Damage tolerance of glass mat/epoxy laminates hybridized with flexible resin under static and impact loading

This study deals with the impact property and damage tolerance of matrix hybrid composite laminates with different laminate constitution. The matrix hybrid composite laminates consisted of the laminae with a conventional epoxy resin and the laminae with a flexible epoxy resin modified from the conventional resin to avoid the interlaminar delamination. The impact energy absorption ratio greatly depended on the matrix resin placed at the impact face. The energy absorption was almost constant if the conventional resin was placed at the impact surface layer, while it increased exponentially with the increasing fraction of the flexible resin if the flexible resin was placed at the impact face. The impact energy was absorbed by the damage development and propagation in the laminate with conventional resin laminae as the impacted face, while it was absorbed by both the recoverable deformation of the flexible resin and the damage propagation in the laminate with flexible resin laminae as the impacted face.     

The fatigue threshold, surface condition and fatigue limit of steel wire

To test the hypothesis that fatigue cracks in drawn, pearlitic steel wire propagate from pre-existing surface defects which can be treated as cracks, the fatigue limits of five different wires have been statistically determined. The fatigue thresholds were measured using a new AC potential drop method and the initial defect depths then calculated using the equation a_o=1π(ΔK_th/2σ_e)² and compared with observed values.

For higher strength steel wires (σ_u>1800 MPa) the agreement was very good; for the lower strength steel wire (σ_u=1469 MPa), however, the observed values were smaller than the calculated ones. The reasons for this discrepancy are discussed. A quantitative model is developed from the hypothesis and the influence of residual tensile stresses, decarburization and polishing on the fatigue limit of drawn steel wire is assessed.     

Properties of poly(butylene terephthatlate) polymerized from cyclic oligomers and its composites

The high viscosity of thermoplastic matrices hampers fiber impregnation. This problem can be overcome by using low viscous polymeric precursors such as cyclic butylene terephthalate (CBT^® resins), which polymerize to form a thermoplastic matrix. This allows thermoset production techniques, like resin transfer molding (RTM), to be used for the production of textile reinforced thermoplastics. Due to the processing route and more specifically the time-temperature profile, inherent to the RTM process, the crystallites of the matrix consist out of well-defined, thick and well-oriented crystal lamellae. Together with a high overall degree of crystallinity and a low density of tie molecules, these large and perfect crystals cause polymer brittleness. Matrix brittleness lowers the transverse strength of unidirectional composites to below the matrix strength, but leaves the mechanical properties in the fiber direction unaffected. Although not a valid option for the RTM production route, crystallization from a truly random melt and at a sufficiently high cooling rate would substantially improve the ductility.     

Compression resistance and hysteresis of carbon fibre tows with grown carbon nanotubes/nanofibres

Growth of carbon nanotubes (CNT) or carbon nano-fibres (CNF) on fibrous substrates is a way to increase the fracture toughness of fibre reinforced composites (FRC), with encouraging results reported in the recent years. The issues for these materials related to manufacturing of these composites are, however, less investigated. Following the study of compressibility of woven carbon fibre preforms with CNT/CNFs grown on the fibres using the CVD method [Compos Sci Technol 2011; 71(3): 315-325], this paper describes compression tests on the carbon tows used in these fabrics. The results of the measurements include pressure vs. thickness diagrams in consecutive compression cycles and hysteresis of the compression. The results confirm a drastic change of compressibility of fibrous assemblies in the presence of CNT/CNF grafting.     

Compressibility of carbon woven fabrics with carbon nanotubes/nanofibres grown on the fibres

Growth of carbon nanotubes (CNT) or carbon nano-fibres (CNF) on carbon fibrous substrates is a way to increase the fracture toughness of fibre reinforced composites (FRC), with encouraging results reported in the recent years. If these nano-engineered FRC (nFRC) are destined to leave laboratories and enter industrial-scale production, a question of adapting the existing composite manufacturing methods will arise. The paper studies compressibility of woven carbon fibre performs (two types of fabrics) with CNT/CNF grown on the fibres using the CVD method. The results include pressure vs thickness and pressure vs fibre volume fraction diagrams for one and four layers of the fabric. Morphology of the nFRC is studied with SEM. It is shown that the pressure needed to achieve the target fibre volume fraction of the preform increases drastically (for example, from 0.05 MPa to more than 0.5 MPa for a fibre volume fraction of 52%) when CNT/CNF are grown on it. No change in nesting of the fabric plies is noticed. The poor compressibility can lower the achievable fibre volume fraction in composite for economical vacuum assisted light-RTM techniques and increase the pressure requirements in autoclave processing.     

