Mechanical response of carbon fiber composite sandwich panels with pyramidal truss cores

The combination of light carbon fiber reinforced polymer (CFRP) composite materials with structurally efficient sandwich panel designs offers novel opportunities for ultralight structures. Here, pyramidal truss sandwich cores with relative densities ρ̄ in the range 1-10% have been manufactured from carbon fiber reinforced polymer laminates by employing a snap-fitting method. The measured quasi-static shear strength varied between 0.8 and 7.5 MPa. Two failure modes were observed: (i) Euler buckling of the struts and (ii) delamination failure of the laminates. Micro-buckling failure of the struts was not observed in the experiments reported here while Euler buckling and delamination failures occurred for the low (ρ̄≤1%) and high (ρ̄>1%) relative density cores, respectively. Analytical models for the collapse of the composite cores by these failure modes are presented. Good agreement between the measurements and predictions based on the Euler buckling and delamination failure of the struts is observed while the micro-buckling analysis over-predicts the measurements. The CFRP pyramidal cores investigated here have a similar mechanical performance to CFRP honeycombs. Thus, for a range of multi-functional applications that require an "open-celled" architecture (e.g. so that cooling fluid can pass through a sandwich core), the CFRP pyramidal cores offer an attractive alternative to honeycombs. © 2012 Elsevier Ltd. All rights reserved.

Fabrication of high-aspect-ratio polymer microstructures and hierarchical textures using carbon nanotube composite master molds

Scalable and cost effective patterning of polymer structures and their surface textures is essential to engineer material properties such as liquid wetting and dry adhesion, and to design artificial biological interfaces. Further, fabrication of high-aspect-ratio microstructures often requires controlled deep-etching methods or high-intensity exposure. We demonstrate that carbon nanotube (CNT) composites can be used as master molds for fabrication of high-aspect-ratio polymer microstructures having anisotropic nanoscale textures. The master molds are made by growth of vertically aligned CNT patterns, capillary densification of the CNTs using organic solvents, and capillary-driven infiltration of the CNT structures with SU-8. The composite master structures are then replicated in SU-8 using standard PDMS transfer molding methods. By this process, we fabricated a library of replicas including vertical micro-pillars, honeycomb lattices with sub-micron wall thickness and aspect ratios exceeding 50:1, and microwells with sloped sidewalls. This process enables batch manufacturing of polymer features that capture complex nanoscale shapes and textures, while requiring only optical lithography and conventional thermal processing. © 2011 The Royal Society of Chemistry.

The soft impact response of composite laminate beams

The quasi-static and dynamic responses of laminated beams of equal areal mass, made from monolithic CFRP and Ultra high molecular weight Polyethylene (UHMWPE), have been measured. The end-clamped beams were impacted at mid-span by metal foam projectiles to simulate localised blast loading. The effect of clamping geometry on the response was investigated by comparing the response of beams bolted into the supports with the response of beams whose ends were wrapped around the supports. The effect of laminate shear strength upon the static and dynamic responses was investigated by testing two grades of each of the CFRP and UHMWPE beams: (i) CFRP beams with a cured matrix and uncured matrix, and (ii) UHMWPE laminates with matrices of two different shear strengths. Quasi-static stretch-bend tests indicated that the load carrying capacity of the UHWMPE beams exceeds that of the CFRP beams, increases with diminishing shear strength of matrix, and increases when the ends are wrapped rather than through-bolted. The dynamic deformation mode of the beams is qualitatively different from that observed in the quasi-static stretch-bend tests. In the dynamic case, travelling hinges emanate from the impact location and propagate towards the supports; the beams finally fail by tensile fibre fracture at the supports. The UHMWPE beams outperform the CFRP beams in terms of a lower mid-span deflection for a given impulse, and a higher failure impulse. Also, the maximum attainable impulse increases with decreasing shear strength for both the UHMWPE and CFRP beams. The ranking of the beams for load carrying capacity in the quasi-static stretch-bend tests is identical to that for failure impulse in the impact tests. Thus, the static tests can be used to gauge the relative dynamic performances of the beams. © 2013 Elsevier Ltd. All rights reserved.

