SOCIETY FOR THE ADVANCEMENT OF
MATERIAL AND PROCESS ENGINEERING
44th International SAMPE Symposiumand Exhibition
VOLUME 44
Book 2 of 2 Books
EVOLVING AND REVOLUTIONARY
TECHNOLOGIES FOR THE NEW MILLENNIUM
Edited by'
Dr. Leslie Jay Cohen
Jerome L. Bauer
William E. Davis
Long Beach Convention Center
Long Beach, California
May 23-27, 1999
XXXV
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
High Temperature Polymer Matrix-Carbon Fiber Composites—Performance Issues and Future Needs 1098
Roger J Morgan, E Eugene Shin, Jiang Zhou and Jiming Zhou
Intelligent RTM Processing of Composites 1111
JohnM Fildes and Isaac M Daniel
Phenolic Resin Systems for Pultrusion, Filament Winding and
other Composite Fabrication Methods 1123
John G Taylor
Hygrothermal-Resistant Epoxy Cured by Cyanate and its Composites 1134
Bao Jianwen, Chen Xiangbao and Yi Xiao-Su
Fire Safe Materials—I
Chairmen: Usman Sorathia, Naval Surface Warfare Center
Louis Nash, U S Coast GuardR&D Center
Flammability Study ofAdvanced Engineering Thermoplastics 1142
S Gandhi, R N Walters and R E Lyon
Polydimethylsiloxaneand Layered Silicate Nanocomposites 1151
Timothy C Chao, Aref Jallouli, Gary T Burns and Dimitns E Katsoulis
Testing and Analysis ofMarine Composite Structures in Elevated
Temperature Conditions 1165
George L Petne, Usman Sorathia and L Will Warren
Fire-Induced Responsein Foam Encapsulants 1179
T Y Chu, M L Hobbs, K L Enckson, T A Ulibarri,A M Renlund, W Gill, L L Humphries and T T Borek
Predicting Electronic Failure from Smoke 1194
Tina J Tanaka
Tough,Void-Free Flame Retardant Phenolic Composites:Processability and Properties 1206
C S Tyberg, S L Lin, K Bergeron, M Sankarapandian,
P Shih, A C Loos, J E McGrath, J S Riffle and U Sorathia
Low-Cost Fire Retardant Composites for Bus Seat Upholstery 1217
W Kowbel, J R Patel and J C Withers
On-Line/In-Process NDE
Chairman: Dr Donald Palmer, The Boeing Company
Sensors for Resin Tranfer Molding 1227
Roger E Engelbart
xlvu
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
On-Line NDE of a Commercial Transportation Beam Fabricated
by CRTM® 1233
Roger E. Engelbart
Hybrid Ultrasonic System for On-Line Control ofFiber Placement
Process 1240
B. Boro Djordjevic, F. Lanzia DeScalea and T. Berndt
Nondestructive Evaluation ofBond Quality Using Rayleigh Waves 1246
Benjamin Zurn and Susan C. Mantell
NDE Characterization of Composites with High Temperature
Optical Fiber Sensors 1255
T. Wavering, J. Greene, S. Meller, P. Furrow, R. Clark, Jr.,
C. Kozikowski, T. Bailey, K. Murphy, Mike Camden and Larry Simmons
Thermal Management for Space Systems—IChairmen: Jim Colder, Material Innovations, Inc.
