General definition of 3D warp interlock fabric architecture

3D warp interlock fabric can be used as a fibrous reinforcement for composite material. Despite of the numerous research papers dealing with this specific woven structure, few researches were conducted to clearly define this multi-layer fabric. Moreover, in many research papers, unskilled scientists of weaving technology have some difficulty to describe the different components of the 3D warp interlock fabric and sometimes make some confusion between the different architecture. Then, with a lack of a clear definition of these 3D multi-layer fabrics, most of the research papers are conducted on a very limited number of structures such as orthogonal, angle and layer to layer interlock.Thus, based on different definitions proposed by skilled scientists, a new general definition of a 3D warp interlock fabric has been proposed to better describe the position of the several yarns located inside the 3D woven structure. Thanks to this improved definition, we hope that the scientific community will use it in order to better design new architectures and conduct finer research based on these product parameters.     

Determination of the out-of-plane tensile strength using four-point bending tests on laminated L-angle specimens with different stacking sequences and total thicknesses

Laminated composite materials are increasingly used for the design of aircraft primary structures subjected to complex 3D loadings. The delamination observed in curved parts ensuring the junction between the different perpendicular panels is one of the most critical failure mechanisms. The present article proposes a complete protocol to identify the out-of-plane tensile strength of specimens composed of unidirectional plies. Firstly, a method to design a four-point bending (4 PB) test on L-angle specimens has been proposed. Secondly, a test campaign on T700GC/M21 laminated L-angle specimens has been performed at ONERA. Thirdly, the analysis of these tests with different methods has been performed to demonstrate that such a test is relevant to determine the material out-of-plane tensile strength, which seems to be independent of the stacking sequence and of the total thickness of the specimen, thus allowing the use of this strength in a 3D failure criterion. Finally, the different advantages and drawbacks of 4 PB tests performed on curved beams are discussed.     

Effect of shape memory alloy actuation on the dynamic response of polymeric composite plates

Dynamic properties such as the natural frequency of a structure have a significant role in the design process. The importance of this consideration is because of resonance. In this case, the amplitude of the vibration is magnified to levels that may lead to a catastrophic event. While the usual design process depends on the collected experiences and statistical data, a developing trend is to implement smart technologies to develop smart structures that are capable of self-monitoring, diagnostics and repair. Smart material components such as shape memory alloys (SMAs) and piezoelectric ceramics are increasingly being used by vibration control practitioners. In this paper, the alteration of the natural frequency of composite structures using nitinol-based shape memory alloy wires will be presented using the analyses of strain energy perturbations on a plate. These governing strain equations will be solved analytically and numerically to show the effect of point forces acting in a distributive manner and the subsequent effect it has on the plate’s stiffness and hence it’s natural frequency. Different SMA configurations placement will be studied and compared to computational and experimental findings in order to optimize the control strategy.     

Progressive damage analysis as a design tool for composite bonded joints

This paper discusses the application of progressive damage analysis (PDA) methods as a design tool. Two case studies are presented in which the effects of changing design features on the strength of bonded composite joints are evaluated. It is shown that the trends of parametric evaluations performed with full-featured PDA models can be unintuitive and the trends can be opposite to those obtained with traditional design criteria. The joint configurations that were tested exhibit multiple damage modes, requiring several different PDA tools to accurately predict the structural peak loads. For damage tolerant structures that exhibit complex sequences of multiple failure mechanisms, traditional failure prediction tools are insufficient. Parametric PDA models encompassing a bonded joint specimen's design space have the potential to reveal unintuitive and advantageous design changes.     

Multiscale modelling of the composite reinforced foam core of a 3D sandwich structure

A key objective dealing with 3D sandwich structures is to maximize the through-thickness stiffness, the strength of the core and the core to faces adhesion. The Napco^® technology was especially designed for improving such material properties and is under investigation in this paper. In particular, the potential of the process is characterized using a micromechanical modelling combined to a parametric probabilistic model. An experimental analysis is further detailed and validates the theoretical estimates of the core-related elastic properties. It is readily shown that the technology is able to produce parts with significantly improved mechanical properties. Finally, thanks to the probabilistic aspect of the modelling, the study allows to establish a link between the randomness of the process and the uncertainties of the final mechanical properties. Thus, the present approach can be used to optimize the technology as well as to properly design structures.     

