SOCIETY FOR THE ADVANCEMENT OF

MATERIAL AND PROCESS ENGINEERING

46th International SAMPE Symposiumand Exhibition

VOLUME 46

Book 2 of 2 Books

2001:

A MATERIALS AND PROCESSES ODYSSEY

Edited byUnas Repecka

Frederick F. Saremi

Long Beach Convention Center

Long Beach, California

May 6-10,2001

Book 2

INNOVATIVE COMPOSITE BRIDGE CONSTRUCTION

Chairmen: Dr. Hota GangaRao, West Virginia University/Constructed Facilities

Jerome O'Connor, New York State Department of

Transportation/Bridges

Design and Construction ofMarket Street Bridge—WV 1321

HOTA V S GANGARAO and KRIT LAOSIRIPHONE

Evaluation of Mechanical Properties of Glass Fiber

Wrapped CCA-Treated Wood Coupons 1331

S ANEGUNTA, R K GUPTA and H V S GANGARAO

New York's Experience with FRP Bridge Decks 1341

JEROMES O'CONNOR

Innovative Materials for Bridges of the 21st Century 1352

JOHN M HOOKS

Experimental Investigation on the Out-of-Plane

Response of Unreinforced Brick Walls Retrofitted

with FRP Composites 1364

A MOSALLAM, M HAROUN, T ALMUSALLAM and S FARAIG

Effect of Advanced Composites on Creep and

Shrinkage of Concrete 1372

WASSIM NAGUIB and AMIR MIRMIRAN

ADVANCED METHODS IN ANALYSIS/SIMULATION—II

Chairmen: Dr. C.C. Chamis, NASA Glenn Research Center

Prof. Levon Minnetyan, Clarkson UniversityDr. Frank Abdi, AlphaStar Corporation

Life Prediction of X37 Space Vehicle 1381

VICTOR CHIN, ALFREDO DEL MUNDO, T CASTILLO and R LATHAM

Filament Winding Simulation of a Composite OverwrappedPressure Vessel 1393

SHEKHAR KAMAT, XIAOFENG SU, BRADLEY S FORSYTH, CHRISTOPHER KEDDY,HAROLD D BEESON and CHRISTOS CHAMIS

xviii

Impact, and Tension after Impact of Composite LaunchSpace Structure 1402DADE HUANG, FRANK ABDI and MOHSEN KHATIBLOU

Elastic Moduli of Cracked Laminates with Shear Coupling 1412

JAMES M WHITNEY

Finite Element Analysis of Endless Fiber

Reinforced Thermoplastics 1424

W MICHAELI, 0 FISCHER, M STEINBERG and J FORSTER

ELECTRONIC AND MICROELECTRONIC: PACKAGINGAND ASSEMBLIES

Chairmen: Dr. John A Emerson, Sandia National Laboratories/

Organic Materials

Dr. Guo Feng Xu, Nelco International Corporation

Etching Carbon Fiber Laminates as a Precursor

to Electroless Plating 1438

GREGORY L YOUNG and HONG XU

Benzoxazine: New Chemistry for Building Advanced

Printed Wiring Boards 1451

ROGER TIETZE, YEFIM BLYAKHAM, PRADIP BHATTand MOHAMMAD CHAUDHARI

The Effect of Shelf Life on the Bond Strength of Etched

Filled PTFE PC Board Materials 1458

PAUL D WIENHOLD

Kinetic Studies of Curing Process and Gelation ofHighPerformance Thermosets Based on Ternary Systems of