Dr. Howard Katzman, The Aerospace Corporation
Material Property Projections for 3-D Graphite Fiber Reinforced
Aluminum Matrix Composites forThermal Management 1265
Brian J. Sullivan
An Investigation ofMetal Matrix Graphite Compositesfor Satellite Electronics 1275
C.P. Schaffer, W. Riley and P. Burns
Development ofAl Matrix Composite Components for
Thermal Management Applications 1281
Maxim L. Seleznev, James A. Cornie and Mark A. Ryals
Carbon-Carbon Thermal Doublers for Spacecraft 1292
Suraj P. Rawal, Chuck Rasbach and Wei Shih
Space Environmental Effects—III
Chairmen: Jacqueline Townsend, NASA Goddard Space Flight Center
Joyce Dever, NASA Lewis Research Center
A Radiation Shielding Code for Spacecraft and its Validation 1299
J.L. Shinn, F.A. Cucinotta, R.C. Singleterry, J.W. Wilson,F.F. Badavi, G.D. Badhwar, J. Miller, C. Zeitlin, L. Heilbronn,R.K. Tripathi, M.S. Clowdsley and J.H. Heinbockel
xlviii
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Investigation ofAtomic Oxygen Erosion ofPolyimide Kapton H
Exposed to aPlasmaAsherEnvironment 1312
Aaron Snyder
Diffusion Effects Upon Space Outgassing Times 1327
Thomas H. Sutherland
Advances in Composite M&P Technology—IIChairman: Longin B. Greszczuk, The Boeing Company
UV-VARTM Fabrication ofLow Cost Composite Structures 1338
MarkA. Livesay
Pressure Vessels: A Possible Application of Low Energy E-Beam Curing 1345
F. Guasti and E. Rosi
Electron Beam Cured Composites 1354
P. Parrot, S. His and F. Boursereau
Microgravity Processing ofAerogel Material on the STS-95
Space Shuttle Mission 1359
Scott C. Brown, J. Tim Hartness, Randy L. Thompson,
Laurant Sibille andRaymond Cronise
Application of High Modulus Polyarylene Resins in Advanced Composites 1365
Mark S. Trimmer, Robin S. Geralds, MarkR. Isomaki and
Brian M.Wilson
New High-Performance, Self-Reinforced Foams as Multifunctional
Cores for Composite Structures 1375
Farshad Motamedi, Mark S. Trimmer, Petra Waller, Ernie Silva and
AnnaYen
Fire Safe Materials—II
Chairmen: Usman Sorathia, Naval Surface Warfare Center
Richard Lyons, Federal Aviation Administration
Inorganic Intumescent Coating for Improved Fire Protection of GRP 1385
Dwight E. Veinot, Dat T. Nguyen, Kevin B. Langille and
UsmanA. Sorathia
A Numerical Model for Suppression ofa Burning Solid Surface
in Boundary Layer Flow 1395
Ramagopal Ananth, Chuka C. Ndubizu, P.A. Tatem,
Gopal Patnaik and K. Kailasanath
xlix
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Cyanate Ester Clay Nanocomposites: Synthesis and Flammability Studies 1408
Jeffrey W Gilman, Richard Harris, Jr and Douglas Hunter
Cyanate Esters with Improved Fire Resistance 1424
Borsheng Lin
Thermal Performance of a Class of Silicone Matrix Composites 1431
J H Koo, S Venumbaka, M J Miller, D Wilson, D A Beckley,D Calamito and C Blackmon
Data Analysis and Structural Substantiation
Chairman: Scott Reeve, LockheedMartin Aeronautical Systems
C-130 Hercules Composite Flaps Fatigue Test Program 1442
J Ayling
The Effect of Tows and Filament Groups on the Properties ofDiscontinuous Fiber Composites 1449
Roger Rondeau, Scott Reeve and Gary Bond
Fundamentals of Fiber Orientation and Application ofAutomatedImage Analysis to High-Theta Specimens 1461
Gary G Bond
