Fracture analysis of Kevlar-49/epoxy and e-glass/epoxy doublers for reinforcement of cracked aluminum plates

Adhesively bonded composite patch repair is efficient means to regain load carrying capacity, alleviate the crack growth, and improve the service life of the damaged structure. In this paper, three dimensional finite element models are developed to examine the fracture behavior of a single edge V-notched Aluminum plate repaired with Kevlar-49/epoxy or e-glass/epoxy pre-preg patches on both sides. Contour integral method was used for evaluating the stress intensity factor (SIF), an indicator of the crack stability. The load transfer mechanisms, stress distribution, damage variable (D), and crack mouth opening displacement (CMOD), were also presented to estimate the effectiveness of composite patch repair. The influence of the patch material, crack length and the adhesive thickness has been investigated. Results have shown that the crack induced damage increased nonlinearly with a larger crack size. With the composite patch repairs, SIF is reduced to 1/7–1/10 of that of the bare plate and CMOD decreased by 79%. The damage variable is reduced significantly and the load capacity is increased. A thinner adhesive layer results in a higher percentage of load shared by the composite patch.     

Numerical analysis of the stress intensity factors for repaired cracks from a notch with bonded composite semicircular patch

In this paper, we investigated the crack growth behaviour of cracked thin aluminium plate repaired with bonded composite patch. The finite element method is used to study the performance of the bonded composite reinforcement or repair for reducing the stress concentration at a semicircular lateral notch and repairing cracks emanating from this kind of notch. The effects of the adhesive properties and the patch size on the stress intensity factor variation at the crack tip in mode I were highlighted. The obtained results show that the stress concentration factor at the semicircular notch root and the stress intensity factor of a crack emanating from notch are reduced with the increase of the diameter and the number of the semicircular patch. The maximal reduction of stress intensity factor is about 42% and 54%, respectively, for single and double patch. However, the gain in the patch thickness increases with the increase of the crack length and it decreases when the patch thickness increases. The adhesive properties must be optimised in order to increase the performance of the patch repair or reinforcement.     

Optimum shapes of scarf repairs

Adhesively bonded scarf repairs are the preferred method for repairing composite structures, limited mainly by the amount of material removal associated with scarfing. In addition to the high strength restoration, scarf repairs also enable recovery of the original external surface as required by aerodynamic and/or external mould line considerations. However, scarf repairs almost inevitably result in the removal of undamaged material to make way for the scarf insert. This can be a particularly significant issue for thick structures, because the scarf length can vary between 20 and 100 times the thicknesses of the parent structure. In this investigation, an optimisation method has been developed for determining the optimum repair shapes for a given biaxial loading condition. The optimum scarf shape is determined by numerically solving the resulting non-linear differential equation governing the scarf angle. The optimum and near-optimum shapes are presented and discussed with respect to computational modelling using the finite element method.     

Finite element modeling of lamb wave propagation in anisotropic hybrid materials

A finite element approach for modeling of acoustic emission sources and signal propagation in hybrid multi-layered plates is presented. Modeling results are validated by Laser vibrometer measurements and comparison to calculated dispersion curves. We investigate hybrid plates as typically found in composite pressure vessels, composed of fiber reinforced polymers with arbitrary stacking sequences and attached metal or polymer materials. Hybrid plate thickness, the ratio between anisotropic and isotropic materials and material properties are varied. Lamb-wave propagation in a geometry representative of a pressure vessel is modeled. It is demonstrated, that acoustic emission sources in multi-layered structures can cause Lamb-waves superimposed by guided waves within the individual layers.     

Experimental validation of post-filling flow in vacuum assisted resin transfer molding processes

In Liquid Composite Molding (LCM) processes with compliant tool, such as Vacuum Assisted Resin Transfer Molding Process (VARTM), resin flow continues even after the inlet is closed due to the preform deformation and pressure gradient developed during infusion. The resin flow and thickness changes continue until the resin pressure becomes uniform or the resin gels. This post-filling behavior is important as it will determine the final thickness and fiber volume fraction distribution in the cured composite. In this paper, a previously proposed one dimensional coupled flow and deformation process model has been compared with the experimental data in which the resin pressure and part thickness at various locations during the post-filling stage is recorded. Two different post-infusion scenarios are examined in order to determine their impact on the final part fiber volume fraction and thickness. The effects of different venting arrangements are demonstrated. The model predictions compare favorably with the experimental data, with the minor discrepancies arising due to the variability of material properties.     

