Experimental evaluation of gas permeability through damaged composite laminates for cryogenic tank

This paper describes some recent experimental techniques for leakage assessment in conjunction with permeability results of composite laminates with matrix cracks in relation to the application of composite laminates to cryogenic fuel tank structures. Tensile loadings were applied to CFRP tubular specimens utilizing a cryogenic loading system for leak measurement at room temperature (RT) and at liquid nitrogen temperature (LN₂T). Helium gas permeability through damaged CFRP under both RT and LN₂T conditions was compared. Furthermore, an experimental method for evaluating the effect of crack intersecting angle on the gas leakage was proposed, and measured results were presented.     

Two-dimensional strain-based interactive failure theory for multidirectional composite laminates

A 2-D strain-based interactive failure theory is developed to predict the final failure of composite laminates subjected to multi-axial in-plane loading. The stiffness degradation of a laminate during loading is examined based on the individual failure modes of the maximum strain failure theory, and a piecewise linear incremental approach is employed to describe the nonlinear mechanical behavior of the laminate. In addition, an out-of-plane failure mode normal to the laminate is also investigated to more accurately predict the failure of multidirectional laminates. The theoretical results of the failure model presented are compared with the experimental data provided by the World-Wide Failure Exercise, and the accuracy of the model’s predictive capabilities is investigated.     

Cryogenic delamination growth in woven glass/epoxy composite laminates under mixed-mode I/II fatigue loading

This paper investigates the fatigue delamination growth behavior in woven glass fiber reinforced polymer (GFRP) composite laminates under mixed-mode I/II conditions at cryogenic temperatures. Fatigue delamination tests were performed with the mixed-mode bending (MMB) test apparatus at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K), in order to obtain the delamination growth rate as a function of the range of the energy release rate, and the dependence of the delamination growth behavior on the temperature and the mixed-mode ratio of mode I and mode II was examined. The energy release rate was evaluated using three-dimensional finite element analysis. The fractographic examinations by scanning electron microscopy (SEM) were also carried out to assess the mixed-mode fatigue delamination growth mechanisms in the woven GFRP laminates at cryogenic temperatures.     

Forming induced wrinkling of composite laminates with mixed ply material properties; an experimental study

One disadvantage of multi-layer forming of unidirectional (UD) prepreg tape is the risk of out-of-plane wrinkling. This study aims to show how mixed ply material properties affect global wrinkling behaviour.An experimental study was performed using pre-stacked UD prepreg on a forming tool with varying cross sections. Parameters studied include local interply friction, effects of co-stacking and fibre stresses in critical fibre directions. Experimental evaluation was performed on out-of-plane defect height, type and location. The study shows that fibre stresses in some fibre directions were crucial for the shearing required to avoid wrinkling. The same fibre stresses may cause wrinkling if the lamina is stacked in a non-beneficial order. Changing the friction locally, or reducing the number of difficult combinations of fibre angles, improves the forming outcome slightly. However, in order to make a significant improvement, co-stacking or different fibre stacking is required.     

Toughening and self-healing of epoxy matrix laminates using mendable polymer stitching

This paper presents an experimental study into a new type of stitched fibre–polymer laminate that combines high interlaminar toughness with self-healing repair of delamination damage. Poly(ethylene-co-methacrylic acid) (EMAA) filaments were stitched into carbon fibre/epoxy laminate to create a three-dimensional self-healing fibre system that also provides high fracture toughness. Double cantilever beam testing revealed that the stitched EMAA fibres increased the mode I interlaminar fracture toughness (by ∼120%) of the laminate, and this reduced the amount of delamination damage that must subsequently be repaired by the self-healing stitches. The 3D stitched network was effective in delivering self-healing EMAA material extracted from the stitches into the damaged region, and this resulted in high recovery in the delamination fracture toughness (∼150% compared to the original material). The new self-healing stitching method provides high toughness which resists delamination growth while also having the functionality to repeatedly repair multiple layers of damage in epoxy matrix laminates.     

Numerical evaluation of shear strengthening performance of CFRP sheets/strips and sprayed epoxy coating repair systems

A numerical study is conducted to evaluate the shear strengthening performance of two repair systems: CFRP sheets/strips and a sprayed epoxy coating. Micromechanical constitutive models for the CFRP sheets/strips and sprayed FRP coating proposed by Liang et al. [Liang Z, Lee HK, Suaris W. Micromechanics-based constitutive modeling for unidirectional laminated composites. Int J Solids Struct 2006;43:5674–89] and Lee et al. [Lee HK, Avila G, Montanez C. Numerical study on retrofit and strengthening performance of sprayed fiber-reinforced polymer. Eng Struct 2005;27:1476–87] and Lee and Simunovic [Lee HK, Simunovic S. Modeling of progressive damage in aligned and randomly oriented discontinuous fiber polymer matrix composites. Composites: Part B 2000;31:77–86] in conjunction with damage models, are implemented into the finite element code ABAQUS to solve boundary value problems. Using the implemented computational model, numerical simulations of four-point bending tests on concrete beams repaired with the repair systems are conducted to quantify their strengthening abilities. The numerical tests yield load–deflection curves from which the shear strengthening performance of the repair systems is evaluated. Furthermore, the present prediction is compared with available experimental data to assess the accuracy of the proposed computational model.     

