Fracture toughness determination of adhesive and co-cured joints in natural fibre composites

Adhesive bonding has become more efficient in the last few decades due to the adhesives developments, granting higher strength and ductility. On the other hand, natural fibre composites have recently gained interest due to the low cost and density. It is therefore essential to predict the fracture behavior of joints between these materials, to assess the feasibility of joining or repairing with adhesives. In this work, the tensile fracture toughness (Gc n) of adhesive joints between natural fibre composites is studied, by bonding with a ductile adhesive and co-curing. Conventional methods to obtain Gc n are used for the co-cured specimens, while for the adhesive within the bonded joint, the J-integral is considered. For the J-integral calculation, an optical measurement method is developed for the evaluation of the crack tip opening and adherends rotation at the crack tip during the test, supported by a Matlab sub-routine for the automated extraction of these quantities. As output of this work, an optical method that allows an easier and quicker extraction of the parameters to obtain Gc n than the available methods is proposed (by the J-integral technique), and the fracture behaviour in tension of bonded and co-cured joints in jute-reinforced natural fibre composites is also provided for the subsequent strength prediction. Additionally, for the adhesively- bonded joints, the tensile cohesive law of the adhesive is derived by the direct method.

Cognitive models for the concept of angle

Tese de doutoramento em Filosofia

Numerical prediction of delamination onset in carbon/epoxy composites drilling

Despite the fact that their physical properties make them an attractive family of materials, composites machining can cause several damage modes such as delamination, fibre pull-out, thermal degradation, and others. Minimization of axial thrust force during drilling reduces the probability of delamination onset, as it has been demonstrated by analytical models based on linear elastic fracture mechanics (LEFM). A finite element model considering solid elements of the ABAQUS® software library and interface elements including a cohesive damage model was developed in order to simulate thrust forces and delamination onset during drilling. Thrust force results for delamination onset are compared with existing analytical models.

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.

A study on the modeling of sandwich functionally graded particulate composites

Dual-phase functionally graded materials are a particular type of composite materials whose properties are tailored to vary continuously, depending on its two constituent's composition distribution, and which use is increasing on the most diverse application fields. These materials are known to provide superior thermal and mechanical performances when compared to the traditional laminated composites, exactly because of this continuous properties variation characteristic, which enables among other advantages smoother stresses distribution profile. In this paper we study the influence of different homogenization schemes, namely the schemes due to Voigt, Hashin-Shtrikman and Mod-Tanaka, which can be used to obtain bounds estimates for the material properties of particulate composite structures. To achieve this goal we also use a set of finite element models based on higher order shear deformation theories and also on first order theory. From the studies carried out, on linear static analyses and on free vibration analyses, it is shown that the bounds estimates are as important as the deformation kinematics basis assumed to analyse these types of multifunctional structures. Concerning to the homogenization schemes studied, it is shown that Mori-Tanaka and Hashin-Shtrikman estimates lead to less conservative results when compared to Voigt rule of mixtures.

Mathematical modeling and simulation of heat flow through pultrusion die assembly system for thermoset composites

Pultrusion is an industrial process used to produce glass fibers reinforced polymers profiles. These materials are worldwide used when performing characteristics, such as great electrical and magnetic insulation, high strength to weight ratio, corrosion and weather resistance, long service life and minimal maintenance are required. In this study, we present the results of the modelling and simulation of heat flow through a pultrusion die by means of Finite Element Analysis (FEA). The numerical simulation was calibrated based on temperature profiles computed from thermographic measurements carried out during pultrusion manufacturing process. Obtained results have shown a maximum deviation of 7%, which is considered to be acceptable for this type of analysis, and is below to the 10% value, previously specified as maximum deviation. © 2011, Advanced Engineering Solutions.