Damage monitoring and analysis of composite laminates with an open hole and adhesively bonded repairs using digital image correlation

High performance composite materials, such as Carbon–Fibre Reinforced Plastic (CFRP) composites, are being increasingly used in aerospace industry, such as fuselage primary structures in Boeing 787 or Airbus 350, where high strength and stiffness are required at minimum weight [1]. The design of composite structures frequently includes discontinuities such as cut-outs for access and fastener holes for joining and they become critical regions under thermo-mechanical loading. Understanding of notched specimen behaviour is necessary for the design of complex structures where parts are mostly connected with bolts and rivets [2]. The effect of these discontinuities on the behaviour of composite materials is an important topic because it causes a relatively large reduction in strength compared to the unnotched laminate [3]. In the first part of the current work, the assessment of the damage process taking place in notched (open-hole) specimens under uniaxial tensile loading was studied. Two-dimensional (2D) and three-dimensional (3D) Digital Image Correlation (DIC) techniques were employed to obtain full-field surface strain measurements in carbon–fibre/epoxy M21/T700 composite plates with different stacking sequences in the presence of an open circular hole. Penetrant enhanced X-ray radiographs were taken to identify damage location and extent after loading around the hole. DIC strain fields were compared to numerical predictions. In the second part of the study, DIC techniques were used to characterise damage and performance of adhesively bonded patch repairs in composite panels under tensile loading. This part of work relates to strength/stiffness restoration of damaged composite aircraft that becomes more important as composites are used more extensively in the construction of modern jet airliners. In the current work, external bonded patches have been studied. Adhesively bonded repairs are the most common type of repair carried out with composite materials [1], [4]. The behaviour of bonded patches under loading was monitored using DIC full-field strain measurements. Location and extent of damage identified by X-ray radiography correlates well with DIC strain results giving confidence to the technique for structural health monitoring of bonded patches.     

New peel stopper concept for sandwich structures

The paper addresses the damage tolerance of sandwich structures, where the prevention and limitation of delamination failure are highly important design issues. Due to the layered composition of sandwich structures, face–core interface delamination is a commonly observed failure mode, often referred to as peeling failure. Peeling between the sandwich face sheets and the core material drastically diminishes the structural integrity of the structure. This paper presents a new peel stopper concept for sandwich structures. Its purpose is to effectively stop the development of debonding/delamination by rerouting the delamination, and to confine it to a predefined zone in the sandwich structure. The suggested design was experimentally tested for different material compositions of sandwich beams subjected to three-point bending loading. For all the tested sandwich configurations the suggested peel stopper was able to stop face–core delamination and to limit the delamination damage to restricted zones.     

Numerical and experimental assessment of the mechanical properties of 3D printed 18-Ni300 steel trabecular structures produced by Selective Laser Melting – a lean design approach

ABSTRACT

Lattice and trabecular structures are excellent candidates for energy absorbing applications such as personal protective equipment or any sort of bumper. Additive manufacturing technologies allow more freedom in the design of new topologies such as trabecular and lattice structures overcoming the limitation of the traditional manufacturing processes. In the present research, an investigation on the ductile behaviour of additive structures is presented. In a first phase, a series of 18-Ni300 steel specimens with different geometries has been printed using the SLM (Selective Laser Melting) technology. Experimental quasi-static tests on those samples were numerically reproduced, in order to retrieve the actual stress state, quantify the plastic strain at failure and calibrate a ductile damage model. In a second phase, trabecular structures, made of the same material and processed with the same technology as the samples, were produced and experimentally tested in a compression test. Simulations including the calibrated model were used to reproduce the response of the elementary trabecular cell subjected to different loading conditions (micro-scale simulations). This kind of simulations is very time-consuming and not suitable for the design/optimisation of large structures made by thousands of elementary cells. To overcome this limitation, in a third phase of the project, an effective and efficient design methodology has been implemented. Each elementary cell is modelled as an equivalent non-linear three-dimensional spring. The force–displacement (torque–rotation) relations in different directions were obtained with the previously described micro-scale FE simulations. In this manner, the computational costs can be reduced by many orders of magnitude allowing the study of complex real systems.     

Design analysis of three-layered structural composites based on post-consumer recycled plastics and wood residues

Three-layered structural composites were produced from municipal plastic wastes and wood flour residues to investigate the effects of design parameters on their flexural and impact performance. The studied parameters include wood content, thickness of individual composite layers, as well as stacking sequence and configuration (symmetric and asymmetric structures). The results indicate that the core layer has a lower influence on the flexural properties of structural beams in comparison with the skins. But depending on beam configuration (stacking sequence), different flexural characteristics can be obtained using the same composite layers. The classical beam theory was used to predict the flexural modulus with high precision. In addition, performance of the beams under impact tests was shown to be independent from their stacking sequences and layer thicknesses for each configuration.     

