Strain energy release rate calculations for various cases of delaminations emanating from matrix cracks are developed and used to predict the onset of delaminations and their growth size as a function of applied tension and shear loads in composite laminates. The method determines the matrix crack spacing, the delamination onset load, the delamination size at onset and, through the use of a newly proposed delamination resistance curve, the size of delaminations as they grow under load. The method can be applied to any symmetric laminate. Comparisons to test results in the literature for a variety of layups and materials shows very good agreement with the exception of cases where significant edge delaminations appear before delaminations caused by matrix cracks.

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Manufacturing variations in the automated fiber placement (AFP) process are one of the causes of gaps and overlaps. These manufacturing variations can be due to robot inaccuracy, tow lateral movement on the roller, tow width variation or tow compaction. An experimental setup was built to measure and investigate these various sources of manufacturing variations and their relative contributions to gap and overlap defects. This setup consisted of a commercial AFP head instrumented with additional sensors. Among all the measured sources of variations, lateral movement of the tow on the compaction roller was the biggest contributor to gaps and overlaps. The distributions of these sources of variations were fit with probability density functions. Random samples from these fits were used to simulate adjacent tows and predict the occurrence of gap and overlap defects. The distribution of predicted gaps correlated closely with the distribution of experimentally measured gaps. Thus, this approach of using statistical information about the sources of manufacturing variations to predict the frequency and magnitude of defects in a layup was validated.@en

The behavior of delaminations and fiber breakage resulting from three-point bending test is a major concern in the study of composites. This research focused on analyzing fiber breakage and delaminations in advanced placed ply composite laminates through a series of tests. In order to compare simulation results with the experimental data, the cohesive zone model was implemented for analyzing the damage in the model. The results of the simulation were validated using experimental results. The predicted damage initiation load exhibited an approximate 20% deviation from the actual test loads and the discrepancy stems are analyzed.

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Flexible composite marine propellers can aid the marine industry in reducing carbon emissions and underwater radiated noise pollution. The structural integrity of the blades can be assessed using structural health monitoring. One of these methods is the measurement and analysis of damage-induced acoustic emission signals. This paper experimentally investigates the feasibility of using embedded piezoelectric sensors for the measurement of acoustic emissions throughout a submerged flexible composite marine propeller blade. A full-scale glass-fibre reinforced polymer blade has been manufactured with 24 embedded sensors. While suspended in artificial seawater, acoustic emissions were simulated on the blade. The measurements show that the embedded piezoelectric sensors can measure acoustic emissions while the blade is submerged. Further, the distance from source to sensor over which the acoustic emission is measurable was investigated. For a noise level of 40 dB and a source amplitude of 70 dB between 100 and 250 kHz, an average maximum measurable distance of 124 mm was obtained. For higher frequencies, the distance drops and for lower noise levels the distance increases.@en

The marine industry is increasingly considering the use of flexible composite marine propellers for their potential to reduce carbon emissions and underwater radiated noise. Given the early stage of development of flexible composite propellers, there are unknowns on their structural degradation. Structural health monitoring (SHM) can provide additional insight into the occurrence and propagation of degradation in these structures. A passive and lightweight method of SHM is the measurement and processing of acoustic emissions (AE) that are induced by different degradation mechanisms. The current research investigates the measurement of AE signals in composite marine propeller blades using embedded piezoelectric sensors. A full-scale glass-fibre polymer composite propeller blade is suspended in a tank filled with artificial seawater. The propeller blade contains 24 embedded piezoelectric sensors that were installed between laminas during manufacturing. Additionally, the tank includes an array of hydrophones for validation of the results. AE signals are simulated on the blade using underwater pencil lead breaks. The measured AE signals are assessed for their amplitude and frequency content. The results demonstrate the feasibility of measuring AE signals in composite marine propeller blades using embedded piezoelectric sensors and hydrophones.@en

Improvements in current design approaches require further studies of the damage interaction effects of composite materials subjected to repeated out-of-plane concentrated loads. To that end, a combined simulation and experimental investigation on composite laminate under repeated indentations is reported. The repeated indentations consist of seven identical peak-force indentations that are separately applied to the centre of the laminate. The results show that delaminations grow in all seven indentations, which can be interpreted as a continuous degradation of the effective delamination growth threshold with each subsequent indentation. More specifically, the second indentation effective delamination growth threshold is 62.4 MPa, which is about 19 % lower compared to the first one (77.2 MPa). Subsequently, the delamination growth threshold degraded approximately linearly with indentation. This effective delamination growth threshold reduction can be associated with the occurrence and evolution of the crack-rich zone preceding the delamination front.