Hybrid thermoset polymeric composites – an Innovation towards sustainability

In this study, a new waste management solution for thermoset glass fibre reinforced polymer (GFRP) based products was assessed. Mechanical recycling approach, with reduction of GFRP waste to powdered and fibrous materials was applied, and the prospective added-value of obtained recyclates was experimentally investigated as raw material for polyester based mortars. Different GFRP waste admixed mortar formulations were analyzed varying the content, between 4% up to 12% in weight, of GFRP powder and fibre mix waste. The effect of incorporation of a silane coupling agent was also assessed. Design of experiments and data treatment was accomplished through implementation of full factorial design and analysis of variance ANOVA. Added value of potential recycling solution was assessed by means of flexural and compressive loading capacity of GFRP waste admixed mortars with regard to unmodified polymer mortars. The key findings of this study showed a viable technological option for improving the quality of polyester based mortars and highlight a potential cost-effective waste management solution for thermoset composite materials in the production of sustainable concrete-polymer based products.

MASS CONSERVATION ENHANCEMENT OF FREE BOUNDARY FLOWS IN COMPOSITES MANUFACTURING

Undesirable void formation during the injection phase of the liquid composite molding process can be understood as a consequence of the non-uniformity of the flow front progression, caused by the dual porosity of the fiber perform. Therefore the best examination of the void formation physics can be provided by a mesolevel analysis, where the characteristic dimension is given by the fiber tow diameter. In mesolevel analysis, liquid impregnation along two different scales; inside fiber tows and within the spaces between them; must be considered and the coupling between these flow regimes must be addressed. In such case, it is extremely important to account correctly for the surface tension effects, which can be modeled as capillary pressure applied at the flow front. When continues Galerkin method is used, exploiting elements with velocity components and pressure as nodal variables, strong numerical implementation of such boundary conditions leads to ill-posing of the problem, in terms of the weak classical as well as stabilized formulation. As a consequence, there is an error in mass conservation accumulated especially along the free flow front. This article presents a numerical procedure, which was formulated and implemented in the existing Free Boundary Program in order to significantly reduce this error.

Mass Conservation Enhancement of Free Boundary Mesolevel Flows during LCM Processes of Composites Manufacturing

Undesirable void formation during the injection phase of the liquid composite moulding process can be understood as a consequence of the non-uniformity of the flow front progression, caused by the dual porosity of the fibre perform. Therefore the best examination of the void formation physics can be provided by a mesolevel analysis, where the characteristic dimension is given by the fibre tow diameter. In mesolevel analysis, liquid impregnation along two different scales; inside fibre tows and within the open spaces between them; must be considered and the coupling between these flow regimes must be addressed. In such case, it is extremely important to account correctly for the surface tension effects, which can be modelled as capillary pressure applied at the flow front. Numerical implementation of such boundary conditions leads to ill-posing of the problem, in terms of the weak classical as well as stabilized formulation. As a consequence, there is an error in mass conservation accumulated especially along the free flow front. This contribution presents a numerical procedure, which was formulated and implemented in the existing Free Boundary Program in order to significantly reduce this error.

Deep crustal structure across a young passive margin from wide-angle and reflection seismic data (The Sardinia Experiment) - I. Gulf of Lion's margin

