Influence of curvature geometry of laminated FRP composite panels on delamination damage in adhesively bonded lap shear joints

Three dimensional non-linear finite element analyses of Lap Shear Joints (LSJs) made with curved laminated FRP composite panels having pre-existing delaminations between the first and second plies of the strap adherend have been carried out using contact and Multi-Point Constraint elements (MPC). Progressive growth of delamination has been simulated by sequential release of the MPC elements. Strain Energy Release Rate (SERR), being an indicative parameter has been computed using Virtual Crack Closure Technique (VCCT) for assessing the growth and propagation of the delamination damage fronts. The inter-laminar stresses and the SERRs at the two fronts of the pre-embedded delamination are found to be significantly influenced by the delamination size. The three individual modes of SERR on the two delamination fronts are found to be much different from each other, indicating dissimilar rates of propagation. The curvature geometry of adherends significantly influences the SERR values. It is seen that decrease of radius of curvature of adherend panels, keeping their widths unchanged, increases the SERR values. Flatter FRP composite adherends have superior resistance to delamination damage propagation as compared to LSJs made with curved composite laminated panels.     

Delamination propagation analyses of spar wingskin joints made with curved laminated FRP composite panels

Initiation and propagation of inter-laminar delamination in adhesive bonded spar wingskin joint (SWJ) made with laminated fibre-reinforced plastic (FRP) composite curved panels have been studied employing three-dimensional finite element analyses. In-plane and out-of-plane normal and shear stress distributions are seen to be highly three-dimensional in nature. Tsai-Wu coupled stress failure criteria have been employed to identify critical locations of onset of delamination-induced damage. This occurs underneath the toe-end of the spar overlap and at the inter-laminar surface between the first and second plies of the curved FRP wingskin panel. Significant edge effects on the joint strength have been observed due to the curvature geometry of the composite wingskin panels. Non-linear finite element analyses have been carried out for study of delamination propagation using contact and multi point constraint (MPC) elements. The use of contact elements prevents inter-penetration of delaminated surfaces. Whereas, sequential release of MPC elements facilitates computation of opening, sliding and cross-sliding modes of delamination-induced strain energy release rates (SERR) by using virtual crack closure technique. Variation in delamination lengths significantly effects the variation of peel and inter-laminar shear stresses and different modes of SERRs. Variations on the two delamination fronts are seen to be quite different indicating dis-similar propagation rates. The Mode I SERR (G_I) predominantly governs the delamination propagation in the SWJ.     

Through-the-width delamination damage propagation characteristics in single-lap laminated FRP composite joints

Three-dimensional non-linear finite element analyses have been carried out to study the effects of through-the-width delaminations on delamination damage propagation characteristics in adhesively bonded single-lap laminated FRP composite joints. The delaminations have been presumed either to pre-exist or to get evolved due to coupled stress failure criteria in the laminated FRP composite adherends near the overlap ends beneath the ply adjacent to the overlap region. The out-of-plane stresses in the adhesive layer, the interlaminar stress distributions along the delamination fronts and the strain energy release rates (SERRs) corresponding to the three individual modes have been evaluated for varying positions of the delaminations pre-embedded in either of the adherends. A good matching between the present 3D results and experimental and analytical solution of the literature has been established for the undamaged and a damaged model. A significant difference in the interlaminar stresses and the SERR values has been observed and is largely dependent on the adherends (bottom or top) possessing the through-the-width delamination damages. Also, the interlaminar stresses and SERR values along the two corresponding delamination fronts are different. Accordingly, it can be concluded that the positions of the through-the-width delaminations significantly influence the delamination damage propagation behaviour vis-a-vis the performance of the composite joint.     

Analysis of thermoelastic interaction of manufacturing stresses along the interface on interlaminar delamination progression in multi-ply composite laminates

This paper deals with the study of interaction of manufacturing thermal residual stresses and mechanical loading in penny-shaped delaminations embedded between dissimilar, anisotropic fiber composite layers by conducting two sets of three-dimensional thermoelastic finite element analyses with and without residual stress effects. Modified crack closure integral (MCCI) techniques based on the concepts of linear elastic fracture mechanics (LEFM) have been used to calculate the distribution of individual modes of strain energy release rates (SERR) to investigate the interlaminar delamination initiation and propagation characteristics. Asymmetric variations of strain energy release rates obtained along the delamination front are caused by the overlapping stress fields due to the coupling effect of thermal and mechanical loadings. It is found that parameters such as ply sequence and orientation, thermoelastic anisotropy and material heterogeneity, and ply properties of the delaminated interface dictate the interlaminar fracture behavior of multi-ply laminated FRP composites.     

