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Conventional and Over Molded Sheet Molded Compound (SMC) University of Tennessee, Knoxville TRACE: Tennessee Research and Creative Exchange Masters Theses Graduate School 12-2019 Conventional and Over Molded Sheet Molded Compound (SMC) MOHAMMED ZAHID ABBAS KHURAISHI University of Tennessee, [email protected] Follow this and additional works at: https://trace.tennessee.edu/utk_gradthes Recommended Citation ABBAS KHURAISHI, MOHAMMED ZAHID, "Conventional and Over Molded Sheet Molded Compound (SMC). " Master's Thesis, University of Tennessee, 2019. https://trace.tennessee.edu/utk_gradthes/5679 This Thesis is brought to you for free and open access by the Graduate School at TRACE: Tennessee Research and Creative Exchange. It has been accepted for inclusion in Masters Theses by an authorized administrator of TRACE: Tennessee Research and Creative Exchange. For more information, please contact [email protected]. To the Graduate Council: I am submitting herewith a thesis written by MOHAMMED ZAHID ABBAS KHURAISHI entitled "Conventional and Over Molded Sheet Molded Compound (SMC)." I have examined the final electronic copy of this thesis for form and content and recommend that it be accepted in partial fulfillment of the equirr ements for the degree of Master of Science, with a major in Materials Science and Engineering. UDAY KUMAR VAIDYA, Major Professor We have read this thesis and recommend its acceptance: CLAUDIA RAWN, KURT EDWARD SICKAFUS Accepted for the Council: Dixie L. Thompson Vice Provost and Dean of the Graduate School (Original signatures are on file with official studentecor r ds.) Conventional and Over Molded Sheet Molded Compound (SMC) A Thesis Presented for the Master of Science Degree The University of Tennessee, Knoxville Mohammed Zahid Abbas Khuraishi December 2019 Copyright 2019 by Mohammed Zahid Abbas Khuraishi ii Acknowledgements I would like to express my gratitude to my thesis advisor Dr. Uday Vaidya for his advice, guidance and composite materials expertise throughout my thesis research. I would also like to thank my committee members, Dr. Kurt E. Sickafus and Dr. Claudia J. Rawn for giving their time to provide input for my research. I am grateful for the funding and resources that were provided by the Institute for Advanced Composites Manufacturing Innovation (IACMI), Oak Ridge National Laboratory (ORNL), and the University of Tennessee for this thesis work. I would like to thank IDI Composites for providing me with the materials for this work. I would like to thank Stephen Young, James Eun, and Niko Maldonado at the University of Tennessee for assisting me with X-ray CT scan and polishing of samples at SERF. I would like to thank Dr. Ahmed Arabi Hassen for his continuous guidance. I would like to thank my staff and current fellow graduate students, Dr. Nitilaksha Hiremath, Pritesh Yeole, Vidya Hiremath, Ryan Spencer, Saurabh Pethe, Surbhi Kore, Kaustubh Mungale, Jared Hughes, Komal Kooduvalli, Mason Rucinski, Eilish Stanek, Jacob Williams, Muhammed Ibrahim, Cliff Herring, and Benjamin Schwartz for all their support and time during this thesis research. I would like to thank Stephen Sheriff at the Fiber Composites Manufacturing Facility for his mechanical expertise and support. I would like to thank Vanina Ghossein and Dr. Hicham Ghossein for their unquantifiable support in my Master’s program. Finally, I want to thank my parents, Mohammed Shoeeb Abbas Khuraishi and Fatima Shoeeb, and my sisters Rubiyaa Khan, and Saaraa Abbaas and my brother-in-law Mudasir Ahmed Khan, and my cousin Musavir Ahmed Khan for their love, support, encouragement, and patience throughout my pursuit of this MS in Materials Science and Engineering. iii Abstract Composite materials are desired for automobile, aerospace, and other high-tech applications due to their impressive physical properties and resilience. The use of composite materials in vehicle structures could reduce the weight and thereby the fuel consumption of vehicles. Sheet Molding Compound (SMC) is extensively used in automobile industries such as front end panels, roof panels, deck lids, trunk front fender-hood assemblies, bumper beams, heater, and air conditioner housings, and other exterior and interior body components. To enhance the stiffness and light-weighting of the vehicles, overmolded structures can be utilized. These overmolded structures often have two or more materials integrated generally, fiberglass, carbon fiber, and natural fibers. This research aims to combine two high-performance constituents to create an overmolded composite capable of meeting performance criteria for a vehicle - high strength and high stiffness. To create the overmolded structures, two fiberglass SMC were chosen with vinyl ester and polyester resin system as the core. Two layers of ± 45° Textile grade carbon fiber (TCF) was used as overmolded material. The SMC was fabricated using hot compression molding process and overmolded composite was fabricated using a VARTM process with hot compression molding. Epoxy was used as an adhesive to bond the SMC and TCF. Non-destructive testing was performed on a representative panel before destructive testing to examine the bonding between the SMC and TCF. The overmolded composite was tested for mechanical characterization, bonding characterization and X-ray tomography was performed to check the orientation of the fibers in SMC. It was found that the bonding of overmolded composite was stronger than the SMC. iv Table of Contents Chapter 1 – Introduction ................................................................................................................. 1 Chapter 2 – Literature Review ........................................................................................................ 5 2.1 - Sheet Molding Compound (SMC) ...................................................................................... 5 2.2 - Fiber orientation used in SMC ............................................................................................ 9 2.3 - Resin Systems ................................................................................................................... 10 2.4 - Rheology ........................................................................................................................... 17 2.5 - Applications of SMC ........................................................................................................ 19 2.6 - Textile Grade Carbon Fiber (TCF) ................................................................................... 20 2.7 - Overmolded Composite: ................................................................................................... 23 2.8 - Uniqueness in This Work ................................................................................................. 27 Chapter 3 – Materials and Methods .............................................................................................. 28 3.1 - Overmolded Composite Materials .................................................................................... 28 3.2 - Processing of SMC Plates ................................................................................................. 28 3.3 - Processing of C-ply Composites ....................................................................................... 32 3.4 - Ultrasonic Inspection/Nondestructive Evaluation (NDE) ................................................ 34 3.5 - Thermogravimetric Analysis ............................................................................................ 34 3.6 - Micro x-ray Photoelectron Spectroscopy.......................................................................... 34 3.7 - Scanning Electron Microscopy ......................................................................................... 35 3.8 - Optical Microscopy ........................................................................................................... 35 3.9 - Micro x-ray Computed Tomography ................................................................................ 35 3.10 - Mechanical Characterization of SMC and C-ply Composite ......................................... 36 3.11 - Bonding Characterization of Overmolded Plates ........................................................... 37 Chapter 4 – Results and Discussions ............................................................................................ 38 4.1 - Ultrasonic Inspection/Nondestructive Testing .................................................................. 38 4.2 - Characterization of SMC and C-ply Composite ............................................................... 46 4.3 - Thermogravimetric Analysis ............................................................................................ 95 4.4 - X-ray Photoelectron Spectroscopy ................................................................................... 98 4.4 - Bonding Characterization ............................................................................................... 101 4.5 - Micro x-ray Computed Tomography .............................................................................. 111 4.6 – Scanning Electron Microscopy ...................................................................................... 113 Chapter 5 – Conclusions and Future work .................................................................................. 118 v 5.1 - Concluding Remarks on C-ply Composite ..................................................................... 118 References ..................................................................................................................................
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