Rapidly cured out-of-autoclave laminates: understanding and controlling the effect of voids on laminate fracture toughness

Voids are one of the most significant defects found within composites and have been demonstrated to reduce the performance of composite structures. The understanding of the impact of the size and distribution of voids on laminate properties is still limited because voids have proven difficult to deliberately control. This study aims to understand the mechanisms by which voids are generated within out-of-autoclave cured laminates. In this study, a process of prepreg conditioning was developed to control the level of voids within test laminates. Non-conditioned laminates highlighted signs of void growth (1.5%), while conditioned laminates showed consistently low levels of voids (<0.3%). Mass spectrometry indicated higher levels of aqueous and solvent volatiles within the non-conditioned prepreg. Finally, Mode II fracture testing revealed a 21% improvement in toughness for the non-voided laminates. A model on the effect of voids within the Mode II stress state has also been proposed.

Rapidly cured epoxy/anhydride composites: effect of residual stress on laminate shear strength

The drive towards rapid cure thermosetting composites requires a better understanding of the residual stresses that develop during curing. This study investigates the impact of residual stresses on the interlaminar shear strength of resin-infused epoxy/anhydride carbon-fibre laminates. The magnitude of the residual stress was varied by changing the initial injection cure temperature between 75 °C and 145 °C. The corresponding cycle times and the final glass transition temperature of the resin were also measured. The experimentally measured chemical shrinkage and thermal expansion properties of the resin after vitrification were used as inputs to a finite element analysis to calculate the peak residual stresses in the composite. An increase in the initial cure temperature from 85 to 135 °C resulted in an increase of 25% in the residual stress, which led to an experimentally measured reduction in the composite's short beam shear strength of approximately 16% (8 MPa), in good agreement with model prediction.

Elastic bending of steel-polymer-steel (SPS) laminates to a constant curvature

The shear strain of the interlayer in the elastic regime for a Steel-Polymer-Steel (SPS) laminate material has been studied during bending to a constant curvature. An analytical model is developed and the influence of process parameters are analyzed. The tension in the cover sheets is also determined and, finally, a moment diagram is calculated. The results show that the moment in the SPS laminate is nonuniform along the bent strip even though the curvature is constant because of the tension and compression forces introduced in the cover sheets by the shear reaction force of the interlayer material.

Mode II delamination toughness of Z-pinned laminates

Mode II delamination toughness of z-pin reinforced composite laminates is investigated using finite element (FE) method. The z-pin pullout process is simulated by the deformation and breakage of non-linear springs. A critical shear stress criterion based on linear elastic fracture mechanics is used to simulate crack growth in an end-notched-flexure (ENF) beam made of z-pinned laminates. The mode II toughness is quantified by the potential energy release rate calculated using the contour integral method. This FE model is verified for an unpinned ENF composite beam. Numerical results obtained indicate that z-pins can significantly increase the mode II delamination toughness of composite laminate. The effects of design variables on the toughness enhancement of z-pinned laminates are also studied, which provides an important technological base and useful data to optimize and improve the z-pinning technique.

Characterization of melded carbon fibre/epoxy laminates

‘Melding’ is a novel in situ method for joining thermosetting composite structures, without the need of adhesives. Laminate joining is achieved using uncrosslinked resin matrix of the pre-preg. This study used Hexply914C pre-preg material to characterize melded CFRP structures produced using the melding method. A designated area of a laminate was maintained at temperatures below 40 °C retaining uncured (B-staged) material, while the remainder of the laminate was cured at 175 °C. After a 2.5 h cure cycle, the cured region showed a high degree of cure (0.88) and glass transition temperature (176 °C). The uncured area of the same laminate was cured in a second stage, simulating an in situ melded joint. By controlling the temperature and duration of the intermediate dwell and affecting minimum viscosity values prior to final cure, low values of porosity (<0.5%) were achieved. The mechanical properties of the resulting joint were consistent throughout the melded laminate. Flexural strength (1600 MPa), flexural modulus (100–105 MPa) and short beam strength (105–115 MPa) values observed where equivalent or greater than those found in the recommended autoclave cured control specimens. After the entire laminate was post cured, glass transition temperatures of 230 °C (peak tan δ) were observed in all areas of the laminate.

