{"title":"Numerical Simulation of the Damage Characteristics of Carbon fiber-reinforced Aluminum Laminates under Hypervelocity Impact Based on the FE-SPH Adaptive Method","authors":"Renjie Cao, Jianyu Chen, Xianzhao Song, Dianlei Feng, Chong Peng, Zhiqian Li","doi":"10.1007/s10443-024-10303-3","DOIUrl":"10.1007/s10443-024-10303-3","url":null,"abstract":"<div><p>Carbon fiber-reinforced aluminum laminate (CARALL) is a composite material made of carbon fiber-reinforced plastics (CFRP) and aluminum plates bonded by adhesive. It is widely used in the aerospace industry because of its high strength. In this study, the damage characteristics of carbon fiber-reinforced aluminum laminates under hypervelocity impact(HVI) is investigated using the finite element smoothed-particle hydrodynamics (FE-SPH) adaptive method. Firstly, the simulations of the aluminum projectile impacting the CFRP laminate and the aluminum plate at hypervelocity are carried out based on the FE-SPH adaptive method, and the numerical results are in good agreement with the experimental results, which verifies the reliability of the numerical model of the CFRP laminate. Afterwards, the damage characteristics of CARALL under different initial physical conditions including impact velocities, bonding sequences, and projectile shapes are investigated. Numerical results obtained from the FE-SPH adaptive method indicate that CFRP laminates in carbon fiber-reinforced aluminum laminates exhibit “X” shaped penetration channels at impact velocities ranging from 3 km/s to 6 km/s. Under the same impact conditions, the bonding sequence (CARALL with Al/CFRP/Al) shows the best protection performance. The sharp nose projectile causes the most significant damage to CARALL, while the spherical projectile causes the least under hypervelocity impact.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 3","pages":"817 - 847"},"PeriodicalIF":2.3,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144125560","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Muhammet Raci Aydin, Volkan Acar, Ferit Cakir, Omer Gundogdu
{"title":"Effect of Manufacturing Parameters on Low-Velocity Impact Behavior of Aramid, Carbon and Glass Fiber Reinforced Polymer Composites Using Taguchi Experimental Design","authors":"Muhammet Raci Aydin, Volkan Acar, Ferit Cakir, Omer Gundogdu","doi":"10.1007/s10443-024-10298-x","DOIUrl":"10.1007/s10443-024-10298-x","url":null,"abstract":"<div><p>This research presents a comprehensive experimental analysis to assess the effect of manufacturing parameters such as fiber orientation angle, number of layers and fabric types on the low-velocity impact behavior (LVI) of fiber-reinforced laminated composites. Three different types of fibers (Carbon (C), Aramid (A), and Glass (G)), three different number of layers (4, 8, 12), and three different fiber orientation angles (0°/90°, 30°/60°, 45°/-45°) were examined to identify the most advantageous structures considering LVI behavior. Given the extensive range of configurations to be evaluated for the parameters of interest, the number of laminates was systematically reduced using a statistical experimental design approach, the Taguchi method. The manufacturing was carried out using the vacuum-assisted resin transfer molding (VARTM) method. The LVI tests were conducted experimentally at different energy levels. The most effective levels in terms of maximum contact force were obtained with glass fiber, 12 layers, and 30°/60° orientation angle, while the most effective levels in terms of energy absorption ability were aramid fiber, 12 layers, and 0°/90° orientation angle. In addition, doubling (from 4 to 8) the number of layers in aramid fiber laminates resulted in 94% increase in contact force and a 120% increase in absorbed energy. Tripling (from 4 to 12) the number of layers in glass fiber laminates led to a 117% increase in maximum contact force and a 229% increase in absorbed energy. Considering these increasing trends in the design stages can provide significant advantages. The study aims to determine the most effective manufacturing parameters and configurations concerning impact behavior.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 3","pages":"849 - 877"},"PeriodicalIF":2.3,"publicationDate":"2025-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144125506","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Takashi Fujiwara, Masaki Takeuchi, Che Daoyuan, Yao Liang, Naoki Nishioka, Mitsuhiro Okayasu