Residual strength of composite laminates containing scarfed and straight-sided holes

This investigation is motivated by the needs to quantify the load-carrying capacity of composite laminates with scarfed holes, a damage cut-out shape employed to achieve flush repairs of composites. Both experimental testing and analytical modelling were carried out to investigate the damage progression behaviour of composite laminates containing either straight-sided or scarfed holes. Hoop strains were recorded by strain gauges located along the scarf surface and the results indicate a much greater extent of damage progression than specimens containing straight-sided holes. Three different strength-prediction models were employed to quantify the residual strength, including an analytical cohesive zone model developed in this work, an analytical inherent-flaw fracture mechanics method and a finite element-based continuum damage model. Comparisons of the experimental results with the model predictions reveal that the continuum damage model, calibrated using data from coupons with straight-sided holes, provides promising correlation with experimental results.     

Experimental study on the stitching reinforcement of composite laminates with a circular hole

Experimental study is carried out on the stitching reinforcement of composite laminates containing a circular hole. First, the tensile strength and stiffness are measured, and their dependence on stitching parameters such as stitching needle span, row spacing, edge distance and stitching type are analyzed. Next, the strain distribution and concentration are investigated analytically and experimentally for different stitching parameters, external load and edge location of the hole. It is shown that the results of stitching reinforcement are quite different for composite laminates with a circular hole, which could provide proper stitching parameters for designers.     

Fatigue response of APC-2 composite laminates at elevated temperatures

The response of thermoplastic AS-4/PEEK composite laminates of two lay-ups, such as cross-ply and quasi-isotropy, subjected to tension–tension (T–T) fatigue loading at elevated temperatures was investigated. It is found that the ultimate strength of cross-ply laminate is higher than that of quasi-isotropic laminate at various temperatures, so does the fatigue strength. However, the slope of normalized stress vs. cycles curves in the quasi-isotropic laminates is higher than that of the cross-ply laminates at elevated temperatures. Finally, the simple semi-empirical predictive models in statistical analysis and multiple regressions are proposed and provided for design and application purposes.     

Characterization of transverse tensile, interlaminar shear and interlaminate fracture in CF/EP laminates with 10 wt% and 20 wt% silica nanoparticles in matrix resins

The transverse tensile properties, interlaminar shear strength (ILSS) and mode I and mode II interlaminar fracture toughness of carbon fibre/epoxy (CF/EP) laminates with 10 wt% and 20 wt% silica nanoparticles in matrix were investigated, and the influences of silica nanoparticle on those properties of CF/EP laminates were characterized. The transverse tensile properties and mode I interlaminar fracture toughness (G_IC) increased with an increase in nanosilica concentration in the matrix resins. However, ILSS and the mode II interlaminar fracture toughness (G_IIC) decreased with increasing nanosilica concentration, especially for the higher nanosilica concentration (20 wt%). The reduced G_IIC value is attributed to two main competing mechanisms; one is the formation of zipper-like pattern associated with matrix microcracks aligned 45° ahead of the crack tip, while the other is the shear failure of matrix. The ratio of G_IIC/G_IC decreased with the concentration of silica nanoparticles, comparable with similar CF/EP laminates with dispersed CNTs in matrix. Fractographic studies showed that interfacial failure between carbon fibre and epoxy resin occurred in the neat epoxy laminate, whereas a combination of interfacial failure and matrix failure occurred in the nanosilica-modified epoxy laminates, especially those with a higher nanosilica concentration (20 wt%).     