Investigation of Damage Growth in Single Lap Joints of Composite Laminates

In this paper, growths of different types of failures including adhesion, cohesion and delamination for a single lap joint (SLJ) of composite laminates were investigated using three-dimensional geometrically nonlinear finite element analysis and by adopting a suitable modeling technique. A unique damage modeling method called sub-laminate modeling was employed for the modeling of damages of different failure modes so as to avoid the oscillatory stress and displacement fields around the damage front. The strain energy release rate (SERR) parameter was used for studying the damage growth and the individual and total components of the SERR along the various damage fronts are evaluated using the virtual crack closure technique (VCCT) based on the linear elastic fracture mechanics (LEFM) approach. This study reveals: that the opening mode is the dominant mode of the propagation for the adhesion and delamination damages, while the sliding mode is dominant for the cohesion failure; that the cohesion failure grows at a faster rate than the adhesion failure; and that the delamination front entrapped within the overlap region in the top adherend of the SLJ grows faster when the delamination damages are present simultaneously in both the adherends. This is particularly true when the delamination centers are exactly aligned with the overlap ends of the joint.     

Effect of the aspect ratio of the pre-existing rectangular adhesion failure on the structural integrity of the adhesively bonded single lap joint

Non-linear three dimensional (3-D) finite element analyses (FEA) of the single lap joints (SLJs) having pre-existing rectangular adhesion failure in the interface of the strap adherend and the adhesive have been carried out. The effect of the size, the shape and the aspect ratio of the pre-existing rectangular adhesion failure on (i) the strength, (ii) the interfacial stresses and (iii) the strain energy release rates (SERRs) in the vicinity of the adhesion failure front have been presented in this research work. The SLJ is subjected to uniformly applied tensile load. The adherends are made with very high strength steels and the adhesive is a commercially available AV119. The analyses of the adhesion failure propagation have been carried out by sequentially releasing the constraints of the nodes ahead of the pre-existing adhesion failure front in finite element model. The SERR values in the vicinity of the adhesion failure fronts are computed using the virtual crack closure technique (VCCT) for assessment of the structural integrity of the SLJ. The strength of the SLJ, the interfacial stresses, and the three modes of strain energy release rates (SERRs) have been found to be significantly affected by the shape and size of adhesion failures. The SERRs and interfacial stresses along the rectangular adhesion failure front are compared with the corresponding values around the circular adhesion failure front of same area, pre-existing in the SLJ. It is observed that the circular and rectangular adhesion failures of the same area will have dissimilar growth rate and the mode II is the dominant failure mode. The total strain energy release rate and the failure strength, computed from the 3-D FEA of the SLJ is in good agreement with the experimental fracture toughness of the AV119 adhesive and the experimentally obtained failure loads, respectively.     

Interlaminar Stresses at the Delamination Fronts in Tubular Adhesive Joints with Delaminated Composite Adherends

The use of composite materials has been extensively increasing in the recent decades, mainly due to their high strength and stiffness to weight ratios, as well as their non-corrosive attribute. Adhesive joints are used effectively to join composites to composites or to dissimilar materials. Components made of composites may contain some defects in the form of delaminations that may adversely affect their overall behavior and response when subjected to different loading systems. Interlaminar stresses (including out-of-plane stresses) are caused by the mismatch in material properties, especially in Poisson's ratio and the so-called 'coefficient of mutual influence' (between adjacent layers). The goal of this paper is to evaluate the interlaminar stresses that exist at the delamination fronts in a composite pipe, hosting a small delamination, adhesively bonded to an aluminum pipe. The aim is also to study the effect of various parameters (such as delamination length, depth, fiber orientation angles, and stacking sequence) that influence the performance, using the finite element method. The system is subjected to a torsional moment, which can be considered as a critical loading condition in tubular adhesive joints. Results of the study provide valuable information about the behavior of adhesive joints with delaminated composite adherends, and reveal the nature and distribution of interlaminar stresses along various delaminated fronts under torsional moments.     