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The multimodal and dispersive character of ultrasonic guided waves (UGW) offers the potential for non-destructive evaluation of fiber-reinforced composite (FRC) materials. In this study, a methodology for in situ stiffness assessment of FRCs using UGWs is introduced. The proposed methodology involves a comparison between measured wave speeds of the fundamental symmetric and antisymmetric guided wave modes with a pre-established dataset of UGW speeds and translation of them to corresponding stiffness properties, i.e., 𝐴𝐵𝐷-components, in an inverse manner. The dispersion relations of guided waves have been calculated using the semi-analytical finite element method. First, the performance of the proposed methodology has been assessed numerically. It has been demonstrated that each of the independent 𝐴𝐵𝐷-components of the considered laminate can be approximated with an error lower than 10.4% compared to its actual value. The extensional and bending stiffness properties can be approximated within an average error of 3.6% and 9.0%, respectively. Secondly, the performance of the proposed methodology has been assessed experimentally. This experimental assessment has been performed on a glass fiber-reinforced composite plate and the results were compared to mechanical tensile and four-point bending tests on coupons cut from the plate. Larger differences between the estimated 𝐴𝐵𝐷-components according to UGW and mechanical testing were observed. These differences were partly attributed to the variation in material properties across the test plate and the averaging of properties over the measurement area. @en

An approach to determine the specific energy dissipated during cyclic loading of metal alloys with load ratios between 0 and 1 is developed. The dissipated energy per cycle is determined by using a limiting procedure to obtain the area enclosed between successive loading and unloading curves and can be used for low-, medium-, and high-cycle fatigue. Comparisons with published data from two aluminum, one titanium, and one steel alloy show that the predictions capture the test results very well. A universal curve relating cycles to failure to two nondimensional parameters is derived. It is shown, in some limiting cases, that the method leads to power law equations with the parameters in these equations determined directly from the complete stress–strain curve of the material with no need to fit experimental data. Furthermore, if certain conditions are satisfied, the method is consistent with the existence of an endurance limit and Miner's rule.

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To improve current design approaches for composite structures, it is required to further investigate the damage interaction effects of composite materials under multiple out-of-plane concentrated loads. It is first necessary to comprehend the dependence of the effective delamination threshold, which describes whether a delamination grows on pre-existing delamination damage in composite laminates. A combined experimental and numerical study is presented, in which two sequential out-of-plane quasi-static indentations are applied to fully clamped composite laminated panels, with changing distances between the two indentation locations changing. The results show that the second indentation delamination is more likely to propagate, particularly in the straight-line direction from the second indentation site to the first one, which can be interpreted as a decrease in the effective delamination threshold associated with microcracks ahead of the delamination front. The relevant percentage reduction is 37% and is independent of the imposed indentation load. As a crucial take-away, designers should be mindful that the damage interaction effects could result in greater damage than the sum of the individual cases.@en

Marine propellers made of fibre-reinforced composites have demonstrated the potential to outperform metallic propellers in terms of efficiency and under-water noise radiation. For full realisation of this potential in a tailored design process with realistic constraints, accurate information on the hydrodynamic loads acting on composite marine propellers and the structural integrity is of key importance. It is conceptualised that this information can be acquired without disturbing propeller hydrodynamics using a network of piezoelectric sensors embedded inside the blade. In this paper, feasibility of this concept has been investigated numerically and experimentally. Hydrodynamic loads on a composite propeller obtained from numerical simulations were used to assess the sensitivity of piezoelectric sensors in measuring the dynamic strain field due to the blade deformation. Subsequently, 25 small-scale carbon-epoxy composite samples were manufactured with embedded piezoelectric wafer sensors of different sizes, and subjected to non-destructive and destructive loading scenarios. Feasibility of measuring strains at different frequency ranges and damage-induced acoustic emissions was quantitatively assessed from these experiments. Furthermore, the influence of the embedded sensors on the ultimate strength and toughness of the specimens was investigated. It was found that at least 92% of the studied propeller blade would have dynamic strains measurable up to the first four harmonics by the considered piezoelectric sensors. In a four-point bending setup, it was additionally demonstrated that the embedded piezoelectric sensor captured damage-induced acoustic emissions up to specimen failure with an average signal to noise ratio of 17 dB. The results indicate that embedded piezoelectric sensor networks can have the capability to measure both low-frequency dynamic strains in composite marine propeller blades and damage-related acoustic emissions.

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The recording and processing of acoustic emissions can be used to identify and localise damage mechanisms occurring in engineering structures. In plate-like structures, acoustic emissions propagate through the structure as guided waves. With a measurement location away from the source location, dispersion effects in the guided wave distort the acoustic emission signal. The distortion of the original signal hampers identification of damage mechanisms. This research describes and assesses a method to reconstruct the original acoustic emission signal using dispersion compensation. Simulations and experiments are performed involving thick glass-fibre reinforced plastic laminates. The signal reconstruction on the simulated data gives a reasonable representation of the simulated signal at the location of interest. In the experimental case, similarity slightly degrades. Deviation in arrival time between original measurement and reconstruction is attributed to a possible discrepancy in material properties in reality versus the properties used in the reconstruction.

