Interface delamination of the thermal barrier coating subjected to local heating

To investigate the possible failure modes of the thermal barrier coating (TBC) used to protect the scramjet combustion chamber, the local heating via laser beam irradiation was utilized to simulate the service condition of high thermal flux and high temperature gradient. Firstly, the experimental method and process were described and the typical fracture morphology of the TBC under test were provided. Then, the theoretical and finite element modeling were carried out to study the temperature, deformation and stresses of the specimen when the top ceramic coat was subjected to local heating, and to demonstrate the mechanism on the failure of the TBC. It is revealed that the interface delamination shall appear and ultimately lead to the failure of the TBC under such thermal loading of local quick heating. According to the outcome of this study, the driving force of the interface delamination is influenced greatly by the key structural parameters and performance matching. Moreover, by utilizing the rules of the effects of these parameters on the fracture driving force, there is some possibility for the designer to optimize the performances of the TBC.

Adhesively-bonded Patch Repair with Composites

Adhesively-bonded composite patch repairs over cracked or corrosion-damaged metallic aircraft structures have shown great promise for extending life of ageing structures. This study presents the numerical investigation into the interface behaviour of adhesively-bonded cracked aluminum alloy substrate patched with fibre-reinforced composite material. The adhesive is modelled as an elasto-plastic bilinear material to characterise the debond behaviour, while the defective substrate is regarded as linear elastic continuum. Two typical patch shapes were selected based on information available in the literature. Geometric and material nonlinear analyses for square and octagonal patches were performed to capture peel and shear stresses developed between the substrate and the patch to examine the possibility of interface delamination/debonding. Parametric studies on adhesive thickness and patch thickness were carried out to predict their infuence on damage tolerance of repaired structures.

Adhesively-bonded Patch Repair with Composites

Adhesively-bonded composite patch repairs over cracked or corrosion-damaged metallic aircraft structures have shown great promise for extending life of ageing structures. This study presents the numerical investigation into the interface behaviour of adhesively-bonded cracked aluminum alloy substrate patched with fibre-reinforced composite material. The adhesive is modelled as an elasto-plastic bilinear material to characterise the debond behaviour, while the defective substrate is regarded as linear elastic continuum. Two typical patch shapes were selected based on information available in the literature. Geometric and material nonlinear analyses for square and octagonal patches were performed to capture peel and shear stresses developed between the substrate and the patch to examine the possibility of interface delamination/debonding. Parametric studies on adhesive thickness and patch thickness were carried out to predict their infuence on damage tolerance of repaired structures.

Análisis del comportamiento de las tuberías de poliéster reforzado con fibra de vidrio con capa de arena