A design of laminated composite plates using graded orthotropic fiber-reinforced composite plies

A new lamination scheme is proposed through the design of a graded orthotropic fiber-reinforced composite ply for achieving continuous variations of material properties along the thickness direction of laminated composite plates. First, a micro-structure of graded unidirectional fiber-reinforced composite ply is designed and its effective graded elastic properties are estimated using finite element procedure. Next, the new lamination scheme is demonstrated through the conversion of a conventional laminated composite plate (CLCP) into a conventional-graded laminated composite plate (CGLCP) utilizing presently designed graded orthotropic composite ply. The suitability of this conversion/proposed lamination scheme is substantiated through the bending analysis of both the plates (CLCP and CGLCP).     

碳纤维增强环氧树脂复合材料修复N80Q钢管的力学性能

为考察碳纤维增强环氧树脂复合材料对环状腐蚀的N80Q钢管的修复效果,采用数值分析和全尺寸爆破试验对修复后的力学性能进行了研究,分析了缺陷轴向长度、缺陷深度和修复层厚度对修复效果的影响。结果表明:碳纤维增强环氧树脂复合材料对N80Q钢管的修复效果显著,经试验测试, 6 mm深缺陷的N80Q管道由碳纤维增强环氧树脂复合材料修复后爆破压力值提高了0.985倍;缺陷轴向长度对N80Q管道修复后的强度影响较小,随着缺陷轴向长度的增加,管道爆破压力值仅下降了3.5%;而缺陷深度对N80Q管道修复后的强度影响较明显,与无缺陷管道相比, 6 mm深缺陷管道修复后爆破压力值下降了9.9%, 7 mm深缺陷管道修复后爆破压力值下降了20.6%。     

Whole-field strain analysis and damage assessment of adhesively bonded patch repair of CFRP laminates using 3D-DIC and FEA

The problem of damage evolution in composite structures, the way it propagates, performance and behavior is of paramount importance in utilizing them for structural applications. In the present work, an experimental study is carried out using digital image correlation (DIC) technique to analyze the behavior of adhesively bonded patch repair of carbon/epoxy unidirectional composite laminates under tensile loading. The damaged panel is repaired with both double and single sided circular patch made of same parent material. Damage initiation and propagation in notched and repaired panel as well as patch debonding is studied using 3D-DIC. Also a 3-D finite element analysis is carried out and obtained strain values are compared with the experimental prediction. They are found to be in good agreement.     

Effects of thickness and fiber volume fraction variations on strain field inhomogeneity

In this study, variations in thickness and fiber volume fraction are investigated as causes of elastic strain inhomogeneity in composite laminates under an applied transverse load. Standard carbon/epoxy tensile specimens were fabricated from unidirectional pre-impregnated material using two different manufacturing techniques that produced two different levels of surface roughness. Fiber volume fraction variation was computed by analyzing optical micrographs of the samples. During loading and unloading of the samples two-dimensional surface strain fields were measured on the specimen using digital image correlation. It was shown that in both cases the strain in the specimen is not uniform, as is generally assumed. Using finite element simulations the effects of fiber volume fraction variation and thickness variation were modeled individually and in combination. The simulations agree well with the experimental results and suggest that thickness variations are the dominant mechanisms involved in this elastic strain inhomogeneity.     

Numerical and exact models for free vibration analysis of cylindrical and spherical shell panels

The present paper shows a comparison between classical two-dimensional (2D) and three-dimensional (3D) finite elements (FEs), classical and refined 2D generalized differential quadrature (GDQ) methods and an exact three-dimensional solution. A free vibration analysis of one-layered and multilayered isotropic, composite and sandwich cylindrical and spherical shell panels is made. Low and high order frequencies are analyzed for thick and thin simply supported structures. Vibration modes are investigated to make a comparison between results obtained via the FE and GDQ methods (numerical solutions) and those obtained by means of the exact three-dimensional solution. The 3D exact solution is based on the differential equations of equilibrium written in general orthogonal curvilinear coordinates. This exact method is based on a layer-wise approach, the continuity of displacements and transverse shear/normal stresses is imposed at the interfaces between the layers of the structure. The geometry for shells is considered without any simplifications. The 3D and 2D finite element results are obtained by means of a well-known commercial FE code. Classical and refined 2D GDQ models are based on a generalized unified approach which considers both equivalent single layer and layer-wise theories. The differences between 2D and 3D FE solutions, classical and refined 2D GDQ models and 3D exact solutions depend on several parameters. These include the considered mode, the order of frequency, the thickness ratio of the structure, the geometry, the embedded material and the lamination sequence.     

