Effect of Fibre Orientation on Impact Damage Resistance of S2/FM94 Glass Fibre Composites for Aerospace Applications: An Experimental Evaluation and Numerical Validation

This study aims to investigate the influence of fibre orientation and varied incident energy levels on the impact-induced damage of S2/FM94, a kind of aerospace glass fibre epoxy/composite regularly used in aircraft components and often subjected to low-velocity impact loadings. Effects of varying parameters on the impact resistance behaviour and damage modes are evaluated experimentally and numerically. Laminates fabricated with four different fibre orientations 0/90/+45/−458s, 0/90/90/08s, +45/−4516s, and 032 were impacted using three energy levels. Experimental results showed that plates with unidirectional fibre orientation failed due to shear stresses, while no penetration occurred for the 0/90/90/08s and +45/−4516s plates due to the energy transfer back to the plate at the point of maximum displacement. The impact energy and resulting damage were modelled using Abaqus/Explicit. The Finite Element (FE) results could accurately predict the maximum impact load on the plates with an accuracy of 0.52% to 13%. The FE model was also able to predict the onset of damage initiation, evolution, and the subsequent reduction of the strength of the impacted laminates. The results obtained on the relationship of fibre geometry and varying incident impact energy on the impact damage modes can provide design guidance of S2/FM94 glass composites for aerospace applications where impact toughness is critical.

Comparison of Failure for Thin-Walled Composite Columns

The novelty of this paper, in relation to other thematically similar research papers, is the comparison of the failure phenomenon on two composite profiles with different cross-sections, using known experimental techniques and advanced numerical models of composite material failure. This paper presents an analysis of the failure of thin-walled structures made of composite materials with top-hat and channel cross-sections. Both experimental investigations and numerical simulations using the finite element method (FEM) are applied in this paper. Tests were conducted on thin-walled short columns manufactured of carbon fiber reinforced polymer (CFRP) material. The experimental specimens were made using the autoclave technique and thus showed very good strength properties, low porosity and high surface smoothness. Tests were carried out in axial compression of composite profiles over the full range of loading—up to total failure. During the experimental study, the post-buckling equilibrium paths were registered, with the simultaneous use of a Zwick Z100 universal testing machine (UTM) and equipment for measuring acoustic emission signals. Numerical simulations used composite material damage models such as progressive failure analysis (PFA) and cohesive zone model (CZM). The analysis of the behavior of thin-walled structures subjected to axial compression allowed the evaluation of stability with an in-depth assessment of the failure of the composite material. A significant effect of the research was, among others, determination of the phenomenon of damage initiation, delamination and loss of load-carrying capacity. The obtained results show the high qualitative and quantitative agreement of the failure phenomenon. The dominant form of failure occurred at the end sections of the composite columns. The delamination phenomenon was observed mainly on the outer flanges of the structure.

Analysis of hypervelocity impacts: The tungsten case

The atomistic mechanisms of damage initiation during high velocity (v up to 9 km/s, kinetic energies up to 200 keV) impacts of W projectiles on a W surface have been investigated using parallel molecular-dynamics simulations involving large samples (up to 40 million atoms). Various aspects of the impact at high velocities, where the projectile and part of the target materials undergo massive plastic deformation, breakup, melting, and vaporization, are analyzed. Different stages of the penetration process have been identified through a detailed examination of implantation, crater size and volume, sputtered atoms, and dislocations created by the impacts. The crater volume increases linearly with the kinetic energy for a given impactor; and the total dislocation length increases with the kinetic energy but depends itself on the size of the impactor. Furthermore, the total dislocation length is less dependent of the fine details of the interatomic potential. The results are rationalized based on the physical properties of bcc W.

Effect of pH and Al Cations on Chromate Inhibition of Galvanic-Induced Corrosion of AA7050-T7451 Macro-Coupled to 316SS

The performance of chromate in protecting AA7050-T7451 coupled to 316SS in simulated fastener environments, including those representative of the boldly exposed surfaces and downhole conditions, was investigated utilizing a number of electrochemical and surface characterization techniques. The influence of pH and Al3+ on the galvanic coupling behavior and damage evolution on AA7050 as a function of chromate concentration were assessed. The degree of chromate inhibition was observed to decrease as pH decreased, owing to chromate speciation and reduced capacity to suppress the hydrogen evolution reaction (HER) compared to the oxygen reduction reaction (ORR). The addition of 0.1 M Al3+ significantly increased HER kinetics and produced a large buffer effect which overwhelmed the ability of chromate to slow damage propagation on AA7050. Assessment of cathodes indicated that Cu was more important than 316SS in driving damage initiation, but less active than 316SS in supporting high-rate damage propagation in simulated crevice environments. The implications of this study for actual bimetallic systems are discussed.