Ultrasonic Guided Waves For NDE of Adhesively Bonded Structures

A rather sophisticated guided wave technology is introduced to solve a practical aging aircraft problem of delaminations and/or corrosion detection in either a lap splice joint or a tear strap. A Double Spring Hopping Probe is designed to achieve excellent contact on a curved aircraft structures. A guided wave resonance tuning concept for frequency is also discussed with respect to attaining reliable bond integrity measurements. A variety of experiments are discussed including experiments performed during the field trial on a Boeing 737-222 aircraft.     

Strain energy release rate based damage analysis of functionally graded adhesively bonded tubular lap joint of laminated FRP composites

Strain energy release rate (SERR) based damage analyses of functionally graded adhesively bonded tubular lap joints of laminated fiber reinforced plastic (FRP) composites under varied loadings have been studied using three-dimensional geometrically non-linear finite element (FE) analyses. FE simulations have been carried out when a tubular joint is subjected to axial and pressure loadings. SERR is utilized as the characterizing and governing parameter for assessing damages emanating from the critical location. Individual and total SERR over the damage front have been computed using modified crack closure integral (MCCI) based on the concept of linear elastic fracture mechanics. Results reveal that damage initiation locations in tubular joints subjected to axial and pressure loadings are entirely different. Furthermore, modes responsible for propagation of such damages in tubular joints under axial and pressure loadings are also different. Based on the FE simulations, tubular joints under pressure loading are found to be more vulnerable for damage initiation and its propagation. Furthermore, the damage propagation behavior of tubular joints with pre-embedded damages at the critical location has been compared between conventional mono-modulus adhesives and functionally graded adhesives with appropriate material gradation profile. Results indicate that material gradient profile of the adhesive layer offers excellent reduction in SERR for shorter interfacial failure lengths in tubular joints under axial loading which is desired to delay the damage growth. Improved crack growth resistance in the joint enhances the structural integrity and service life of the tubular joint structure. However, considerable reduction in SERR has not been noticed in the said joint when subjected to pressure loading. Hence, the use of functionally graded adhesive along the bond layer is recommended for the designer/technologist while designing tubular joint under general loading condition.     

Adhesion failure propagation in adhesively-bonded single-lap laminated FRP composite joints

This paper deals with three-dimensional non-linear finite element analyses to study the behaviour of embedded adhesion failure propagation in adhesively-bonded single-lap laminated FRP composite joints clamped at one end and subjected to uniform extension at the other end. Because of loading eccentricity and joint material heterogeneity, the embedded adhesion failure is likely to initiate from the stress singularity points and will propagate from either end of the adhesive layer along the adherend–adhesive interfaces. The effects of interaction of such failures and their propagations along the interfaces of the adherends and adhesive are the main concerns of this paper. The peel and shear stresses have been computed along the mid-surface of the adhesive layer for varying adhesion failure lengths to find out the influence of adhesion failure length on the strength of the joint being analyzed. The concept of fracture mechanics has been used to calculate the strain energy release rate (SERR) as the adhesion failure propagates using the virtual crack closure technique (VCCT). It is seen that mode-II SERR is predominant in the propagation of such adhesion failures. The SERR values computed with respect to the adhesion failure lengths being propagated from the two ends of the adhesive layer are seen to be different.     

Impact of interfacial stresses distribution of structures reinforced by composites FRP: new model of the laminate layers

This work allows us to determine the interfacial stresses concentrations which are the cause of the debonding phenomenon in the structures strengthened by composites fiber-reinforced plastic (FRP). This method permits to replace the classic techniques based on welding and bolting the elements of the structure that give stresses concentrations to the level of the assembly zone. The technique of reinforcement by patches in composites gives more resistance and rigidity, but it can give stresses concentrations to the edges of the reinforcement zone which can exceed the ultimate loads of the structure and cause failures. In this work, an original interfacial stress theory is developed between the structure and the composite (FRP) and has finalized, taking into account, the mechanical and thermal loads coupled with the shear lag effects. This original method carried out the terms neglected by the previous studies, such as shear lag effect of structure and composites, and thermal load coupled with the model of mechanical and fiber orientation effect. The geometrical and physical parameters taken into account play an important role in the stresses values concentration and thus the phenomenon of delamination     

Progressive failure and experimental study of adhesively bonded composite single-lap joints subjected to axial tensile loads