{"title":"Mechanical Properties of Epoxy- and Dicyclopentadiene-Based Carbon-Fiber-Reinforced Plastics at Low and Room Temperatures","authors":"Takashi Fujiwara, Masaki Takeuchi, Che Daoyuan, Yao Liang, Naoki Nishioka, Mitsuhiro Okayasu","doi":"10.1007/s10443-024-10302-4","DOIUrl":"10.1007/s10443-024-10302-4","url":null,"abstract":"<div><p>In this study, the material properties of carbon-fiber-reinforced polymers (CFRPs) were investigated at room temperature (20 °C) and cryogenic temperature (–196 °C). Two types of CFRPs incorporating thermoset resins, namely epoxy (E) and dicyclopentadiene (D), were employed to evaluate their mechanical properties and failure behaviors. For low-temperature testing, an originally designed apparatus was utilized, in which mechanical properties were evaluated using a polystyrene container filled with liquid nitrogen (LN). The LN level was maintained automatically via a capacitance sensor-based monitoring system that regulated its replenishment as necessary. The results revealed that the bending and fatigue strengths of both CFRP types increased by approximately 30% at –196 °C compared to those at 20 °C. This enhancement may be attributed to various reasons, including increased internal strain induced by the disparity in thermal expansion coefficients between the carbon fiber and the resin. CFRP exhibited relatively higher creep resistance at –196 °C, compared to that at 20 °C. Under static bending load, E-CFRP displayed a sudden stress drop at approximately 2% bending strain, likely due to delamination between the epoxy resin and carbon fibers. In contrast, D-CFRP demonstrated enhanced strain tolerance, sustaining strains exceeding 5% without severe delamination, which can be attributed to the superior wettability of dicyclopentadiene with carbon. Details of the wettability and the above material properties of both CFRPs were analyzed in this paper.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 3","pages":"895 - 907"},"PeriodicalIF":2.3,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144125678","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Effect of Various Defects on Tensile Strength of C/SiC Composites: Experiments and Image-Based Finite Element Analysis","authors":"Jiyuan Li, Guicheng Zhao, Shigang Ai","doi":"10.1007/s10443-024-10300-6","DOIUrl":"10.1007/s10443-024-10300-6","url":null,"abstract":"<div><p>Due to the limitation of manufacturing techniques, voids, low density areas and wrinkle defects inevitably occur during the fabricating process of ceramic matrix composites (CMCs). This study aims to reveal the effect of various defects (voids, low density areas and wrinkle defects) on the tensile strength of plain weave C/SiC composites. The micro-computed tomography (μ-CT) test was used to assess the quantity and distribution of defects within the material. Based on the μ-CT images, finite element models (IB-FEM) of the C/SiC composites with different defect types and contents were reconstructed. The tensile strength of plain weave C/SiC composites containing defects at different temperatures was obtained through experiments and simulations, demonstrating excellent consistency. The effect of different types and contents of defects on the tensile strength of C/SiC composites is investigated and discussed, which is of great significance to enhance understanding of the influence of defects on the mechanical behavior of CMCs.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 3","pages":"1135 - 1152"},"PeriodicalIF":2.3,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144125679","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Dakshayini B Subbappa, Kishore Babu Kancherla, Benjamin Raju, Debiprosad Roy Mahapatra
{"title":"Enhancing Toughness and Thermal Stability Using YSZ Nanoparticle in Glass Fabric Composites","authors":"Dakshayini B Subbappa, Kishore Babu Kancherla, Benjamin Raju, Debiprosad Roy Mahapatra","doi":"10.1007/s10443-024-10301-5","DOIUrl":"10.1007/s10443-024-10301-5","url":null,"abstract":"<div><p>Glass fiber composites are widely used in industries due to their cost-effectiveness and thermal insulation properties despite being less performant than carbon fiber composites. Enhancing glass fiber composites’ thermal and mechanical properties is beneficial when alternatives are lacking. This paper reports useful optimization results using Yttria-Stabilized Zirconia (YSZ) nano-additives in E-Glass Fabric Composites (GFC) to improve these properties and underlying mechanisms. The composite’s combined thermo-mechanical optimization is reported for the first time. The study determined that incorporating optimally (3wt%) nano-YSZ into the thermoset matrix phase and then infusing it into the GFC system through optimized processing parameters significantly enhances compressive residual strain and also the compressive, tensile and flexural strengths and fracture toughness. Key findings include a 12.3% increase in thermal stability over a temperature range of 25–100 °C and improvements in interfacial adhesion and interfacial crack inhibition, resulting in a 75% increase in storage modulus and a 40% enhancement in mode-I fracture toughness in the YSZ-matrix that translated to a 9% increase in the YSZ-Glass fabric interface. Additionally, mode-II fracture toughness increased by 18%, and the mode-II to mode-I fracture toughness ratio, indicating interlaminar strength enhancement, was superior to other types of ceramic additives used in GFCs at higher concentrations. Flexural stiffness and strength increased by 30% and 94%, respectively, at 100 °C due to the nano-scale effects and fiber-matrix interface interactions. This optimization demonstrates that a dilute nano-ceramic dispersion can significantly improve the performance of lightweight, multifunctional composites in thermo-structural applications such as aerospace, automotive, microwave transparent structures, and electronic packaging.