Sustainable waste recycling solution for the glass fibre reinforced polymer composite materials industry

In this paper the adequacy and the benefit of incorporating glass fibre reinforced polymer (GFRP) waste materials into polyester based mortars, as sand aggregates and filler replacements, are assessed. Different weight contents of mechanically recycled GFRP wastes with two particle size grades are included in the formulation of new materials. In all formulations, a polyester resin matrix was modified with a silane coupling agent in order to improve binder-aggregates interfaces. The added value of the recycling solution was assessed by means of both flexural and compressive strengths of GFRP admixed mortars with regard to those of the unmodified polymer mortars. Planning of experiments and data treatment were performed by means of full factorial design and through appropriate statistical tools based on analyses of variance (ANOVA). Results show that the partial replacement of sand aggregates by either type of GFRP recyclates improves the mechanical performance of resultant polymer mortars. In the case of trial formulations modified with the coarser waste mix, the best results are achieved with 8% waste weight content, while for fine waste based polymer mortars, 4% in weight of waste content leads to the higher increases on mechanical strengths. This study clearly identifies a promising waste management solution for GFRP waste materials by developing a cost-effective end-use application for the recyclates, thus contributing to a more sustainable fibre-reinforced polymer composites industry.

Uncertainty assessment approach for composite structures based on global sensitivity indices

The problem of uncertainty propagation in composite laminate structures is studied. An approach based on the optimal design of composite structures to achieve a target reliability level is proposed. Using the Uniform Design Method (UDM), a set of design points is generated over a design domain centred at mean values of random variables, aimed at studying the space variability. The most critical Tsai number, the structural reliability index and the sensitivities are obtained for each UDM design point, using the maximum load obtained from optimal design search. Using the UDM design points as input/output patterns, an Artificial Neural Network (ANN) is developed based on supervised evolutionary learning. Finally, using the developed ANN a Monte Carlo simulation procedure is implemented and the variability of the structural response based on global sensitivity analysis (GSA) is studied. The GSA is based on the first order Sobol indices and relative sensitivities. An appropriate GSA algorithm aiming to obtain Sobol indices is proposed. The most important sources of uncertainty are identified.

Uncertainty analysis based on sensitivity applied to angle-ply composite structures

This article describes a finite element-based formulation for the statistical analysis of the response of stochastic structural composite systems whose material properties are described by random fields. A first-order technique is used to obtain the second-order statistics for the structural response considering means and variances of the displacement and stress fields of plate or shell composite structures. Propagation of uncertainties depends on sensitivities taken as measurement of variation effects. The adjoint variable method is used to obtain the sensitivity matrix. This method is appropriated for composite structures due to the large number of random input parameters. Dominant effects on the stochastic characteristics are studied analyzing the influence of different random parameters. In particular, a study of the anisotropy influence on uncertainties propagation of angle-ply composites is carried out based on the proposed approach.

From local to global importance measures of uncertainty propagation in composite structures

The influence of uncertainties of input parameters on output response of composite structures is investigated in this paper. In particular, the effects of deviations in mechanical properties, ply angles, ply thickness and on applied loads are studied. The uncertainty propagation and the importance measure of input parameters are analysed using three different approaches: a first-order local method, a Global Sensitivity Analysis (GSA) supported by a variance-based method and an extension of local variance to estimate the global variance over the domain of inputs. Sample results are shown for a shell composite laminated structure built with different composite systems including multi-materials. The importance measures of input parameters on structural response based on numerical results are established and discussed as a function of the anisotropy of composite materials. Needs for global variance methods are discussed by comparing the results obtained from different proposed methodologies. The objective of this paper is to contribute for the use of GSA techniques together with low expensive local importance measures.