Benzoxazine, Epoxy and Phenolic Resins 1466

SARAWUT RIMDUSIT and HATSUO ISHIDA

Semiconductor Molding Compounds Based

on Polybenzoxazines 1481

ANTHONY A GALLO

Novel Composites for Laser Diode Thermal Management 1491

W KOWBEL, W CHAMPION, R HIZNAY, J WEBB, J C WITHERS and S CHOI

Methods to Fabricate Strong Micron-Thick

Bondlines for Microsystems 1498

RACHEL K GIUNTA, MICHAEL S KENT JESSICA HALL,

JOHN A EMERSON and DARA L WOERDEMAN

xix

COMPOSITES FOR SPACECRAFT

Chairman: Dr. Edward Silverman, TRW Space and Technology

Low Moisture Absorption Epoxy Composites for Satellite

and Moisture Critical Applications 1506

DAVID LEACH and JACK BOYD

Characterization of Graphite Fiber/Polyimide Compositesfor RLV Applications 1515

CHERYL L BOWMAN, JAMES K SUTTER, JOHN C THESKEN and

BRIAN P RICE

Method to Enhance the Kz of a Pitch Fiber Laminate 1530

JOHN BOOTLE

Structural Testing of Carbon-Carbon Radiator Panel 1538

EDWARD SILVERMAN

Carbon-Carbon Honeycomb Panels for Aerospace Applications. . .1552

WALLY HANSEN

Mode I Fracture of a Carbon Fiber-Reinforced Bismaleimide

Composite at Cryogenic Temperatures 1557

STEVEN L DONALDSON and RAN Y KIM

PULTRUSION

Chairman: Dr. Clem C. Hiel, W. Goldsworthy & Associates

Replicating the Thermal Environment in a Simulated

Thermoplastic Pultrusion Process 1564

FREDERICKA BROWN, RAY KOZAK, BRENDAN O'TOOLE and ROBERT BOEHM

Design Manual Development for FRP Structural Shapes:Practical and Durability Considerations 1576

JOHN J LESKO, SCOn W CASE, THOMAS E COUSINS, DAN WITCHER

and GLENN P BAREFOOT

Implementation of the Deep DWB in the Dickey Creek Bridge.... 1587

M.D HAYES, C WALDRON, T SCHNIEPR J J LESKO and T C COUSINS

Preliminary Development of a Durability Model for

Concrete Filled FRP Piles 1597

MIGUEL PANDO, JOHN LESKO and SCOTT CASE

Composite Trailer: From Prototype to Industrialisation 1612

JAN VERHAEGHE

xx

FLYWHEEL MATERIALS AND APPLICATIONS

Chairman: Dr. Steve DeTeresa, Lawrence Livermore Laboratory

Stress Relaxation in Composite Flywheels 1621

JEROME TTZENG

Matrix-Dominated Performance of Thick-Section Fiber

Composites for Flywheel Applications 1631

S J DETERESA, L M ALLISON, D C FREEMAN and S E GROVES

Properties of Fiber Composites for Advanced FlywheelEnergy Storage Devices 1643

S J DETERESA and S E GROVES

Optimal Design of Multi-Direction Composites Flywheel Rotors . . .1657

YASSER GOWAYED, GEORGE T FLOWERS and JEFFREY J TRUDELL

FIRE SAFETY OF MATERIALS—I

Chairmen: Usman Sorathia, Naval Surface Warfare Center/Carderock

Richard Lyon, FAA

Fire Hazard Assessment in Submarine Plastic Waste

Stowage Compartments 1668

C C NDUBIZU, R A BROWN, PA TATEM and F W WILLIAMS

Performance Requirements for Fire Safetyof Materials in U.S. Navy Ships and Submarines 1683

U SORATHIA, G LONG, M BLUM, J NESS and T GRACIK

Flammability and Mechanical Properties of a New

Fire Resistant Epoxy 1695

RICHARD E LYON and LAUREN M CASTELLI

Developments in Fire Proof Composites 1707

PIET VAN DINE and USMAN SORATHIA

Fire Issues in Engineered Wood Composites for Naval

Waterfront Facilities 1713

L JAVIER MALVAR, ROBERT TICHY and DAVID E PENDLETON

INTERNAL REINFORCEMENT OF CONCRETE MEMBERS

Chairmen: Prof. Damian Kachlakev, California PolytechnicState University/Civil and Environmental Engineering

Prof. TarekAlmusallam, KingSaud University/Civil Engineering

XXI

Bonding between the Concrete and Polymer

Composite Tendon 1723

WAI HOW SOONG, S RIZKALLA and J RAGHAVAN

The Performance of Bond of FRP

Reinforcement in Concrete 1738

VITAUTS TAMUZS, ROBERTS APINIS, JANIS MODNIKS and

RALEJS TEPFERS

Hollow FRP Rebar—Its Unique ManufacturingProcess and Applications 1749

THOMAS S OHNSTAD and DAMIAN I KACHLAKEV

Effects of Shear Strengthening with GFRP on

Reinforced Concrete Beams 1759

TANARAT POTISUK, DAMIAN I KACHLAKEV, THOMAS H MILLER and

SOLOMON C S YIM

FEA of the Horsetail Creek Bridge Strengthenedwith FRP Laminates 1772

KAS1DIT CHANSAWAT, DAMIAN I KACHLAKEV, THOMAS H MILLER and

SOLOMON C S YIM

Bond Behavior of FRP Reinforcing Bars—The State-of-the-Art.. .

