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.

Response of clamped sandwich beams subjected to high-velocity impact by sand slugs

The dynamic response of end-clamped sandwich and monolithic beams of equal areal mass subjected to loading via high-velocity slugs of dry and water-saturated sand is measured using a novel laboratory-based method. The sandwich beams comprise aluminium face sheets and an aluminium honeycomb core: the effect of sandwich core strength and beam thickness on the dynamic beam deflection is investigated by varying the orientation and height of the anisotropic aluminium honeycomb core material. High-speed imaging is used to measure the transient transverse deflection of the beams and to record the dynamic modes of deformation. The measurements show that sandwich beams with thick, strong cores are optimal and that these beams significantly outperform monolithic beams of equal mass. The water-saturated sand slugs cause significantly higher deflections compared to the dry sand slugs having the same mean slug velocity and we demonstrate that this enhanced deflection is due to the larger mass of the water-saturated slugs. Finally, we show that the impact of sand slugs is equivalent to the impact of a crushable foam projectile. The experiments using foam projectiles are significantly simpler to perform and thus represent a more convenient laboratory technique. © 2014 Elsevier Ltd. All rights reserved.

Multi-hit armour characterisation of metal-composite bi-layers

The ballistic performance of equi-mass plates made from (i) stainless steel (SS); (ii) carbon fibre/epoxy (CF) laminate and (iii) a hybrid plate of both materials has been characterised for a spherical steel projectile. The hybrid plate was orientated with steel on the impact face (SSCF) and on the distal face (CFSS). The penetration velocity (V 50) was highest for the SS plate and lowest for the CF plate. A series of double impact tests were performed, with an initial velocity V I and a subsequent velocity V II at the same impact site. An interaction diagram in (V I,V II) space was constructed to delineate penetration from survival under both impacts. The degree of interaction between the two impact events was greater for the CFSS plate than for the SSCF plate, implying that the distal face has the major effect upon the degree of interaction.

A method and tool for 'cradle to grave' embodied carbon and energy impacts of UK buildings in compliance with the new TC350 standards

As operational impacts from buildings are reduced, embodied impacts are increasing. However, the latter are seldom calculated in the UK; when they are, they tend to be calculated after the building has been constructed, or are underestimated by considering only the initial materials stage. In 2010, the UK Government recommended that a standard methodology for calculating embodied impacts of buildings be developed for early stage design decisions. This was followed in 2011-12 by the publication of the European TC350 standards defining the 'cradle to grave' impact of buildings and products through a process Life Cycle Analysis. This paper describes a new whole life embodied carbon and energy of buildings (ECEB) tool, designed as a usable empirical-based approach for early stage design decisions for UK buildings. The tool complies where possible with the TC350 standards. Initial results for a simple masonry construction dwelling are given in terms of the percentage contribution of each life cycle stage. The main difficulty in obtaining these results is found to be the lack of data, and the paper suggests that the construction and manufacturing industries now have a responsibility to develop new data in order to support this task. © 2013 The Authors. Published by Elsevier B.V. All rights reserved.

Mechanisms of projectile penetration in Dyneema® encapsulated aluminum structures

Polymer composites comprising ultra-high molecular weight polyethylene (UHWMPE) fibers in a compliant matrix are now widely used in ballistic applications with varying levels of success. This is primarily due to a poor understanding of the mechanics of penetration of these composites in ballistic protection systems. In this study, we report experimental observations of the penetration mechanisms in four model systems impacted by a 12.7 mm diameter spherical steel projectile. The four model targets designed to highlight different penetration mechanisms in Dyneema® UHWMPE composites were: (i) a bare aluminum plate; (ii) the same plate fully encased in a 5.9 mm thick casing of Dyneema®; (iii) the fully encased plate with a portion of the Dyneema® removed from the front face so that the projectile impacts directly the Al plate; and (iv) the fully encased plate with a portion of the Dyneema® removed from the rear face so that the projectile can exit the Al plate without again interacting with the Dyneema®. A combination of synchronized high speed photography with three cameras, together with post-test examination of the targets via X-ray tomography and optical microscopy was used to elucidate the deformation and perforation mechanisms. The measurements show that the ballistic resistance of these targets increases in the order: bare Al plate, rear face cutout target, fully encased target and front face cutout target. These findings are explained based on the following key findings: (a) the ballistic performance of Dyneema® plates supported on a foundation is inferior to Dyneema® plates supported along their edges; (b) the apparent ballistic resistance of Dyneema® plates increases if the plates are given an initial velocity prior to the impact by the projectile, thereby reducing the relative velocity between the Dyneema® plate and projectile; and (c) when the projectile is fragmented prior to impact, the spatially and temporally distributed loading enhances the ballistic resistance of the Dyneema®. The simple model targets designed here have elucidated mechanisms by which Dyneema® functions in multi-material structures. © 2014 Elsevier Ltd.

Laboratory-scale fluidized bed rig for high-temperature tube wastage studies

As part of a study of the wear of candidate heat exchanger tube materials for use in fluidized bed combustors, two similar laboratory-scale rigs have been built and characterized. Specimens of selected alloys are carried on counter-rotating rotors immersed in a fluidized bed, and are exposed to particle impact velocities of up to approximately 3 ms-1 at temperatures up to 1000°C. The performance of this design of apparatus has been investigated in detail. The effects of several experimental variables have been studied, including angle of particle impact, specimen speed, position of the rotor within the fluidized bed, duration of exposure, bed material particle size, degradation of the bed material, degree of fluidization of the bed, and size of specimen. In many cases the results obtained with steel specimens at elevated temperatures are similar to those observed with polymeric specimens at low temperatures.