Phase morphology of nanofibre interlayers: Critical factor for toughening carbon/epoxy composites

Electrospun thermoplastic nanofibres were employed to toughen carbon/epoxy composites by direct deposition on carbon fibre fabrics, prior to resin impregnation and curing. The toughening mechanism was investigated with respect to the critical role of phase morphology on the toughening effect in carbon/epoxy composites. The influences of solubility in epoxy and melting characteristics of thermoplastics were studied towards their effects on phase structure and delamination resistance. For the three different thermoplastic nanofibre interlayers used in this work, i.e. poly(ε-caprolactone) (PCL), poly(vinylidene fluoride) (PVDF) and polyacrylonitrile (PAN) nanofibre interlayers, only PCL nanofibres produced toughening. Although cylinder-shaped fibrous macrophases existed in all three interlayer regions, only PCL nanofibres had polymerisation-induced phase separation with epoxy, forming ductile thermoplastic-rich particulate microphases on the delamination plane. These findings clearly show that the polymerisation-induced phase separation is critical to the interlayer toughening by thermoplastic nanofibres. An optimal concentration (15 wt.%) of PCL solution for electrospinning was found to produce composites with enhanced mode I interlaminar fracture toughness (G_IC), stable crack growth and maintained flexural strength and modulus.     

Recent developments on damage modeling and finite element analysis for composite laminates: A review

Under complex environments such as continuous or cyclic loads, the stiffness degradation for the laminated composites such as the carbon fiber reinforced polymer matrix composites is an important physical and mechanical response to the damage and failure evolution. It is essential to simulate the initial and subsequent evolution process of this kind of damage phenomenon accurately in order to explore the mechanical properties of composite laminates. This paper gives a comprehensive review on the general methodologies on the damage constitutive modeling by continuum damage mechanics (CDM), the various failure criteria, the damage evolution law simulating the stiffness degradation, and the finite element implementation of progressive failure analysis in terms of the mechanical response for the variable-stiffness composite laminates arising from the continuous failure. The damage constitutive modeling is discussed by describing the evolvement of damage tensors and conjugate forces in the CDM theory. The failure criteria which interpret the failure modes and their interaction are compared and some advanced methods such as the cohesive theory which are used to predict the damage evolution properties of composites are also discussed. In addition, the solution algorithm using finite element analysis which implements progressive failure analysis is summarized and several applicable methods which deal with the numerical convergence problem due to singular finite element stiffness matrices are also compared in order to explore the whole failure process and ultimate load-bearing ability of composite laminates. Finally, the multiscale progressive failure analysis as a popular topic which associates the macroscopic with microscopic damage and failure mechanisms is discussed and the extended finite element method as a new finite element technique is expected to accelerate its practical application to the progressive failure analysis of composite laminates.     

Numerical study of the structural behaviour of impacted composite laminates subjected to compression load

Composite materials allow all the benefits which a high specific strength involves, in a design process their application involves many critical problems. Currently, these problems, such as environmental conditions, notch sensitivity, damaging under low velocity impacts, are taken into account by means of the application of conservative design safety factors regarding the ultimate tensile strength. In order to try to reduce these safety factors, this work aimed to study and to understand the impact damage growing mechanisms due to compression loads. To this purpose, compression tests have been experimentally performed on composite panels, which have been previously subjected to low velocity impact phenomena, considering impact energies of 6 J, 10 J and 13 J respectively. Moreover, numerical model able to simulate Low Velocity Impacts (LVI) and Compression After Impacts (CAI) onto CFRP panels is proposed. A single explicit finite element analysis has been carried out by using the Abaqus^® finite element code; the need to build a numerical model, which allows simulation in only one analysis both LVI and CAI steps, depends on the difficulty to import the impact damage distribution into a separate compression analysis. In fact, in only one analysis the compression step can occur directly onto the impacted plate, which allows to consider the effective impact damage distribution as the starting configuration for quasi static analysis under operating loads.     

A concept for the generation of out-of-plane distortion from tailored FRP laminates

The phenomenon of thermally induced distortions in unsymmetrical laminates is well understood, and it may be shown that a square, unsymmetrical 0.90 laminate will tend to form two stable geometries with a snap-through phenomenon between them. This paper discusses laminates in which at each point the lay-up is symmetrical across the laminate mid-plane, but which still exhibit multiple stable geometries. The number of stable geometries can be controlled by the details of the lay-up from the minimum of two to, in principle, an unlimited number. In addition it will be shown how a similar process can be used to generate multiple stable stress states and geometries in unidirectional laminates. This paper represents a very preliminary experimental investigation of the design space available for such composite laminates. Possible applications of composites with multiple stable geometries are noted.     

New environmentally friendly composite laminates with epoxidized linseed oil (ELO) and slate fiber fabrics

This work focuses on the development of new composite laminates based on the use of epoxidized linseed oil (ELO) as matrix and reinforcement fabrics from slate fibers with different silane treatments. The curing behavior of the ELO resin is followed by differential scanning calorimetry (DSC) and the gelation is studied by oscillatory rheometry and gel-time. Composite laminates of ELO matrix and slate fabrics are manufactured by Resin Transfer Molding (RTM) and the mechanical properties of the composite laminates are tested in tensile, flexural and impact conditions. The effects of different silane coupling agents on fiber-matrix interface phenomena are studied by scanning electron microscopy (SEM). As in other siliceous fibers, silane treatment leads to improved mechanical performance but glycidyl silane treatment produces the optimum results as the interactions between silanized slate fiber and epoxidized linseed oil are remarkably improved as observed by scanning electron microscopy (SEM).     