Micro-infiltration of three-dimensional porous networks with carbon nanotube-based nanocomposite for material design

Epoxy composite beams reinforced with a complex three-dimensional (3D) skeleton structure of nanocomposite microfibers were fabricated via micro-infiltration of 3D porous microfluidic networks with carbon nanotube nanocomposites. The effectiveness of this manufacturing approach to design composites microstructures was systematically studied by using different epoxy resins. The temperature-dependent mechanical properties of these multifunctional beams showed different features which cannot be obtained for those of their individual components bulks. The microfibers 3D pattern was adapted to offer better performance under flexural solicitation by the positioning most of the reinforcing microfibers at higher stress regions. This led to an increase of 49% in flexural modulus of a reinforced-epoxy beam in comparison to that of the epoxy bulk. The flexibility of this method enables the utilization of different thermosetting materials and nanofillers in order to design multifunctional composites for a wide variety of applications such as structural composites and components for micro-electromechanical systems.     

Observation and analysis of self-organized surface grain structures in silica films under nonepitaxial growth mode

Silica films under present reactive electron beam deposition conditions have depicted a novel self-organized surface grain structures when probed through atomic force microscopy, 2D fast Fourier transform and glancing incidence X-ray diffraction techniques. The formation of such ordered surface grain structures is observed to be strongly correlated to the nucleation and growth process of the silica films. However, the nature of the substrate (amorphous or crystalline) and multilayer geometries have influenced the shapes, sizes and abundances in the grain structures and the ordering. The strain mediation of such ordered structures when buried under polycrystalline layers like Gd₂O₃ have shown to influence both the grain size as well as roughness. A variety of grain structure evolutions and morphological changes in silica layers were noticed in different multilayer geometries. It is, hence, inferred that by appropriately using combinations of these materials, it is possible to have a control over the multilayer morphology and grain structures, which is a very relevant factor in developing precision ultraviolet laser coatings.     

A novel concept to develop composite structures with isotropic negative Poisson’s ratio: Effects of random inclusions

Materials with negative Poisson’s ratio (NPR) effects have been studied for decades. However, the studies have mainly focused on 2D periodic structures which only have NPR effects in certain in-plane directions. In this paper, a novel concept is proposed to develop composite structures with isotropic NPR effects using NPR random inclusions. The study starts from a finite element analysis of deformation mechanisms of two 2D representative cells which are embedded with a re-entrant square and a re-entrant triangle, respectively. Based on the analysis results, the re-entrant triangles are selected as random inclusions into a matrix to form 2D composite structures. Four such composite structures are built with different numbers of inclusions through a parametric model, and their NPR effects and mechanical behaviors are analyzed using the finite element method. The results show that the isotropic NPR effects of composites can be obtained with high random re-entrant inclusions. Thus, the novel concept proposed is numerically proved by this study.     

What can wave energy learn from offshore oil and gas?

This title may appear rather presumptuous in the light of the progress made by the leading wave energy devices. However, there may still be some useful lessons to be learnt from current 'offshore' practice, and there are certainly some awful warnings from the past. Wave energy devices and the marine structures used in oil and gas exploration as well as production share a common environment and both are subject to wave, wind and current loads, which may be evaluated with well-validated, albeit imperfect, tools. Both types of structure can be designed, analysed and fabricated using similar tools and technologies. They fulfil very different missions and are subject to different economic and performance requirements; hence 'offshore' design tools must be used appropriately in wave energy project and system design, and 'offshore' cost data should be adapted for 'wave' applications. This article reviews the similarities and differences between the fields and highlights the differing economic environments; offshore structures are typically a small to moderate component of field development cost, while wave power devices will dominate overall system cost. The typical 'offshore' design process is summarized and issues such as reliability-based design and design of not normally manned structures are addressed. Lessons learned from poor design in the past are discussed to highlight areas where care is needed, and wave energy-specific design areas are reviewed. Opportunities for innovation and optimization in wave energy project and device design are discussed; wave energy projects must ultimately compete on a level playing field with other routes to low CO? energy and/or energy efficiency. This article is a personal viewpoint and not an expression of a ConocoPhillips position.     

Extended finite element fracture analysis of a cracked isotropic shell repaired by composite patch

An extended finite element method (XFEM) is developed to study fracture parameters of cracked metal plates and tubes that are repaired on top of the crack with a composite patch. A MATLAB® stand‐alone code is prepared to model such structures with eight‐noded doubly curved shell elements in the XFEM framework. Crack trajectory studies are performed for a diagonally cracked panel under fatigue loading. Verification studies are investigated on different shell type structures such as a cracked spherical shell and cracked cylindrical pipe with different crack orientations. The effects of using patch repairs with different fibre orientations on the reduction of stress intensity factors (SIFs) is also studied which can be useful for design purposes. XFEM is selected as any crack geometry can be embedded in the finite element mesh configuration with no need to coincide the crack geometry with meshed elements and so re‐meshing with fine mesh generation is not needed in the current method.     