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To develop a simplified and physically sound delamination-failure criterion, this paper reports a joint experimental and numerical study in which out-of-plane quasi-static indentations with different indentation forces were applied to the centre of fully clamped rectangular carbon fibre-reinforced polymer (CFRP) laminates. The results show that two basic micro-delamination growth modes, which are separately dominated by opening and sliding microcracks, can be distinguished according to the fracture morphologies of the delaminations along the 0° fibre direction. Both are driven by the out-of-plane shear stress σ13, and the corresponding delamination failure threshold is the out-of-plane shear strength S13. Based on these results, a concise Hashin-type delamination-propagation criterion containing only a single stress component and single strength parameter is proposed, which, by incorporating it into the finite element model, the delamination growth along the fibre directions of multidirectional CFRP laminates can be precisely predicted; the prediction error is less than 10 %.@en

Impact experiments of thick fabric carbon/epoxy laminate specimens, with small thickness ratio, are conducted at distinct energy levels and thicknesses to characterise the damage process. These specimens and loading conditions are representative of a new generation of critical structural components in aviation, such as wing spars, landing gear beams and fittings, that are increasingly being made entirely from composites. The tests address the need to better understand the damage process for specimens with a small thickness ratio since existing experimental impact data for large thickness ratio (thin laminates) may not be directly applicable. Two energy levels, two different fabric layups and two impact methods (drop-weight and gas-cannon) were used. Data from high-speed cameras were processed in a novel way, providing the force during impact. C-scans and micrographs were used to characterise damage. The results show that specimens with a thickness ratio of 5 (20 mm thick) experience more bending compared to specimens with a ratio 2.5 (40 mm thick). For gas-cannon impacts, this results in a higher delaminated area. The drop-weight impacts show almost no differences in damage size for the thickness range analysed. The influence of layup on the global impact response is negligible, but locally it can result in significant variations in dent depth. The dent depth scales linearly with the impact energy and the delaminated area linearly with the impact velocity. There is no clear correlation between the compression-after-impact failure mechanisms and the residual strength. Impact damage, at the current energy levels, showed a minimal reduction of residual strength.

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On the 15t hof December 1965 the motion picture “Flight of the Phoenix” was released in the United States of America theatres. In the closing movie credits the following text is shown:It should be remembered. . . that Paul Mantz, a fine man and a brilliant flyer gave his life in the making of this film. Who was Paul Mantz? What happened? And what can we learn from a movie crash? This paper will examine the Tallmantz Phoenix P-1 accident which was captured on film for the motion picture “Flight of the Phoenix”. This paper will study the “Flight of the Phoenix“ story, the people involved and the special purpose aircraft build. Literature will be reviewed and analyses will be done to gain new insights to the crash of the Tallmantz Phoenix which occurred on July 8th1965@en

Onset Theory (previously known as Strain Invariant Failure Theory) is a physics-based composite failure criterion attempting to predict failure at the level of constituents rather than for a homogenized ply. Applying Onset Theory correctly requires a number of steps. As a starting point for other researchers, a consistent approach is developed by resolving contradictions found in literature. This includes the micromechanical FEA process used to determine the individual fiber and matrix strains, such as correct choice of representative volume elements (RVEs), the use of transformed RVEs, boundary conditions, and the location of data extraction points. Analytical expressions are provided to determine the full state of strain in a ply, including in-plane and out-of-plane Poisson’s strains and thermally induced mechanical strains. Literature definitions of the critical invariants are discussed, and a trend in critical distortional invariants is observed. Assumptions and limitations of the theory are identified. Finally, a failure envelope is compared to World Wide Failure Exercise test data.

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The effect of matrix and fibre cracks on the static strength and stiffness of uni-directional plies and cross-ply laminates under tensile loads was examined with the goal of understanding the main damage mechanisms. The size of matrix cracks emanating from cracked fibres was determined and found to be in excellent agreement with test results. This was used to predict static tensile failure of uni-directional laminates and was shown to be in good to excellent agreement with test results for six different materials. The approach was extended to fatigue loading by determining the number of cycles for the plastic zone ahead of a matrix crack tip to fail. It was combined with an approach to quantify the effect of matrix cracks under any in-plane loading previously developed by the authors to predict changes in laminate stiffness as a function of cycles. Comparisons with test results showed good to excellent agreement between predicted and measured laminate stiffness as a function of fatigue cycles.

