High Temperature Shear Strength of T650-35/HFPE-II-52 Polyimide Matrix Unidirectional Composite
The shear strength of a 4-ply unidirectional composite laminate consisting of carbon fibers (T650-35) and a polyimide matrix (HFPE-II-52) was measured over a temperature range of 25 to 315°C. The tests were performed using a Iosipescu test sample, modified to provide a more uniform shear stress distribution across the gauge section and loaded with an Arcan type test fixture. The test specimen design is based on the results of an extensive finite element study. Shear strength tests were performed on dry, 50% RH and 100% RH moisture saturated samples. Results of the experiment show that shear strength decreases from approximately 120 MPa at 25°C to 60 MPa at 315°C and that moisture saturated samples have a 5–10 MPa lower shear strength than dry samples.
Optimal Substrate Preheating Model for Thermal Spray Deposition of Thermosets onto Polymer Matrix Composites

 High velocity oxy-fuel (HVOF) sprayed, functionally graded polyimide/WC-Co composite coatings on polymer matrix composites (PMC's) are being investigated for applications in turbine engine technologies. This requires that the polyimide, used as the matrix material, be fully crosslinked during deposition in order to maximize its engineering properties. The rapid heating and cooling nature of the HVOF spray process and the high heat flux through the coating into the substrate typically do not allow sufficient time at temperature for curing of the thermoset. It was hypothesized that external substrate preheating might enhance the deposition behavior and curing reaction during the thermal spraying of polyimide thermosets. An additional difficulty arises from the low thermal conductivity and low specific heat capacity of the PMC substrate, which prevent effective substrate preheating by the HVOF jet as in the case of metallic substrates. A simple analytical process model for the deposition of thermosetting polyimide onto polymer matrix composites by HVOF thermal spray technology has been developed. The model incorporates various heat transfer mechanisms and enables surface temperature profiles of the coating to be simulated, primarily as a function of substrate preheating temperature. Four cases were modeled: (i) no substrate preheating; (ii) substrates electrically preheated from the rear; (iii) substrates preheated by hot air from the front face; and (iv) substrates electrically preheated from the rear and by hot air from the front. Thermal properties of the polyimide needed for the simulations were determined by Differential Scanning Calorimetry (DSC) and Thermo-Gravimetric Analysis (TGA). Microstructural characterization of the coatings and the morphology of polyimide splats sprayed both with and without substrate preheating were analyzed using standard metallographic techniques. Coating temperature in cases (iii) and (iv) never dropped below the crosslinking temperature of the polyimide feedstock. This was the critical condition required for the curing reaction and successful deposition of thermosets by HVOF thermal spraying.
The Influence of Sizings on the Durability of High-Temperature Polymer Composites
To increase performance and durability of high-temperature composites for potential rocket engine components, it is necessary to optimize wetting and interfacial bonding between high-modulus carbon fibers and high-temperature polyimide resins. Sizings commercially supplied on most carbon fibers are not compatible with polyimides. In this study, the chemistry of sizings on two high-modulus carbon fibers (M40J and M60J, Toray) was characterized as was the chemistry of PMR-II-50 fluorinated polyimide resin. The carbon fibers were characterized using single filament wetting, scanning electron microscopy, Fourier transform infrared spectroscopy, and X-ray photoelectron spectroscopic measurements. The polyimide matrix resins were coated onto glass filaments for characterization by wetting measurements. Surface energy components were obtained by wetting with nondispersive (methylene iodide), acidic (ethylene glycol), and basic (formamide) probes. A continuous desizing system that uses an environmentally friendly chemical-mechanical process was developed for tow level fiber. Composites were fabricated with fibers containing the manufacturer's sizing, desized, and further treated with a reactive finish. Results of room temperature tests after thermal aging show that the reactive finish produces a higher strength and more durable interface compared to the manufacturer's sizing. When exposed to moisture blistering tests, however, the better-bonded composite displayed a tendency to delaminate, presumably due to trapping of volatiles.