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 3","pages":"909 - 935"},"PeriodicalIF":2.3,"publicationDate":"2025-01-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144125570","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Experimental and Numerical Study of Damage Performance and Sensitivity of Thin-Walled Carbon Fiber Tubes to Low-Energy Transverse Impact","authors":"Zhong Luo, Xinyu Sun, Bing Yu, Chengshuang Zhang","doi":"10.1007/s10443-024-10290-5","DOIUrl":"10.1007/s10443-024-10290-5","url":null,"abstract":"<div><p>Thin-walled carbon fiber tubes can be used as support structures for satellite antennas but low-energy impacts may produce invisible damage. In this paper, a finite element model (FEM) of thin-walled carbon fiber tube is proposed for predicting low-energy transverse impact damage. Impact damage sensitivity studies have also been carried out. Low-energy transverse impact damage experiments at energies of 2 J, 4 J, 6 J, 8 J and 10 J were performed to validate the FEM. The maximum error of peak load between experimental and FEM is 7.8%. Both experiments and finite element modelling show that the peak load and damage time increase with increasing impact energy, and that the energy absorbed by the tube also increases. The direction of cracking from impact is similar to the direction of the outermost lamination. For the modulus of elasticity and the outermost layup angle, the layup angle has the greatest degree of damage sensitivity, with a dimensionless damage sensitivity parameter of 4.72.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 2","pages":"639 - 657"},"PeriodicalIF":2.3,"publicationDate":"2024-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143778078","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Failure Analysis of Glass/Epoxy Composite Subjected to Different In-Plane Biaxial Loading Conditions","authors":"A. Kobeissi, P. Rahme, L. Leotoing, D. Guines","doi":"10.1007/s10443-024-10297-y","DOIUrl":"10.1007/s10443-024-10297-y","url":null,"abstract":"<div><p>In recent years, several studies have been initiated to comprehend and predict the failure mechanisms of composite materials. The principal objective of these investigations is to develop a robust failure theory capable of accurately predicting the behavior of composite materials under various loading conditions. The absence of a reliable failure theory capable of effectively predicting composite failure under multi-axial loading makes this area of research particularly promising. Numerous investigations have been carried out to characterize the behavior of composite materials under diverse multi-axial loading conditions. These studies involve the generation of failure envelopes and subsequent comparisons with various failure theories. In this specific study, the traction/traction quadrant of the experimental failure envelope for a 0.5 mm thick plain-weave glass/epoxy composite is generated. Biaxial tests on cruciform specimens are conducted to obtain failure stresses under different loading conditions. The failure investigation validates the capability of the original composite cruciform specimen combined with aluminum tabs for accurately assessing the biaxial failure of composites. Subsequently, the experimental failure envelope is compared with various interactive and non-interactive failure criteria. Notably, the Tsai-Hill and Norris Distortional Energy theories demonstrate substantial agreement with the experimental results.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 2","pages":"525 - 542"},"PeriodicalIF":2.3,"publicationDate":"2024-12-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143778072","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Failure Analysis and Process Optimization in Hydroforming of Fiber Metal Laminates: An Experimental and Numerical Investigation","authors":"Cheng Gang, Hamza Blala, Cheng Pengzhi, Zhang Shenglun, Ruan Shangwen, Meng Zhang","doi":"10.1007/s10443-024-10299-w","DOIUrl":"10.1007/s10443-024-10299-w","url":null,"abstract":"<div><p>This paper explores the application of active hydroforming for Fiber Metal Laminates (FMLs) in aircraft fairing components, in response to the aerospace industry's growing demand for lightweight yet robust materials. Despite the significant potential of FMLs, their complex structure presents major challenges in forming processes. This study investigates the effects of critical parameters, including Bulging Pressure (B<sub>P</sub>) and Blank Holder Pressure (B<sub>HP</sub>), on FML thickness reduction, surface quality, and filling rate. Simulations were conducted using Abaqus, while Hashin's theory was applied to predict damage initiation in the fiber layers. The results revealed a significant interaction between B<sub>P</sub> and B<sub>HP</sub>, which must be carefully managed to avoid defects. A bulging pressure between 1.2 and 2.4 MPa produced well-formed FML parts without defects, although the deformation was insufficient to achieve full die cavity filling and shape accuracy. The minimum required liquid pressure was derived from the FML's ultimate tensile strength, thickness, and sample radius. Finally, a novel active hydroforming curve was introduced, leading to complete FML filling. This research addresses critical forming challenges and demonstrates the feasibility of transitioning from traditional aluminum or composite fairings to advanced FML components in aerospace applications, paving the way for broader adoption.