Michele Meo

Prediction of stiffness and stresses in z-fibre reinforced composite laminates

Abstract The mechanical properties of z-pinned composite laminates were examined numerically. Finite element calculations have been performed to understand how the through-thickness reinforcement modifies the engineering elastic constants and local stress distributions. Solutions were found for four basic laminate stacking sequences, all having two percent volume fraction of z-fibres. For the stiffness analysis, a micro-mechanical finite element model was employed that was based on the actual geometric configuration of a z-pinned composite unit cell. The numerical results agreed very well with some published solutions. It showed that by adding 2% volume fraction of z-fibres, the through-thickness Youngs modulus was increased by 22–35%. The reductions in the in-plane moduli were contained within 7–10%. The stress analysis showed that interlaminar stress distributions near a laminate free edge were significantly affected when z-fibres were placed within a characteristic distance of one z-fibre diameter from the free edge. Local z-fibres carried significant amount of interlaminar normal and shear stresses.

Acoustic emission source localization and velocity determination of the fundamental mode A0 using wavelet analysis and a Newton-based optimization technique

This paper investigates the development of an in situ impact detection monitoring system able to identify in real-time the acoustic emission location. The proposed algorithm is based on the differences of stress waves measured by surface-bonded piezoelectric transducers. A joint time-frequency analysis based on the magnitude of the continuous wavelet transform was used to determine the time of arrival of the wavepackets. A combination of unconstrained optimization technique associated with a local Newtons iterative method was employed to solve a set of nonlinear equations in order to assess the impact location coordinates and the wave speed. With the proposed approach, the drawbacks of a triangulation method in terms of estimating a priori the group velocity and the need to find the best time-frequency technique for the time-of-arrival determination were overcome. Moreover, this algorithm proved to be very robust since it was able to converge from almost any guess point and required little computational time. A comparison between the theoretical and experimental results carried out with piezoelectric film (PVDF) and acoustic emission transducers showed that the impact source location and the wave velocity were predicted with reasonable accuracy. In particular, the maximum error in estimation of the impact location was less than 2% and about 1% for the flexural wave velocity.

Impact localization in composite structures of arbitrary cross section

This article proposes an in situ structural health monitoring method able to locate the impact source and to determine the flexural Lamb mode A0 velocity in composite structures with unknown lay-up and cross section. The algorithm is based on the differences of the stress waves measured by six surface-attached acoustic emission piezoelectric (lead zirconate titanate) sensors and is branched off into two steps. In the first step, the magnitude of the squared modulus of continuous wavelet transform, which guarantees high accuracy in the time–frequency analysis of the acoustic waves, was used to identify the time of arrival of the flexural Lamb wave. Then, the coordinates of the impact location and the group speed values are obtained by solving a set of non-linear equations through a combination of local Newton’s iterative method associated with line search and polynomial backtracking techniques. The proposed method, in contrast to the current impact localization algorithms, does not require a priori knowledge of the anisotropy angular-group velocity pattern of the measured waveforms as well as the mechanical properties of the structure. To validate this method, experimental location testing was conducted on two different composite structures: a quasi-isotropic carbon fibre–reinforced plastic laminate and a sandwich panel. The results showed that source location was achieved with satisfactory accuracy (maximum error in estimation of the impact location was approximately 3 mm for quasi-isotropic carbon fibre–reinforced plastic panel and nearly 2 mm for sandwich plate), requiring little computational time (nearly 1 s). In addition, the values of the fundamental flexural Lamb mode A0 obtained from the optimization algorithm were compared with those determined by a numerical spectral finite element method.

Low-velocity impact behavior of fiber metal laminates

The low-velocity impact response of a range of fiber metal laminate (FML) panels was investigated through testing and finite element simulations. The objective of this study was to understand the impact-damage resistance of these novel composites, so that they can be designed optimally for impact-resistant aircraft applications. The FML panels were made up of aluminum alloy 7475 T761 and unidirectional S2 glass/epoxy oriented in a cross-ply configuration. Experimental tests were performed using a free-fall drop dart testing machine. The plate specimens were constrained on a circular edge by the clamping fixture. The shape and the nature of the damage inflicted by impact were evaluated using both destructive cross-sectional microphotography and nondestructive ultrasonic techniques. The tests showed that FML laminates are capable of absorbing energy through localized plastic deformation and through failure at the interface between the layers. In particular, delaminations occurred in the back face of the aluminum-alloy sheet and its adjacent fiber-reinforced epoxy layer and in between adjacent fiber-reinforced epoxy layer. The finite element code, LS-DYNA3D, was used to perform numerical simulations of low-velocity impact to predict the complex damage propagations. The computed post-impact deformed shapes and damage patterns were found to be fairly close to experimental results.

Impact damage resistance and damage suppression properties of shape memory alloys in hybrid composites—a review

Composite materials are known to have a poor resistance to through-the-thickness impact loading. There are various methods for improving their impact damage tolerance, such as fiber toughening, matrix toughening, interface toughening, through-the-thickness reinforcements, and selective interlayers and hybrids. Hybrid composites with improved impact resistance are particularly useful in military and commercial civil applications. Hybridizing composites using shape memory alloys (SMA) is one solution since SMA materials can absorb the energy of the impact through superelastic deformation or recovery stress, reducing the effects of the impact on the composite structure. The SMA material may be embedded in the hybrid composites (SMAHC) in many different forms and also the characteristics of the fiber reinforcements may vary, such as SMA wires in woven laminates or SMA foils in unidirectional laminates, only to cite two examples. We will review the state of the art of SMAHC for the purpose of damage suppression. Both the active and passive damage suppression mechanisms will be considered.

