14 V. Ayyagari et al. (a) (b) Fig. 1 The variants of polymer-metal composites: (a) continuously embedded metal fiber in the polymer [6], and (b) Partially embedded metal fibers in the polymer [2] Specimen Fabrication and Testing Polymer matrix-metal wire composites can be used as functional structures in a variety of applications requiring the conductivity of metal and the lightweight provided by polymer supports (e.g., lightweight heat exchangers). In many applications, the polymer structure may be pressurized, such as by a working fluid in a heat exchanger and may be subject to a differential pressure that may cause a partially free-standing metal wire to pull out of the polymer support structure. For this investigation, a specimen was designed and fabricated that allowed for testing of multiple partially free-standing wires embedded in a polymer structure that is subjected to a differential pressure (i.e., a polymer pressure vessel with metal stringers). The cross-section of the composite specimen that was fabricated and tested in this investigation can be seen in Figure 2. Fig. 2 (left) Cross-media coupons (middle) Cross-sectioned coupon exposing free-standing wires inside (right) The geometrical parameters of the cross-media coupons as seen from top cross-section view To maintain its integrity in applications where the polymer structure is pressurized, the composite structure should not leak at the metal wire/polymer interface during operation, i.e. maintain the sealing in pressurized condition. Currently, there
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