A model for the compression of a random assembly of carbon nanotubes

A model for calculation of the compression resistance of a random assembly of carbon nanotubes (CNTs) is proposed. The model is based on the theory of geometry and compression of fibrous materials with randomly oriented fibres. It accounts for the orientation distribution and volume fraction of CNTs in the assembly, the bending rigidity of a CNT and its decrease after onset of buckling and for friction and slippage between CNTs. The model also allows for calculation the number of contacts between CNTs in the assembly and of the percolation threshold. The predicted compression resistance is compared with experimental data on compression of “buckydisks” made of CNTs.     

Permeability prediction for the meso–macro coupling in the simulation of the impregnation stage of Resin Transfer Moulding

The impregnation stage of the Resin Transfer Moulding process can be simulated by solving the Darcy equations on a mould model, with a ‘macro-scale’ finite element method. For every element, a local ‘meso-scale’ permeability must be determined, taking into account the local deformation of the textile reinforcement. This paper demonstrates that the meso-scale permeability can be computed efficiently and accurately by using meso-scale simulation tools. We discuss the speed and accuracy requirements dictated by the macro-scale simulations. We show that these requirements can be achieved for two meso-scale simulators, coupled with a geometrical textile reinforcement modeller. The first solver is based on a finite difference discretisation of the Stokes equations, the second uses an approximate model, based on a 2D simulation of the flow.     

Stress distribution in outer and inner plies of textile laminates and novel boundary conditions for unit cell analysis

The local stress–strain distribution in a unit cell of a textile laminate depends on the distance of the ply to the surface, the number of plies in the laminate, and the stacking sequence. A conventional meso FE analysis employs boundary conditions for a unit cell of the textile composite based on the assumption of periodicity in the thickness direction. In that case, the stress concentration can be drastically underestimated, especially in outer plies. This paper describes the interaction of plies, local stresses and displacements. To avoid the analysis of the whole laminate and to reduce it to the boundary value problem on one unit cell only, novel boundary conditions are introduced. These conditions are based on the analysis of a single unit cell: they account for the number of the plies in the laminate, distinguish between the outer and inner plies, and reproduce the meso stress–strain state with good precision.     

Internal geometry evaluation of non-crimp 3D orthogonal woven carbon fabric composite

Measurements of the internal geometry of a carbon fiber non-crimp 3D orthogonal woven composite are presented, including: waviness of the yarns, cross sections of the yarns, dimensions of the yarn cross sections, and local fiber volume fraction. The measured waviness of warp and fill yarns are well below 0.1%, which shows that the fabric termed here “non-crimp” has nearly straight in-plane fibers as-produced, and this feature is maintained after going through all steps of fabric handling and composite manufacturing. The variability of dimensions of the yarns is in the range of 4–8% for warp and fill directions, while the variability of the yarn spacing is in the range of 3–4%. These variability parameters are lower than respective ranges of variability of the yarn waviness and the cross-sectional dimensions in typical carbon 2D weave and 3D interlock weave composites, which are also illustrated in this work for comparison.     

On Stress Intensity Factors of Multiple Cracks at Small Distances in 2-D Problems

In the present work a method is proposed to predict stress intensity factors (SIFs) of strongly interacting cracks at spacings that are substantially smaller than crack lengths. The method is intended for applications where cracks are observed in stack-like/staggered arrangements as in damage patterns of some natural materials with dense lamellar microstructures. The new calculation procedure is inspired by the analytical method of Kachanov (1987) that due to its simplicity has shown to be a powerful tool for analysis of crack interactions. Although in 3-D the accuracy of Kachanov’s method remains good at quite close spacings, in 2-D problems it, however, quickly drops as the distance between cracks decreases, underestimating the effect of crack interactions, especially in ordered staggered arrangements. In this work we introduce new modeling assumptions that are suited for problems where stress fields have high gradients – a typical situation in the case of closely spaced parallel cracks. The accuracy of the method is examined on the example of two stacked cracks. The use of SIFs for estimation of material elastic compliance is also discussed.