Uncertainty propagation in inverse reliability-based design of composite structures

An approach for the analysis of uncertainty propagation in reliability-based design optimization of composite laminate structures is presented. Using the Uniform Design Method (UDM), a set of design points is generated over a domain centered on the mean reference values of the random variables. A methodology based on inverse optimal design of composite structures to achieve a specified reliability level is proposed, and the corresponding maximum load is outlined as a function of ply angle. Using the generated UDM design points as input/output patterns, an Artificial Neural Network (ANN) is developed based on an evolutionary learning process. Then, a Monte Carlo simulation using ANN development is performed to simulate the behavior of the critical Tsai number, structural reliability index, and their relative sensitivities as a function of the ply angle of laminates. The results are generated for uniformly distributed random variables on a domain centered on mean values. The statistical analysis of the results enables the study of the variability of the reliability index and its sensitivity relative to the ply angle. Numerical examples showing the utility of the approach for robust design of angle-ply laminates are presented.

Comparative analysis of drills for composite laminates

The characteristics of carbon fiber-reinforced plastics allow a very broad range of uses. Drilling is often necessary to assemble different components, but this can lead to various forms of damage, such as delamination which is the most severe. However, a reduced thrust force can decrease the risk of delamination. In this work, two variables of the drilling process were compared: tool material and geometry, as well as the effect of feed rate and cutting speed. The parameters that were analyzed include: thrust force, delamination extension and mechanical strength through open-hole tensile test, bearing test, and flexural test on drilled plates. The present work shows that a proper combination of all the factors involved in drilling operations, like tool material, tool geometry and cutting parameters, such as feed rate or cutting speed, can lead to the reduction of delamination damage and, consequently, to the enhancement of the mechanical properties of laminated parts in complex structures, evaluated by open-hole, bearing, or flexural tests.

Feasibility of the extended finite element method for the simulation of composite bonded joints

Adhesive-bonding for the unions in multi-component structures is gaining momentum over welding, riveting and fastening. It is vital for the design of bonded structures the availability of accurate damage models, to minimize design costs and time to market. Cohesive Zone Models (CZM’s) have been used for fracture prediction in structures. The eXtended Finite Element Method (XFEM) is a recent improvement of the Finite Element Method (FEM) that relies on traction-separation laws similar to those of CZM’s but it allows the growth of discontinuities within bulk solids along an arbitrary path, by enriching degrees of freedom. This work proposes and validates a damage law to model crack propagation in a thin layer of a structural epoxy adhesive using the XFEM. The fracture toughness in pure mode I (GIc) and tensile cohesive strength (sn0) were defined by Double-Cantilever Beam (DCB) and bulk tensile tests, respectively, which permitted to build the damage law. The XFEM simulations of the DCB tests accurately matched the experimental load-displacement (P-d) curves, which validated the analysis procedure.

Development of a new pultrusion equipment to manufacture thermoplastic matrix composite profiles

This paper describes the design and manufacture of a low-cost full scale pultrusion prototype equipment and discusses the production and obtained mechanical properties of polypropylene/glass (GF/PP) reinforced composite ba rs fabricated by using the prototype equipment. Three different GF/PP pre-impregnated ra w-materials, a commercial GF/PP comingled system from Vetrotex, a GF/PP powder coat ed towpreg [1-3] and, a GF/PP pre- consolidated tape (PCT) produced in our laboratorie s, were used in the production of composite bars that were subsequently submitted to mechanical testing in order to determine the relevant mechanical properties and quantify the consolidation quality. Samples of the different composite profiles were also observed und er SEM microscopy.

Drilling of fibre reinforced plastic laminates

The use of fibre reinforced plastics – FRP’s – in structures is under a considerable increase. Advantages of their use are related with their low weight, high strength and stiffness. The improvement of the dynamic characteristics has been profitable for aeronautics, automobile, railway, naval and sporting goods industries. Drilling is a widely used machining technique as it is needed to assemble parts in a structure. This is a unique machining process, characterized by the existence of two different mechanisms: extrusion by the drill chisel edge and cutting by the rotating cutting lips. Drilling raises particular problems that can reduce mechanical and fatigue strength of the parts. In this work, quasi-isotropic hybrid laminates with 25% of carbon fibre reinforced plies and 4 mm thickness are produced, tested and drilled. Three different drill geometries are compared. Results considered are the interlaminar fracture toughness in Mode I – GIc –, thrust force during drilling and delamination extent after drilling. A bearing test is performed to evaluate tool influence on the load carrying capacity of the plate. Results consider the influence of drill geometry on delamination. A correlation linking plate damage to bearing test results is presented.

