Lamination residual stresses in cross-plied fiber composites
Lamination residual stresses in cross-plied fiber composites
Chamis, C. C.↗
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Laminated sheet composites reinforced with modular filament sheet
Aluminum and magnesium composite sheet laminates reinforced with low density, high strength modular filament sheets are produced by diffusion bonding and explosive bonding. Both processes are accomplished in normal atmosphere and require no special tooling or cleaning other than wire brushing the metal surfaces just prior to laminating.
Reece, O. Y.↗
Elastic moduli of laminated anisotropic composites.
Elastic moduli of laminated anisotropic composites, specifically glass-filament-reinforced resin cylindrical pressure vessels and cross-ply and angle-ply plates
COMPOSITE MATERIAL↗
Pressure-Localizing Inserts for Bagging Laminations
Devices compress composite laminates to conform to tight inside corners of molds. Proposed use of pressure-localizing insert allows composite laminates to be compacted into tight corners by conventional pressure or vacuum-bagging techniques. Because of manufacturing technique, larger selection of part shapes becomes amenable to lamination.
Schmaling, Dave↗
IACMI Project 4.2: Thermoplastic Composite Development for Wind Turbine Blades
(Section 5.1) Composites made from Arkema’s Elium® thermoplastic resin and Johns Manville fiberglass were researched during this project for applications in wind blade manufacturing. A techno-economic model was developed to model this wind blade manufacturing process using these materials in place of traditional composites made with thermoset resin. This model was based on manufacturing a 61.5-meter wind blade, which showed a 4.7% reduction in wind blade cost as compared traditional thermoset materials. These cost savings were not from the thermoplastic material costing less than traditional thermoset materials, but rather from decreased capital costs, faster cycle times and reduced energy requirements and labor costs. (Section 5.2) An infusion and curing model was developed for thermoplastic composite wind blades using PAM-RTM. The primary goal was to demonstrate the infusion simulation for the Elium® resin system on a 13-meter wind blade. Additionally, the exotherm temperature was predicted and compared to measurements, which showed model results within 10% of actual measurements. (Section 5.3) Composite laminate panels and composite sandwich panels with a balsa core were produced; specimens were cut and characterized. Similar composite specimens were made with Elium® thermoplastic resin and Hexion thermoset epoxy (RIMR135/RIMH1366) to enable comparisons between these resin systems. The static test methods included: tensile, compression, in-plane shear, interlaminar shear, flexural, sandwich core shear flexure, and single cantilever beam tests for sandwich beams. Fatigue testing at room temperature was completed to composite laminate panels at a stress ratio of R=0.1 and R=10. In addition, fatigue testing to laminate panels was completed at -30°C, and at room temperature after conditioning specimens at 70°C and 90% relative humidity. Overall, mechanical test results from Elium® composites are similar to epoxy composites. (Section 5.4) Elium composite panels were produced with intentional defects such as voids and nonwetting of fibers to begin to understand performance sensitivity to defects. A thermal digital image correlation (TDIC) method provides high spatial resolution strain field at elevated temperatures and can be used to identify defective regions within composite panels. Flexural modulus differences of 21% were seen between defect and non-defect panels. Other Elium® composite panels were forced to be defective by boiling the resin after infusion, which created voids throughout the composite laminate. X-ray computed tomography scanning was used to view the internal structure of the defect panels. Defect panels had a significant reduction in fatigue life as compared to baseline panels produced without intentional defects. (Section 5.5) Lap shear specimens were fabricated to compare the lap shear strength of an off-the-shelf adhesive (Plexus MA590) and two new adhesives developed by Arkema (Bostik SAF30 90 and Bostik SAF30 120). ISO standard 4587:2003 was used to standardize the testing method and sample fabrication. Lap shear specimens were made at 1mm, 3mm, and 10mm thicknesses. The Bostik adhesive lap shear test results were similar to Plexus for all thicknesses. (Section 5.6) Fiber-reinforced polymer (FRP) composites are typically used in high-performance applications (e.g., aerospace), and their expansion into high-volume industries (e.g. consumer automotive and wind turbine blade manufacturer or similar) is hindered by their cost and a lack of efficient manufacturing techniques. Monitoring the curing process of these composites during manufacturing can improve the efficiency of the process, and therefore reduce the manufacturing cost. Cure monitoring techniques were developed that use probabilistic estimation methods and surface temperature measurements made using infrared cameras. These techniques enable real-time monitoring of the infusion process to locate manufacturing flaws, and they can, potentially, estimate residual stresses in the part. Their commercialization will help facilitate expansion of FRP composites in high-volume industries. (Section 5.7) A 13-meter composite wind blade was produced with Elium® resin and Johns Manville fiberglass; this blade was made with VARTM processing similar to how megawatt-scale wind blades are currently manufactured, but no post-mold heating was used for this thermoplastic composite blade. The wind blade underwent full-scale validation for static loading (4-different load orientations) and flapwise fatigue loading to simulate 20-years of operational loads. The thermoplastic composite wind blade withstood the loading without any noted issues and performed similar to results from a previous full-scale validation to an equivalent epoxy composite wind blade produced with the same blade molds. (Section 5.8) A study was conducted to determine the feasibility of recycling composite wind turbine blade components fabricated with glass fiber reinforced Elium® thermoplastic resin. Dissolution, which is a process unique to thermoplastic matrices, allows recovery of both the polymer matrix and full-length glass fibers, while maintaining their stiffness and strength throughout the recovery process. The economics of recycling is favorable if 50% of the glass fiber is recovered and resold for a process of $\$$ 0.28/kg, and 90% of the resin is recovered and resold at a price of $\$$ 2.50/kg.(Section 10) Recommendations are outlined for commercializing thermoplastic resin for composite wind blade production, in addition to recommended areas for future research.
