Showing papers on "Composite laminates published in 2016"

A review on design for manufacture of variable stiffness composite laminates

Abstract: The use of curvilinear fibre paths to develop variable stiffness laminates is now recognised as a promising technique offering great potential for performance improvements over conventional ‘straight fibre’ laminates. Its manufacture is feasible by fibre placement technologies, such as automated fibre placement. However, these technologies present a set of limitations that need to be included in the design to guarantee the manufacturability and quality of the composite laminates. Although this approach experiences an increasing interest from the specialised literature, most of the works completed overlook the manufacturing reality and, as a result, variable stiffness laminates are not used in industry. This work aims to provide a review of the State-of-the-Art on design for manufacture of variable stiffness in order to highlight the current gaps and research needs. As a conclusion, tools for analysis of the effect of manufacturing defects, manufacturing optimisation of gaps/overlaps or cycle time and the ...

Hybrid effects in thin ply carbon/glass unidirectional laminates: Accurate experimental determination and prediction

Abstract: Experimental results are presented which allow the hybrid effect to be evaluated accurately for thin ply carbon/epoxy–glass/epoxy interlayer hybrid composites. It is shown that there is an enhancement in strain at failure of up to 20% for very thin plies, but no significant effect for thicker plies. Hybrid specimens with thick carbon plies can therefore be used to measure the reference carbon/epoxy failure strain. The latter is significantly higher than the strain from all-carbon specimens in which there is an effect due to stress concentrations at the load introduction. Models are presented which illustrate the mechanisms responsible for the hybrid effect due to the constraint on failure at both the fibre and ply level. These results give a good understanding of how variability in the carbon fibre strengths can translate into hybrid effects in composite laminates.

An investigation of hygrothermal effects on adhesive materials and double lap shear joints of CFRP composite laminates

Abstract: This paper was aimed to investigate the hygrothermal effects on the mechanical behavior of the double lap shear joints of Carbon/Epoxy composite laminates, which were bonded using epoxy adhesive film SY14. First, experimental method was used to evaluate the hygrothermal dependent properties of the adhesive and the static response of composite laminate double lap joints at various environment conditions. The specimens were grouped into room temperature/dry (RD), room temperature/wet (RW), elevated temperature/dry (ED) and elevated temperature/wet (EW). The wet specimens were immersed in deionized water at temperature of 90 °C for 60 h and the elevated temperature is 95 °C. Tensile tests were carried out at room temperature and elevated temperature (95 °C) in a controlled chamber. Results showed that the elastic modulus and tensile strength decreased about 24% and 27% respectively after exposure to humidity environment. And a large degradation was found when exposure to high temperature while the plasticity became notable. The failure modes of the double lap shear joints were studied by visual inspection. It was found that both adhesive and cohesive failure happened for dry specimens at room temperature. While failure modes were dominated by cohesive failure after moisture exposure and adhesive failure at elevated temperature. Second, a finite element model was utilized to simulate the damage evolution of the double lap joints. The moisture diffusion process, swelling stress and thermal stress were included. And hygrothermal dependent cohesive law was considered to study the damage evolution. It revealed that failure modes were highly dependent on the weaker strength of adhesive and cohesive. Moisture absorption caused large degradation in cohesive strength, so the failure modes were mostly cohesive failure. Elevated temperature decreases strength of adhesive seriously, so adhesive failure dominates. Good agreement was achieved between the predicted failure loads and experimental results. And the predicted failure modes were also consistent with the experimental phenomenon.

A quasi-static indentation test to elucidate the sequence of damage events in low velocity impacts on composite laminates

Abstract: Any attempt to achieve composite laminates with improved damage tolerance to low velocity impacts must depart from the understanding of the sequence of damage mechanisms taking place. To this purpose, a series of quasi-static indentation experiments was conducted on AS4D/TC350 carbon/epoxy specimens. The induced damage at different indenter displacements was characterized using electron microscopy and C-scan, while the residual indentation profiles were captured with a 3D surface roughness machine. The indentation depth was shown to have relaxed after the test, reaching a steady value after 14 days. For the conditions explored, the relaxation was not dependent on the damage extent. The results showed that matrix cracking is in fact the crucial damage mechanism as it is responsible for the first sudden loss of load capacity and triggers the progressive growth of delaminations.

Forming induced wrinkling of composite laminates: A numerical study on wrinkling mechanisms

Abstract: When manufacturing composite aircraft components consisting of uni-directional prepreg laminates, Hot Drape Forming (HDF) is sometimes used. One issue with HDF is that, in contrast to hand lay-up w ...