Aunque las primeras fábricas de tubos de poliéster reforzado con fibra de vidrio en España datan del año 1984, no es sino hasta el año 1996 cuando se comienza su utilización masiva como un sustituto de las tuberías de fribrocemento, que ya habían sido prohibidas por la legislación, debido a los efectos cancerígenos de este material. Desde entonces se ha prodigado la utilización de todas las diferentes tipologías de esta clase de tubería, de conformidad a los procesos de fabricación empleados que se encuentran recopilados en el AWWA Manual M45 (Fiberglass Pipe Design), obteniéndose muy diversos resultados. Durante estos años, ha surgido una creciente preocupación en los usuarios de este tipo de tuberías dadas las continuas y numerosas averías en todo el ámbito geográfico. Esto ha promovido el desarrollo de la presente investigaicón, que se ha dividido en dos partes y que ha concluido con la determinación de un nuevo mecanismo específico de fractura. La primera parte se centró en la obtención y desarrollo del modelo teórico que hemos venido a denominar como "Teoría de la Caja Mecánicamente Contaminada", y que está basado en la contaminación o separación por un impacto de dos de las tres capas que forman la tubería, la capa intermedia de arena y la capa más interna o "inner layer". La consecuencia es la disminución del canto resistente, la rotura del inner layer y la entrada de fluido a la capa de arena. Para la evaluación de la magnitud de esta separación se ha desarrollado un modelo analítico que ha determinado la existencia de una relación cuadrática que la rige, y que ha sido verificado mediante ensayos de impacto sobre probetas de tuberías, alcanzando ajustes de hasta el 92%. Así, se ha determinado que impactos de muy baja intensidad, del entorno de 90 a 160 Julios en tuberías Filament Winding continuo PN 16-20 (de 800 a 1000mm) pueden comprometer seriamente la integridad estructural de la tubería sin dejar, en un principio, muesca o traza alguna que pueda alertar del problema. Los siguientes pasos en el estudio se dirigieron a determinar qué otros mecanismos, aparte del golpe, podrían contaminar la tubería y a estudiar el consiguiente avance de la fractura a las capas externas. Se trataba además de analizar la aparición en el tubo de unas misteriosas manchas en forma de "piel de leopardo" y de otros fenómenos aparecidos en las averías como que algunas de las deformaciones de la rotura por presión interna son hacia el interior del tubo y no al revés, como habría sido de esperar a priori. Se optó entonces por comenzar la que ha constituido la segunda parte de la investigación. Para ello se recurrió a realizar ensayos hidráulicos en banco de pruebas a alta presión, cuyos resultados fueron sorprendentes al descubrir que en el proceso se producía la hidrólisis de la resina de poliéster no catalizada que fluía hacia el exterior del tubo. Como consecuencia se llevaron a cabo nuevos ensayos físicos y químicos para estudiar la migración del material y la hidrólisis producida en el proceso de fractura. En este estudio, resultó muy relevante el hecho de sobrepasar o no la presión que producía el desagarro entre las capas del tubo. En definitiva, en esta investigación, que ha constado de estudios analíticos y estudios experimentales, químicos y numéricos, se ha determinado un nuevo mecanismo de fractura que explica gran parte de los fallos acontecidos en las tuberías de poliéster reforzado con fibra de vidrio. Como aplicación se exponen recomendaciones para mejorar el comportamiento mecánico de esta tipología y evitar así los sobrecostes millonarios producidos por su reposición. Numerous and continuous failures in fiberglass reinforced polyester pipes of different companies and manufacturing processes of the AWWA Manual M45 (Fiberglass Pipe Design), have prompted the development of this research, that has concluded with a specific mechanism describing pipe fractures. This research was carried out via two independent studies. The first one is the development of the hypothesis that turned into the Mechanically Contaminated Layer Theory. This theory describes the fracture mchanism which explains a significant part of massive failures due to the existence of a sand layer placed near the neutral axis in the core making the composite very sensitive to impacts in fibreglass reinforced polyester pipes. These failures create interface delamination and consequently fluid can leak into supporting sand backfill thereby iniating the fracture process. In order to assess the delimination magnitude, an analytic method is developed and a squared root law between delamination and energy applied proposed. Vertical blunt ram testts on samples extracted from complete pipes have been carried out to verify this theory, reaching a goodness of fit up to 92%. It is concluded that low energy impacts, around 90-160J in 800-1000mm diameter PN 16-20 continuous filament winding pipes, can seriously compromise their structural integraty with no external trace. The next step in the study was to determine what other mechanism, apart from the brittle hit, could contaminate the pipe and to analyse the consequente advance of the fracture to the external layers. Another aim was to analyse two phenomena occurred in real pipe failures. The first one is the appearance on the tube of "leopard fur" stains on some of the analysed failures, and the other phenomenon is the "inverse fracture", in which the deformations of the failure due to internal pressure are towards the inside of the tube and not the other way round, as it would be expected. It was then chosen to follow a new branch of the investigation by hydraulic high-pressure bench tests that study seepage and load transmission. The results were very surprising as it was discovered that in the process, hydrolysis of the non-catalysed polyester resin occured, flowing towards the outer of the pipe, which entailed the development of chemical and physical tests of the exuded material to study material migration and hydrolysis of the fracture process. In this particular study it was relevant to exceed or not the pressure that produced the rip between the layers of the tube. In conclusion, a new breakage mechanism in FRP pies with sand-filled layer has been found, which explains a high part of the failure global cases. The whole failure process is justified by the Mechanically Contaminated Layer Theory, which has been corroborated by means of analytical, numerical and experimental studies. Several recommendations are also provided in order to improve the mechanical behaviour of this typology and avoid the millionaire overruns generated by its massive failures.

A pseudo-transient solution strategy for the analysis of delamination by means of interface elements

Recent efforts in the finite element modelling of delamination have concentrated on the development of cohesive interface elements. These are characterised by a bilinear constitutive law, where there is an initial high positive stiffness until a threshold stress level is reached, followed by a negative tangent stiffness representing softening (or damage evolution). Complete decohesion occurs when the amount of work done per unit area of crack surface is equal to a critical strain energy release rate. It is difficult to achieve a stable, oscillation-free solution beyond the onset of damage, using standard implicit quasi-static methods, unless a very refined mesh is used. In the present paper, a new solution strategy is proposed based on a pseudo-transient formulation and demonstrated through the modelling of a double cantilever beam undergoing Mode I delamination. A detailed analysis into the sensitivity of the user-defined parameters is also presented. Comparisons with other published solutions using a quasi-static formulation show that the pseudo-transient formulation gives improved accuracy and oscillation-free results with coarser meshes

