Structural design, manufacturing and testing of the new wing for the CSIR's Modular UAS in composite materials

In the framework of an international collaboration with South Africa CSIR, the structural design, manufacturing and testing of the new wing for the Modular UAS in composite materials has been performed.

On the influence of polymeric nanofibers in laminated composite materials. Studio dell'influenza di nanofibre polimeriche in materiali compositi laminati

During the last years an increased interest about the reinforcement of laminated composites by means of polymeric nanofibers has been growth. During this master-degree-thesis work, unidirectional and plane-textile composites have been interleaved with Nylon 6.6, PCL and mixed (Nylon 6.6+PCL) nanofibrous mats and the DCB (mode I interlaminar fracture toughness), ENF (mode II interlaminar fracture toughness and DMA (damping capability) tests have been performed. Regarding the interlaminar fracture toughness, marked increases have been recorded; while further investigation about damping capability is requested.

Masonry columns confined by composite materials: Experimental investigation

This study wants to analyze the effectiveness of different reinforcement typologies for masonry columns, in particular Fiber-Reinforced Polymer (FRP) and FRCM. The behavior of 10 solid – brick columns that are externally wrapped by FRP sheets and 2 unreinforced columns are presented in this study. The specimens are subjected to axial load until failure occurs. Three different confinement schemes were experimentally analyzed in order to evaluate and compare the effectiveness of the proposed strengthening techniques: 1) Grid carbon FRP (CFRP_G); 2) Grid glass FRP (GFRP_G); 3) Uniaxial carbon FRP (CFRP_U). Two different configurations of the reinforcing system were investigated: FRP sheets are applied as external reinforcement along the perimeter of the masonry columns in the form of continuous and discontinuous wrap, respectively. The results, compared with those for un-reinforced columns, indicate an increases in ultimate load, stiffness and ductility.

Advanced Non-Destructive Inspections focused on composite materials application for the automotive and marine sectors

The goal of this master thesis is to explain in detail the application of Non-Destructive-Inspection on the Automotive and the Marine sectors. Nowadays, these two particular industries faces many challenges, including increased global competition, the need for higher performance, a reduction in costs and tighter environmental and safety requirements. The materials used for these applications play key roles in overcoming these challenges. So, also an NDI procedure need to be planned in order to avoid problems during the manufacturing process and the after sale life of the structures. The entire thesis work has been done in collaboration with Vetorix Engineering.

Design and development of the new composite-material mainplane of the Dallara T12 race car

Abstract (US) Composite material components design and production techniques are discussed in the present graduation paper. In particular, this paper covers the design process and the production process of a carbon-fiber composite material component for a high performance car, more specifically, the Dallara T12 race car. This graduation paper is split in two. After a brief introduction on existing composite materials (their origins and applications), the first part of the present paper covers the main theoretical concepts behind the design of composite material components: particular focus will be given to carbon-fiber composites. The second part of the present paper covers the whole design and production process that the candidate carried out to create the new front mainplane of the Dallara T12 race car. This graduation paper is the result of a six-months-long internship that the candidate conducted as Design Office Trainee inside Dallara Automobili S.p.A. Abstract (ITA) La presente tesi di laurea discute le metodologie progettuali e produttive legate alla realizzazione di un componente in materiale composito. Nello specifico, viene discussa la progettazione e la produzione di un componente in fibra di carbonio destinato ad una vettura da competizione. La vettura in esame è la Dallara T12. Il lavoro è diviso in due parti. Nella prima parte, dopo una breve introduzione sull’origine e le tipologie di materiali compositi esistenti, vengono trattati i concetti teorici fondamentali su cui si basa la progettazione di generici componenti in materiale composito, con particolare riguardo ai materiali in fibra di carbonio. Nella seconda parte viene discusso tutto il processo produttivo che il candidato ha portato a termine per realizzare il nuovo alettone anteriore della Dallara T12. La presente tesi di laurea è il risultato del lavoro di progettazione che il candidato ha svolto presso l’Ufficio Tecnico di Dallara Automobili S.p.A. nel corso di un tirocinio formativo di sei mesi.

