1,720,952 research outputs found
DIC-based monitoring on debonding crack propagation in wrapped composite joints
No full textWrapped composite joint is an innovative technique which connects steel hollow sections through bonding such that the fatigue performance is improved compared to welded joint. In this paper, a DIC-based method of monitoring surface strains is proposed to quantify the debonding crack propagation within the composite wrap layers during high cycle fatigue loading. A constant strain threshold was used to obtain crack length based on strain distribution curves extracted from DIC. Sensitivity analysis of such threshold showed that within the ‘steady strain slope’ region, the influence of threshold choice on calculated crack length is insignificant, but a good choice of threshold can help obtain more stable results. During cyclic loading, it was found that stiffness degradation and crack development of the joint is arrested due to friction effect at the cracked interface. Static tests after cyclic loading showed that the joint can still sustain its original static resistance.Steel & Composite Structure
Measurement of damage growth in ultrasonic spot welded joint
No full textUltrasonic spot welding is a joining technique for thermoplastic composites with great potential regarding processing speed and cost. To investigate the damage tolerance and possible inherent damage arresting behavior of multi-spot welded joints, a technique is necessary to measure damage growth in the joints under cyclic loading. Visual inspection is not possible because the damage is not located on the outside surface and conventional techniques such as C-scan are not practical during a fatigue test because the specimen would have to be removed from the setup. This paper details a methodology for quantifying damage growth rates in singlespot welded joints using surface strain measurements made by Digital Image Correlation. This represents the first step towards developing a methodology for quantifying damage progression behavior in complex multi-spot welded joints.Structural Integrity & CompositesAerospace Structures & Computational Mechanic
Enhancement of mode I fracture toughness of adhesively bonded secondary joints using different layup patterning of CFRP
No full textDelamination growth in fibre reinforced polymer composites is generally evaluated with experiments that have been standardized for quasi-static load conditions. These tests characterize unidirectional delamination growth in mode I (DCB), mode II (ELS or ENF) of mixed mode conditions (MMB). However, little attention is paid in literature to the applicability of these tests to in-service delamination problems that are generally characterized by planar delamination growth. In this study, the relation between planar delamination growth, induced by transverse quasi-static indentation loading, and these unidirectional delamination tests was investigated. To that aim, prior planar delamination growth tests reported in literature, performed at EPFL, were analysed to identify up to what extent this planar growth could be correlated to the concepts of strain energy release and strain energy density. Once this appeared to successful, an experimental setup was designed to measure the delamination boundary during the transverse indentation loading of planar delamination specimens made of nontransparent carbon fibre reinforced polymer composites. With that set-up, quasi-static and fatigue planar delamination growth experiments were performed, and delamination contours could be successfully captured. While the quasi-static tests revealed limited growth, evaluation with numerical simulations revealed that the indentation force required to extend the delamination quasi-statically would cause damage to the specimen. This is attributed to the increasing length of the delamination contour when delaminations expand, which is not the case with standard unidirectional specimen. With the fatigue tests, however, delamination growth was achieved, but interestingly enough two phases were observed; first the delamination propagated in a planar fashion, while at some point in time work did not exceed an apparent threshold. Instead of no growth, however, the delamination still increased but then in a transverse manner. What makes this study of particular interest, is that the strain energy density as criterion could capture the strain energy offered (work) along the entire delamination contour, while the strain energy release rate described the resistance to delamination growth. This latter observation is in agreement with the original concept employed by Griffith when he formulated the basis of linear elastic fracture mechanics. This presentation present the experiments performed, the analysis of results, and will conclude with a proposal how to relate standard unidirectional tests to planar growth, considering that these standard tests contain little to no information on transverse phenomena with respect to strain energy density (work) and strain energy release (dissipation).Structural Integrity & Composite
Development and characterization of hybrid thin-ply composite materials
No full textThin-ply composites are recognized as a key solution for the manufacturing of high-performance composite structures due to the unique mechanical properties and the increased design versatility that they offer. They are obtained with state-of-the-art fiber spreading methods where high-count (6-24K filaments) tows of technical fibers (carbon, glass) are thinned by spreading into flat unidirectional tapes which are then combined with a polymer matrix to create pre-impregnated (prepregs) tapes of reduced thickness. In recent years, the industrialization of fiber spreading and impregnation processes enabled the large-scale production of homogenous thin-ply prepregs with thicknesses down to about 15μm per ply, which attracted the interest of the research community. However, the high production cost due to the complexity of the manufacturing methods and the inherent brittleness of thin-ply composites limit their wider adoption by the composites industry[1]. Fiber hybridization (i.e combining at least two types of fibers in a common matrix) is emerging as a promising approach for alleviating these drawbacks towards laminates with balanced characteristics in terms of mechanical properties and cost-efficiency. Currently, most studies on thin-ply hybrids employ simple interlayer (ply-by-ply) configurations mainly due to difficulties in manufacturing of more complex hybrid architectures[2]. However, simulation tools predict that notable improvements can