Nonlinear ABAQUS Simulations for Notched Concrete Beams

The numerical simulation of concrete fracture is difficult because of the brittle, inelastic-nonlinear nature of concrete. In this study, notched plain and reinforced concrete beams were investigated numerically to study their flexural response using different crack simulation techniques in ABAQUS. The flexural response was expressed by hardening and softening regime, flexural capacity, failure ductility, damage initiation and propagation, fracture energy, crack path, and crack mouth opening displacement. The employed techniques were the contour integral technique (CIT), the extended finite element method (XFEM), and the virtual crack closure technique (VCCT). A parametric study regarding the initial notch-to-depth ratio (ao/D), the shear span-to-depth ratio (S.S/D), and external post-tensioning (EPT) were investigated. It was found that both XFEM and VCCT produced better results, but XFEM had better flexural simulation. Contrarily, the CIT models failed to express the softening behavior and to capture the crack path. Furthermore, the flexural capacity was increased after reducing the (ao/D) and after decreasing the S.S/D. Additionally, using EPT increased the flexural capacity, showed the ductile flexural response, and reduced the flexural softening. Moreover, using reinforcement led to more ductile behavior, controlled damage propagation, and a dramatic increase in the flexural capacity. Furthermore, CIT showed reliable results for reinforced concrete beams, unlike plain concrete beams.

Failure mechanics analysis of AISI 4340 steel using finite element modeling of the milling process

A slot cutting operation is studied in this paper using a rotating/translating flat end milling insert. Milling operation usually comprises up-milling and down-milling processes. These two types of processes have different behaviors with opposite trends of the forces thus making the operation complex in nature. A detailed Finite Element (FE) model is proposed in this paper for the failure analysis of milling operation by incorporating damage initiation criterion followed by damage evolution mechanism. The FE model was validated with experimental results and good correlations were found between the two. The failure criteria field variable (JCCRT) was traced on the workpiece to observe the amount and rate of cutting during the machining process. It was found that the model was able to predict different failure energies that are dissipated during the machining operation which are finally shown to be balanced. It was also shown that the variation of these energies with the tool rotation angle was following the actual physical phenomenon that occurred during the cutting operation. Among all the energies, plastic dissipation energy was found to be the major contributor to the total energy of the system. A progressive failure analysis was further carried out to observe the nature of failure and the variation of stress components and temperature occurring during the machining process. The model proposed in this study will be useful for designers and engineers to plan their troubleshooting in various applications involving on-spot machining.

Numerical and digital image correlation analysis of tensile behavior of thin-ply hybrid laminates with discontinuous carbon sandwiched by continuous glass and carbon

Thin-ply hybrid laminates of glass and carbon fibers have been widely adopted in engineering pseudo-ductility. In this study, a Finite Element model is proposed using Abaqus to predict pseudo-ductility in thin-ply laminates consisting of three materials. These materials comprise continuous carbon (CC) and continuous glass sandwiching partial discontinuous carbon (DC). The model adopts the Hashin criterion for damage initiation in the fibers and the mixed-mode Benzeggagh-Kenane criterion on cohesive surfaces for delamination initiation and propagation. Numerically predicted stress–strain results are verified with experimental results under tensile loading. Results show pseudo-ductility increases with the increase in DC layers, and pseudo-yield strength and strain increase with the increase in CC layers. 3D-Digital Image Correlation results indicate delamination growth on pseudo-ductile laminates, and the calculated Poisson’s ratios show pseudo-ductility occurs below 0.27. Moreover, Poisson’s ratio decreases with an increase in pseudo-ductility.

Short beam shear damage analysis of GLARE laminates based on digital image correlation and finite element analysis

The short beam shear performance of GLARE 3A-3/2 laminates with adhesive layers was investigated by combining the short beam test and the digital image correlation technique. The failure behavior was further analyzed based on finite element simulation and micro failure morphology. The results show an 8% and 58% difference in the short beam strength and bending displacement at failure of laminates along two orthogonal directions; The damage behavior of laminates is determined by the bottom unidirectional glass fiber reinforced plastic (GFRP) layers. The two typical failure modes are matrix and fiber fracture in the GFRP layer caused by local bending deformation, and interlaminar delamination between GFRP layers; The distribution of surface strain [Formula: see text] indicates the damage initiation and evolution process. The simulation result of the finite element model established in ABAQUS/Explicit shows consistency with digital image correlation analysis, which provides an effective method to predict the damage behavior of specimens with different ply structures.

Mechanical model and numerical simulation of composite laminates subjected to low velocity impact

A mechanical model of laminated plates subjected to low velocity impact is proposed in this paper. The model studies the attenuation of impactor velocity affected by air resistance, intra-laminar damage initiation based strain, intra-laminar damage evolution based on damage parameters and delamination damage. Based on this mechanical model and ABAQUS platform, the experiment of Shi is numerically simulated. It is found that the predicted contact force, energy absorption and delamination damage of laminates are in good agreement with the experimental results, indicating that the established mechanical model can be used to predict the mechanical response and damage characteristics of composite laminates subjected to low velocity impact.