Experimental tests and finite element method (FEM) simulation were implemented to investigate T700/TDE86 composite laminate single-lap joints with different adhesive overlap areas and adherend laminate thickness. Three-dimensional finite element models of the joints having various overlap experimental parameters have been established. The damage initiation and progressive evolution of the laminates were predicted based on Hashin criterion and continuum damage mechanics. The delamination of the laminates and the failure of the adhesive were simulated by cohesive zone model. The simulation results agree well with the experimental results, proving the applicability of FEM. Damage contours and stress distribution analysis of the joints show that the failure modes of single-lap joints are related to various adhesive areas and adherend thickness. The minimum strength of the lap with defective adhesive layer was obtained, but the influence of the adhesive with defect zone on lap strength was not decisive. Moreover, the adhesive with spew-fillets can enhance the lap strength of joint. The shear and normal stress concentrations are severe at the ends of single-lap joints, and are the initiation of the failure. Analysis of the stress distribution of SL-2-0.2-P/D/S joints indicates that the maximum normal and shear stresses of the adhesive layer emerge on the overlap ends along the adhesive length. However, for the SL-2-0.2-D joint, the maximum normal stress emerges at the adjacent middle position of the defect zone along the adhesive width; for the SL-2-0.2-S joint, the maximum normal stress and shear stress emerge on both edges along the adhesive width.     

Prediction of the tensile load-bearing capacity of a co-cured single lap joint considering residual thermal stresses

In this paper, stress distributions in a co-cured single lap joint subjected to a tensile load were investigated using the finite element analysis. Residual thermal stresses, which resulted from the curing process of the co-cured single lap joint, were also considered. Since the adhesive layer in the co-cured single lap joint was about 10 μm thick, very thin compared with the thickness of both adherends, the interface between the steel and composite adherends was assumed to be perfectly bonded. The co-cured single lap joint was analyzed with respect to several bond parameters such as the bond length and stacking sequence of the composite adherend. The failure mechanism of the co-cured single lap joint was partial cohesive failure in the composite material, which was significantly affected by the interfacial tensile stress at the free edge of the co-cured single lap joint. Interfacial tensile stress was a primary factor that caused interfacial delamination between the steel and composite adherends in the co-cured single lap joint. Finally, tensile load-bearing capacities calculated from the Ye-delamination failure criterion were compared with the experimental results, and relatively good agreement was found.     

体外粘贴FRP结构加固的残余剪切应力实验研究

本文测定了FRP的固化使被粘薄板产生的应变,得出薄板板面不同位置及不同树脂型号在固化过程中界面剪切应力随时间的增长曲线,分析了界面剪切应力发展及分布规律。试验方法及结果对FRP结构加固的选材、施工及监控具指导意义。     

Stress Analysis of Tubular Adhesive Joints with Delaminated Adherend

The use of adhesive joints is becoming increasingly important in aerospace, automotive and other industries where the use of traditional fasteners is discouraged. When using composite adherends, the use of adhesively bonded joints is preferable rather than the traditional bolts and other types of fasteners, because they do not require holes, thereby removing the problems of stress concentrations around the holes. However, when using an adhesively bonded joint, there will be concentrations of the distributions of shear and peel stresses within the adhesive layer which should be controlled effectively. Therefore, the investigation of such stress variation has attracted many researchers. The aforementioned stress distributions become more complicated if the composite adherend contains a pre-existing delamination. Delamination is one of the most common failure modes in laminated composite materials; it can occur due to sudden impact by an external object, during the manufacturing process (e.g., during the filament winding process), or as a result of excessive stresses due to an applied load. It is clear that the existence of a delamination in any composite structure causes a reduction in its stiffness and in some critical situations, it may cause complete failure. This paper investigates the effect of delamination on the structural response of an adhesively bonded tubular joint with composite and aluminum adherends. The finite element method, using the commercial package ABAQUS, is used to conduct a parametric investigation. The effects of the delamination's spatial location, length, width, and the applied loading are studied. Results provide interesting insight (not necessarily intuitive) into the effect of an interlayer delamination on the stress distribution within the adhesive.     