Assessment of delamination in composite beams using shear horizontal (SH) wave mode

Interaction of Lamb waves with structural damage can lead to wave mode conversion. In this study, the shear horizontal (SH) wave, from the mode conversion of the fundamental symmetric Lamb wave (S0), was used for quantitative identification of delamination in composite beams, based on advanced signal processing using an inverse approach. SH wave propagation under various delamination conditions in CF/EP beams made of orthotropic plain woven fabrics was simulated, and signal characteristics were extracted in terms of the concept of digital damage fingerprints (DDF). With the aid of an artificial neural algorithm, the relation between the DDF of delamination-scattered SH mode and damage parameters was calibrated, whereby the occurrence, location and size of delamination in the composite beams were assessed. The approach was experimentally validated, and the results demonstrate the effectiveness of SH mode for quantitative damage evaluation of composite structures.

The influence of temperature on the forming behavior of metal/polymer laminates in sheet metal forming

The influence of temperature on the forming behavior of an aluminum/polypropylene/aluminum (APA) sandwich sheet was studied. Shear and tensile tests were performed to determine the mechanical properties of the laminate and the component materials as a function of process temperature. The forming limit diagram (FLD) of the laminate was established for two different temperatures, and its springback behavior was examined in four-point bend and channel bend tests. Cup forming tests were performed at various test temperatures to determine the limiting drawing ratio (LDR) and the tendency for wrinkling at these temperatures. Although there was only a minor influence of temperature on the mechanical properties and the FLD values of the laminate, the bend test results reveal that springback can be reduced by forming at higher temperature. The decreasing strength of the core material with rising process temperature led to an increased tendency of the laminate to wrinkle in the heated cup drawing tests.

Melding: a new alternative to adhesive bonding

Melding, a novel method for joining composites is examined in this paper. The method uses Quickstep ™ technology to retain partially cured areas of a composite laminate, enabling subsequent bonding operations. The effect of melding on the mechanical properties of the composite has been investigated. Flexural testing of HexPly 914 indicates consistent properties throughout a melded section. Flexural strength values of 1.36±O.03 GPa compared to 1.35±O.03 GPa for a standard laminate were recorded. In order to achieve sufficient bond strength, the portion of the composite to be joined must have a significant proportion of uncured matrix. The ability of Hexply 914 prepreg to retain sufficient bonding potential to form a strong joint was also investigated. HexPly 914 Lap Shear results indicated no significant variation in strength values between co-cured and melded joins, with a recorded
strength value of 15.0±0. 7 MPa.

A family of simple and robust finite elements for linear and geometrically nonlinear analysis of laminated composite plates

A family of simple, displacement-based and shear-flexible triangular and quadrilateral flat plate/shell elements for linear and geometrically nonlinear analysis of thin to moderately thick laminate composite plates are introduced and summarized in this paper.

The developed elements are based on the first-order shear deformation theory (FSDT) and von-Karman’s large deflection theory, and total Lagrangian approach is employed to formulate the element for geometrically nonlinear analysis. The deflection and rotation functions of the element boundary are obtained from Timoshenko’s laminated composite beam functions, thus convergence can be ensured theoretically for very thin laminates and shear-locking problem is avoided naturally.

The flat triangular plate/shell element is of 3-node, 18-degree-of-freedom, and the plane displacement interpolation functions of the Allman’s triangular membrane element with drilling degrees of freedom are taken as the in-plane displacements of the element. The flat quadrilateral plate/shell element is of 4-node, 24-degree-of-freedom, and the linear displacement interpolation functions of a quadrilateral plane element with drilling degrees of freedom are taken as the in-plane displacements.

The developed elements are simple in formulation, free from shear-locking, and include conventional engineering degrees of freedom. Numerical examples demonstrate that the elements are convergent, not sensitive to mesh distortion, accurate and efficient for linear and geometric nonlinear analysis of thin to moderately thick laminates.

Investigation on the forming behaviour of metal/polymer laminates

A metal/polymer laminate is a new light weight sheet material suitable to replace conventional steel or aluminium sheet in future car designs. In this study the effect of material composition and process conditions on the forming behaviour of metal/polymer laminates in sheet metal forming was investigated by experimental, analytical and numerical methods.