17 WIND ENERGY↗
Fracture behavior of thick, laminated graphite/epoxy composites
The effect of laminate thickness on the fracture behavior of laminated graphite epoxy (T300/5208) composites was studied. The predominantly experimental research program included the study of the 0/+ or - 45/90 sub ns and 0/90 sub ns laminates with thickness of 8, 32, 64, 96 and 120 plies and the 0/+ or - 45 sub ns laminate with thickness of 6, 30, 60, 90 and 120 plies. The research concentrated on the measurement of fracture toughness utilizing the center-cracked tension, compact tension and three point bend specimen configurations. The development of subcritical damage at the crack tip was studied nondestructively using enhanced X-ray radiography and destructively using the laminate deply technique. The test results showed fracture toughness to be a function of laminate thickness. The fracture toughness of the 0 + or - 45/90 sub ns and 0/90 sub ns laminates decreased with increasing thickness and asymptotically approached lower bound values of 30 ksi square root of in. (1043 MPa square root of mm and 25 ksi square root of in (869 MPa square root of mm respectively. In contrast to the other two laminates, the fracture toughness of the 0/+ or - 45 sub ns laminate increased sharply with increasing thickness but reached an upper plateau value of 40 ksi square root of in (1390 MPa square root of mm) at 30 plies. Fracture toughness was independent of crack size for both thin and thick laminates for all three laminate types except for the 0/90 sub 2s laminate which spilt extensively. The center cracked tension, three point bend and compact tension specimens gave comparable results.
Harris, C. E.↗
Modelling of thick composites using a layerwise laminate theory
The layerwise laminate theory of Reddy (1987) is used to develop a layerwise, two-dimensional, displacement-based, finite element model of laminated composite plates that assumes a piecewise continuous distribution of the tranverse strains through the laminate thickness. The resulting layerwise finite element model is capable of computing interlaminar stresses and other localized effects with the same level of accuracy as a conventional 3D finite element model. Although the total number of degrees of freedom are comparable in both models, the layerwise model maintains a 2D-type data structure that provides several advantages over a conventional 3D finite element model, e.g. simplified input data, ease of mesh alteration, and faster element stiffness matrix formulation. Two sample problems are provided to illustrate the accuracy of the present model in computing interlaminar stresses for laminates in bending and extension.
Robbins, D. H., Jr.↗
Development of a Higher Order Laminate Theory for Modeling Composites with Induced Strain Actuators
A refined higher order plate theory is developed to investigate the actuation mechanism of piezoelectric materials surface bonded or embedded in composite laminates. The current analysis uses a displacement field which accurately accounts for transverse shear stresses. Some higher order terms are identified by using the conditions that shear stresses vanish at all free surfaces. Therefore, all boundary conditions for displacements and stresses are satisfied in the present theory. The analysis is implemented using the finite element method which provides a convenient means to construct a numerical solution due to the discrete nature of the actuators. The higher order theory is computationally less expensive than a full three dimensional analysis. The theory is also shown to agree well with published experimental results. Numerical examples are presented for composite plates with thicknesses ranging from thin to very thick.
Chattopadhyay, Aditi↗
A layered composite with a broken laminate
The problem of a laminate composite in the presence of a crack located normal to the bond lines is considered. Stress analysis of the limiting case when the crack extends to the bond lines is carried out. An integral transform technique is used to formulate the problem in terms of a singular integral equation. The power of stress singularity around the crack tip terminating at the interface is obtained using the above technique. The singular integral equation is solved numerically and the effect of material properties on the stress intensity factor is calculated.
Gupta, G. D.↗
A layered composite with a broken laminate.
The problem of a laminate composite in presence of a crack located normal to the bond lines is considered. Stress analysis of the limiting case when the crack extends to the bond lines is carried out. Integral transform technique is used to formulate the problem in terms of a singular integral equation from which the power of stress singularity around the crack tip terminating at the interface is obtained. The singular integral equation is solved numerically and the effect of material properties on the stress intensity factor is calculated.
Gupta, G. D.↗
Fracture analysis of notched composites
The problem of part-through cracks emanating from a central notch in a composite laminate is considered. The composite laminate is modeled as an orthotropic plate and along the branches, it is assumed that the stresses are carried by the fibers only. The stresses along the uncracked portions are assumed to be proportional to the crack opening displacement at the point. After formulating the branched crack problem, the model is applied to a(+45 deg)25 composite laminate. The stress concentration factors for the fibers are computed for various values of the spring constant K. Sample results showing the crack opening displacement are also displayed.
