Monitoring of delamination onset and growth during Mode I and Mode II interlaminar fracture tests using guided waves

A delamination monitoring method was proposed to characterize Mode I and Mode II delamination onset in carbon fiber/epoxy (CF/EP) composite laminates through interrogation of guided waves activated and captured using piezoelectric actuators and sensors in a pitch–catch configuration. Mode I and Mode II interlaminar fracture tests were conducted using double cantilever beam (DCB) and end notch flexure (ENF) specimens to evaluate the proposed method. The changes in wave propagation velocity and wave magnitude (or attenuation), and the degree of waveform similarity between excitation and response signals, were calculated as delamination-sensitive wave parameters and plotted versus displacement recorded using a materials testing system. The kink points determined from wave parameter–displacement curves agreed well with the deviation from linearity (NL), visual observation (VIS) and maximum load (Max) points, which are often used in conventional methods for determining interlaminar fracture toughness. The propagation characteristics of the A₀ wave mode in a low frequency range were demonstrated to have high sensitivity to Mode I and in particular Mode II delamination onset in CF/EP composite laminates. It was concluded that the guided waves propagating in the DCB and ENF specimens were capable of determining Mode I and Mode II interlaminar fracture toughness, complementing current practices based on visual inspection or trivial interrogation using load–displacement curve alone.     

An experimental study on the effects of matrix cracking to the stiffness of glass/epoxy cross plied laminates

Three independent measurement techniques are applied to characterize glass fiber laminates. The effects of distributed fatigue damage to the stiffness related behavior of cross plied laminates are quantified. Tensile and flexural stiffness reduction is obtained from quasi-static testing. Vibration testing shows the degradation of flexural and in-plane shear stiffnesses. The reduction of the phase velocity of symmetric S₀ mode is observed from the experimental dispersion curves of Lamb waves. However, the mutual agreement of these results is less satisfactory than was earlier seen for virgin laminates. The phenomena causing the discrepancies are proposed and discussed.     

Mode III interlaminar fracture of carbon/epoxy laminates using the Six-Point Edge Crack Torsion (6ECT)

The recently proposed Six-Point Edge Crack Torsion (6ECT) test was used to evaluate the mode III interlaminar fracture of carbon/epoxy laminates. Plate specimens with starter delaminations in 0/0, 0/90 and 0/45 interfaces were tested. Data reduction was performed with an effective crack scheme validated in a previous numerical study. The tests allowed the evaluation of fairly unambiguous initiation G_IIIC values and of subsequent R-curves. Examinations of specimen cross-section showed considerable lengths of pure interlaminar propagation in specimens with starter delaminations in 0/90 and 0/45 interfaces. The latter specimens had the lowest initiation G_IIIC values.     

Experimental determination of residual stresses in composite laminates [02/θ2]s

The present work aims to determine the residual stresses in carbon fiber/epoxy composite laminates, by means of the incremental hole-drilling method. Based on mechanical theories of composite laminates and an elastic plate with a circular hole, the relationship between the relaxed strains on the surface of laminates and the residual stresses in laminates was established. This newly deduced theoretical formula was adapted into the incremental hole-drilling method and allowed us to further study the residual stresses in the through-thickness direction for various composite laminates. Related numerical modeling of composite laminate with a hole was built to calibrate the coefficients within the formula. Experiments were conducted and the residual stresses in composite laminates [0₂/θ₂]_s are presented. The proposed approach was validated with the consistence between our results for cross-ply laminates and those in literature.     

Laser-generated ultrasonic guided waves in fiber-reinforcedplates-theory and experiment

A pulsed laser source and a capacitance transducer detector have been used to record the propagation of guided waves in carbon fiber-reinforced polymer composite laminates. Despite the multimode nature of the recorded data, it is shown that the phase velocity dispersion curve of the a₀ mode can be extracted readily from the waveforms. Experimental dispersion curves have been compared to phase velocity predictions from a global matrix theory. Reasonable correlation between theory and experiment is obtained, demonstrating the validity of the calculations and experimental method     

Piezoelectric transducer arrangement for the inspection of large composite structures

The aim of the present work is to develop a system of smart devices that could be permanently attached on the surface of the composite structure and monitor the interaction of low-frequency Lamb waves with defects. A linear array of transmitters would generate a relatively uniform wavefront allowing the inspection of large areas with a limited number of sensors. The asymmetric A₀ Lamb mode is generated in carbon fibre reinforced plastic (CFRP) quasi-isotropic laminates using an array of thin piezoceramic transmitters operating in-phase. In this paper, the effect of damage size on the propagation of Lamb waves is presented. Experimental verification is also presented in multidirectional CFRP composite panels. Critical size impact damage is detected. Finally, the technique is applied to a stiffened panel. Damage on the skin or flange is detectable while damage on the web or cap is not detected with the current experimental set up.     

