 5 kg weight is used to make impact. Height, temperature and required impact energy is
set through software interface. Impacts of 15 joule and 20 joule were made. The settings for 20 joule
impact are as follows:
Energy
20 Joule

Height
599.7 mm

Mass
5 kg

Temperature
26 `C

One of the samples having E-glass reinforcement and epoxy matrix after impact is
shown in adjacent figure.

After impact, compression test were performed for both impacted and non impacted samples of glass
with epoxy composites. The samples were fixed in fixture as shown in following figures. The fixture was
then place in Instron testing machine.

The zero position of machine was manually adjusted so that loading is in between 0.0150-0.0200 KN.
Thickness, height and width of samples was entered. The machine was started and continued to
increase load till the breakage of samples or the declination of load displacement curve. The impacted
samples got fracture in their middle while non impacted samples did not show any fix location of
fracture and got fracture at weak portion of composite. The fractured samples after compression are
shown in following figures (impacted on left, non-impacted on right).

5. Composite lay-up and fibre placements

Mentor

Erdem Selver

Introduction:
Among many different types of composite layup, one is making pre forms of
fibers yarns and then infusing it by resin. The equipment used here is a robotic
four-axis tow placement machine, shown in adjacent figure. Tow can be

placed in any orientation i-e, 0, 45, 90. The same machine can be used for tufting once the pre form is
ready.

Pre-form Making:
First the foam was placed below the pins so that threads of tufting can be held tightly once fiber
layers are set up. The foam was then covered by peel ply to remove the fiber layers. The pins were then
fastened by nuts. The program was then fed and run on the computer to start the placement of tows
and making of layers. Glass fiber was used to place 14 layers at 0 and 90 degree angle.

The above figures show the step by step process of tow placement
from left to right. After forming 14 layers of fiber, tufting was done.
5 lines of threads making loops on each side were made. The lower
portion of whole layup is shown in adjacent figure where black
threads making loops of tufting are quite visible.

Vacuum Bagging:
Once tufting is done, its now easy to remove whole layup from metal base and pins. First the flat mold
is cleaned. Teflon sheet is place and tapped to remove the composite after curing. Top and bottom
mesh was placed and taped. Then whole layup is removed from its panel and placed above the bottom
mesh.

Extra fibers were removed. One peel ply is placed at the top below the upper mesh. Finally the vacuum
bag was made with the help of sealing tape. It was then vacuumed and checked for half an hour with
gauge to ensure no leakage of air from the bag. This whole process is shown in above figures step by
step from left to right.

6. Laser Processing
Demonstration by:

Col. Khalid

Laser metal deposition:

Laser metal deposition is the additive manufacturing method in
which metal wire or metal powder is melt to form a desired shape.
For melting of metals, LASER is used. A solid substrate of the same
material is used as base. A metal powder is fed by mixing it with
argon gas because of its inert behavior. The powder metal feeder is
shown in adjacent figure.

The metal powder from the feeder comes into deposition chamber,
where it melts by class 4 diode LASER. The internal view of chamber
is shown in left figure. The powder and LASER beam are coaxial.
Before metal deposition the substrate is cleaned by sand blasting
process.

Laser drilling:
A very small diameter holes can be drilled with the help of LASER. The equipment and holes produced by
it is shown in following figures.

References
[1]

http://www.nccef.co.uk/Facilities/Non-DestructiveTesting.aspx

[2]

http://www.nccef.co.uk/Facilities/MechanicalandImpactTesting.aspx