Low-velocity impact tests on carbon/epoxy composite laminates: A benchmark study

Abstract: Low-velocity impacts (LVI) on composite laminates pose significant safety issues since they are able to generate extended damage within the structure, mostly delaminations and matrix cracking, while being hardly detectable in visual inspections. The role of LVI tests at the coupon level is to evaluate quantities that can be useful both in the design process, such as the delamination threshold load, and in dealing with safety issues, that is correlating the internal damage with the indentation depth. This paper aims at providing a benchmark of LVIs on quasi-isotropic carbon/epoxy laminates; 2 laminates are tested, 16 and 24 plies and a total of 8 impact energies have been selected ranging from very low energy impacts up to around 30 J. Delamination threshold loads, shape and extension of delaminations as well as post-impact 3D measurements of the impacted surface have been carried out in order to characterize the behavior of the considered material system in LVIs. The analysis of test results relevant to the lowest energies pointed out that large contact force fluctuations, typically associated to delamination onset, occurred but ultrasonic scans did not reveal any significant internal damage. Due to these unexpected results, such tests were further investigated through a detailed FE model. The results of this investigation highlights the detrimental effects of the dissipative mechanisms of the impactor. A combined numerical–experimental approach is thus proposed to evaluate the effective impact energies.

Chemical and thermal shrinkage in thermosetting prepreg

Abstract: A methodology for predicting residual cure deformation and stresses in composite laminates during cure is proposed. The technique employs an unbalanced cross-ply strip denoted as a “bi-lamina” strip to measure the in situ development of chemical and thermal shrinkage deformation during a specified thermal cycle. The constitutive model of the composite material was developed based on self-consistent micro-mechanical homogenization with variable resin thermo-mechanical material properties during the cure cycle. The resin properties were determined as a function of cure and temperature using different experimental techniques, including differential scanning calorimetry, digital image correlation, rheometry and dynamic mechanical analysis. The predicted bending deflection profiles of the strip agreed closely with experimental observations. The proposed methodology can be used to validate the material model of the resin and composite during the cure cycle.

Carbon fiber-reinforced epoxy filament-wound composite laminates exposed to hygrothermal conditioning

Abstract: This study focuses on the evaluation of the effect of hygrothermal conditioning on tensile, compressive, in-plane and interlaminar shear properties, and also on the viscoelastic characteristics of carbon fiber/epoxy laminates. Flat unidirectional laminates were manufactured by dry filament winding and cured under hot compression. The laminates were later exposed to hygrothermal conditioning in a chamber, following the recommendations of ASTM D5229M. All composite coupons were tested before and after conditioning. An analytical Fickian model was used to fit experimental data, showing very good estimates. Shear strength and modulus reduced to about 30 and 38 %, respectively. All specimens presented acceptable failure modes; shear specimens failed at the gage section with delaminations and fiber/matrix debonding, whereas short beam specimens failed via delaminations at the specimen mid-plane. Moisture penetration through the carbon/epoxy surface lead to interfacial debonding and matrix plasticization. Puck’s failure envelope accurately predicted failure under compressive and shear loading.

Mechanical behavior of Kevlar/basalt reinforced polypropylene composites

Abstract: In this study, mechanical behavior of thermoplastic composites reinforced with two-dimensional plain woven homogeneous and hybrid fabrics of Kevlar/basalt yarns was studied. Five types (two homogeneous and three hybrids) of composite laminates were manufactured using compression molding technique with polypropylene (PP) resin. Static tensile and in-plane compression tests were carried out to evaluate the mechanical properties of the laminates. The tension and in-plane compression tests had shown that the composites with the combination of Kevlar and basalt yarns present better tensile and in-plane compressive behavior as compared to their base composites. Improvement in the properties such as elastic modulus, strength and failure strain in both tension and in-plane compression was observed due to the hybridization. Numerical simulations were performed in ABAQUS/Standard by implementing a user-defined material subroutine (VUMAT) based on Chang-Chang criteria. Good agreement between the experimental and numerical simulations was achieved in terms of damage patterns.

XFEM simulation of delamination in composite laminates

Abstract: In this paper, the extended finite element method (XFEM) is extended to simulate delamination problems in composite laminates. A crack-leading model is proposed and implemented in the ABAQUS® to discriminate different delamination morphologies, i.e., the 0°/0° interface in unidirectional laminates and the 0°/90° interface in multidirectional laminates, which accounts for both interlaminar and intralaminar crack propagation. Three typical delamination problems were simulated and verified. The results of single delamination in unidirectional laminates under pure mode I, mode II, and mixed mode I/II correspond well with the analytical solutions. The results of multiple delaminations in unidirectional laminates are in good agreement with experimental data. Finally, using a recently proposed test that characterizes the interaction of delamination and matrix cracks in cross-ply laminates, the present numerical results of the delamination migration caused by the coupled failure mechanisms are consistent with experimental observations.