Building Block Approach for Composite Aircraft StructureEMD and Production (Allowables and Building Block Testingfor DOD/NASA Vehicles) 1471
Glenn C Grimes
Division ofResponsibilities, Between Prepreggers and their
Customers, for Composite Material Characterization 1483
L J Hart-Smith
Materials and Structures
Chairman: Mike Robinson, The Boeing Company
Damage Growth in Notched Polymeric Composites Subjected to
Adverse Environments 1495
Stephanie E Buck, David W Lischer and Sia Nemat-Nassei
Development of Sandwich Panel with CFRP Honeycomb Core for HSCT 1507
Hiroyuki Nakamura, Kazunobu Umeki and Kazuhiko Nomoto
Basic Errors Appear to be Hampering Composite Aircraft Improvements 1517
Michael R PiggottandJ Wang
1
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
A Novel Epoxy Formulation for High InterlaminarFracture Toughnessand Low Moisture Absorption of GR/EP Laminates 1527
King-Fu Li, Wen-Hsien Wang and Ren-Jie Yen
Composite DesignChairmen: Steve Hahn, The Boeing Company
Scott Johnson, The Boeing Company
Effect of Imperfections on Shear Crimping ofSoft Core Sandwich
Composites 1539
J SteveMills, Milton H Schneider, Jr andAkashV Vangam
Impact Response ofDouble-Wall Glass/Epoxy Composite Plate Structure 1551
S T Jenq and J C Chen
Shock Absorbing Design of Composite Leaf Spring Landing Gear 1564
Dong-Min Kim and Myung-Kyu Hur
Environmental Conditioning ofHigh TemperatureAddition Polymers 1576
Fred E Arnold and Andrew Guy
Preliminary Design Using Composite Ternary Diagram Software 1583
Thomas J Whitney, Matthew J Davies, James M Whitney
and Stephen Mitchell
Composite Materials for Safety Applications: A Case Study 1592
G Potter, L Luong and G Thiel
Design and Failure of Composite Lattice Conical Shells 1603
An Hou and Kurt Gramoll
Thermal Management for Space Systems—IIChairmen: Jim Calder, Material Innovations, Inc
Dr Howard Katzman, The Aerospace Corporation
Considerations and Approaches for Joining Advanced Thermal
Management Materials 1617
Daniel R Harngan and Thomas F Kenney, Jr
EncapsulatedThermal Pyrolytic Graphite MaterialSolutions
for Thermal Management 1626
Mark J Montesano
Affordable Lightweight Highly Conductive Polymer Composite
Electronic Packaging 1633
JohnL Paretti
h
PAPERS, AUTHORS, SESSIONS AND SESSION CHAERMEN
Page
Composite Bridge ApplicationsChairman: IssamHarik, University ofKentucky/CivilEngineering
Static Testing on FRP Bridge Deck Panels 1643
IssamHarik, P. Alagusundaramoorthy, Robin Siddiqui,
Roberto Lopez-Anido, Steve Morton, Piyush Dutta and
Bahram Shahrooz
Effects ofSub-Zero Temperature Environment on Concrete Beams
Repaired or Upgraded with Advanced Polymer Composites 1655
Piyush K. Dutta and Stephen Morton
Fatigue Evaluation of FRP-Concrete Bridge Deck on Steel Girders
at High Temperature 1666
Roberto Lopez-Anido, Piyush Dutta, John Bouzon,
Steve Morton, Bahram Shahrooz and Issam Harik
Analysis of Composite Overwrap for Reinforced Concrete Columns 1676
M.V.Vanik
Guidelines for Design of Concrete Structures Reinforced with FRP
Materials 1689
Narendra Taly and Hota V.S. GangaRao
Processing for Dimensional Control
Chairmen: Dr. John Russell, Air Force Research LaboratoryJohn M. Griffith, The Boeing Company/St Louis
On Reduction ofResidual Stresses in IM7/977-3 Thermosetting