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The mechanical performance of laminated composite structures can be improved significantly by spatially varying the stiffness properties within the laminate, resulting in a so-called Variable Stiffness (VS) laminate. Typically, the stiffness variation in VS laminates is achieved by steering the fibres within the laminae, resulting in an in-plane variation of stacking sequence and thus an in-plane variation of mechanical properties of the laminate and subsequent load-redistribution within the laminate. The authors use a different approach to design VS composite cylinders, which does not rely on fibre steering. Instead, in-plane variation of the stacking sequence is achieved by stacking patches of unidirectional material or fabric, each of different in-plane dimension. Such a laminate can be designated as straightfibre variable stiffness (SFVS) composite laminate. A method developed at TU Delft to design SFVS laminates is modified to optimize the buckling load of composite cylinders. In this method, the laminate is divided into a discrete number of regions, for each of which the stacking sequence is optimised individually. Stacking sequence continuity is enforced by an algorithm inspired on cellular automata (CA) which relies on the application of a set of simple design rules. The modified method is applied to optimize the buckling load for composite cylinders. The buckling load of the optimised designs is evaluated using commercial finite element software. The effect of the number of design regions into which the cylinder is divided is considered. To conclude an outlook is given on how the modified method can be applied to the design of aerospace structures. @en

Piezoelectric sensors can be embedded in carbon fibre-reinforced plastics (CFRP) for continuous measurement of acoustic emissions (AE) without the sensor being exposed or disrupting hydro- or aerodynamics. Insights into the sensitivity of the embedded sensor are essential for accurate identification of AE sources. Embedded sensors are considered to evoke additional modes of degradation into the composite laminate, accompanied by additional AE. Hence, to monitor CFRPs with embedded sensors, identification of this type of AE is of interest. This study (i) assesses experimentally the performance of embedded sensors for AE measurements, and (ii) investigates AE that emanates from embedded sensor-related degradation. CFRP specimens have been manufactured with and without embedded sensors and tested under four-point bending. AE signals have been recorded by the embedded sensor and two reference surface-bonded sensors. Sensitivity of the embedded sensor has been assessed by comparing centroid frequencies of AE measured using two sizes of embedded sensors. For identification of embedded sensor-induced AE, a hierarchical clustering approach has been implemented based on waveform similarity. It has been confirmed that both types of embedded sensors (7 mm and 20 mm diameter) can measure AE during specimen degradation and final failure. The 7 mm sensor showed higher sensitivity in the 350–450 kHz frequency range. The 20 mm sensor and the reference surface-bounded sensors predominately featured high sensitivity in ranges of 200–300 kHz and 150–350 kHz, respectively. The clustering procedure revealed a type of AE that seems unique to the region of the embedded sensor when under combined in-plane tension and out-of-plane shear stress. @en

The aim of the paper is to experimentally validate a numerical design methodology for optimizing composite wings subject to gust and fatigue loading requirements and to assess the effect of fatigue on the aeroelastic performance of the wing. Traditionally, to account for fatigue in composite design, a knockdown factor on the maximum stress allowable is applied, resulting in a conservative design. In the current design methodology, an analytical fatigue model is used to reduce the conservativeness and exploit the potential of composite materials. To validate the proposed analytical model, a rectangular composite wing is designed and manufactured to be critical in strength, buckling and fatigue. An experimental campaign comprising wind tunnel and fatigue tests is performed. In the wind tunnel, both static and dynamic aeroelastic experiments are conducted to validate the numerical dynamic aeroelastic model. The fatigue test is used to validate the analytical fatigue model and to understand the effect of fatigue on aeroelastic properties of the wings. The results from experimental campaign validated both the aeroelastic predictions as well as fatigue predictions of the numerical design methodology. However the fatigue process resulted in degradation of the wing stiffness leading to change in the aeroelastic response of the wing. 

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This paper proposes an analytical model that uses historical damage dimension data to deduce physical impactor characteristics (size and energy) that has caused a certain resulting damage. Maintenance tasks occur in operations due to impact, however the source of the damage caused in the event remains in most cases unknown. Consequently, by inferring what has caused a certain type of damage from the distribution of the damage type and severity relative to impactor types, maintainers can be better prepared in terms of what to expect from a given impactor source. The developed model introduces a novel transition deformation region between the local deformation and the global plate deflection, allowing for fast and accurate predictions of the impact event. Using the known aluminium structural properties and damage dimensions, the damage data is converted into impactor data. The model is applied in a case study using 120 fuselage dent damages dimensions (length, width, and depth) from a Boeing 777 fleet. The results show that the model deduces impactor characteristics for 94% of the considered damages, ranging up to 240 J and 110 mm for impactor energy and radius respectively.

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