Ballistic impact response of laminated hybrid materials made of 5086-H32 aluminum alloy, epoxy and Kevlar® fabrics impregnated with shear thickening fluid

Abstract: The ballistic impact behavior of hybrid composite laminates synthesized for armor protection was investigated. The hybrid materials, which consist of layers of aluminum 5086-H32 alloy, Kevlar® 49 fibers impregnated with shear thickening fluid (STF) and epoxy resin were produced in different configurations using hand lay-up technique. The hybrid materials were impacted by projectiles (ammunitions of 150 g power-point) fired from a rifle Remington 7600 caliber 270 Winchester to strike the target at an average impact velocity and impact energy of 871 m/s and 3687 J, respectively. The roles of the various components of the hybrid materials in resisting projectile penetration were evaluated in order to determine their effects on the overall ballistic performance of the hybrid laminates. The effects of hybrid material configuration on energy dissipation during ballistic impacts were investigated in order to determine a configuration with high performance for application as protective armor. The energy dissipation capability of the hybrid composite targets was compared with the initial impact energy of low caliber weapons (according to NATO standards) in order to determinate the protection level achieved by the developed hybrid laminates. Deformation analysis and penetration behavior of the targets were studied in different stages; the initial (on target front faces), intermediate (cross-section), and final stages (target rear layers). The influence of target thickness on the ballistic impact response of the laminates were analyzed. Differences in ballistic behavior were observed for samples containing Kevlar® impregnated with STF and those containing no STF. Finally, mechanisms of failure were investigated using scanning electron microscopic examination of the perforations.

Damage sequence in thin-ply composite laminates under out-of-plane loading

Abstract: The study of the damage sequence in polymer-based composite laminates during an impact event is a difficult issue. The problem can be more complex when the plies are thin. In this paper, quasi-static indentation tests were conducted on thin-ply laminates to understand qualitatively the damage mechanisms and their sequence during low-velocity impact loading. TeXtreme® plain weave plies were used with two different thicknesses, 0.08 mm and 0.16 mm (referenced as ultra-thin-ply and thin-ply, respectively), and tested under different load levels. Load–displacement curves were analyzed and the extent of damage was inspected using optical microscopy and ultrasonic technique. The results showed that the damage onset occurs earlier in thin-ply laminates. The damage onset in thin-ply laminates is matrix cracking which induces delaminations, whereas for ultra-thin-ply laminates is due to delaminations which are induced by shear forces and small amount of matrix cracking. Moreover, the fiber breakage appears earlier in ultra-thin-ply laminates.

The damping–modulus relationship in flax–carbon fibre hybrid composites

Abstract: The trade-off between the elastic modulus and damping capacity as a function of fibre composition in carbon–flax hybrid composite laminates was investigated. Hybrid composite laminates with varying carbon–flax fibre–epoxy content were prepared using a combination of compression moulding and vacuum bagging. The elastic modulus and damping loss coefficients were determined by free-vibration in longitudinal and flexural modes, and modelled using a rule of hybrid mixtures (ROHM) and laminate theory. The models were in close agreement with the experimental data for both the longitudinal and flexural modes and thus appeared to be a feasible method of predicting the stiffness–damping relationship in this system of hybrid composite laminates. The experimental data of the tensile strength was found to also follow the ROHM. However, the experimental data of the flexural strength deviated negatively from the theoretical prediction, exhibiting lower values than the predicted ones.

Integrated XFEM-CE analysis of delamination migration in multi-directional composite laminates

Abstract: Progressive damage and failure in composites are generally complex and involve multiple interacting failure modes. Depending on factors such as lay-up sequence, loading and specimen configurations, failure may be dominated by extensive matrix crack-delamination interactions, which are very difficult to model accurately. The present study further develops an integrated extended finite element method (XFEM) and cohesive element (CE) method for three-dimensional (3D) delamination migration in multi-directional composite laminates, and validates the results with experiment performed on a double-cantilever beam (DCB). The plies are modeled by using XFEM brick elements, while the interfaces are modeled using CEs. The interaction between matrix crack and delamination is achieved by enriching the nodes of cohesive element. The mechanisms of matrix fracture and delamination migration are explained and discussed. Matrix crack initiation and propagation can be predicted and delamination migration is also observed in the results. The algorithm provides for the prediction of matrix crack angles through the ply thickness. The proposed method provides a platform for the realistic simulation of progressive failure of composite laminates.