Elastodynamic erosion of thermal barrier coatings

The finite element method is used to analyze the elastodynamic response of a columnar thermal barrier coating due to normal impact and oblique impact by an erosive particle. An assessment is made of the erosion by crack growth from preexisting flaws at the edge of each column: it is demonstrated that particle impacts can be sufficiently severe to give rise to columnar cracking. First, the transient stress state induced by the normal impact of a circular cylinder or a sphere is calculated in order to assess whether a 2D calculation adequately captures the more realistic 3D behavior. It is found that the transient stress states for the plane strain and axisymmetric models are similar. The sensitivity of response to particle diameter and to impact velocity is determined for both the cylinder and the sphere. Second, the transient stress state is explored for 2D oblique impact by a circular cylindrical particle and by an angular cylindrical particle. The sensitivity of transient tensile stress within the columns to particle shape (circular and angular), impact angle, impact location, orientation of the angular particle, and to the level of friction is explored in turn. The paper concludes with an evaluation of the effect of inclining the thermal barrier coating columns upon their erosion resistance. © 2011 The American Ceramic Society.

Development of a tool for rapidly assessing the implementation difficulty and emissions benefits of innovations

Consumer goods manufacturers aiming to reduce the environmental impact associated with their products commonly pursue incremental change strategies, but more radical approaches may be required if we are to address the challenges of sustainable consumption. One strategy to realize step change reductions is to prepare a portfolio of innovations providing different levels of impact reduction in exchange for different levels of organizational resource commitment. In this research a tool is developed to support this strategy, starting with the assumption that through brainstorming or other eco-innovation approaches, a long-list of candidate innovations has been created. The tool assesses the potential greenhouse gas benefit of an innovative option against the difficulty of its implementation. A simple greenhouse gas benefit assessment method based on streamlined LCA was used to analyze impact reduction potential, and a novel measure of implementation difficulty was developed. The predictions of implementation difficulty were compared against expert opinion, and showed similar results indicating the measure can be used sensibly to predict implementation difficulty. The assessment of the environmental gain versus implementation difficulty is visualized in a matrix, showing the trade-offs of several options. The tool is deliberately simple with scalar measures of CO 2 emissions benefits and implementation difficulty so tool users must remain aware of other potential environmental burdens besides greenhouse gases (e.g. water, waste). In addition, although relative life cycle emissions benefits of an option may be low, the absolute impact of an option can be high and there may be other co-benefits, which could justify higher levels of implementation difficulty. Different types of consumer products (e.g. household, personal care, foods) have been evaluated using the tool. Initial trials of the tool within Unilever demonstrate that the tool facilitates rapid evaluation of low-carbon innovations. © 2011 Elsevier Ltd. All rights reserved.

Strategies for product recovery decisions

Product recovery is beset by uncertainty regarding the quality of end-of-life (EOL) products, and in order to ascertain the reusability of these products, they have to undergo expensive tests. This undermines the profitability of the recovery process. The key to improve the effectiveness of product recovery is to improve the quality of information available before testing. Emerging data capture technologies can significantly improve the availability of information. However, in order to maximise the potential of these technologies, appropriate decision-making algorithms that exploit such information must be developed. We model the recovery process using a decision-theoretic approach, and derive strategies to ascertain the reusability of EOL products, and also to decide when tests are beneficial. We show that improving the quality of information leads to increase in effectiveness of the recovery process by reducing the need for tests. Copyright © 2009 Inderscience Enterprises Ltd.

Predicting the acoustics of squeak and rattle

This paper discusses the development of a computationally efficient numerical method for predicting the acoustics of rattle events upfront in the design cycle. The method combines Finite Elements, Boundary Elements and SEA and enables the loudness of a large number of rattle events to be efficiently predicted across a broad frequency range. A low frequency random vibro-acoustic model is used in conjunction with various closed form analytical expressions in order to quickly predict impact probabilities and locations. An existing method has been extended to estimate the statistics of the contact forces across a broad frequency range. Finally, broadband acoustic radiation is predicted using standard low, mid and high frequency vibro-acoustic methods and used to estimate impact loudness. The approach is discussed and a number of validation examples are presented.

Wetness loss prediction for a low pressure steam turbine using computational fluid dynamics

Two-phase computational fluid dynamics modelling is used to investigate the magnitude of different contributions to the wet steam losses in a three-stage model low pressure steam turbine. The thermodynamic losses (due to irreversible heat transfer across a finite temperature difference) and the kinematic relaxation losses (due to the frictional drag of the drops) are evaluated directly from the computational fluid dynamics simulation using a concept based on entropy production rates. The braking losses (due to the impact of large drops on the rotor) are investigated by a separate numerical prediction. The simulations show that in the present case, the dominant effect is the thermodynamic loss that accounts for over 90% of the wetness losses and that both the thermodynamic and the kinematic relaxation losses depend on the droplet diameter. The numerical results are brought into context with the well-known Baumann correlation, and a comparison with available measurement data in the literature is given. The ability of the numerical approach to predict the main wetness losses is confirmed, which permits the use of computational fluid dynamics for further studies on wetness loss correlations. © IMechE 2013 Reprints and permissions: sagepub.co.uk/journalsPermissions.nav.