Instant electrode fabrication on carbon-fiber-reinforced plastic structures using metal nano-ink via flash light sintering for smart sensing

The electrical-resistance-change method (ERCM) is a potential smart-sensing technique for carbon-fiber-reinforced plastic (CFRP) structures. However, a practical way to fabricate electrodes on CFRP structures, such as ink-jet printing with metal nano-inks, is necessary to reduce the time required for the process. As metal nano-inks can be sintered in a few milliseconds under ambient conditions using white-flash-light irradiation from a xenon lamp, the parameters of flash-light sintering such as light energy, duration, and number of pulses were investigated. The light intensity, which is the light energy divided by duration, was found to be an indicator of whether low electrical resistance was attained along with strong adhesion to the CFRP plate. The contact resistance between the electrode and CFRP plate was also examined in a tensile test to confirm the durability. The electrode sintered by flash light with the properly selected parameters exhibited high quality and strain monitoring capability.     

Use of hypar-shell structures with textile reinforced cement matrix composites in lightweight constructions

The main goal of this paper is to define a design procedure for modular, lightweight and freeform structures by quantifying the relative importance of serviceability limit states and ultimate limit states. The modular building stones of the freeform structures under study are sandwich panels with a foamed polyurethane core and TRC (textile reinforced concrete) faces, shaped in the form of hyperbolic paraboloids (hypars). The shape of these modular building stones allows the production of structural elements on a reusable doubly-curved mould. For the dimensioning of the global modular structure, two states are important according to the Eurocodes: the ultimate limit states and the serviceability limit states. Due to the lightweight aspect of the modular structure, the serviceability limit states will gain in importance: stiffness and crack formation become important factors, as does the influence of repeated loading. These factors and their influence on the final design of the proposed structures will therefore be discussed in this paper.     

Assessment of Eurocode-like design equations for the shear capacity of FRP RC members

Fibre reinforced polymer (FRP) bars represent an interesting alternative to conventional steel as internal reinforcement of reinforced concrete (RC) members where some properties such as durability, magnetic transparency, insulation, are of primary concern. The present paper focuses on the assessment of Eurocode-like design equations for the evaluation of the shear strength of FRP RC members, as proposed by the guidelines of the Italian Research Council CNR-DT 203 [CNR-DT 203/2006. Guide for the design and construction of concrete structures reinforced with fiber-reinforced polymer bars. National Research Council, Rome, Italy; 2006]. Both the concrete and the FRP stirrups contributions to shear are taken into account: the new equations derived with reference to Eurocode equations for shear of steel RC members are verified through comparison with the equations given by ACI, CSA and JSCE guidelines, considering a large database of members with and without shear reinforcement failed in shear.     

拉压刚度不同桁架的动力参变量变分原理和保辛算法

对于一些展开结构,为达到其设计性能,必须采用特殊的索、膜结构,这些索、膜部件表现出不同的拉压性质。具有拉、压不同性质的材料或结构的力学分析,体现出较强的非线性特征,需要针对这类问题发展有效的求解算法。本文建立了由拉压刚度不同杆单元组成的桁架结构的动力学参变量变分原理,将拉压刚度不同桁架问题的非线性动力分析转换为线性互补问题求解。结合时间有限元方法构造了求解此问题的保辛数值积分方法,此方法不需要迭代和刚度矩阵更新,避免了迭代求解方法的收敛问题,计算过程稳定、高效。     

Electric Field Distributions inside Deformed Optical Fibre Cables

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Ply-interleaving technique for joining hybrid carbon/glass fibre composite materials

Efficiently joining materials with dissimilar mechanical and thermal properties is fundamental to the development of strong and lightweight load-bearing hybrid structures particularly for aerospace applications. This paper presents a ply-interleaving technique for joining dissimilar composite materials. The load-carrying capacity of such a joint depends strongly on several design parameters such as the distance between ply terminations, the spatial distribution of ply terminations, and the stiffness and coefficients of thermal expansion of the composites. The effects of these factors on the strength of quasi-isotropic hybrid carbon/glass fibre composite are investigated using combined experimental, analytical and computational methods. Through fractographic analyses significant insights are gained into the failure mechanism of the hybrid joints, which are then used to aid the development of predictive models using analytical and high fidelity computational methods. To characterise the interaction between transverse matrix cracking and delamination, continuum damage mechanics model and cohesive zone model are employed. The predictions are found to correlate well with experimental data. These modelling tools pave the way for optimising hybrid joint concepts, which will enable the structural integration of dielectric windows required for multifunctional load-bearing antenna aircraft structures.