Prediction and measurement of forced response of a composite blade undergoing nonlinear vibration

The main objective of this project is to experimentally demonstrate geometrical nonlinear phenomena due to large displacements during resonant vibration of composite materials and to explain the problem associated with fatigue prediction at resonant conditions. Three different composite blades to be tested were designed and manufactured, being their difference in the composite layup (i.e. unidirectional, cross-ply, and angle-ply layups). Manual envelope bagging technique is explained as applied to the actual manufacturing of the components; problems encountered and their solutions are detailed. Forced response tests of the first flexural, first torsional, and second flexural modes were performed by means of a uniquely contactless excitation system which induced vibration by using a pulsed airflow. Vibration intensity was acquired by means of Polytec LDV system. The first flexural mode is found to be completely linear irrespective of the vibration amplitude. The first torsional mode exhibits a general nonlinear softening behaviour which is interestingly coupled with a hardening behaviour for the unidirectional layup. The second flexural mode has a hardening nonlinear behaviour for either the unidirectional and angle-ply blade, whereas it is slightly softening for the cross-ply layup. By using the same equipment as that used for forced response analyses, free decay tests were performed at different airflow intensities. Discrete Fourier Trasform over the entire decay and Sliding DFT were computed so as to visualise the presence of nonlinear superharmonics in the decay signal and when they were damped out from the vibration over the decay time. Linear modes exhibit an exponential decay, while nonlinearities are associated with a dry-friction damping phenomenon which tends to increase with increasing amplitude. Damping ratio is derived from logarithmic decrement for the exponential branch of the decay.

Creep deflection of low-strength reinforced concrete flexural members strengthened with carbon fiber composite sheets

The low-strength concrete is defined as a concrete where the compressive cubic strength is less than 15 MPa. Since the beginning of the last century, many low-strength concrete buildings and bridges have been built all over the world. Being short of deeper study, composite sheets are prohibited in strengthening of low-strength reinforced concrete members (CECS 146; ACI 440). Moreover, there are few relevant information about the long-term behavior and durability of strengthened RC members. This fact undoubtedly limits the use of the composite materials in the strengthening applications, therefore, it is necessary to study the behaviours of low-strength concrete elements strengthened with composite materials (FRP) for the preservation of historic constructions and innovation in the strengthening technology. Deformability is one of criteria in the design of concrete structures, and this for functionality, durability and aesthetics reasons. Civil engineer possibly encounters more deflection problems in the structural design than any other type of problem. Many materials common in structural engineering such as wood, concrete and composite materials, suffer creep; if the creep phenomenon is taken into account, checks for serviceability limit state criteria can become onerous, because the creep deformation in these materials is in the same order of magnitude as the elastic deformation. The thesis presents the results of an experimental study on the long-term behavior of low-strength reinforced concrete beams strengthened with carbon fiber composite sheets (CFRP). The work has investigated the accuracy of the long-term deflection predictions made by some analytical procedures existing in literature, as well as by the most widely used design codes (Eurocode 2, ACI-318, ACI-435).

Analisi sperimentale degli effetti di temperature elevate sul comportamento strutturale dei rinforzi in FRP

In questa tesi si è voluta porre l’attenzione sulla suscettibilità alle alte temperature delle resine che li compongono. Lo studio del comportamento alle alte temperature delle resine utilizzate per l’applicazione dei materiali compositi è risultato un campo di studio ancora non completamente sviluppato, nel quale c’è ancora necessità di ricerche per meglio chiarire alcuni aspetti del comportamento. L’analisi di questi materiali si sviluppa partendo dal contesto storico, e procedendo successivamente ad una accurata classificazione delle varie tipologie di materiali compositi soffermandosi sull’ utilizzo nel campo civile degli FRP (Fiber Reinforced Polymer) e mettendone in risalto le proprietà meccaniche. Considerata l’influenza che il comportamento delle resine riveste nel comportamento alle alte temperature dei materiali compositi si è, per questi elementi, eseguita una classificazione in base alle loro proprietà fisico-chimiche e ne sono state esaminate le principali proprietà meccaniche e termiche quali il modulo elastico, la tensione di rottura, la temperatura di transizione vetrosa e il fenomeno del creep. Sono state successivamente eseguite delle prove sperimentali, effettuate presso il Laboratorio Resistenza Materiali e presso il Laboratorio del Dipartimento di Chimica Applicata e Scienza dei Materiali, su dei provini confezionati con otto differenti resine epossidiche. Per valutarne il comportamento alle alte temperature, le indagini sperimentali hanno valutato dapprima le temperature di transizione vetrosa delle resine in questione e, in seguito, le loro caratteristiche meccaniche. Dalla correlazione dei dati rilevati si sono cercati possibili legami tra le caratteristiche meccaniche e le proprietà termiche delle resine. Si sono infine valutati gli aspetti dell’applicazione degli FRP che possano influire sul comportamento del materiale composito soggetto alle alte temperature valutando delle possibili precauzioni che possano essere considerate in fase progettuale.