Delamination of kaolinite - potassium acetate intercalates by ball-milling

Structural changes in intercalated kaolinite after wet ball-milling were examined by scanning electron microscopy (SEM), X-ray diffraction (XRD), specific surface area (SSA) and Fourier Transform Infrared spectroscopy (FTIR). The X-ray diffraction pattern at room temperature indicated that the intercalation of potassium acetate into kaolinite causes an increase of the basal spacing from 0.718 to 1.42 nm, and with the particle size reduction, the surface area increased sharply with the intercalation and delamination by ball-milling. The wet ball-milling kaolinite after intercalation did not change the structural order, and the particulates have high aspect ratio according SEM images.

Mechanism of kaolinite sheets curling via the intercalation and delamination process

Kaolinite naturally occurs in the plate form for the interlayer hydrogen bond and the distortion and adaption of tetrahedron and octahedron. But kaolinite sheets can be exfoliated to nanoscrolls artificially in laboratory through multiple-step displacement intercalation. The driving force for kaolinite sheet to be curled nanoscroll originates from the size discrepancy of Si–O tetrahedron and Al–O octahedron. The displacement intercalation promoted the platy kaolinite sheets spontaneously to be scrolled by eliminating the interlayer hydrogen bond and atomic interaction. Kaolinite nanoscrolls are hollow tubes with outer face of tetrahedral sheet and inner face of octahedral sheet. Based on the theoretical calculation it is firstly reported that the minimum interior diameter for a single kaolinite sheet to be scrolled is about 9.08 nm, and the optimal 24.30 nm, the maximum 100 nm, which is verified by the observation of scanning electron microscope and transmission electron microscope. The different adaption types and discrepancy degree between tetrahedron and octahedron generate various curling forces in different directions. The nanoscroll axes prefer the directions as [100], [1 �10], [110], [3 �10], and the relative curling force are as follows, [3 �10] > [100] = [1�10] > [110].

Effect of various factors influencing the delamination behavior of surfactant intercalated layered double hydroxides

The delamination-restacking behavior of a number of layered double hydroxides (LDHs) differing in [M-II]/[M-III] ratio, constituent metal ions and intercalated surfactant anions in different organic solvents has been studied. Colloidal dispersion due to delamination and the stability of the colloid obtained have been found to be not affected much by the nature of the constituent metal ions but increase with increase in the size of the surfactant anion. LDHs with low [M-II]/[M-III] ratio delaminate better than the ones with high [M-II]/[M-III] ratio. Delamination is best in alcohols such as 1-butanol, 1-hexanol, 1-octanol and I-decanol, while a little delamination occurs in nonpolar solvents such as hexane. In all the cases, the original layered solid could be obtained through restacking of layers from the colloidal dispersion.

Ultrasonic evaluation of delamination in quasi-isotropic CFRP laminates subjected to low-velocity impact

Ultrasonic C-Scan is used very often to detect flaws and defects in the composite components resulted during fabrication and damages resulting from service conditions. Evaluation and characterization of defects and damages of composites require experience and good understanding of the material as they are distinctly different in composition and behavior as compared to conventional metallic materials. The failure mechanisms in composite materials are quite complex. They involve the interaction of matrix cracking, fiber matrix interface debonding, fiber pullout, fiber fracture and delamination. Generally all of them occur making the stress and failure analysis very complex. Under low-velocity impact loading delamination is observed to be a major failure mode. In composite materials the ultrasonic waves suffer high acoustic attenuation and scattering effect, thus making data interpretation difficult. However these difficulties can be overcome to a greater extent by proper selection of probe, probe parameter settings like pulse width, pulse amplitude, pulse repetition rate, delay, blanking, gain etc., and data processing which includes image processing done on the image obtained by the C-Scan.

Role of interface curvature on stress distribution under indentation for ZrN/Zr multilayer coating

Contact damage in curved interface nano-layeredmetal/nitride (150 (ZrN)/10 (Zr) nm) multilayer is investigated in order to understand the role of interface morphology on contact damage under indentation. A finite element method (FEM) model was formulated with different wavelengths of 1000 nm, 500 nm, 250 nm and common height of 50 nm, which gives insight on the effect of different curvature on stress field generated under indentation. Elastic-plastic properties were assigned to the metal layer and substrate while the nitride layer was assigned perfectly elastic properties. Curved interface multilayers show delamination along the metal/nitride interface and vertical cracks emanating from the ends of the delamination. FEM revealed the presence of tensile stress normal to the interface even under the contact, along with tensile radial stresses, both present at the valley part of the curve, which leads to vertical cracks associated with interfacial delamination. Stress enhancement was seen to be relatively insensitive to curvature. (C) 2014 Elsevier B.V. All rights reserved.