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 2","pages":"733 - 761"},"PeriodicalIF":2.3,"publicationDate":"2024-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143778074","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Sarina Schulte, Hannes Schäfer, Christoph Vogel, Vineet Shah, Stephen Kroll, Andrea Siebert-Raths
{"title":"Environmentally Resistant Flax Fiber-Reinforced Composites for Aircraft Applications: Aviation Stress Tests with Optical and Mechanical Analyses","authors":"Sarina Schulte, Hannes Schäfer, Christoph Vogel, Vineet Shah, Stephen Kroll, Andrea Siebert-Raths","doi":"10.1007/s10443-024-10296-z","DOIUrl":"10.1007/s10443-024-10296-z","url":null,"abstract":"<div><p>Flax fiber-reinforced composites (FFRCs) must be resistant to environmental conditions to use them for external components in aviation. It was investigated how contact with typical aviation liquids, i.e. water, jet fuel and hydraulic oil, affects the optical and mechanical properties of twill fabric epoxy resin-based FFRCs. These influences were compared to the effect of UV weathering. Samples were exposed to these conditions for up to 28 days at RT. Uncoated samples with different fiber contents served as references and were compared with coated samples. A polyurethane/epoxy-based aircraft coating system and a partially biobased automotive interior coating as a more sustainable alternative were examined. The main damage for the uncoated samples was caused by UV weathering and water. UV light leads to photo-oxidation, causing material erosion. Water is absorbed by the hydrophilic flax fibers. Subsequent swelling leads to deformation and delamination. Thus, the damage was more severe for a higher fiber content. No effect could be demonstrated by immersion in jet fuel and hydraulic oil, as they are hardly absorbed by the fibers. Both coatings showed good protection against UV weathering and delayed water absorption. Nevertheless, mechanical damage was found for the FFRC covered with the fossil coating after 28 days of immersion in water. FFRC with an appropriate coating could therefore be suitable for use in aviation, but prolonged contact with water should be avoided. Protective measures should focus on preventing water uptake and UV irradiation, as these cause significantly more damage than jet fuel and hydraulic oil.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 5","pages":"1975 - 1995"},"PeriodicalIF":2.9,"publicationDate":"2024-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s10443-024-10296-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145184067","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Micro-Scale Orthogonal Cutting of CFRP/AFRP Laminates: Modeling and Experimental Analysis","authors":"Huan Chen, Hualin Zheng, Xinman Yuan, Guixin Wang","doi":"10.1007/s10443-024-10288-z","DOIUrl":"10.1007/s10443-024-10288-z","url":null,"abstract":"<div><p>With the ongoing advancement of composite materials, CFRP/AFRP laminates, which integrate the benefits of carbon fiber-reinforced polymer (CFRP) and aramid fiber-reinforced polymer (AFRP), have become increasingly utilized in aerospace applications. The distinct material properties of carbon fibers and aramid fibers result in differing fracture and damage mechanisms during machining. Thus, understanding the cutting and damage mechanisms of CFRP/AFRP composites is crucial to achieving high-quality machined surfaces. In this study, a micro-scale orthogonal cutting finite element model (FEM) is developed for CFRP/AFRP laminates, and corresponding orthogonal cutting experiments are conducted. The cutting process and damage formation mechanisms are analyzed for four typical fiber cutting angles from a microscopic perspective. The findings reveal that carbon fibers, due to their brittleness, primarily undergo shear and bending fractures, while aramid fibers, exhibiting higher ductility, predominantly experience shear and tensile fractures. The surface quality of CFRP/AFRP laminates declines as the fiber cutting angle increases. The cutting force initially rises and then declines as the fiber angle increases, peaking at a 90° fiber cutting angle. The simulated cutting process and cutting forces correspond well with experimental results. Additionally, subsurface damage is assessed, showing that it increases with cutting depth and decreases with cutting speed, stabilizing at higher cutting speeds.</p></div>","PeriodicalId":468,"journal":{"name":"Applied Composite Materials","volume":"32 2","pages":"763 - 790"},"PeriodicalIF":2.3,"publicationDate":"2024-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143778075","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}