The effect of shear strength on the ballistic response of laminated composite plates

The ballistic performance of clamped circular carbon fibre reinforced polymer (CFRP) and Ultra High Molecular Weight Polyethylene (UHMWPE) fibre composite plates of equal areal mass and 0/90 lay-up were measured and compared with that of monolithic 304 stainless steel plates. The effect of matrix shear strength upon the dynamic response was explored by testing: (i) CFRP plates with both a cured and uncured matrix and (ii) UHMWPE laminates with identical fibres but with two matrices of different shear strength. The response of these plates when subjected to mid-span, normal impact by a steel ball was measured via a dynamic high speed shadow moiré technique. Travelling hinges emanate from the impact location and travel towards the supports. The anisotropic nature of the composite plate results in the hinges travelling fastest along the fibre directions and this results in square-shaped moiré fringes in the 0/90 plates. Projectile penetration of the UHMWPE and the uncured CFRP plates occurs in a progressive manner, such that the number of failed plies increases with increasing velocity. The cured CFRP plate, of high matrix shear strength, fails by cone-crack formation at low velocities, and at higher velocities by a combination of cone-crack formation and communition of plies beneath the projectile. On an equal areal mass basis, the low shear strength UHMWPE plate has the highest ballistic limit followed by the high matrix shear strength UHMWPE plate, the uncured CFRP, the steel plate and finally the cured CFRP plate. We demonstrate that the high shear strength UHMWPE plate exhibits Cunniff-type ballistic limit scaling. However, the observed Cunniff velocity is significantly lower than that estimated from the laminate properties. The data presented here reveals that the Cunniff velocity is limited in its ability to characterise the ballistic performance of fibre composite plates as this velocity is independent of the shear properties of the composites: the ballistic limit of fibre composite plates increases with decreasing matrix shear strength for both CFRP and UHMWPE plates. © 2013 Elsevier Masson SAS. All rights reserved.

High performance fibre-reinforced cementitious composite (CARDIFRC) - Performance and application to retrofitting

This paper describes first some of the recent performance checks on the high performance fibre-reinforced cementitious composite CARDIFRC and then its application to the retrofitting of damaged concrete beams. It is shown that an even distribution of fibres throughout the bulk of the material is crucial to its excellent fatigue performance and to the reduction in the autogenous shrinkage strains. The distribution of fibres in beams, cylinders and strips is examined using computerised tomography imaging and traditional image analysis. Thin strips of CARDIFRC are used to retrofit damaged concrete beams which are subjected to thermal cycling. It is shown that neither the load carrying capacity of the retrofitted beams nor the bond between retrofit strips and concrete deteriorates with thermal cycling. The load carrying capacity of retrofitted beams is predicted with a model based on fracture mechanics, and the predictions are shown to be in good agreement with test data. © 2006 Elsevier Ltd. All rights reserved.

Mechanical and fracture properties of cement-based bi-materials after thermal cycling

This study investigates the effect of thermal cycles on the fracture properties of the cement-based bi-materials. Sixty eight cubes were exposed to a varied number of 24-hour thermal cycles ranging from 0 to 90 and subsequently were tested in a wedge splitting configuration. The mechanical and fracture properties of normal strength and high strength concretes are substantially improved after 30 thermal cycles, but less so after 90 thermal cycles both in isolation and when bonded to an ultra high-performance fibre-reinforced cement-based composite. © 2009 Elsevier Ltd. All rights reserved.

Hybrid core carbon fiber composite sandwich panels: Fabrication and mechanical response

Carbon fiber reinforced polymer (CFRP) composite sandwich panels with hybrid foam filled CFRP pyramidal lattice cores have been assembled from a carbon fiber braided net, 3D woven face sheets and various polymeric foams, and infused with an epoxy resin using a vacuum assisted resin transfer process. Sandwich panels with a fixed CFRP truss mass have been fabricated using a variety of closed cell polymer and syntactic foams, resulting in core densities ranging from 44-482kgm-3. The through thickness and in-plane shear modulus and strength of the cores increased with increasing foam density. The use of low compressive strength foams within the core was found to result in a significant reduction in the compressive strength contributed by the CFRP trusses. X-ray tomography led to the discovery that the trusses develop an elliptical cross-section shape during pressure assisted resin transfer. The ellipticity of the truss cross-sections increased, and the lattice contribution to the core strength decreased as the foam density was reduced. Micromechanical modeling was used to investigate the relationships between the mechanical properties and volume fractions of the core materials and truss topology of the hybrid core. The specific strength and moduli of the hybrid cores lay between those of the CFRP lattices and foams used to fabricate them. However, their volumetric and gravimetric energy absorptions significantly exceeded those of the materials from which they were fabricated. They compare favorably with other lightweight energy absorbing materials and structures. © 2013.