Design and testing of a fiber-metal-laminate bird-strike-resistant leading edge

One of the major concerns related to flight safety is the impact of birds. To minimize the risks, there is the need to improve impact resistance of aircraft by developing high-performance materials and better structural design of aircraft structures. Because of their remarkable impact properties, fiber metal laminates with layers of aluminum alloy and high-strength glass-fiber composite are potential candidate materials to be employed for aircraft structures susceptible to bird strikes. This paper describes an experimental and numerical campaign aimed at assessing the bird strike resistance of a fiber-metal-laminate-composite leading edge for the wing of a transport aircraft. Three different fiber-metal-laminate leading-edge structures were designed using advanced finite element simulations; they were manufactured and finally tested to analyze their impact-energy-absorbing capabilities. The finite element models were developed, adopting a Lagrangian approach in such a way to be able to correctly simulate impacts with large deformations and perforations of the structures and to characterize the different inelastic/brittle behaviors and failure modes of the fiber metal laminates. The numerical simulations were generally in good agreement with the experimental values, demonstrating the robustness of the developed finite element simulations in supporting the design of bird-strike-resistant aircraft structures.

Residual fatigue life estimation using a nonlinear ultrasound modulation method

Predicting the residual fatigue life of a material is not a simple task and requires the development and association of many variables that as standalone tasks can be difficult to determine. This work develops a modulated nonlinear elastic wave spectroscopy method for the evaluation of a metallic components residual fatigue life. An aluminium specimen (AA6082-T6) was tested at predetermined fatigue stages throughout its fatigue life using a dual-frequency ultrasound method. A modulated nonlinear parameter was derived, which described the relationship between the generation of modulated (sideband) responses of a dual frequency signal and the linear response. The sideband generation from the dual frequency (two signal output system) was shown to increase as the residual fatigue life decreased, and as a standalone measurement method it can be used to show an increase in a materials damage. A baseline-free method was developed by linking a theoretical model, obtained by combining the Paris law and the Nazarov–Sutin crack equation, to experimental nonlinear modulation measurements. The results showed good correlation between the derived theoretical model and the modulated nonlinear parameter, allowing for baseline-free material residual fatigue life estimation. Advantages and disadvantages of these methods are discussed, as well as presenting further methods that would lead to increased accuracy of residual fatigue life detection.

Multifunctional SMArt composite material for in situ NDT/SHM and de-icing

The past few decades have seen significant growth in the development and application of multifunctional media for the enhancement of material properties, thermo-mechanical and sensing properties. This research work reports a novel approach in which a multifunctional material, herein referred to as SMArt composite, can be employed as a structural health monitoring system for strain sensing and damage detection (SMArt sensing and SMArt thermography), but also as an embedded ice protection tool for structural applications (referred as SMArt de-icing). Such a material, obtained by embedding shape memory alloy (SMA) wires within traditional carbon reinforced plastic composites, relies on the possibility of using the wires both to increase the mechanical properties of composites panels and to exploit their intrinsic electrothermal properties. The electrical resistance variation and the internal power resistive heating source provided by the SMA network, enable a built in and fast assessment of the strain distribution and in situ damage visualization via thermographic imaging. The efficiency of these techniques was experimentally validated on a number of SMArt composite laminates with single and multiple internal defects at various depths. The results showed that strain sensing and damage detection were achieved with high spatial resolution and accuracy, without the need to use large external heaters or complex signal processing techniques.

Structural response of laminated composite plates to blast load

Abstract This work deals with three-dimensional numerical simulations of damage caused by air blast on fully clamped rectangular plates. The study examines the performance of both metallic and CFRP laminates subjected to blast loads using commercial LS-DYNA software, including a cohesive damage model to represent delamination. The blast load was simulated using a CONWEP algorithm and MMALE approach with fluid–structure interaction between the Eulerian blast and Lagrangian target models. The simulation results are presented and compared with the experimental data, showing good agreement in terms of dynamic deflection, damage morphology and residual deformation.

Nonlinear elastic wave tomography for the imaging of corrosion damage

This paper presents a nonlinear elastic wave tomography method, based on ultrasonic guided waves, for the image of nonlinear signatures in the dynamic response of a damaged isotropic structure. The proposed technique relies on a combination of high order statistics and a radial basis function approach. The bicoherence of ultrasonic waveforms originated by a harmonic excitation was used to characterise the second order nonlinear signature contained in the measured signals due to the presence of surface corrosion. Then, a radial basis function interpolation was employed to achieve an effective visualisation of the damage over the panel using only a limited number of receiver sensors. The robustness of the proposed nonlinear imaging method was experimentally demonstrated on a damaged 2024 aluminium panel, and the nonlinear source location was detected with a high level of accuracy, even with few receiving elements. Compared to five standard ultrasonic imaging methods, this nonlinear tomography technique does not require any baseline with the undamaged structure for the evaluation of the corrosion damage, nor a priori knowledge of the mechanical properties of the specimen.