Polymer Composites 1697
Mohamed S. Genidy, Madhu S. Madhukar and John D. Russell
In-Situ Monitoring ofResidual Strain DevelopmentDuring CompositeCure 1706
Allan S. Crasto, Ran Y. Kim and John D. Russell
Composite Part Thickness Variability ImpactonAssembly 1718
John M. Griffith and Holly J. Thomas
Processing for Dimensional Control 1732
Karl M. Nelson, MarkS. Wilenski, Anoush Poursartip andGoran Fernlund
Process Modeling forDimensional Control—SensivityAnalysisofa Composite Spar Process 1744
Goran Fernlund, Anoush Poursartip, Karl Nelson,Mark Wilenski and Frederick Swanstrom
Hi
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Sensor Selections for the Characterization of Composite PrepregMaterials 1756
Matthew B. Buczek, Dan Blackman and Steven Darfler
ThermoplasticsChairman: Dr. Norman J. Johnston, NASA Langley Research Center
Impact Damage in E-Glass/Polypropylene Compared to E-Glass
Thermoset Laminates 1768
Stacey J. Rios and Roy Arrowood
IM7/LaRC MPEI-5Polyimide Composites 1780
Roberto J. Cano, Brian J. Jensen and Jill E. Bennett
Processing and Properties of Polyimide Foam 1792
T.H. Hou, E.S. Weiser, E.J. Siochi, T.L. St. Clair
andB.W. Grimsley
Processing and Properties ofPolyimide Composites made from
"Salt-Like" Solution Precursors 1807
T.H. Hou, R.J. Cano, T.L. St. Clair, Y. Echigoand H. Kaneshiro
Tape-Drop Transient Model forIn-situ Automated Tape Placement
ofThermoplastic Composites 1820
Robert C, Costen and Joseph M. Marchello
Affordable Processing and PrototypingChairmen: Dr. Frances Abrams, AirForce Research Laboratory/MLBC
Mike Louderback, Northrop Grumman Corporation
Mechanical Properties of Recovered Carbon Fibers 1831
John F. Unser, K. Chandrashekhara, Virgil J. Flaniganand Nicholas S. Berring
Process and Cost Modeling of Commingled Yarn Based Laminates 1840
Nicolas Bernet, Pierre-Etienne Bourban
and Jan-Anders E. Manson
Design and Fabrication of Materials for Laser Shape DepositionManufacturing 1849
Xiao Chun Li, Jurgen Stampfl and Fritz B. Prinz
Pultrudable Resin from Soybean Oil 1857
K. Chandrashekhara, Virgil J. Flanigan, Nicholas S. Berring
and John F. Unser
liii
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Automated Fabrication of Custom Bone Implants Using Rapid
Prototyping 1866
Cheri Steidle, Don Klosterman, Richard Chartoff,
George Graves and Nora Osborne
Carbon-Carbon ApplicationsChairmen: Keith Bowman, AirForce Research Laboratory
Joe Garibotti, Applied Material Technologies, Inc.
Low-Cost Pitch and Phenolic-Based C-C Composites for
Passive Thermal Management 1878
W. Kowbel, J. Webb and J.C. Withers
Development of an Intermediate Temperature Carbon-Carbon
Heat Exchanger for Aircraft Applications 1888
R. Daniel Stevenson, Daniel L. Vrable and Roland J. Watts
Brazing of Carbon-Carbon for an Aircraft Heat Exchanger 1898
Kristen M. Kearns, David P. Anderson and R. Watts
Functionally Graded Joints for Carbon/Carbon Composites:
Micro-Raman Spectroscopy Characterization 1909
M. Amer, T. El-Raghy, M. Barsourn and I. Weiss
Degradation in Mechanical Properties of Carbon/Carbon
Composites after Partial Oxidation 1919
Nyan-Hwa Tai, K-Kuan Yang and Li-Cheng Deng
Low-Cost Oxidation Resistant C-C Composites 1930
W. Kowbel, C. Bruce, J.R. Patel and J.C. Withers