The conjugate margins system of the Gulf of Lion and West Sardinia (GLWS) represents a unique natural laboratory for addressing fundamental questions about rifting due to its landlocked situation, its youth, its thick sedimentary layers, including prominent palaeo-marker such as the MSC event, and the amount of available data and multidisciplinary studies. The main goals of the SARDINIA experiment, were to (i) investigate the deep structure of the entire system within the two conjugate margins: the Gulf of Lion and West Sardinia, (ii) characterize the nature of the crust, and (iii) define the geometry of the basin and provide important constrains on its genesis. This paper presents the results of P-wave velocity modelling on three coincident near-vertical reflection multi-channel seismic (MCS) and wide-angle seismic profiles acquired in the Gulf of Lion, to a depth of 35 km. A companion paper [part II Afilhado et al., 2015] addresses the results of two other SARDINIA profiles located on the oriental conjugate West Sardinian margin. Forward wide-angle modelling of both data sets confirms that the margin is characterised by three distinct domains following the onshore unthinned, 33 km-thick continental crust domain: Domain I is bounded by two necking zones, where the crust thins respectively from 30 to 20 and from 20 to 7 km over a width of about 170 km; the outermost necking is imprinted by the well-known T-reflector at its crustal base; Domain II is characterised by a 7 km-thick crust with anomalous velocities ranging from 6 to 7.5 km/s; it represents the transition between the thinned continental crust (Domain I) and a very thin (only 4-5 km) "atypical" oceanic crust (Domain III). In Domain II, the hypothesis of the presence of exhumed mantle is falsified by our results: this domain may likely consist of a thin exhumed lower continental crust overlying a heterogeneous, intruded lower layer. Moreover, despite the difference in their magnetic signatures, Domains II and III present the very similar seismic velocities profiles, and we discuss the possibility of a connection between these two different domains.

Deep crustal structure across a young passive margin from wide-angle and reflection seismic data (The Sardinia Experiment) - II. Sardinia's margin

Geophysical data acquired on the conjugate margins system of the Gulf of Lion and West Sardinia (GLWS) is unique in its ability to address fundamental questions about rifting (i.e. crustal thinning, the nature of the continent-ocean transition zone, the style of rifting and subsequent evolution, and the connection between deep and surface processes). While the Gulf of Lion (GoL) was the site of several deep seismic experiments, which occurred before the SARDINIA Experiment (ESP and ECORS Experiments in 1981 and 1988 respectively), the crustal structure of the West Sardinia margin remains unknown. This paper describes the first modeling of wide-angle and near-vertical reflection multi-channel seismic (MCS) profiles crossing the West Sardinia margin, in the Mediterranean Sea. The profiles were acquired, together with the exact conjugate of the profiles crossing the GoL, during the SARDINIA experiment in December 2006 with the French R/V L'Atalante. Forward wide-angle modeling of both data sets (wide-angle and multi-channel seismic) confirms that the margin is characterized by three distinct domains following the onshore unthinned, 26 km-thick continental crust : Domain V, where the crust thins from 26 to 6 km in a width of about 75 km; Domain IV where the basement is characterized by high velocity gradients and lower crustal seismic velocities from 6.8 to 7.25 km/s, which are atypical for either crustal or upper mantle material, and Domain III composed of "atypical" oceanic crust.The structure observed on the West Sardinian margin presents a distribution of seismic velocities that is symmetrical with those observed on the Gulf of Lion's side, except for the dimension of each domain and with respect to the initiation of seafloor spreading. This result does not support the hypothesis of simple shear mechanism operating along a lithospheric detachment during the formation of the Liguro-Provencal basin.

Stress Ratio Effects on the fatigue Properties of Biaxially Loaded Tubular FRP-Specimens – Experimental Study

In this work tubular fiber reinforced specimens are tested for fatigue life. The specimens are biaxially loaded with tension and shear stresses, with a load angle β of 30° and 60° and a load ratio of R=0,1. There are many factors that affect fatigue life of a fiber reinforced material and the main goal of this work is to study the effects of load ratio R by obtaining S-N curves and compare them to the previous works (1). All the other parameters, such as specimen production, fatigue loading frequency and temperature, will be the same as for the previous tests. For every specimen, stiffness, temperature of the specimen during testing, crack counting and final fracture mode are obtained. Prior to testing, a study if the literature regarding the load ratio effects on composites fatigue life and with that review estimate the initial stresses to be applied in testing. In previous works (1) similar specimens have only been tested for a load ratio of R=-1 and therefore the behaviour of this tubular specimens for a different load ratio is unknown. All the data acquired will be analysed and compared to the previous works, emphasizing the differences found and discussing the possible explanations for those differences. The crack counting software, developed at the institute, has shown useful before, however different adjustments to the software parameters lead to different cracks numbers for the same picture, and therefore a better methodology will be discussed to improve the crack counting results. After the specimen’s failure, all the data will be collected and stored and fibre volume content for every specimen is also determinate. The number of tests required to make the S-N curves are obtained according to the existent standards. Additionally are also identified some improvements to the testing machine setup and to the procedures for future testing.

