Nondestructive testing of the delaminated interface between two materials

International audienceWe consider the problem of detecting if two materials that should be in contact have separated or delaminated. The goal is to find an acoustic technique to detect the delamination. We model the delamination as a thin opening between two materials of different acoustic properties, and using asymptotic techniques we derive a asymptotic model where the delaminated region is replaced by jump conditions on the acoustic field and flux. The asymptotic model has potential singularities due to the edges of the delaminated region, and we show that the forward problem is well posed for a large class of possible delaminations. We then design a special Linear Sampling Method (LSM) for detecting the shape of the delamination assuming that the background, undamaged, state is known. Finally we show, by numerical experiments, that our LSM can indeed determine the shape of delaminated regions

Fatigue Damage in Notched Composite Laminates Under Tension-Tension Cyclic Loads

The results are given of an investigation to determine the damage states which develop in graphite epoxy laminates with center holes due to tension-tension cyclic loads, to determine the influence of stacking sequence on the initiation and interaction of damage modes and the process of damage development, and to establish the relationships between the damage states and the strength, stiffness, and life of the laminates. Two quasi-isotropic laminates were selected to give different distributions of interlaminar stresses around the hole. The laminates were tested under cyclic loads (R=0.1, 10 Hz) at maximum stresses ranging between 60 and 95 percent of the notched tensile strength

Fatigue response of notched laminates subjected to tension-compression cyclic loads

The fatigue response of a ((0/45/90/-45)(sub s))(sub 4) T300-5208 graphite-epoxy laminate with a drilled center-hole subjected to various components of tensile and compressive cyclic loads was investigated. Damage evaluation techniques such as stiffness monitoring, penetrant-enhanced X-ray radiography, C-scan, laminate deply and residual strength measurement were used to establish the mechanisms of damage development as well as the effect of such damage on the laminate strength, stiffness and life. Damage modes consisted of transverse matrix cracks, initiating at the hole, in all plies, followed by delamination between plies of different orientation. A characteristic stiffness repsonse during cyclic loading at two load levels was identified and utilized a more reliable indicator of material and residual properties than accumulated cycles. For the load ratios of tension-compression loading, residual tensile strength increased significantly above the virgin strength early in the fatigue life and remained approximately constant to near the end of life. A technique developed for predicting delamination initiation sites along the hole boundary correlated well with experimental evidence

Comparison of Staggered Grid Finite Difference Schemes for Ultrasound Simulation in Curving Composites

The optimization of ultrasonic nondestructive evaluation (NDE) simulation tools for composites has the potential to reduce both individual part inspection time and overall certification time for composite parts and structures. Inspection guidance based on simulation provides increased confidence in the veracity of inspection results in addition to time reductions. This paper outlines ongoing work targeted to advance this objective through the use of finite difference (FD) simulation techniques formulated for composite structures with realistic geometries. Two staggered grid explicit FD schemes which show promise for this purpose are assessed: the Lebedev FD scheme and the rotated staggered grid (RSG) FD scheme. Algorithmic points which provide challenges for complex geometries are addressed, in particular handling of traction free surfaces and bi-material interfaces present at lamina boundaries. Code execution time estimates are performed as well to guide feasible domain sizes relative to algorithm choice and available hardware. Three test cases are simulated: a delaminated plate, a cylinder, and a triclinic lamina. These tests demonstrate that the Lebedev FD scheme needs additional work to handle inter-laminar interfaces and traction free boundaries in the presence of stair-stepping approximations. In contrast, the simple structure of the RSG unit cell makes it more straightforward to construct a 3D simulation technique for curved composite laminates

Shock adhesion test for composite bonded assembly using a high pulsed power generator