Helium gas permeability of montmorillonite/epoxy nanocomposites

Helium gas permeability of silicate clay (montmorillonite) particles/epoxy nanocomposites was examined. The incorporation of increasing amounts of montmorillonite particles reduced the helium gas permeability. Based on Fick’s law, gas permeation behavior of the nanocomposite was evaluated. With the increase of montmorillonite loading, gas diffusivity decreased, while gas solubility increased. Helium diffusion behavior is in agreement to the numerical results based on the Hatta–Taya–Eshelby theory. It has been revealed that dispersion of nanoscale platelets in polymer is effective in improving gas barrier property.     

Nesting effect on the mode I fracture toughness of woven laminates

The fracture toughness of two woven laminates is evaluated for different nesting/shifting values between advanced layers. The analysed woven composites are manufactured using the same resin-reinforcement and same architecture, but have a different tow size (3K/12K). Three different nesting/shifting configurations are applied to the plies at the fracture surface: zero shifting, middle shifting and maximum shifting. Before being tested, the internal geometry of the material is evaluated and any shifting error is measured. For all these configurations mode I fracture tests are carried out. The differences obtained between 3K and 12K cases can be explained by fibre bridging, but not the differences between the nesting configurations. Depending on the nesting/shifting value the delaminated surface waviness is different, and consequently the fracture toughness is also influenced.     

Three-dimensional analysis for rectangular 1–3 piezoelectric fiber-reinforced composite laminates with the interdigitated: electrodes under electromechanical loadings

In this paper, an exact analysis for the rectangular composite laminated plate consisting of 1–3 piezoelectric fiber-reinforced composite layer and orthotropic elastic composite layer subjected to the electric field with the interdigitated electrode (IDE) and arbitrary loads is presented without any simplification. The solution of the derived governing differential equations is obtained through the power series expansion and Fourier expansion methods. An illustrative analysis is carried out to investigate the influence of the stiffness anisotropy, free-strain anisotropy and electric field on the shear curvature of the laminated plate with 1–3 active fiber-reinforced composite layer. The numerical results show that, the magnitude of shear curvature gradually increases as the stiffness anisotropy and the free-strain anisotropy increase, and increasing the electrical field also leads to an increase in shear curvature. Results presented here can be used to assess various approximate theories and enhance the understanding of the static and dynamic response behavior of the 1–3 piezoelectric composite structures.     

Effect of resin system on the mechanical properties and water absorption of kenaf fibre reinforced laminates

The objective of this study is to compare the mechanical and water absorption properties of kenaf (Hibiscus cannabinus L.) fibre reinforced laminates made of three different resin systems. The use of different resin systems is considered so that potentially complex and expensive fibre treatments are avoided. The resin systems used include a polyester, a vinyl ester and an epoxy. Laminates of 15%, 22.5% and 30% fibre volume fraction were manufactured by resin transfer moulding. The laminates were tested for strength and modulus under tensile and flexural loading. Additionally, tests were carried out on laminates to determine the impact energy, impact strength and water absorption. The results revealed that properties were affected in markedly different ways by the resin system and the fibre volume fraction. Polyester laminates showed good modulus and impact properties, epoxy laminates displayed good strength values and vinyl ester laminates exhibited good water absorption characteristics. Scanning electron microscope studies show that epoxy laminates fail by fibre fracture, polyester laminates by fibre pull-out and vinyl ester laminates by a combination of the two. A comparison between kenaf and glass laminates revealed that the specific tensile and flexural moduli of both laminates are comparable at the volume fraction of 15%. However, glass laminates have much better specific properties than the kenaf laminates at high fibre volume fractions for all three resins used.     

Resin infusion analysis of nanoclay filled glass fiber laminates

This paper focuses on the resin flow characteristics of nanoclay filled glass fiber laminates processed by Vacuum Assisted Resin Infusion Molding (VARIM). Laminates with varying quantities of nanoclays (0–5 wt.%) were prepared and the effect of these nanoclays on the epoxy resin flow characteristics was studied. It was found that the flow rate of resin continuously decreased as nanoclay content continuously increased. The reduction in the flow rate was attributed to the rate of change of curing and the subsequent change in viscosity of the nanoclay filled resin. Analysis of infusion process by Darcy’s law show that the permeability of the fiber decreased in the nanoclay filled resin system. Nanoclay filled laminates show improved static and dynamic mechanical properties than that of unfilled resin composites.