Prove di caratterizzazione meccanica del legame di adesione fra FRP ed acciaio

Il progresso nella tecnica di recupero e di rinforzo nelle strutture metalliche con i polimeri fibro-rinforzati FRP (fibre reinforced polymers). 1.1 Introduzione nelle problematiche ricorrenti delle strutture metalliche. Le strutture moderne di una certa importanza, come i grattacieli o i ponti, hanno tempi e costi di costruzione molto elevati ed è allora di importanza fondamentale la loro durabilità, cioè la lunga vita utile e i bassi costi di manutenzione; manutenzione intesa anche come modo di restare a livelli prestazionali predefiniti. La definizione delle prestazioni comprende la capacità portante, la durabilità, la funzionalità e l’aspetto estetico. Se il livello prestazionale diventa troppo basso, diventa allora necessario intervenire per ripristinare le caratteristiche iniziali della struttura. Strutture con una lunga vita utile, come per la maggior parte delle strutture civili ed edilizie, dovranno soddisfare esigenze nuove o modificate: i mezzi di trasporto ad esempio sono diventati più pesanti e più diffusi, la velocità dei veicoli al giorno d'oggi è aumentata e ciò comporta anche maggiori carichi di tipo dinamico.

Sul rinforzo di elementi in C.A.: confronto tra varie normative

Il documento pre-normativo italiano sul rinforzo di strutture in c.a. mediante l’uso di materiale fibrorinforzato. 1.1 INTRODUZIONE La situazione unica dell’Italia per quanto riguarda la conservazione delle costruzioni esistenti, è il risultato della combinazione di due aspetti, come primo, il medio-alto rischio sismico di una gran parte di territorio, come testimoniato dalla zonizzazione sismica recente, e come secondo aspetto, l'estrema complessità di un ambiente edilizio che non ha confronto nel mondo. Le tipologie della costruzione in Italia si distinguono a quelle stimate come patrimonio storico, che in alcuni casi risalgono a circa 2000 anni fa, a quelle che sono state costruite in ultimi cinque secoli, durante e dopo il Rinascimento, che sono considerate come patrimonio culturale ed architettonico dell' Italia (e del mondo!), infine a quelle fatte in tempi recenti, considerevolmente durante e dopo il boom economico del l960 ed ora visti come antiquate. Le due prime categorie in gran parte sono composte dalle edilizie di muratura, mentre agli ultimi principalmente appartengono le costruzioni di cemento armato.

Experimental characterization of carbon-fiber-reinforced polymer laminates

The goal of this thesis is to make static tensile test on four Carbon Fiber Reinforced Polymer laminates, in such a way as to obtain the ultimate tensile strength of these laminates; in particular, the laminates analyzed were produced by Hand Lay-up technology. Testing these laminates we have a reference point on which to compare other laminates and in particular CFRP laminate produced by RTM technology.

Design and implementation of a non-destructive defect detection technique based on UWB-SAR imaging

In the last twenty years aerospace and automotive industries started working widely with composite materials, which are not easy to test using classic Non-Destructive Inspection (NDI) techniques. Pairwise, the development of safety regulations sets higher and higher standards for the qualification and certification of those materials. In this thesis a new concept of a Non-Destructive defect detection technique is proposed, based on Ultrawide-Band (UWB) Synthetic Aperture Radar (SAR) imaging. Similar SAR methods are yet applied either in minefield [22] and head stroke [14] detection. Moreover feasibility studies have already demonstrated the validity of defect detection by means of UWB radars [12, 13]. The system was designed using a cheap commercial off-the-shelf radar device by Novelda and several tests of the developed system have been performed both on metallic specimen (aluminum plate) and on composite coupon (carbon fiber). The obtained results confirm the feasibility of the method and highlight the good performance of the developed system considered the radar resolution. In particular, the system is capable of discerning healthy coupons from damaged ones, and correctly reconstruct the reflectivity image of the tested defects, namely a 8 x 8 mm square bulge and a 5 mm drilled holes on metal specimen and a 5 mm drilled hole on composite coupon.