Estudo de delaminação em compósitos de matriz polimérica

A aplicação do material compósito é neste momento bastante vasta, graças à combinação das suas características específicas, tais como, maior resistência específica e módulos específicos e melhor resistência à fadiga, quando comparados com os metais convencionais. Tais características, quando requeridas, tornam este material ideal para aplicações estruturais. Esta caminhada de sucesso iniciou desde muito cedo, quando o material compósito já era utilizado para fabrico de armas pelos mongóis e na construção civil pelos hebreus e egípcios, contudo, só a partir dos meados do século XX é que despertou interesses para aplicações mais modernas. Atualmente os materiais compósitos são utilizados em equipamentos domésticos, componentes elétricos e eletrónicos, passando por materiais desportivos, pela indústria automóvel e construção civil, até indústrias de grande exigência e visibilidade tecnológica como a aeronáutica, espacial e de defesa. Apesar das boas características apresentadas pelos materiais compósitos, no entanto, estes materiais têm tendência a perderem as suas propriedades quando submetidas a algumas operações de acabamento como a furação. A furação surge da necessidade de ligação de peças de um mesmo mecanismo. Os furos obtidos por este processo devem ser precisos e sem danos para garantir ligações de alta resistência e também precisas. A furação nos materiais compósitos é bastante complexa devido à sua heterogeneidade, anisotropia, sensibilidade ao calor e pelo facto de os reforços serem extremamente abrasivos. A operação de furação pode causar grandes danos na peça, como a delaminação a entrada, defeitos de circularidade do furo, danos de origem térmica e a delaminação à saída que se apresenta como o mais frequente e indesejável. Com base nesses pressupostos é que este trabalho foi desenvolvido de forma a tentar obter processos simples para determinação e previsão de danos em polímeros reforçados com fibras (de carbono neste caso) de forma a precavê-los. De forma a conseguir estes objetivos, foram realizados ensaios de início de delaminação segundo a proposta de Lachaud et al. e ensaios de pin-bearing segundo a proposta de Khashaba et al. Foram também examinadas extensões de danos de acordo com o modelo de Fator de delaminação ajustado apresentado por Davim et al. A partir dos ensaios, de pin-bearing, realizados foram analisadas influências do material e geometria da broca, do avanço utilizado na furação e de diferentes orientações de empilhamentos de placas na delaminação de laminados compósitos e ainda a influências dessas variáveis na força de rutura por pin-bearing. As principais conclusões tiradas daqui são que a delaminação aumenta com o aumento do avanço, o que já era esperado, as brocas em carboneto de tungsténio são as mais recomendas para a furação do material em causa e que a delaminação é superior para a placa cross-ply quando comparada com placas unidirecionais. Para a situação de ensaios de início de delaminação foram analisadas as influências da variação da espessura não cortada por baixo da broca/punção, de diferentes geometrias de brocas, da alteração de velocidade de ensaio e diferentes orientações de empilhamentos de placas na força de início de delaminação. Deste ensaio as principais conclusões são que a força de início de delaminação aumenta com o aumenta da espessura não cortada e a influência da velocidade de ensaio altera com a variação das orientações de empilhamento.