1784

NARENDRATALYandH V S GANGARAO

SPACE ENVIRONMENTAL EFFECT

Chairmen: Patricia Hansen and Jacqueline A. Townsend, NASA

Goddard Space Flight Center

Hubble Space Telescope Third Servicing Mission Retrieved

Metallized Teflon FEP Analysis 1797

JOHNR BLACKWOOD, JACQUELINE A TOWNSEND, PATRICIA A HANSEN,

MARKW MCCLENDON, JOYCE A DEVER, KIM K DE GROH, BENJAMIN B REED,

CHARLES C HE and WANDA C PETERS

Mechanical Properties of Teflon FEP Retrieved from the

Hubble Space Telescope 1811

JOYCE A DEVER, KIM K DE GROH, RUSSELL K MESSER, MARKW McCLENDON,MICHAEL VIENS, L LEN WANG and JONATHAN D GUMMOW

Thermal Contributions to the Degradation of Teflon FEP

on the Hubble Space Telescope 1826

KIM K DE GROH, JOYCE A DEVER, JAMES K SUTTER, JAMES R GAIER,

JONATHAN D GUMMOW, DANIEL A SCHEIMAN and CHARLES HE

xxii

Fabrication and Testing of Habitat Components UsingIn-Situ Materials for Martian Exploration 1841M.-H.Y. KIM, S. A, THIBEAULT, R. L. KIEFER, J. W. WILSON, R. C. SINGLETERRY,J. MOORE, H. HUFF and R, WILKINS

Space Environmentally Stable Polyimides and

Copolyimides Derived from [2,4-Bis(3-aminophenoxy)phenyl]-Diphenylphosphine Oxide 1853KENT A. WATSON, JOHN W. CONNELL and FRANK L. PALMIERI

Evaluation of the Mechanical and Erosion Resistance Qualities of

Composite Materials Exposed to the LEO Space Environment. . .

1864V. ISSOUPOV, 0. V. STARTSEV, V. VIEL, M. DINGUIRARD, C LACABANNEand E. F. NIKISHIN

Satellite Materials Outgassing Effects Knowledgebase 1875B. E. WOOD, B. D. GREEN, 0. M. UY R. R CAIN and SOPO K. YUNG

COMPOSITES DESIGN AND ANALYSIS

Chairman: Prof. Daniel O. Adams, University of Utah/

Mechanical Engineering

PACKS: An Affordable Knowledge-Driven CompositeDesign for Manufacturing Process 1885

RICHARD D. HALE and VIRGINIA M. VASEY-GLANDON

Advanced CAD Software Tools for Cost-Effective

Composite Engineering 1899

OLIVIER GUILLERMIN and JOHAN GRAPE

Parametric Investigation of Cantilevered IsoTruss Beams

Subjected to Axial Compression 1911

LAMAR D. WINKEL, DAVID W. JENSEN and DIL1P K. DAROOKA

Composite Materials for Micro Air Vehicles 1926PETER G. IFJU, SCOTT ETTINGER, DAVID JENKINS and LUIS MARTINEZ

Measurement and Analysis of Fiber-Composite-Reinforced-Foam Sandwich Core Material Properties 1938