High strain rate tensile properties of rapidly cured woven carbon fibre composites

Tensile tests at high speeds corresponding to automotive crash events were conducted to understand the dynamic properties of rapidly cured woven carbon fiber composites. The High Strain Rate (HSR) experiments were conducted on a servo-hydraulic machine at constant velocities up to a maximum of 25 m/s (82 ft/s). Results from HSR tests were compared with the static results to determine the rate sensitivity of the composite. A high speed camera was used to capture the failure at HSR. The tensile properties of rapidly cured laminate were compared to oven cured laminate to justify its productivity while maintaining the desired properties. The methodology used to achieve constant velocity during HSR tests is discussed in detail. The specimen geometry was specially designed to suit the test rig and to achieve high speeds during tests. All the specimens failed with linear elasticity until sudden brittle fracture. The Scanning Electron Microscopy (SEM) images of the fracture zone were used to identify the failure modes observed at static and high strain rates.

Effect of manufacturing method and aging environment on painted automotive carbon fibre composite surfaces

In this paper, the effect of various aging environments on the painted surface finish of unidirectional carbon fibre composite laminates, manufactured by autoclave and a novel out-of-autoclave technique was investigated. Laminates were exposed to water immersion, 95 % relative humidity and cyclic environments for 552 h and the surface finish was evaluated using visual and wave-scan distinctness of image (DOI) techniques. It was found that the laminate surface finish was dependent on the amount of moisture in the aging test. Minor surface waviness occurred on the laminates exposed to the cyclic test, whereas, surface waviness, print through and DOI values were all significantly higher as the laminates absorbed larger quantities of moisture from the hygrothermal and hydrothermal tests. The water immersion test, which was the most detrimental to the surface finish of the painted laminates, produced dense blistering on the autoclave manufactured laminate surface whereas the out-of-autoclave laminate surface produced only a few. It was found that the out-of-autoclave laminate had high substrate surface roughness which resulted in improved paint adhesion and, therefore, prevented the formation of surface blistering with aging. © 2012 Springer Science+Business Media Dordrecht.

Hygrothermal effects on painted carbon fibre composite surfaces

In this article, the effect of hygrothermal aging on the painted surface finish of unidirectional and fabric carbon fibre composite laminates, with and without surfacing film was investigated. The results highlighted the importance of ensuring that the composite surface directly beneath the paint layer is made from a uniform material with a consistent thickness in order to minimise surface defects from occurring during aging. The surfacing film was found to minimise the print through development on the painted unidirectional and twill composite surfaces. However, the surfacing film layer was found to intermingle with the carbon fibre plies during cure, which resulted in an uneven film thickness that caused increased levels of orange peel. The twill laminate painted surface produced high levels of print through and surface waviness that was caused by the large resin rich regions located within the tow intersections at the surface which enlarged due to thermal expansion and swelling of the matrix with hygrothermal aging. It was also noted that the small resin rich regions between the individual carbon fibres on the unidirectional composite surface were sufficiently large to print through the painted surface.

The surface finish of thermally aged carbon fibre reinforced composites using E-glass as a surface barrier

This work investigated the effect of woven E-glass mass (25 g/m2, 50 g/m2, 85 g/m2, 135 g/m2) on the painted surface finish of various thermoset (EPIKOTETM RIM935, EPIKOTETM 04434, Ultratec LpTM ES300, Ultratec LpTM SPV6035) carbon fibre composite laminates, before and after aging at 95 °C for 168 h. The as-moulded laminate surfaces were evaluated using surface profilometry techniques and the painted and aged surfaces were evaluated using a wave-scan distinctness of image (DOI) instrument. It was found that the 25 g/m2 E-glass surface layer assisted with reducing the roughness of the as-moulded surfaces and the long-term waviness of the painted surfaces due to the increase in resin-richness at the surface. The EPIKOTETM 04434 resin system that contained diglycidyl ether of bisphenol F (DGEBF) epoxy had the least change in long-term waviness with thermal aging due to the rigid fluorene-based backbone in comparison to the diglycidyl ether of bisphenol A (DGEBA) systems.