Improving delamination resistance of carbon fiber reinforced polymeric composite by interface engineering using carbonaceous nanofillers through electrophoretic deposition: An assessment at different in-service temperatures

In this article, modification of carbon fiber surface by carbon based nanofillers (multi-walled carbon nanotubes [CNT], carbon nanofibers, and multi-layered graphene) has been achieved by electrophoretic deposition technique to improve its interfacial bonding with epoxy matrix, with a target to improve the mechanical performance of carbon fiber reinforced polymer composites. Flexural and short beam shear properties of the composites were studied at extreme temperature conditions; in-situ cryo, room and elevated temperature (−196, 30, and 120°C respectively). Laminate reinforced with CNT grafted carbon fibers exhibited highest delamination resistance with maximum improvement in flexural strength as well as in inter-laminar shear strength (ILSS) among all the carbon fiber reinforced epoxy (CE) composites at all in-situ temperatures. CNT modified CE composite showed increment of 9% in flexural strength and 17.43% in ILSS when compared to that of unmodified CE composite at room temperature (30°C). Thermomechanical properties were investigated using dynamic mechanical analysis. Fractography was also carried out to study different modes of failure of the composites.     

Tensile load-bearing capacity of co-cured double lap joints

The co-cured joining method has several advantages over the adhesively bonded joining method because both the curing and the joining processes for the composite structures are achieved simultaneously. In this study, the tensile load-bearing capacities of co-cured double lap joints were investigated experimentally and compared with the analytical results calculated by finite element analysis. Co-cured double lap joint specimens with several bond parameters such as bond length, surface roughness, and stacking sequence of the composite laminate were fabricated and tested. From the experimental results, it was found that the failure mechanism of the co-cured double lap joint was cohesive failure by delamination at the first ply of the composite laminate in the co-cured double lap joint. Finally, optimum values of several bond parameters were determined. Analytical tensile load-bearing capacities of the co-cured double lap joints were calculated by the three-dimensional Tsai-Wu failure criterion using stress distributions obtained from finite element analysis.     

钛合金‑芳纶纤维复合材料单搭接胶接接头渐进破坏分析

采用芳纶纤维复合材料与钛合金制备单搭接胶接连接实验件。利用万能实验机、DIC、应变采集系统等手段，对胶接接头的极限载荷、应变场、应变分布和破坏模式进行表征，分析了拉伸载荷下胶接接头的应变分布规律和复合材料层合板刚度折减规律，探究了异质材料单搭接胶接接头的破坏过程。结果表明，胶接接头破坏模式为搭接接头两端胶层界面破坏，中间部位复合材料层间破坏。接头破坏过程为渐进破坏，受载时复合材料端头产生较大的剪切应变，裂纹在此处萌生，并不断向钛合金端头扩展，扩展部位复合材料层合板刚度不断折减，直到搭接面积过小胶层突然发生界面破坏。     

Comparison of cohesive zone elements and smoothed particle hydrodynamics for failure prediction of single lap adhesive joints

This research investigates the use of a meshless smoothed particle hydrodynamics (SPH) method for the prediction of failure in an adhesively bonded single lap joint. A number of issues concerning the SPH based finite element modelling of single lap joints are discussed. The predicted stresses of the SPH finite element model are compared with the results of a cohesive zone based finite element model. Crack initiation and crack propagation in the adhesive layer are also studied. The results show that the peel stresses predicted by the SPH finite element model are higher and the shear stresses are lower than those predicted by the cohesive zone finite element model. The crack initiation and propagation response of the two models is similar, however, the SPH finite element model predicted a lower failure load than the cohesive zone finite element model. It is concluded that the current implementation of SPH method is a promising method for modelling cohesive failure in bonded joins but requires further development to allow for interfacial crack growth and better stress prediction under tensile loading to compete with existing methods.     

Solutions for Clamped Adhesively Bonded Single Lap Joint With Movement of Support End and Its Application to a Carbon Nanotube Junction in Tension

This article presents analytical solutions for a clamped-clamped adhesively bonded single lap joint with movement of supports and its application to studying the failure mechanism of carbon nanotube junctions in a tensile test. In the analytical model, the interface shear and normal stresses, movement of one support end, geometric nonlinearity, and the contact stresses between two cylinders are considered. Analytical solutions are derived for a clamped-clamped single lap joint with movement of one support end first, and then geometrically nonlinear finite element analysis is conducted to verify the present analytical solutions. An equivalent two-dimensional model is presented for a junction self-assembled by two carbon nanotubes, and the failure mechanism of the carbon nanotube junction is then studied by using the present analytical solutions. Structural performance of single lap joints with movement of support ends as boundary conditions is also investigated.