“Equivalent” permeability and flow in compliant porous media

Resin flow modeling for liquid composite molding processes is generally based on assumptions of rigid porous media. This is invalid for process variations utilizing compliant mold. Yet the models built on rigid porous media assumption are used with some success in analyzing such infusions.Previous work showed that for certain porous media the one dimensional flow patterns are similar to those in rigid porous media and the deformation effects can be included in a scaling factor for permeability.This note analyzes the one-dimensional linear and radial flows in porous media with generic constitutive relations between resin pressure, thickness and permeability. It shows that as long as the deformation remains moderate, the effect of deforming porous medium may be incorporated in a single scaling factor for material permeability. This scaling factor depends on material and applied injection pressure, but does not change with time, flow-front position or type of infusion (linear or radial).     

Mechanical property variability in FRP laminates and its effect on failure prediction

Results are presented from an experimental study for the modeling of stochastic behavior of a unidirectional Glass/Polyester composite. An analytical approach is developed for the prediction of failure under general in-plane loading including the variability of strength, stiffness and the thermal expansion coefficients. Monte Carlo simulation and the first-order reliability method are used for comparison and the new method is proved to be in good agreement. Following international design codes, a direct comparison is also presented for failure locii at a specific reliability level as derived by the various probabilistic approaches. Results reveal that a serious overestimation of the reliability of the composite structure is being made when the stochastic nature of the material elastic properties is not taken into account.     

Analysis and validation of thermal and packaging effects of a piezoresistive pressure sensor

Abstract

In this study, a packaged silicon base piezoresistive pressure sensor with thermal stress buffer is designed, fabricated, and studied. A finite element method (FEM) is adopted for designing and optimizing the sensor performance. Thermal and pressure loading on the sensor is applied to make a comparison between experimental and simulation results. Furthermore, a method that transforms simulation stress data into output voltage is proposed in this study, and the results indicate that the experimental result coincides with the simulation data. In order to achieve better sensor performance, a parametric analysis is performed to evaluate the system sensitivity, as well as thermal and packaging effects of the pressure sensor. The design parameters of the pressure sensor include membrane size, sensor chip size, glass thickness, adhesive layer thickness, PCB thickness/material, etc. The findings show that proper selection of the sensor structure and material not only enhances the sensor sensitivity but also reduces the thermal effects as well as the packaging influence.     

Establishing a new Forming Limit Curve for a flax fibre reinforced polypropylene composite through stretch forming experiments

In developing an understanding of the failure in natural fibre reinforced polymer composites, the failure limits of this class of the material system are required. It is found that the conventional Forming Limit Curve is not suitable to predict the failure initiated in the natural fibre composite as principal strains cannot differentiate the strain on the flax fibres and the polypropylene matrix. This study proposes a new Forming Limit Curve for the composite which expresses limiting fibre strain as a function of forming mode depicted by the ratio of minor strain to major strain. The new Forming Limit Curve, along with the Maximum Strain failure criterion have been successfully implemented in FEA simulations, and numerical simulations suggest that the former is more accurate. The current work provides an innovative method to predict the onset of failure in natural fibre composites, which can be applied in composite forming and structural design.     

Design of copper filled fibreglass moulds for manufacturing a customized product using linear programming optimization and finite element analysis

This paper presents a design procedure and cost analysis for a mould made of glass fibre reinforced polyester filled with copper particles (GRP/copper). It also describes their potential use in rotational moulding as an alternative to steel and aluminium moulds operating at high temperatures up to 250 °C. The thermal conductivity of glass reinforced polyester (GRP) was improved by incorporating copper particles acting as fillers in the composite. An optimum composite structure consisting of 25% glass fibres, 45% polyester, and 30% copper was achieved by linear programming search optimization methods. Then a finite element analysis (FEA) of a typical GRP/copper mould made of the optimized composite structure under thermal loading was conducted. The induced thermal stresses obtained from FEA were used to check the failure condition of the mould using the Tsai–Hill failure criterion. The FEA design procedure was also used to determine the mould thickness with a safety factor of at least four. Scheduling and cost analysis showed that 76% reduction in production time and 64% reduction in manufacturing costs have been achieved with the developed method.     

Numerical method for optimizing design variables of carbon-fiber-reinforced epoxy composite coil springs

To successfully reduce a vehicle's weight by replacing steel with composite materials, it is essential to optimize the material parameters and design variables of the structure. In this study, we investigated numerical and experimental methods for determining the ply angles and wire diameters of carbon fiber/epoxy composite coil springs to attain a spring rate equal to that of an equivalent steel component. First, the shear modulus ratio for two materials was calculated as a function of the ply angles and compared with the experimental results. Then, by using the equation of the spring rate with respect to the shear modulus and design variables, normalized spring rates were obtained for specific ply angles and wire diameters. Finally, a finite element model for an optimal composite coil spring was constructed and analyzed to obtain the static spring rate, which was then compared with the experimental results.     