A micropolar cohesive damage model for delamination of composites

A micropolar cohesive damage model for delamination of composites is proposed. The main idea is to embed micropolarity, which brings an additional layer of kinematics through the micro-rotation degrees of freedom within a continuum model to account for the micro-structural effects during delamination. The resulting cohesive model, describing the modified traction separation law, includes micro-rotational jumps in addition to displacement jumps across the interface. The incorporation of micro-rotation requires the model to be supplemented with physically relevant material length scale parameters, whose effects during delamination of modes I and II are brought forth using numerical simulations appropriately supported by experimental evidences. (C) 2015 Elsevier Ltd. All rights reserved.

Uncertainty Quantification in Ultrasonic Wave Based Detection of Delamination in Composite Structures

In this paper we consider the problem of guided wave scattering from delamination in laminated composite and further the problem of estimating delamination size and layer-wise location from the guided wave measurement. Damage location and region/size can be estimated from time of flight and wave packet spread, whereas depth information can be obtained from wavenumber modulation in the carrier packet. The key challenge is that these information are highly sensitive to various uncertainties. Variation in reflected and transmitted wave amplitude in a bar due to boundary/interface uncertainty is studied to illustrate such effect. Effect of uncertainty in material parameters on the time of flight are estimated for longitudinal wave propagation. To evaluate the effect of uncertainty in delamination detection, we employ a time domain spectral finite element (tSFEM) scheme where wave propagation is modeled using higher-order interpolation with shape function have spectral convergence properties. A laminated composite beam with layer-wise placement of delamination is considered in the simulation. Scattering due to the presence of delamination is analyzed. For a single delamination, two identical waveforms are created at the two fronts of the delamination, whereas waves in the two sub-laminates create two independent waveforms with different wavelengths. Scattering due to multiple delaminations in composite beam is studied.

Microscale mechanics for metal thin film delamination along ceramic substrates

The metal thin film delamination along metal/ceramic interface in the case of large scale yielding is studied by employing the strain gradient plasticity theory and the material microscale effects are considered. Two different fracture process models are used in this study to describe the nonlinear delamination phenomena for metal thin films. A set of experiments have been done on the mechanism of copper films delaminating from silica substrates, based on which the peak interface separation stress and the micro-length scale of material, as well as the dislocation-free zone size are predicted.

On The Thermally Induced Interfacial Delamination Of A Segmented Coating

The thermally induced interfacial delamination problem of a segmented coating is investigated using finite element method (FEM). The coating-substrate system, modeled as a coated semi-infinite medium with periodic segmentation cracks within coating, is assumed to be exposed to convective cooling from surface. The failure criterion based on the interfacial fracture toughness is adopted, in which the energy release rate for an interface crack is considered to be the driving force for interfacial delamination extension. The results confirm that a segmented coating has higher delamination resistance than an intact one under the same thermal transients, as the segmentation crack spacing is smaller than a critical value. Based on dimensional analysis, sensitivity analyses of the crack driving force are also obtained as a function of various dimensionless parameters such as time, convection severity and material constants. These results may provide some helpful references for the integrity of coating-substrate systems under thermal loading. (C) 2007 Elsevier B.V. All rights reserved.

Potential-dependent adsorption/desorption of organic adsorbate at HOPG electrode and accompanying delamination of graphite surface

In situ electrochemical scanning tunneling microscopy, alternating current voltammetry, and electrochemical quartz crystal microbalance have been employed to follow the potential-dependent adsorption/desorption processes of nucleic acid bases on highly oriented pyrolytic graphite (HOPG) electrode. The results show that (i) potential-dependent adsorption/desorption of nucleic acid bases on HOPG electrode was accompanied by delamination of the HOPG surface, and the delamination initiates from steps or kinks on the electrode surface, which provide highly active sites for adsorption; (ii) the delamination usually occurred when the electrode potential was changed or when the electrode was at potentials where the phase transition of adsorbate occurred. These results suggest that the surface stress resulting from the interaction between the substrate and adsorbate, as well as the interaction due to potential-induced surface charge distribution and the hysteresis of charge equilibrium are the main factors resulting in HOPG delamination. (C) 1999 The Electrochemical Society. S0013-4651(97)12-013-4. All rights reserved.