be obtained from more complex intralayer (tow-by-tow) and intrayarn (fiber-by-fiber) hybrid architectures[3]. This work focuses on the study of existing fiber spreading methodologies, the development of equipment, and the optimization of composite processing at North Thin Ply Technology (NTPT) Renens, Switzerland, that allowed the manufacturing of hybrid composites with a high degree of fiber dispersion and controlled microstructure. Hybrid prepregs were produced by combining various ratios of dissimilar fibers following different processing routes. Composite laminates were manufactured and a versatile microstructural analysis tool was developed that enabled correlations between the manufacturing route, the resulting microstructural features describing the degree of co-dispersion, and the mechanical performance of the final part. Acknowledgments The research leading to these results has been performed within the framework of the HyFiSyn project and has received funding from the European Union’s Horizon 2020 research and innovation programme under the Marie Skłodowska-Curie grant agreement No 765881. Delamination growth in fibre reinforced polymer composites is generally evaluated with experiments that have been standardized for quasi-static load conditions. These tests characterize unidirectional delamination growth in mode I (DCB), mode II (ELS or ENF) of mixed mode conditions (MMB). However, little attention is paid in literature to the applicability of these tests to in-service delamination problems that are generally characterized by planar delamination growth. In this study, the relation between planar delamination growth, induced by transverse quasi-static indentation loading, and these unidirectional delamination tests was investigated. To that aim, prior planar delamination growth tests reported in literature, performed at EPFL, were analysed to identify up to what extent this planar growth could be correlated to the concepts of strain energy release and strain energy density. Once this appeared to successful, an experimental setup was designed to measure the delamination boundary during the transverse indentation loading of planar delamination specimens made of nontransparent carbon fibre reinforced polymer composites. With that set-up, quasi-static and fatigue planar delamination growth experiments were performed, and delamination contours could be successfully captured. While the quasi-static tests revealed limited growth, evaluation with numerical simulations revealed that the indentation force required to extend the delamination quasi-statically would cause damage to the specimen. This is attributed to the increasing length of the delamination contour when delaminations expand, which is not the case with standard unidirectional specimen. With the fatigue tests, however, delamination growth was achieved, but interestingly enough two phases were observed; first the delamination propagated in a planar fashion, while at some point in time work did not exceed an apparent threshold. Instead of no growth, however, the delamination still increased but then in a transverse manner. What makes this study of particular interest, is that the strain energy density as criterion could capture the strain energy offered (work) along the entire delamination contour, while the strain energy release rate described the resistance to delamination growth. This latter observation is in agreement with the original concept employed by Griffith when he formulated the basis of linear elastic fracture mechanics. This presentation present the experiments performed, the analysis of results, and will conclude with a proposal how to relate standard unidirectional tests to planar growth, considering that these standard tests contain little to no information on transverse phenomena with respect to strain energy density (work) and strain energy release (dissipation).Aerospace Manufacturing Technologie
Deep learning based prediction of fibrous microstructure permeability
No full textKnowledge of permeability of fibrous microstructures is crucial for predicting the mold fill times and resin flow path in composite manufacturing. Herein we report a method to rapidly predict the permeability of 3D fibrous microstructures. Our method relies on predicting the permeability of 2D cross-sections via deep neural networks and extending this capability to 3D microstructures via circuit analogy as a means of reduced order modeling. Approximately 50% of the permeability predictions of 2D cross-sections have 10% or less deviation from the permeability results obtained via flow simulations in Geodict. Computational time required for predicting the permeability of 3D microstructures is reduced from hours to less than 10 seconds. This framework enables fast and accurate prediction of micro-permeability and serves as the first building block towards prediction of fabric mesostructures’ permeability via deep learning based methods.Aerospace Manufacturing Technologie
The role of matrix boundary in the microstructure of unidirectional composites
No full textFinding new ways to evaluate the variability of microstructures, and its effect on macroscopic properties such as permeability and mechanical performance [1,2] is of increasing interest in the composite field. The variability of microstructural features at a three-dimensional level is not fully understood and its effect on macroscale properties is not well established, and mostly analyzed at a phenomenological level [3]. We introduced in recent work a method based on X-ray Computed Tomography for the threedimensional reconstruction of the fibrous microstructure of unidirectional tapes at a single fibre resolution [4]. A schematic of the workflow is represented in Figure 1. Three descriptors are introduced in the work to describe increasing level of complexity in the microstructural organization, from a single fiber path level with differential tortuosity, to group behavior with collective motion, to fibre network connectivity with length of contact. These descriptors and their interdependence highlight local effects like edge-core segregation in microstructural characteristics. However, in order to achieve a more complete definition of the unidirectional tape domain, understanding of matrix-based features and its interrelation with fiber architecture descriptors is needed. In this work, we expand the methodology of Gomarasca et al. [4], to account for matrix-based phenomena such as tape boundary variability, and void formation and morphology. This will be showcased on a unidirectional composite tape including both fiber-based and matrix-based analysis. These methods enable advanced characterization and modelling of microstructural formation and evolution during composite manufacturing.Aerospace Manufacturing TechnologiesAerospace Structures & Computational Mechanic