Transverse impact damage and energy absorption of 3-D multi-structured knitted composite

Knitted composites have higher failure deformation and energy absorption capacity under impact than other textile structural composites because of the yarn loop structures in knitted performs. Here we report the transverse impact behavior of a new kind of 3-D multi-structured knitted composite both in experimental and finite element simulation. The knitted composite is composed of two knitted fabrics: biaxial warp knitted fabric and interlock knitted fabric. The transverse impact behaviors of the 3-D knitted composite were tested with a modified split Hopkinson pressure bar (SHPB) apparatus. The load–displacement curves and damage morphologies were obtained to analyze the energy absorptions and impact damage mechanisms of the composite under different impact velocities. A unit-cell model based on the microstructure of the 3-D knitted composite was established to determine the composite deformation and damage when the composite impacted by a hemisphere-ended steel rod. Incorporated with the unit-cell model, a elasto-plastic constitute equation of the 3-D knitted composite and the critical damage area (CDA) failure theory of composites have been implemented as a vectorized user defined material law (VUMAT) for ABAQUS/Explicit. The load–displacement curves, impact deformations and damages obtained from FEM are compared with those in experimental. The good agreements of the comparisons prove the validity of the unit-cell model and user-defined subroutine VUMAT. This manifests the applicability of the VUMAT to characterization and design of the 3-D multi-structured knitted composite structures under other impulsive loading conditions.     

Numerical prediction and experimental characterisation of meso-scale-voids in liquid composite moulding

Pressure gradients that drive the resin flow during liquid composite moulding (LCM) processes can be very low while manufacturing large composite parts. Capillary pressure becomes the predominant force for tow impregnation and thus meso-scale-voids can be generated, reducing the part quality. In contrast, micro-voids are created at high resin pressure gradients. In this work, a numerical method is presented to predict the creation of meso-scale-voids and their evolution. Experimental validation is conducted by measuring void content of produced composite parts with micro-computed tomography (μ-CT). Additionally, the void content as a function of the modified capillary number Ca^* is determined and the influence of the fibre volume content in the bundles on the meso-scale- and micro-void content is studied.     

Homogenization of braided fabric composite for reliable large deformation analysis of reinforced rubber hose

High pressure rubber hose is in the lamination structure composed of pure rubbers and braided fabric composite layers to have the sufficient strength against the excessive radial expansion and the large deformation, in which the braided fabric layer is woven with wrap and fill tows inclined to each other with the predefined helix angle in the complex periodic pattern. The consideration of detailed geometry of braided fabric layer in the numerical analysis leads to a huge number of finite elements so that the braided fabric layer has been traditionally simplified as an isotropic cylindrical one with the homogeneous isotropic material properties of braid spun tread. However, this simple model leads to the numerical prediction and design with the questionable reliability. In this context, this paper addresses the development of an in-house module, which is able to be interfaced with commercial FEM code, for the reliable large deformation analysis of the reinforced rubber hose with the element number at the level of the traditional simple model. The in-house module is able to not only automatically generate 3-D unit cell (or RVE) model of the braided fabric layer but evaluate the homogenized orthotropic material properties by automatically performing a serious of unit cell finite element analyses based on the superposition method. The validity of the in-house module and the reliability of the homogenization method are verified through the illustrative numerical experiments.     

Bond between FRP composites and concrete: Assessment of design procedures and analytical models

The use of fibre reinforced polymers (FRPs) to strengthen reinforced concrete (RC) structures has gained a wide popularity in the last decades. Although many experimental and analytical studies are available in literature, some issues are still under discussion in the research communities. Since the typical failure mode of FRP–concrete joints is reported to be debonding of the composite from the concrete substrate [1], the estimation of the bond strength between FRP and concrete substrate represents a key issue for the proper use of this technology. For this reason, several analytical models for the evaluation of the FRP–concrete bond strength and few models for the estimation of the effective bond length were proposed (some of them are included in design codes/recommendations/guidelines); however they were not assessed by means of an appropriate experimental database.This work shows an assessment of twenty analytical models for the evaluation of the FRP–concrete bond strength. The assessment is based on the analysis of a wide experimental database collected from the literature. The results are provided distinguishing between the test setup adopted (single or double shear test, bending test) and the material used (post impregnated sheets or pre impregnated laminates). The accuracy of each model was evaluated by means of a simplified statistical analysis. The influence of the test setup and basic material on the accuracy of the model used was analysed as well. Lastly, the accuracy of twelve available models in providing an estimation of the effective bond length was also assessed.