FREDERICK STOLL and ROB BANERJEE

Damage Tolerance of Stitched CompositeSandwich Structures 1947

LARRY E. STANLEY and DANIEL 0. ADAMS

xxni

Lube-Free Composite Bearings: Are They Viable? 1958

CHRISTOS C CHAMIS and LEVON MINNETYAN

Non-Linear Deformation in Composite Structures 1967

R B HESLEHURSTand M J HOKE

AUTOMATED PLACEMENT TECHNOLOGY

Chairman: Dr. Norman Johnston, NASA Langley Research Center

Properties of Automated Tape Placed

LARC-PETI-5 Composites 1973

T H HOU, H L BELVIN and N J JOHNSTON

Automated Fabrication Processes for Large Composite

Aerospace Structures: A Trade Study 1986

MARKB GRUBER, MARK A LAMONTIA and BRIAN J WAIBEL

Automated Fiber Placement of PEEK/IM7 Composites with

Film Interleaf Layers 1998

A BRUCE HULCHER, WILLIAM I BANKS III, R BYRON PIPES, SURENDRA N TIWARI,

ROBERTO J CANO and NORMAN J JOHNSTON

Fabrication of a PEEK/Graphite Composite CryogenicFuel Line 2013ROBERT BECKER, ALLEN NETTLES, RON BUCINELL, ROBERT LANGONE and

JAMES MONDO

Development of a Cure-on-the-Fly Automated Tape Placement

Machine for Electron Beam Curable Prepregs 2024

JAMES W BURGESS, MARKS WILENSKI, HARRY L BELVIN, ROBERTO J CANO

and NORMAN J JOHNSTON

A Prototype Research Laboratory for Automated Fabrication

of High Performance Composites 2037R J CANO, H L BELVIN, N J JOHNSTON, A B HULCHER, J M MARCHELLO, R W

GRENOBLE, MARK S WILENSKI and JAMES W BURGESS

E-BEAM CURING MATERIALS AND PROCESS DEVELOPMENT

Chairman: Prof. Donald Klosterman, University ofDaytonResearch Institute

Improved Epoxy Resins Cured by Electron Beam Irradiation.... 2048

CHRISTOPHER J JANKE, RONNYD LOMAX, SUSAN ROBITAILLE,SHAUN DUGGAN, RAYMUND C SERRANZANA and VINCENT J LOPATA

xxiv

Adhesion between Carbon Fibers and Cationic Matricesin Electron Beam Processed Composites 2063BRIGITTE DEFOORT and LAWRENCE T DRZAL

Cure Kinetics of Cationic Polymerization of Phenyl GlycidylEther (PGE) and Tactixl23 Using CD-1012 as Photoinitiator

....2075

REZA DABESTANI and ILIA N IVANOV

Evolution of Cure, Mechanical Properties, and Residual

Stress during E-Beam Curing of a Polymer Composite 2090J RAGHAVAN

E-Beam Curing of a Novel Liquid Crystal Resin 2103DON KLOSTERMAN, RICHARD CHARTOFF TATTONG, MARY GALASKA,CHRYSA THEODORE and PATRICK HOOD

Constituent Level Examination of an E-Beam Cured

Graphite/Epoxy Composite 2115VERNON BECHEL, CHRISTOPHER JANKE, MARK WILENSKI and G P TANDON

Automated Tape Placement with in-situ Electron Beam Cure:

A Viable Process 2127DANIEL L GOODMAN, DANIEL J WEIDMAN, CATHERINE A BYRNE ALEXANDER N

BYKANOV, THOMAS W POND, WILLIAM M McMAHON and MICHAEL P KOVACH

Electron-Beam Cure of Phenylethynyl-Terminated Oligomers.... 2140J N HAY I HAMERTON B J HOWLIN, G J HOWGATEand P M O'GARA

FIRE SAFETY OF MATERIALS—II

Chairmen: Usman Sorathia, Naval Surface Warfare Center/

Carderock

Jeffrey W. Gilman, NIST/Fire Research Laboratory

Recent Advances in Flame Retardant Polymer Nanocomposites. . .2147

JEFFREY W GILMAN, TAKASHI KASHIWAGI, ALEXANDER B MORGAN, RICHARD H

HARRIS, JR,LORI BRASSELL, WALID H AWAD, RICK D DAVIS, LEONARD CHYALL,

THOMAS SUTTO, PAUL C TRULOVE and HUGH DELONG

FTIR Sampling and Analysis of Combustion Gases for Fire

Toxicity Monitoring 2159L SPEITEL

Characterization of Fire Safe Polymer Matrix Composites for

Naval Applications 2170

J H KOO, B MUSKOPF, G McCORD, P VAN DINE, B SPENCER, U SORATHIA and

S VENUMBAKA

xxv

Fire Resistant Composites for Use on Navy Ships 2183JOHN BOOTLE

Low-Cost, Zero Halogen Optical Cable Jacket to MeetMIL-C-85045 and UL-910 Standards 2190ROBERT F KOVAR, GREG OCNOS, DENNIS KNUDSEN and GAIR BROWN

Fire Resistant Cyanate Ester-Epoxy Blends 2205RICHARD N WALTERS

THERMAL CURING AND MODELING OF COMPOSITES

Chairman: Loren P. Hendrickson, Boeing Canada Technology Ltd.