Deale, F.↗
Fracture analysis of notched composites
In this study the problem of part-through cracks emanating from a central notch in a composite laminate is considered. The composite laminate is modeled as an orthotropic plate and along the branches, it is assumed that the stresses are carried by the fibers only. The stresses along the uncracked portions are assumed to be proportional to the crack opening displacement at that point. After formulating the branched crack problem, the model is applied to a (4 + or - 45 deg) 2s composite laminate. The stress concentration factors for the fibers are computed for various values of the spring constant K.
Delale, F.↗
Integrated mechanics for the passive damping of polymer-matrix composites and composite structures
Some recent developments on integrated damping mechanics for unidirectional composites, laminates, and composite structures are reviewed. Simplified damping micromechanics relate the damping of on-axis and off-axis composites to constituent properties, fiber volume ratio, fiber orientation, temperature, and moisture. Laminate and structural damping mechanics for thin composites are summarized. Discrete layer damping mechanics for thick laminates, including the effects of interlaminar shear damping, are developed and semianalytical predictions of modal damping in thick simply supported specialty composite plates are presented. Applications show the advantages of the unified mechanics, and illustrate the effect of fiber volume ratio, fiber orientation, structural geometry, and temperature on the damping. Additional damping properties for composite plates of various laminations, aspect ratios, fiber content, and temperature illustrate the merits and ranges of applicability of each theory (thin or thick laminates).
Saravanos, D. A.↗
Development of improved LOX compatible laminated gasket composite Final summary report, 16 Jun. 1965 - 16 Jun. 1966
Laminated gasket composite compatible with liquid oxygen
LIQUID OXYGEN /LOX/↗
Preparing polymeric matrix composites using an aqueous slurry technique
An aqueous process was developed to prepare a consolidated composite laminate from an aqueous slurry. An aqueous poly(amic acid) surfactant solution was prepared by dissolving a poly(amic acid) powder in an aqueous ammonia solution. A polymeric powder was added to this solution to form a slurry. The slurry was deposited on carbon fiber to form a prepreg which was dried and stacked to form a composite laminate. The composite laminate was consolidated using pressure and was heated to form the polymeric matrix. The resulting composite laminate exhibited high fracture toughness and excellent consolidation.
Johnston, Norman J.↗
Edge crack growth of thermally aged graphite/polyimide composites
Laminates of Celion 6000/LARC-160 and Celion 6000/PMR-15 graphite/polyimide composite materials were aged in air at temperatures of 202, 232, 260 and 288 C for various times up to 15,000 hours. Three unidirectional specimen types were studied: short beam shear (SBS), flexure, and 153 mm square panels. The interior region of the square panels exhibited little or no property degradation, whereas both laminate materials degraded and cracked preferentially at the specimen edge perpendicular to the fibers. Using a dye penetrant, the specimens were X-rayed and the crack depth measured as a function of time and temperature. A time temperature superposition of the crack data was successfully performed using an Arrhenius form for the shift factor. A direct correlation was found for edge crack depth and SBS strength for the LARC-160 laminates but the correlation for PMR-15 laminates was more complex.
Nelson, J. B.↗
Design of test specimens and procedures for generating material properties of Douglas fir/epoxy laminated wood composite material: With the generation of baseline data at two environmental conditions
In support of the design of wind turbine generator airfoils/blades utilizing Douglas Fir/West System Epoxy laminated composite material, a program was undertaken to define pertinent material properties utilizing small scale test specimens. Task 1 was the development of suitable monotonic tension, compression, short beam shear and full reversed cyclic specimen designs and the companion grips and testing procedures. Task 2 was the generation of the material properties at two environmental conditions utilizing the specimens and procedures developed in Task 1. The monotonic specimens and procedures generated results which compare favorably with other investigators while the cyclic results appear somewhat conservative. Adding moisture and heat or scarf joints degraded the monotonic performance but had a more nebulus effect with cyclic loading.
Johnson, Paul E.↗
Probabilistic nonlinear finite element analysis of composite structures
A probabilistic finite element analysis procedure for laminated composite shells is developed. A total Lagrangian finite element formulation, employing a degenerated three-dimensional laminated composite shell element with the full Green-Lagrange strains and first-order shear deformable kinematics, is used. The first-order second-moment technique for probabilistic finite element analysis of random fields is employed, and results are presented in the form of mean and variance of the structural response. Reliability calculations are made by using the first-order reliability method combined with sensitivity derivatives from the finite element analysis. Both ply-level and micromechanics-level random variables are incorporated, the latter by means of the Aboudi micromechanics model. Two sample problems are solved to verify the accuracy of the procedures developed and to quantify the variability of certain material type/structure combinations. In general, the procedure is quite effective in determining the response statistics and reliability for linear and geometric nonlinear behavior of laminated composite shells.
Engelstad, S. P.↗