Carbon Aerogel Thermal Protection System for Reusable
LaunchVehicles 1940
Scott C. Brown and Randy L. Thompson
Smart Materials and Structures—I
Chairman: Dr. Hiroshi Asanuma, Chiba University
Ionic Polymer-Conductor Composites (IPCC) as Biomimetic Sensors,Actuators & Artificial Muscles—A Review of Recent Findings 1950
M. Shahinpoor
Shape Memory Effect ofBi-Ceramics Glass 1961
T. Matsumura, T. Nakamura, H. Ishii, K. Tajima,Y. Miyazawa and Y. Nishi
Shape Recovery Effect ofS1O2 Glass 1965
T. Matsumura, T. Nakamura, H. Ishii, K. Tajima, K. Oguri and Y. Nishi
liv
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Developmentof CompositeActuators 1969
H. Asanuma, 0. Haga, K. Takemoto, T. Murata and T. Ishii
Progress Towards an Orthogonal Strain State Sensor Based
Optical Fiber Technology 1978
X.D. Jin, T. Rossmanith, M. Rutherford, J.S. Sirkis, A. Dasgupta,D. DeVoe, F.F. Rosenberger, III, V.S. Venkat, Y.C. Shi and C. Askins
Strain Monitoring in Curing of Composites Using EFPI Sensor 1993
Katsuhiko Osaka and Takehito Fukuda
Space Electronics
Chairmen: Robert W. Seibold, Raytheon SystemsDr. Paul Cheng, TRW
Multifunctional Structures Technology—Overview and Status 2005
DavidM. Barnett and Suraj P. Rawal
Matched CTE Composites for COB Applications 2014
W. Kowbel, C. Bruce, S. Picard, W. Champion and J.C. Withers
Substrates for Flip-Chip-on-Board 2023
Eyan Lee andWilliam E. Davis
SM Package Miniaturization Trends and Assembly ReliabilityChallenges 2032
RezaGhaffarian
USAF Manufacturing Technology's Initiativeon Electronics
Parts Obsolescence Management 2044
Anthony Bumbalough
Large-Scale Use of COTS in Space 2052
DavidH.Thornhill
Commercial Approaches for Future Space Systems 2064
Donald C. Mayer, Ronald C. Lacoe, Jon V. Osborn,
Steven C. Moss and Bruce K. Janousek
EffectsofSol-Gel Preparation Conditions on PZT Dielectric Properties 2074
Hsin-Chun Lu, Chun-Hsien Wu, Hsin-Li Kuo and Ting-Chun Chen
Flywheel Energy Storage SystemsChairmen: Charles E. Bakis, Penn State University
Dr. Jerry Fausz, Air Force Research Laboratory
Iv
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Characterization and Process Development of Cyanate Ester
Resin Composites 2081
B.J. Frame
Quantifying Process Induced Residual Stresses in Filament
Wound Composite Parts 2095
JeffM. Ganley, Arup K. Maji and Steven Huybrechts
Tensile Behavior of Filament Wound Composites in Vacuum 2110
Cynthia L. Shirey, Charles E. Bakis and Eric J. Weaver
Optimal Design ofa Hybrid Composite Flywheel Rotor Using
Finite Element Methods 2119
Sung Kyu Ha, Dong Jin Kim and Sang Kyu Choi
Polar Woven Flywheel Rim Design 2133
Brad C. Huang
Health Monitoring ofHigh Energy Density Rotor for Use in
Spacecraft Applications 2145
Chad Fisher and George Lesieutre
Russian Experience in Composite Flywheels Spin-Tests 2155
George G. Portnov
Infrastructure Durability Issues
Chairman: Dr. Howards. Ktiger, HSKAssociates, Inc.
FRP Rehabilitation of Corrosion-Damaged Concrete Structures 2170
Ahmed Debaiky, Mark F. Green and Brian B. Hope
The Effect ofVapor Barrier Encapsulation of Concrete by FRP
Strengthening Systems 2182
Jaime K. Mack and Erika E. Holt
Durability Issues for Composites in Infrastructure 2194
Gary L. Steckel, Gary F. Hawkins and Jerome L. Bauer, Jr.