Finite element analysis of postbuckling and delamination of composite laminates using virtual crack closure technique

The two-dimensional and three-dimensional parametric finite element analysis (FEA) of composite flat laminates with two through-the-width delamination types: 0₄/(±θ)₆//0₄ and 0₄//(±θ)₆//0₄ (θ = 0°, 45°, and “//” denotes the delaminated interface) under compressive load are performed to explore the effects of multiple delaminations on the postbuckling properties. The virtual crack closure technique which is employed to calculate the energy release rate (ERR) for crack propagation is used to deal with the delamination growth. Three typical failure criteria: B-K law, Reeder law and Power law are comparatively studied for predicting the crack propagation. Effects of different mesh sizes and pre-existing crack length on the delamination growth and postbuckling properties of composite laminates are discussed. Interaction between the delamination growth mechanisms for multiple cracks for 0₄//(±θ)₆//0₄ composite laminates is also investigated. Numerical results using FEA are also compared with those by existing models and experiments.     

Mixed Bending-Tension (MBT) test for mode I interlaminar and intralaminar fracture

A new Mixed Bending-Tension (MBT) test is proposed for mode I fracture of laminated composites. The MBT specimen consists of a relatively small pre-cracked laminate adhesively bonded to pin-loaded steel beams. This design reduces significantly the bending stresses that prevent successful application of DCB tests to certain laminates. The MBT was here applied to carbon/epoxy unidirectional [0°]₂₆ and [90°]₂₆ laminates with starter delaminations. Interlaminar initiation G_IC values of [0°]₂₆ laminates agreed well with previous DCB test results, while [90°]₂₆ laminates exhibited 50% higher values. Significant lengths of fairly planar intralaminar crack propagation were seen in the latter laminates. The results showed a fibre bridging related R-curve, which was more pronounced in [0°]₂₆ laminates. The consistency of the present results indicates that the MBT opens new possibilities for the interlaminar and intralaminar mode I fracture.     

Damage Assessment of CFRP [90/±45/0] Composite Laminates over Fatigue Cycles

The present paper develops a stiffness-based model to characterize the progressive fatigue damage in quasi-isotropic carbon fiber reinforced polymer (CFRP) [90/±45/0] composite laminates with various stacking sequences. The damage model is constructed based on (i) cracking mechanism and damage progress in matrix (Region I), matrix-fiber interface (Region II) and fiber (Region III) and (ii) corresponding stiffness reduction of unidirectional plies of 90°, 0° and angle-ply laminates of ±45° as the number of cycles progresses. The proposed model accumulates damages of constituent plies constructing [90/±45/0] laminates by means of weighting factor η ₉₀, η ₀ and η ₄₅. These weighting factors were defined based on the damage progress over fatigue cycles within the plies 90°, 0° and ±45° of the composite laminates. Damage model has been verified using CFRP [90/±45/0] laminates samples made of graphite/epoxy 3501-6/AS4. Experimental fatigue damage data of [90/±45/0] composite laminates have fell between the predicted damage curves of 0°, 90° plies and ±45°, 0/±45° laminates over life cycles at various stress levels. Predicted damage results for CFRP [90/±45/0] laminates showed good agreement with experimental data. Effect of stacking sequence on the model of stiffness reduction has been assessed and it showed that proposed fatigue damage model successfully recognizes the changes in mechanism of fatigue damage development in quasi-isotropic composite laminates.     

Mechanical properties of cross-ply and quasi-isotropic composite laminates processed using aligned multi-walled carbon nanotube/epoxy prepreg

This study examined the processing and mechanical properties of cross-ply and quasi-isotropic composite laminates processed using aligned multi-walled carbon nanotube/epoxy prepreg sheets. Three kinds of CNT/epoxy laminates, ([0°/90°]s, [60°/0°/?60°]s, [0°/45°/90°/?45°]s) were successfully fabricated using aligned CNT/epoxy prepreg sheets. The CNT volume fraction was approximately 10%. No visible void or delamination was observed in composite laminates, and the thickness of each layer was almost equal to that of the prepreg. To evaluate the elastic moduli, E₁₁, E₂₂, and G₁₂, of each ply in the laminates, on-axis and off-axis tensile tests (0°, 45°, 90°) were conducted of aligned CNT/epoxy lamina specimens. The Young’s modulus of CNT/epoxy cross-ply and quasi-isotropic laminates agreed with the theoretical values, which were calculated using classical laminate theory and elastic moduli of CNT/epoxy lamina. The respective failure strains of [0°/90°]s, [60°/0°/?60°]s, and [0°/45°/90°/?45°]s laminates are 0.65, 0.92, 0.63%, which are higher than that of 0° composite lamina (0.5%). Results suggest that the failure strain of 0° layer in composite laminates is improved because of the other layers.     