Identifying microstructural features in unidirectional composite tapes
No full textCarbon fibre-reinforced polymer composites (CFRPs) outperform most structural engineering materials in specific stiffness and/or specific strength, especially in their unidirectional configuration. Unidirectional composites can be found as individual structural elements in cables or pin-loaded straps; they are however most commonly found in the form of tapes, representing a semi-finished product for subsequent processing to laminates by tape laying, winding or press moulding. The outstanding properties of such composites are affected by its microstructure. It influences the structural performance and fatigue life when architected into thin ply composites [1]. The microstructure is also affected by processing conditions, respectively recursively affects processability as observed in the deconsolidation [2] or intimate contact formation [3] during laser assisted tape laying. This work presents a novel approach to identify microstructural features. This is achieved by Voronoi tessellation-based evaluation of the fibre volume content on cross-sectional micrographs, with consideration of the matrix boundary. The method [4] is shown to be robust and is suitable to be automated and has the potential to be expanded into 3d imaging techniques [5]. It further has the potential to discriminate specific microstructural features and to relate them to processing behaviour. The method is experimentally validated on tape samples with characteristic processing history.Aerospace Manufacturing TechnologiesAerospace Structures & Computational Mechanic
Stochastic Modelling of Randomly Oriented Tapes Thermoplastic Composites in Net-Shaped Specimens
No full textDiscontinuous tape composites have considerable attention due to their high formability and tailorable structures. Despite their advantages, this discontinuity leads to complex structures and makes it difficult to predict their mechanical properties. On the other hand, they have high orientational and dimensional sensitivity, which causes spatial variability and complexity in the structure to predict the mechanical properties. This spatial variability is also related to the mould cavity. A constitutive model was improved to explain the relationship between DT orientations and the mould cavity. According to the modelling technique, a random DT distribution was generated by Random Sequential Adsorption then, the Set Voronoi Tessellation was implemented to obtain DT layers. Afterwards, the Classical Laminate Theory and Finite Element Method were applied to compare the virtual net-shaped DT specimens. The results of both methods showed high stiffness at the edges of the specimens.Aerospace Manufacturing Technologie
Comparative life cycle assessment of thermoplastic and thermosetting CFRP in aerospace applications
No full textThis work quantifies and compares the environmental impact of a thermoset CFRP aircraft skin panel to that of a thermoplastic CFRP panel. This comparison is done using a cradle to gate life cycle assessment including impacts from raw material extraction, manufacturing and end of life. In addition, a hotspot analysis was performed to identify processes with the highest contribution to environmental impacts of the panels. The results show that the thermoplastic panel performed better in three endpoint damage categories including damage to human health, ecosystem and resources. The results also identify carbon fibre production, electricity usage for curing/consolidation and prepreging as the major contributors to the life cycle impacts of both panels. This provides decision makers with insights on where to focus on for future improvement actions aimed at reducing the environmental footprint of CFRP structures.Aerospace Manufacturing Technologie
Effect of dwell stage in the cure cycle on toughening of epoxy using thermoplastic multilayers
No full textEpoxies with high cross-linking densities are brittle and hence have a low fracture toughness. However, different methods are known to increase fracture toughness. Numerous approaches are known to incorporate a second phase into the epoxy matrix, such as rubber, inorganic nanoparticles or thermoplastics, referred to as bulk resin modification. These tougheners usually form specific morphologies during the curing phase of epoxy, resulting in improved fracture toughness of the system. Unfortunately, for some tougheners, the addition of second phase into the epoxy system also results in a reduction in overall modulus and limitation in end-use temperature of the system. In the case of thermoplastic tougheners, the second phase is created by diffusion and dissolution, followed by reaction induced phase separation, leading to a morphology in the micrometer range. However, the influence of the curing history beyond phase separation, using two dwell cure cycles with varying dwell time/degree of cure, on the interphase dimension and final morphology for PEI having a contrasting phase behaviour (UCST), is not well understood. The research presented in this work aims to understand the interphase formation, to later attain the desired droplet size and interphase morphology for improved material toughness. This aim is achieved by analyzing the influence of dwell time by considering two main cases for each selected 1st dwell temperature (120-180˚C): (i) wait until the onset of phase separation (OPS) before increasing the temperature to 200°C (second dwell), (ii) wait until 80% degree of cure (80% DOC) before the second dwell. At all processing temperatures, a distinct gradient morphology (Fig. 1a ) was clearly observed for both cases (OPS and 80% DOC). The SEM micrographs revealed the formation of a larger interphase region (71 μm) for the OPS case as compared to the 80% DOC case (56 μm). Figure 1b shows the interphase thickness as a function of 1st dwell temperature for both OPS and 80% DOC cases. It can be seen that the interphase thickness increased with 1st dwell temperature for both cases, until 160˚C after which it slightly decreased for a 1st dwell temperature of 180˚C. This work highlights, i) the importance of the curing process beyond phase separation to control interphase dimension and final morphology and, ii) the influence of both these parameters on the toughness enhancement.Aerospace Manufacturing Technologie
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