Estudo da delaminação em compósitos

As excelentes propriedades mecânicas, associadas ao seu baixo peso, fazem com que os materiais compósitos sejam atualmente dos mais interessantes da nossa sociedade tecnológica. A crescente utilização destes materiais e a excelência dos resultados daí provenientes faz com que estes materiais sejam utilizados em estruturas complexas de responsabilidade, pelo que a sua maquinagem se torna necessária de forma a possibilitar a ligação entre peças. O processo de furação é o mais frequente. O processo de maquinagem de compósitos terá como base os métodos convencionais utilizados nos materiais metálicos. O processo deverá, no entanto, ser convenientemente adaptado, quer a nível de parâmetros, quer a nível de ferramentas a utilizar. As características dos materiais compósitos são bastante particulares pelo que, quando são sujeitos a maquinagem poderão apresentar defeitos tais como delaminação, fissuras intralaminares, arrancamento de fibras ou dano por sobreaquecimento. Para a detecção destes danos, por vezes a inspeção visual não é suficiente, sendo necessário recorrer a processos específicos de análise de danos. Existem já, alguns estudos, cujo âmbito foi a obtenção de furos de qualidade em compósitos, com minimização do dano, não se podendo comparar ainda com a informação existente, no que se refere à maquinagem de materiais metálicos ou ligas metálicas. Desta forma, existe ainda um longo caminho a percorrer, de forma a que o grau de confiança na utilização destes materiais se aproxime aos materiais metálicos. Este trabalho experimental desenvolvido nesta tese assentou essencialmente na furação de placas laminadas e posterior análise dos danos provocados por esta operação. Foi dada especial atenção à medição da delaminação causada pela furação e à resistência mecânica do material após ser maquinado. Os materiais utilizados, para desenvolver este trabalho experimental, foram placas compósitas de carbono/epóxido com duas orientações de fibras diferentes: unidireccionais e em “cross-ply”. Não se conseguiu muita informação, junto do fornecedor, das suas características pelo que se levaram a cabo ensaios que permitiram determinar o seu módulo de elasticidade. Relativamente á sua resistência â tração, como já foi referido, a grande resistência oferecida pelo material, associada às limitações da máquina de ensaios não permitiu chegar a valores conclusivos. Foram usadas três geometrias de ferramenta diferentes: helicoidal, Brad e Step. Os materiais utilizados nas ferramentas, foram o aço rápido (HSS) e o carboneto de tungsténio para as brocas helicoidais de 118º de ângulo de ponta e apenas o carboneto de tungsténio para as brocas Brad e Step. As ferramentas em diamante não foram consideradas neste trabalho, pois, embora sejam reconhecidas as suas boas características para a maquinagem de compósitos, o seu elevado custo não justifica a sua escolha, pelo menos num trabalho académico, como é o caso. As vantagens e desvantagens de cada geometria ou material utilizado foram avaliadas, tanto no que diz respeito à delaminação como á resistência mecânica dos provetes ensaiados. Para a determinação dos valores de delaminação, foi usada a técnica de Raio X. Algum conhecimento já existente relativamente a este processo permitiu definir alguns parâmetros (por exemplo: tempo de exposição das placas ao liquido contrastante), que tornaram acessível o procedimento de obtenção de imagens das placas furadas. Importando estas imagens para um software de desenho (no caso – AutoCad), foi possível medir as áreas delaminadas e chegar a valores para o fator de delaminação de cada furo efetuado. Terminado este processo, todas as placas foram sujeitas a ensaios de esmagamento, de forma a avaliar a forma como os parâmetros de maquinagem afectaram a resistência mecânica do material. De forma resumida, são objetivos deste trabalho: - Caracterizar as condições de corte em materiais compósitos, mais especificamente em fibras de carbono reforçado com matriz epóxida (PRFC); - Caracterização dos danos típicos provocados pela furação destes materiais; - Desenvolvimento de análise não destrutiva (RX) para avaliação dos danos provocados pela furação; - Conhecer modelos existentes com base na mecânica da fratura linear elástica (LEFM); - Definição de conjunto de parâmetros ideais de maquinagem com o fim de minimizar os danos resultantes da mesma, tendo em conta os resultados provenientes dos ensaios de força, da análise não destrutiva e da comparação com modelos de danos existentes e conhecidos.

Production of aluminium based composites reinforced with embedded NiTi by friction stir welding

Dissertação para a obtenção do grau de Mestre em Engenharia Mecânica