Rani Elhajjar

Tracy Gill

Additive manufacturing (AM) for space exploration has become a growing opportunity as long-range space missions evolve. In partnership with the National Space Grant Foundation and NASA, students from the University of Wisconsin-Milwaukee participated in the 2014-15 X-Hab Academic Innovation Challenge, with participants tasked with developing new AM solutions that would be recyclable with minimal loss in mechanical properties. The teams investigated materials, characterization, testing, modeling, and tool development, including the ability to employ reusable carbon-fiber tension ties. The tools developed show that it is possible to employ thermoplastic polymer materials fabricated using AM together with reusable and flexible high-performance carbon-fiber-based composite ties. The AM-printed part is completely recyclable. The carbon-fiber composite ties are repurposed into new structural configurations without loss in properties. The results of this project are now published by SAE International. Studies into Additive Manufacturing for In-Space Manufacturing is a series of interconnected papers that explore: Lessons learned in processing of recycled thermoplastic filaments The criticality of process control on the print process The effects of orientation angles and print parameters on mechanical behavior Microstructural analysis Case studies of tools included in the spacecraft's toolbox

Student Research Papers

Studies into Additive Manufacturing for In-Space Manufacturing

Additive Manufacturing of Aerospace Composite Structures: Fabrication and Reliability introduces the reader to the current state of technologies involved in processing and design of polymer-reinforced fiber composites using additive manufacturing's automated fiber placement methods, through ten seminal SAE International papers. Currently, the material layup strategy in terms of process selection and manufacturability is usually not prioritized in the design phase. Engineers do not have a good way to see how their design choices can affect the manufacturing process beyond their initial structural-level considerations. The result is typically a large amount of experimental testing necessary to qualify the materials and structures typified in the classical building-block approach. Such an environment makes mistakes difficult to solve and, should redesign be required, obtaining reliable information is hard to piece together. Additive Manufacturing of Aerospace Composite Structures: Fabrication and Reliability approaches the question of quality in these structures from a hands-on, solution-driven perspective.

Fabrication and Reliability

Additive Manufacturing of Aerospace Composite Structures

Peter N. Grant

Cindy Ashforth

Presents the latest strategies in the development and use of composite materials for large structures and the effects of defects Practical Design and Validation of Composites Structures: Effects of Defects offers an important guide to the use of fiber-reinforced composites and how they affect the durability and safety of engineering structures such as aircraft, ships, bridges, wind turbines as well as sporting equipment. The text draws on the authors’ direct experience in industry and academia to cover the most recent strategies in the development of composite structures and uniquely integrates the assessment of the effects of defects introduced during production. This comprehensive resource builds on an essential introduction to the characteristics of composites and the most common types of defects encountered in production. The authors review the recent manufacturing methods and technologies used for inspecting composite structures and the design issues related to an analysis of their failure and strength incorporating the variability of processing. The text also contains information on the latest regulatory requirements and the relevant standards associated with the testing and design within a robust design philosophy and approach. This important resource: Offers a comprehensive review of the most current regulatory developments in the use of composites for the construction of complex composite structures Presents information on the basic characteristics of composites Includes testing strategies for determining the impacts of production defects Reviews the most current manufacturing methods and inspection technologies in the field Contains methods for statistical analysis and processing of experimental effects of defects test data Written for professional engineers in mechanical engineering, automotive engineering, aerospace engineering, civil engineering, and energy engineering as well as industry and academic researchers, Practical Design and Validation of Composites Structures: Effects of Defects is the hands-on text that covers the essential information needed to understand the use of composites and how they affect complex engineering projects using composites.

Effects of Defects

Composite Structures

Valeria La Saponara

Anastasia Muliana

Smart Composites: Mechanics and Design addresses the current progress in the mechanics and design of smart composites and multifunctional structures. Divided into three parts, it covers characterization of properties, analyses, and design of various advanced composite material systems with an emphasis on the coupled mechanical and non-mechanical behaviors. Part one includes analyses of smart materials related to electrically conductive, magnetostrictive nanocomposites and design of active fiber composites. These discussions include several techniques and challenges in manufacturing smart composites and characterizing coupled properties, as well as the analyses of composite structures at various length and time scales undergoing coupled mechanical and non-mechanical stimuli considering elastic, viscoelastic (and/or viscoplastic), fatigue, and damage behaviors. Part two is dedicated to a higher-scale analysis of smart structures with topics such as piezoelectrically actuated bistable composites, wing morphing design using macrofiber composites, and multifunctional layered composite beams. The analytical expressions for characterization of the smart structures are presented with an attention to practical application. Finally, part three presents recent advances regarding sensing and structural health monitoring with a focus on how the sensing abilities can be integrated within the material and provide continuous sensing, recognizing that multifunctional materials can be designed to both improve and enhance the health-monitoring capabilities and also enable effective nondestructive evaluation. Smart Composites: Mechanics and Design is an essential text for those interested in materials that not only possess the classical properties of stiffness and strength, but also act as actuators under a variety of external stimuli, provide passive and active response to enable structural health monitoring, facilitate advanced nondestructive testing strategies, and enable shape-changing and morphing structures.

Rani Elhajjar

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