Delamination detection in composites through guided wave field image processing

This study explores the feasibility of using a non-contact guided wave imaging system to detect hidden delamination in multi-layer composites. The study is conducted in two phases. In the first phase, Lamb waves are excited by a lead (Pb) Zirconate Titanate transducer (PZT) mounted on the surface of a composite plate, and the out-of-plane velocity field is measured using a one-dimensional (1D) scanning laser Doppler vibrometer (LDV). From the scanned time signals, wavefield images are constructed and processed to study the interaction of Lamb waves with delamination. The paper presents additional signal and image processing techniques used to highlight the defect in the scanned area. The techniques are demonstrated using experimental data collected from a 1.8 mm thick multi-layer composite. In the second phase, a completely non-contact system is described to excite and measure guided waves. A modulated continuous wave (CW) laser source in conjunction with a photodiode is used to wirelessly excite an attached PZT and the resulting waves are again sensed using the vibrometer. The non-contact system is used to excite and measure elastic waves in a composite channel test article. The elastic wave propagation image sequences are created from the non-contact excitation system.     

Synthesis and electrical properties of cubic NaxWO3 thin films across the metal-insulator transition

Highly oriented (1 0 0) Na_xWO₃ thin films were fabricated in the composition range 0.1 ≤ x ≤ 0.46 by pulsed laser deposition technique. The films showed transition from metallic to insulating behaviour at a critical composition between x = 0.15 and 0.2. The pseudo-cubic symmetry of Na_xWO₃ thin films across the transition region is desirable for understanding the composition controlled metal-insulator transition in the absence of any structural phase transformation. The electrical transport properties exhibited by these films across the transition regime were investigated. While the resistivity varied as T² at low temperatures in the metallic regime, a variable range hopping conduction was observed for the insulating samples. For metallic compositions, a non-linear dependence of resistivity in temperature was also observed from 300 to 7 K, whose exponent varied with the composition of the film.     

XFEM simulation of delamination in composite laminates

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

The effect of PVDF nanofibers on mode-I fracture toughness of composite materials

In this study, the fracture behavior of carbon/epoxy laminates interleaved by polyvinylidene fluoride (PVDF) nanofibers is investigated. For this aim, a mode-I fracture test is conducted on virgin and modified laminates. Unlike the results of other studies, it is shown that PVDF nanofibers can increase mode-I fracture toughness (G_I) noticeably in a specific situation. The results show that G_I is enhanced about 43% and 36% in initiation and propagation stages of the fracture, respectively, using PVDF nanofibers. The morphology of the fractured surface is also presented for investigating the mechanism of toughening.     

Ultrasonic inspection of adhesively bonded CFRP/aluminum joints using pulsed laser scanning

In this study, we propose an ultrasonic inspection technique for detecting disbonds in adhesively bonded carbon fiber-reinforced plastics (CFRP)/aluminum joints using pulsed laser scanning. A specimen with artificially induced square disbonds was scanned by a pulsed laser for ultrasound generation, and the propagating waves were received by a transducer placed on its surface. A series of images of the traveling waves were obtained by processing the received signals. An initial, quick inspection was performed using low-frequency Lamb waves. Changes in the propagation of the Lamb waves were observed at the disbond regions, and disbonds larger than 5 × 5 mm² were successfully detected. A second, detailed inspection of the detected disbond regions was performed using the high-frequency through-transmission ultrasonic method. The shape of the disbond was precisely imaged, and the evaluated size of the disbond matched well with the actual size. We thus demonstrated the efficiency and the feasibility of the proposed technique for the inspection of adhesively bonded CFRP/Al joints.     

Influence of intralaminar cracking on the apparent interlaminar mode I fracture toughness of cross‐ply laminates

One of the major difficulties in interlaminar fracture tests of multidirectional laminates is the high tendency for intralaminar cracking and the resulting wavy crack propagation. Experimental work showed that this occurred in double cantilever beam (DCB) tests of cross‐ply laminates having a starter crack on a 0°/90° interface. Moreover, under steady‐state propagation conditions, the apparent values of the critical strain energy release rate G_Ic were two times higher than those of 0°/0° specimens. In this paper, a finite‐element‐based progressive damage model was used to simulate crack propagation in cross‐ply specimens. The results showed that transverse cracking alone cannot be responsible for the above difference of G_Ic values. Therefore, the higher propagation G_Ic values for cross‐plies must be attributed to the more extensive fibre bridging observed and to plastic deformations of the 90° interfacial ply.     