Curing Optimization of IM7/5250-4 Prepregs underField Repair Conditions 2217KEVIN LEE, PAUL 0 BINEYand YANG ZHONG

Examination of Heat Transfer in Autoclaves 2229MICHAEL HUDEK, MATT SHEWFELT, R MARK SHEAD, ANDREW JOHNSTON,NEZIH MRAD, RICK COLE, J RAGHAVAN and LOREN HENDRICKSON

A Study of Effect of Conducting Additives on Microwave

Heating and Curing Rates of Epoxy 2243SHUANGJIE (SHIRLEY) ZHOU and MARTIN C HAWLEY

Time-Domain-Reflectometry Cure Monitoring 2252NATHANIEL HAGER III and ROMAN DOMSZY

Effect of Part-Tool Interaction on Cure Distortion of Flat

Composite Laminates 2264MICHAEL T CANN and DANIEL 0 ADAMS

Parametric Study of Process Induced Deformation in

Composite Laminates 2278MADHAVA P KOTESHWARA and J RAGHAVAN

A NewLow Temperature Curing Prepreg 2293KAZUTAMI MITANI, KOKI WAKABAYASHI and SHIGETSUGU HAYASHI

EXPERIMENTAL CHARACTERIZATIONATEST METHODSChairman: Prof. Donald F. Adams, Wyoming Test Fixtures, Inc.

Low Temperature Behavior of Carbon Fiber/Epoxy Composites:Matrix and Fiber Influences on Cryogenic Microcracking 2303JOHN F TIMMERMAN, MATTHEW S TILLMAN, BRIAN S HAYES and JAMES C SEFERIS

XXVI

NF3 Plasma Treatment of IM7/5260 for the Improvementof Moisture Resistance. 2312SATOMI OHNO, MOON-HWAN LEE and FUMIO S. OHUCHI

The Notched Strength of Angle Ply Laminates 2321M. R, PIGGOTTand W.ZHANG

Phenomenal Advancements in Non-Contact Ultrasound

for Composites Characterization 2328

MAHESH C. BHARDWAJ and GARY F STEAD

Cure Kinetics and Viscosity Models for Hexcel 8552

Epoxy Resin 2341

PASCAL HUBERT, ANDREW JOHNSTON, ANOUSH POURSARTIP and

KARL NELSON

The Study of Empirical Methodology to Observe DampingCharacteristics of Various Laminate Composite Plates 2355

FAYSAL KOLKAILAH, ELTHARY ELGHANDOUR, TAIKHA OH and JASON BOLOSAN

STATUS AND ASSESSMENT OF THE USE OF FRP

COMPOSITES IN CIVIL INFRASTRUCTURE

Chairmen: Prof. Vistasp M. Karbhari, University of California,San Diego/Structural Engineering

Merle Slater, Structural Composite Construction, Inc.

HITEC Evaluation Plan for Assessment of FRP

Bridge Deck Systems 2366

DAVID REYNAUD and VISTASP M. KARBHARI

FRP Composite Systems for Concrete Structure Repairand Strengthening—Draft of a HITEC Evaluation Plan 2380

DAVID REYNAUD, PAULSCHUMAN and VISTASP M. KARBHARI

Assessment of Health Monitoring and NDE of

Composites Used for Renewal of Civil Infrastructure 2393

HENNING KAISER, VISTASP M. KARBHARI and CHARLES SIKORSKY

Structural Upgrade of Golden Gateway Building

Using Advanced Composites 2405

MERLE SLATER and LARRY McCAULEY

xxvii

TEXTILE COMPOSITES AND BRAIDING

Chairmen: Prof. Frank K. Ko, Drexel University/Materials Engineering

Mike Braley, A&P Technology, Inc.