Strength prediction of adhesively-bonded scarf repairs in composite structures under bending

This work reports on the experimental and numerical study of the bending behaviour of two-dimensional adhesively-bonded scarf repairs of carbon-epoxy laminates, bonded with the ductile adhesive Araldite 2015®. Scarf angles varying from 2 to 45º were tested. The experimental work performed was used to validate a numerical Finite Element analysis using ABAQUS® and a methodology developed by the authors to predict the strength of bonded assemblies. This methodology consists on replacing the adhesive layer by cohesive elements, including mixed-mode criteria to deal with the mixed-mode behaviour usually observed in structures. Trapezoidal laws in pure modes I and II were used to account for the ductility of the adhesive used. The cohesive laws in pure modes I and II were determined with Double Cantilever Beam and End-Notched Flexure tests, respectively, using an inverse method. Since in the experiments interlaminar and transverse intralaminar failures of the carbon-epoxy components also occurred in some regions, cohesive laws to simulate these failure modes were also obtained experimentally with a similar procedure. A good correlation with the experiments was found on the elastic stiffness, maximum load and failure mode of the repairs, showing that this methodology simulates accurately the mechanical behaviour of bonded assemblies.

Drilling tool geometry evaluation for reinforced composite laminates

In this work, a comparative study on different drill point geometries and feed rate for composite laminates drilling is presented. For this goal, thrust force monitoring during drilling, hole wall roughness measurement and delamination extension assessment after drilling is accomplished. Delamination is evaluated using enhanced radiography combined with a dedicated computational platform that integrates algorithms of image processing and analysis. An experimental procedure was planned and consequences were evaluated. Results show that a cautious combination of the factors involved, like drill tip geometry or feed rate, can promote the reduction of delamination damage.

Damage assessment of drilled hybrid composite laminates

Hole drilling operations are common in fibre reinforced plastics - FRP’s - to facilitate fastener assembly to other parts in more complex structures. As these materials are non-homogeneous, drilling causes some damages, like delamination, for example. Delamination can be reduced by a careful selection of drilling parameters, drill material and drill bit geometry. In this work two types of laminates are drilled using different machining parameters and comparing drill geometries. Results show the importance of a cautious selection of these variables when composites’ drilling is involved.

Drilling process of composite laminates – a tool based analysis

“Drilling of polymeric matrix composites structures”

Analyzing objects in images for estimating the delamination influence on load carrying capacity of composite laminates

The use of fiber reinforced plastics has increased in the last decades due to their unique properties. Advantages of their use are related with low weight, high strength and stiffness. Drilling of composite plates can be carried out in conventional machinery with some adaptations. However, the presence of typical defects like delamination can affect mechanical properties of produced parts. In this paper delamination influence in bearing stress of drilled hybrid carbon+glass/epoxy quasi-isotropic plates is studied by using image processing and analysis techniques. Results from bearing test show that damage minimization is an important mean to improve mechanical properties of the joint area of the plate. The appropriateness of the image processing and analysis techniques used in the measurement of the damaged area is demonstrated.

Taper angle optimization of scarf repairs in carbon-epoxy laminates

The increasing use of Carbon-Fibre Reinforced Plastic (CFRP) laminates in high responsibility applications introduces an issue regarding their handling after damage. The availability of efficient repair methods is essential to restore the strength of the structure. The availability of accurate predictive tools for the repairs behaviour is also essential for the reduction of costs and time associated to extensive tests. This work reports on a numerical study of the tensile behaviour of three-dimensional (3D) adhesively-bonded scarf repairs in CFRP structures, using a ductile adhesive. The Finite Element (FE) analysis was performed in ABAQUS® and Cohesive Zone Models (CZM’s) was used for the simulation of damage in the adhesive layer. A parametric study was performed on two geometric parameters. The use of overlaminating plies covering the repaired region at the outer or both repair surfaces was also tested as an attempt to increase the repairs efficiency. The results allowed the proposal of design principles for repairing CFRP structures.