Influence of prepreg conditions on the void occurrence and tensile properties of woven glass fiber-reinforced polyimide composites

The influence of prepreg solvent content on void occurrence in woven glass fiber-reinforced polyimide composites and their tensile properties was studied. A precursor solution of SKYBOND 703 was diluted in an additional solvent (n-methyl pyrrolidone) and the glass woven fabric was immersed in about 40 wt.% polyamic acid, in solvent. Prepregs were dried at 373 K for different time intervals, ranging from 2 to 24 h. Prepregs with varying residual solvent content under each condition were laid up, and their [(0/90)]₄ composite laminates were formed by autoclaving at a hydrostatic pressure of 0.7 MPa. The relationship of drying time with the amount of residual prepreg solvent, as well as with the volume fractions of fiber and voids was investigated. The void geography and content for each composite laminate, and the tensile strength and modulus at room temperature were also evaluated. The results clearly indicated that, depending on the altering residual solvent content in the prepreg, the void geometry and location influenced reduction of the tensile properties of woven fabric composite laminate. An appropriate prepreg resin viscosity during curing, which avoids reduction of the tensile properties, was revealed.     

Effect of temperature on low velocity impact damage and post-impact flexural strength of CFRP assessed using ultrasonic C-scan and micro-focus computed tomography

The effect of temperature on the low velocity impact resistance properties and on the post-impact flexural performance of CFRP laminates were studied. With this aim, 150 × 75 mm cross-ply carbon fibre/epoxy laminates with a [0/90/90/0]_2s layup, therefore with a total of sixteen layers, were impacted at ambient temperature (30 °C) and at elevated temperatures (55, 75 and 90 °C) at a velocity of 2 m/s using a drop weight impact tower. This was followed by flexural tests carried out at ambient temperature using a three-point bending rig. Damage assessment of impact and post-impact behaviour were carried out using ultrasonic C-scan and microfocus X-ray computed tomography (μCT). Interrupted flexural tests using μCT allowed delamination propagation to be observed. In general, lower projected damage was observed at elevated temperatures, which resulted also in a possible hindrance to delamination and shear cracks propagation during impact and in a greater amount of retained flexural strength after impact.     

Influence of cobalt phase on thermal shock resistance of Al2O3-TiC composites evaluated by indentation technique

Cobalt-coated Al₂O₃ and TiC powders were prepared using an electroless method to improve resistance to thermal shock. The mixture of cobalt-coated Al₂O₃ and TiC powders (about 70 wt.% Al₂O₃-Co + 30 wt.% TiC-Co) was hot-pressed into an Al₂O₃-TiC-Co composite. The thermal shock properties of the composite were evaluated by indentation technique and compared with the traditional Al₂O₃-TiC composite. The composites containing 3.96 vol.% cobalt exhibited better resistance to crack propagation, cyclic thermal shock and higher critical temperature difference (ΔT_c). The calculation of thermal shock resistance parameters (R parameters) shows that the incorporation of cobalt improves the resistance to thermal shock fracture and thermal shock damage. The thermal physic parameters are changed very little but the flexure strength and fracture toughness of the composites are improved greatly by introducing cobalt into Al₂O₃-TiC (AT) composites. The better thermal shock resistance of the composites should be attributed to the higher flexure strength and fracture toughness.     

Lamb wave evaluation and localization of transverse cracks in cross-ply laminates

This paper investigates the effect of transverse cracks on the S ₀ mode velocity in GFRP and CFRP cross-ply laminates, and proposes a new AE source location method that considers the change in the S ₀ mode velocity due to the transverse cracks. We found experimentally that the stiffness and the velocity decreased as the transverse crack density increased. Analytical predictions deduced from the combination of the complete parabolic shear-lag analysis, the classical plate theory and the laminated plate theory are in good agreement with the experimental results. Utilizing this relationship between the velocity and the mechanical damage, we located AE sources of transverse cracks in cross-ply laminates with the calculated in situ velocity. We were able to show that highly accurate source location requires the reduction of the in situ value of the velocity. The present method is simple but quantitative and useful in health-monitoring for detecting and localizing the damage in composite structures.