In a context of the rising use of composite assemblies in aeronautic or defense fields, the assessment of their strength is a key issue. The method developed in this study attempts to provide solutions. A shock adhesion test based on short compressive loads, obtained by a high pulsed power generator, is proposed as a proof test to ensure the quality of composite bonded assemblies. A calibrated load induces a local tensile stress able to damage the bond interface. The high pulsed power source is the GEnerateur de Pression Isentropique device (Isentropic Pressure Generator), used to generate the required stresses, with a 450 ns pulse duration to test assemblies above the mm thickness range. The understanding of the mechanisms of wave propagation and tensile stress generation within these multilayer assemblies are scientific challenges. The ability of the technique to induce a tensile stress able to disbond the laminates and the assemblies is demonstrated. This paper details the response of carbon epoxy laminates and their bonded assemblies to a shock loading near the damage threshold

FRP-to-masonry bond durability assessment with infrared thermography method

The bond behavior between FRP composites and masonry substrate plays an important role in the performance of externally bonded reinforced masonry structures. Therefore, monitoring the bond quality during the application and subsequent service life of a structure is of crucial importance for execution control and structural health monitoring. The bond quality can change during the service life of the structure due to environmental conditions. Local detachments may occur at the FRP/substrate interface, affecting the bond performance to a large extent. Therefore, the use of expedite and efficient non-destructive techniques for assessment of the bond quality and monitoring FRP delamination is of much interest. Active infrared thermography (IR) technique was used in this study for assessing the bond quality in environmentally degraded FRP-strengthened masonry elements. The applicability and accuracy of the adopted method was initially validated by localization and size quantification of artificially embedded defects in FRP-strengthened brick specimens. Then, the method was used for investigating the appearance and progression of FRP delaminations due to environmental conditions. GFRP-strengthened brick specimens were exposed to accelerated hygrothermal ageing tests and inspected periodically with the IR camera. The results showed environmental exposure may produce large progressive FRP delaminations.Fundação para a Ciência e Tecnologi

Completion of evaluation of manufacturing processes for B/Al composites containing 0.2mm diameter boron fibers

Four fabricators produced a total of 54 B/1100 Al, B/6061 Al, and B/2024 Al panels for evaluation. The 8 ply unidirectional, 45 to 50 volume percent, panels were made using 0.20 mm diameter boron fibers which were obtained from a single supplier. Hot press consolidation was carried out in vacuum except for one set of dry woven tape panels which were hot pressed in air. A single testing contractor conducted nondestructive inspection, metallography, fractography and mechanical property tests. The mechanical property tests included 21 and 260 C tensile tests and 21 C shear tests. Panel quality, as measured by nondestructive evaluation, was generally good as were the 21 C tensile properties. The panels hot pressed in air delaminated in the shear tests. Shear strength values were lower in these panels. But tensile strengths were not affected by the delaminations because of the relation between the tensile loading direction and the delaminations. Composite tensile strength was found to be proportional to the volume percent boron and the aluminum matrix rather than to the tape used or fabrication technique. Suitability of these composites for 260 C service was confirmed by tensile tests

Incorporation of composite defects from ultrasonic NDE into CAD and FE models

Fiber-reinforced composites are widely used in aerospace industry due to their combined properties of high strength and low weight. However, owing to their complex structure, it is difficult to assess the impact of manufacturing defects and service damage on their residual life. While, ultrasonic testing (UT) is the preferred NDE method to identify the presence of defects in composites, there are no reasonable ways to model the damage and evaluate the structural integrity of composites. We have developed an automated framework to incorporate flaws and known composite damage automatically into a finite element analysis (FEA) model of composites, ultimately aiding in accessing the residual life of composites and make informed decisions regarding repairs. The framework can be used to generate a layer-by-layer 3D structural CAD model of the composite laminates replicating their manufacturing process. Outlines of structural defects, such as delaminations, are automatically detected from UT of the laminate and are incorporated into the CAD model between the appropriate layers. In addition, the framework allows for direct structural analysis of the resulting 3D CAD models with defects by automatically applying the appropriate boundary conditions. In this paper, we show a working proof-of-concept for the composite model builder with capabilities of incorporating delaminations between laminate layers and automatically preparing the CAD model for structural analysis using a FEA software