Helmuth Langmaack Toftegaard

Water-cooled non-thermal gliding arc for adhesion improvement of glass-fibre-reinforced polyester

A non-equilibrium quenched plasma is prepared using a gliding-arc discharge generated between diverging electrodes and extended by a gas flow. It can be operated at atmospheric pressure and applied to plasma surface treatment to improve adhesion properties of material surfaces. In this work, glass-fibre-reinforced polyester plates were treated using an atmospheric pressure gliding-arc discharge with air flow to improve adhesion with a vinylester adhesive. The electrodes were water-cooled so as to operate the gliding arc continually. The treatment improved wettability and increased the density of oxygen-containing polar functional groups on the surfaces. Double cantilever beam specimens were prepared for fracture mechanic characterization of the laminate adhesive interface. It was found that gliding-arc treatment significantly increases the fracture resistance in comparison with a standard peel-ply treatment.

Damage tolerance and structural monitoring for wind turbine blades.

The paper proposes a methodology for reliable design and maintenance of wind turbine rotor blades using a condition monitoring approach and a damage tolerance index coupling the material and structure. By improving the understanding of material properties that control damage propagation it will be possible to combine damage tolerant structural design, monitoring systems, inspection techniques and modelling to manage the life cycle of the structures. This will allow an efficient operation of the wind turbine in terms of load alleviation, limited maintenance and repair leading to a more effective exploitation of offshore wind.

Multivariate data-driven modelling and pattern recognition for damage detection and identification for acoustic emission and acousto-ultrasonics

Different methods are commonly used for non-destructive testing in structures; among others, acoustic emission and ultrasonic inspections are widely used to assess structures. The research presented in this paper is motivated by the need to improve the inspection capabilities and reliability of structural health monitoring (SHM) systems based on ultrasonic guided waves with focus on the acoustic emission and acousto-ultrasonics techniques. The use of a guided wave based approach is driven by the fact that these waves are able to propagate over relatively long distances, and interact sensitively and uniquely with different types of defect. Special attention is paid here to the development of efficient SHM methodologies. This requires robust signal processing techniques for the correct interpretation of the complex ultrasonic waves. Therefore, a variety of existing algorithms for signal processing and pattern recognition are evaluated and integrated into the different proposed methodologies. As a contribution to solve the problem, this paper presents results in damage detection and classification using a methodology based on hierarchical nonlinear principal component analysis, square prediction measurements and self-organizing maps, which are applied to data from acoustic emission tests and acousto-ultrasonic inspections. At the end, the efficiency of these methodologies is experimentally evaluated in diverse anisotropic composite structures.

Environmental effect on the mechanical properties of commingled-yarn-based carbon fibre/polyamide 6 composites

The main objective of this experimental investigation was to evaluate the changes from accelerated ageing on selected properties of carbon fibre/polyamide 6 composites based on hybrid yarns. In this study, two types of mechanical tests were performed to measure the environmental influence on the material properties. They are three-point bending to measure the flexural strength and stiffness, and short beam three-point bending to measure the interlaminar shear strength. The 10-mm-thick quasi-isotropic carbon fibre/polyamide 6 composites with 52% volume fraction of carbon fibre to be tested were manufactured by autoclave consolidation. The test samples were dried, and subsequently exposed to 60℃ and 100% relative humidity at different lengths of time up to 2500 h, followed by drying at 23℃ and 50% relative humidity. Few samples were additionally completely dried at 70℃ in vacuum for 21 months. Tests were also performed on as manufactured and dried material at low temperature (–45℃) and high temperature (115℃). The measured mechanical properties decreased with exposure time at 60℃ and 100% relative humidity. Both the bending stiffness and the strength degrade to a level of about 65%, whereas interlaminar shear strength drops to about 87% of the property values of the unexposed (initially dried) material. The bending stiffness and strength at −45℃ are about 87% of the properties at room temperature, whereas at 115℃ the stiffness drops to 75% and the strength drops to 60% of the properties at room temperature. The interlaminar shear strength values also drop to about 75% at both −45℃ and 115℃. Extreme temperatures and long-time exposure to humidity of quasi-isotropic carbon fibre/polyamide 6 laminates can thus reduce the bending stiffness and strength by up to 35% and the interlaminar shear strength by up to 25%.

Plasma treatment of carbon fibres and glass-fibre-reinforced polyesters at atmospheric pressure for adhesion improvement

Atmospheric pressure plasma treatment is useful for adhesion improvement, because cleaning, roughening and addition of polar functional groups can be expected at the surfaces. Its possible applications in the wind energy industry include plasma treatment of fibres and fibre-reinforced polymer composites before assembling them to build wind turbine blades. In the present work, unsized carbon fibres are continuously treated using a dielectric barrier discharge plasma in helium at atmospheric pressure, and carbon fibre reinforced epoxy composite plates are manufactured for the mechanical test. The plasma treatment improved fracture toughness, indicating that adhesion between the fibres and the epoxy was enhanced by the treatment. In addition, glass-fibre-reinforced polyester plates are treated using a gliding arc and an ultrasound enhanced dielectric barrier discharge, improving the wettability and/or the adhesive strength with a vinylester resin.

Effect of shot peening on the residual stress and mechanical behaviour of low-temperature and high-temperature annealed martensitic gear steel 18CrNiMo7-6

A martensitic gear steel (18CrNiMo7-6) was annealed at 180 °C for 2h and at ∼ 750 °C for 1h to design two different starting microstructures for shot peening. One maintains the original as-transformed martensite while the other contains irregular-shaped sorbite together with ferrite. These two materials were shot peened using two different peening conditions. The softer sorbite + ferrite microstructure was shot peened using 0.6 mm conditioned cut steel shots at an average speed of 25 m/s in a conventional shot peening machine, while the harder tempered martensite steel was shot peened using 1.5 mm steel shots at a speed of 50 m/s in an in-house developed shot peening machine. The shot speeds in the conventional shot peening machine were measured using an in-house lidar set-up. The microstructure of each sample was characterized by optical and scanning electron microscopy, and the mechanical properties examined by microhardness and tensile testing. The residual stresses were measured using an Xstress 3000 G2R diffractometer equipped with a Cr Kα x-ray source. The correspondence between the residual stress profile and the gradient structure produced by shot peening, and the relationship between the microstructure and strength, are analyzed and discussed.

Delamination initiated by a defect

Composite materials in wind turbines are mainly joined with adhesives. Adhesive joining is preferable since it distributes the stresses over a larger area. This study shows how a defect can influence the fracture behaviour of adhesively joined composite. Repeated experiments are performed using double cantilever beam specimens loaded with bending moments. The specimens consist of two 8 mm thick GFRP-laminates which are joined by a 3 mm thick epoxy adhesive. A thin foil close to one of the laminates is used to start the crack. For some of the specimens a defect is created by an initial load-unload operation. During this operation, a clamp is used in order to prevent crack propagation in the main direction. For the specimens without defect, the crack propagates in the middle of the adhesive layer. For the specimens with defect, the crack directly deviates into the laminate. After about 25 mm propagation in the laminate, the crack returns to the adhesive. Compared to the adhesive the fracture energy for the laminate is significantly higher.