Mechanical Properties and Durability of Advantex®
Glass Fiber Composites 2209
Gary Williams, James Gauchel and Mark Greenwood
Effect of Concrete Based Alkaline Solutions on Short Term
Response of Composites 2222
K. Murphy, Z. Zhang and V.M. Karbhari
lvi
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Effects ofExtended Freeze-Thaw Exposure on Composite
Wrapped Concrete Cylinders 2231
J. Rivera, V.M. Karbhari and P.K. Dutta
The Development ofLow Temperature Cure Resin Systemsfor External Sheet Reinforcement of Concrete Structures 2240
Marc Imbrogno, Makoto Saito and HowardKliger
Durability Issues for FRP Reinforcement to Concrete Structures 2246
Max L. Porter
Textile CompositesChairmen: Dr. Frank K. Ko, Drexel University
Dr. Ignaas Verpoest, Katholicke University/Leuven
Innovative Materials and Manufacturing Processes for the Cost
Effective Manufacture of Composite Airframe Structures 2255
Andrew Mills, Graham Burley and Rob Backhouse
Effective Braided Preforms for Crush Elements in Car 2268
Hiroyuki Hamada
Development of Cost-Effective Preform Technology for EngineeredFabric Reinforcements 2277
Vasilios Brachos, Guy A. Rossi and Wayne D. Kirk
Stitch Parameter Effects on Interlaminar Fracture Toughness
of CFRP Laminates 2289
Yutaka Iwahori and Takashi Ishikawa
Microwave Reflectivity of Carbon Fiber Triaxial Woven Fabrics
for Antenna Reflector 2301
Shinji Suesada andAkihito Watanabe
Damage Development in Knitted Fabric Composites: Experimentand Modelling 2310
G. Huysmans and I. Verpoest
Test Methods
Chairman: Dr. DonaldAdams, University ofWyoming/CompositeMaterials Research
Use of the Wyoming Combined Loading Compression (CLC)
Fixture to Test Unidirectional Composites 2322
Scott L. Coguill and Donald F. Adams
lvii
PAPERS, AUTHORS, SESSIONS AND SESSION CHAIRMEN
Page
Selection of the ProperWedge Grip Surface for Tensile TestingComposite Materials 2332
Ronda J. Coguill and Donald F. Adams
Through Thickness Tensile Strength Test Specimen Design for 3-D
Woven Reinforced Composites 2346Brian J. Sullivan
Mixed Mode Stable Crack Extensions Through Stiffened Specimens 2358Abdel-Hamid I. Mourad, Eltahry Elghandour and Faysal A. Kolkailah
ImpactTesting and Simulation of Sandwich Structures 2368J.M. Kenny and L. Torre
High Temperature PolymerMatrix-Carbon Fiber Composites—Critical Degradation Mechanisms and Test Methodologies 2382
E. Eugene Shin, Roger J. Morgan, Jiang Zhou, James K. Sutter
and MaryAnn Meador
Smart Materials and Structures Technology—IIChairman: Dr. HiroshiAsanuma, Chiba University
Health Monitoring ofSiC/AI Composites with Embedded Optical Fiber 2397H. Asanuma, H. Du, T. Kishi, K. Ichikawa, K, Maeno,C. Prat, H. Kurihara, T. Chandra and D. Yu
Thermoelectric Properties ofCalcium Hexaboride Sintered Body 2406Noriyuki Takashima, Jun-Ichi Kawano, Kiyotaka Mori,Yoshitake Nishi, Yasuyuki Miyazawa and Jun-Ichi Matsushita
The Strain Induced by Low Magnetic Field of Fe-Pd Alloy 2416H. Yabe, R. Kondo, K. Oguri, M. Iwase, T. Kaneko, T. Kuji,H-H. Uchida and Y. Nishi
Fatigue Crack Detection ofFiber-Metal Laminate by EmbeddedOptical Fiber
24210. Haga, H. Asanuma and H. Koyama
Composite Bridge ApplicationsChairman: Issam Harik, University ofKentucky/Civil Engineering
Monocoque Designs of a Fiber-Reinforced Plastic Pedestrian Bridge:A Summary ofthe Air Force Research Laboratory Activities 2430
Keith B. Bowman and David H. Mollenhauer
lviii