Fabrication and Mechanical Properties of PolymorphismComposites Inserted with Knitted Polyethylene Fabric

Reinforced Polyethylene 2409

TATSURO FUKUI, ASAMI NAKAI HIROYUKI HAMADA and KAZUAKI NISHIYABU

Design Methodology of a Ductile Hybrid FRP for Concrete

Structures by the Braidtrusion Process 2421

FRANK P HAMPTON, HOA LAM, FRANK K KO and HARRY G HARRIS

Robotic Three-Dimensional Stitching Technology 2433

JURGEN WITTIG and FRANK RATTAY

Advancements in Braided Materials Technology 2445MIKE BRALEY and MOLLY DINGELDEIN

Geometry of 3D Braided Rectangular Preformwith Axial Yarns 2455

XUEKUN SUN and YOUQI WANG

Tailored Fibre Placement—Cost-Effective Preforms for

High Loaded Composites 2463DIRK FELTIN and KONRAD GLIESCHE

An Integrated Modelling Strategy for Processing and

Properties of Textile Composites 2472I VERPOEST, G HUYSMANS, Y LUO, R S PARNAS, A PRODROMOU

and S L LOMOV

TOW PLACEMENT

Chairmen: Dr. Jim Criss, Lockheed Martin

JeffHendrix, Consultant

Advanced Technology Tape Laying for Affordable

Manufacturing of Large Composite Structures 2484MICHAEL N GRIMSHAW, CARROLL G GRANT and JOSE MANUEL LUNA DIAZ

A Manufacturing Procedure for Composite Laminate Production

with Precision Fiber Placement 2495D W KELLY, R WILLGOSS, R LI and A CROSKY

xxviii

E-BEAM CURING COMPOSITE APPLICATIONS

Chairman: Paige Kirn, Lockheed Martin Aeronautics

EB Processing for Repair of Commercial Aircraft—

A Status Report 2507VINCENT J LOPATA and ERNIE FIDGEON

Innovative E-Beam Cured Structures for Aircraft 2515

MARGARET ROYLANCE and PAIGE KIRN

Electron-Beam Processable Polyimides for High-PerformanceComposite Applications 2526ANDREAE HOYT

Electron-Beam Processing of Thermoplastics: A Review 2536MICHAEL STERN

Influence of Thermal Post Curing on Electron Beam

Cured Composites 2550

BRIGITTE DEFOORT and LAWRENCE T DRZAL

FIRE SAFETY OF MATERIALS—III

Chairmen: Usman Sorathia, Naval Surface Warfare Center/Carderock

Dr. Shaheed Qureshi, Georgia-Pacific Resins

All-Phenolic Sandwich Structures for Aircraft

Interior Applications 2562

INGO KLEBA, EDMUND HABERSTROH and ANDREA KRAEMER

Fire Resistant Coatings for Polymeric Fibers 2577

W KOWBEL.K PATELandJ C WITHERS

Hybrid Composites with Glass/Carbon Fibers and

Inorganic/Organic Matrices. 2582

JAMES GIANCASPRO, P BALAGURU and RICHARD LYON

Fire Performance and Mechanical Property Characterization

of a Phenolic Matrix Syntactic Foam Core Material for

Composite Sandwich Structures 2593

NOEL J TESSIER

OFFSHORE OIL AND GAS APPLICATIONS

Chairman: Douglas B. Johnson, Lincoln Composites/Advanced Technical Products

xxix

Polysiloxane Modification of Phenolic for Composite Piping 2600

JOIE L FOLKERS and RALPH S FRIEDRICH

Composite Choke and Kill Line Development and Test Results . . .2607

DONALD D BALDWIN and DOUGLAS B JOHNSON

Application of Spoolable Composite Tubing to Oil and

Gas Industry Flowlines 2622

CHRIS LUNDBERG, WILLIAM D STRINGFELLOW, TOMAS WALSH and

HARRIS REYNOLDS

Filament Wound Composite Property Optimization with

Zoltek 48K Carbon Fiber 2634

PAUL WALSH, RICH DROPEK and RON ROSER

Development of a Heat-Activated Coupling for Composite

Pipe Systems 2651

RANDY A JONES, SU-SENG PANG, GUOQIANG LI, RICHARD H LEA and

MICHAEL A STUBBLEFIELD

Author Index 1-1

Company Index 1-9

Subject Index 1-15

XXX