The Comparison of Various Foam Polymer Types in Composite Sandwich Panels Subjected to Full Scale Air Blast Loading

Full scale air blast testing has been performed on a range of polymeric foam composite panels. These panels employed glass fibre reinforced polymer (GFRP) face-sheets with different polymer foam cores, namely: Styrene acrylonitrile (SAN); Polyvinylchloride (PVC) and Polymethacrylimide (PMI). The three sandwich panels were all subjected to 100 kg TNT equivalent blast loading at a stand-off distance of 15 m, and the responses of the panels were measured using Digital Image Correlation (DIC). The extent of damage in the sandwich panels was then inspected via post-blast sectioning, and it was found that the SAN core suffered the least damage, and the PMI suffered the most. The DIC showed that the deflection of the SAN core sandwich panel was much less than the other two foam polymer cores, due to less damage meaning a greater stiffness was retained. All blast research to date is part of a programme sponsored by the Office of Naval Research (ONR)

X-ray CT analysis after blast of composite sandwich panels

Four composite sandwich panels with either single density or graded density foam cores and different face-sheet materials were subjected to full-scale underwater blast testing. The panels were subjected to 1kg PE4 charge at a stand-off distance of 1 m. The panel with graded density core and carbon fiber face-sheets had the lowest deflection. Post-blast damage assessment was carried out using X-ray CT scanning. The damage assessment revealed that there is a trade-off between reduced panel deflection and panel damage. This research has been performed as part of a program sponsored by the Office of Naval Research (ONR)

Ballistic impact behaviour of glass fibre reinforced polymer composite with 1D/2D nanomodified epoxy matrices

In this paper, experimental studies on the ballistic impact behaviour of nanomodified glass fibre-reinforced polymer (GFRP) are reported. The epoxy matrix of the GFRP was modified by the addition of graphene platelets (GNPs), carbon nanotubes (CNTs), combined hybrid hexagonal boron nitride nanosheets (BNNS)/CNT, and combined boron nitride nanotubes (BNNTs)/GNPs nanoparticles. Ballistic impact tests were carried out on GFRP laminates at two projectile velocities of 76 ± 1 m s−1 for full-field deformation measurements and 134.3 ± 1.7 m s−1 for perforation tests. The behaviour of the plates during impact was recorded using digital image correlation (DIC), in order to monitor strain and out-of-plane deformation in panels with nanoreinforced matrices. Following penetrative impact tests, pulse thermography was used to characterise the delamination of impacted plates. The results of full-field deformation, exit velocity and energy absorption measurements from the ballistic tests show significant improvements in impact resistance for the panels made from nanomodified epoxies relative to laminates with the unmodified epoxy matrix. The highest absolute absorbed energy was observed for the GFRP panels fabricated using the epoxy matrix loaded with BNNT/GNP at 255.7 J, 16.8% higher than the unmodified epoxy matrix

Comparison of different quasi-static loading conditions of additively manufactured composite hexagonal and auxetic cellular structures

Auxetic cellular structures have the potential to revolutionise sandwich panel cores due to their potential superior energy absorption capability. Because of their negative Poisson's ratio, auxetics behave counterintuitively and contract orthogonally under an applied compressive force, resulting in a densification of material in the vicinity of the applied load. This study investigates three cellular structures and compares their compressive energy absorbing characteristics under in-plane and axial loading conditions. Three unit cell topologies are considered; a conventional hexagonal, re-entrant and double arrowhead auxetic structures. The samples were additively manufactured using two different materials, a conventional Nylon and a carbon fibre reinforced composite alternative (Onyx). Finite element simulations are experimentally validated under out of and in-plane loading conditions and the double arrowhead (auxetic) structure is shown to exhibit comparatively superior energy absorption. For the carbon fibre reinforced material, Onyx, the specific energy absorbed by the double arrowhead geometry was 125% and 244% greater than the hexagonal (non-auxetic) and re-entrant (auxetic) structures respectively

On the extent of fracture toughness transfer from 1D/2D nanomodified epoxy matrices to glass fibre composites

Abstract: In this study, the effects of adding nanofillers to an epoxy resin (EP) used as a matrix in glass fibre-reinforced plastic (GFRP) composites have been investigated. Both 1D and 2D nanofillers were used, specifically (1) carbon nanotubes (CNTs), (2) few-layer graphene nanoplatelets (GNPs), as well as hybrid combinations of (3) CNTs and boron nitride nanosheets, and (4) GNPs and boron nitride nanotubes (BNNTs). Tensile tests have shown improvements in the transverse stiffness normal to the fibre direction of up to about 25% for the GFRPs using the ‘EP + CNT’ and the ‘EP + BNNT + GNP’ matrices, compared to the composites with the unmodified epoxy (‘EP’). Mode I and mode II fracture toughness tests were conducted using double cantilever beam (DCB) and end-notched flexure (ENF) tests, respectively. In the quasi-static mode I tests, the values of the initiation interlaminar fracture toughness, GICC, of the GFRP composites showed that the transfer of matrix toughness to the corresponding GFRP composite is greatest for the GFRP composite with the GNPs in the matrix. Here, a coefficient of toughness transfer (CTT), defined as the ratio of mode I initiation interlaminar toughness for the composite to the bulk polymer matrix toughness, of 0.68 was recorded. The highest absolute values of the mode I interlaminar fracture toughness at crack initiation were achieved for the GFRP composites with the epoxy matrix modified with the hybrid combinations of nanofillers. The highest value of the CTT during steady-state crack propagation was ~ 2 for all the different types of GFRPs. Fractographic analysis of the composite surfaces from the DCB and ENF specimens showed that failure was by a combination of cohesive (through the matrix) and interfacial (along the fibre/matrix interface) modes, depending on the type of nanofillers used

Strain-rate-dependent mechanics and impact performance of epoxy-based nanocomposites

Strain-rate-dependent mechanical properties and impact performance of manufactured epoxy-based nanocomposites are investigated. As reinforcements, fumed silica (FS) and halloysite nanotube (HNT) are used alongside Albipox 1000 and Nanopox F700. First, the internal structures of the composites are visualised using scanning electron microscopy (SEM). To identify the strain-rate-dependent mechanical properties, three-point bend tests are conducted at three different strain rate levels. For the impact resistance, Charpy impact tests are performed. For further investigations of the mechanical properties of the composites, mean-field homogenisation (MFH) and finite element (FE) analyses on the representative volume elements (RVE) are performed for each type of composite material. Overall, the modelling and experiments are in good agreement and account for the mechanical behaviour of these epoxy-based nanocomposites

Failure analysis using X-ray computed tomography of composite sandwich panels subjected to full-scale blast loading

The tailorable mechanical properties and high strength-to-weight ratios of composite sandwich panels make them of interest to the commercial marine and naval sector, however, further investigation into their blast resilience is required. The experiments performed in this study aimed to identify whether alterations to the composite skins or core of a sandwich panel can yield improved blast resilience both in air and underwater. Underwater blast loads using 1.28 kg TNT equivalent charge at a stand-off distance of 1 m were performed on four different composite sandwich panels. Results revealed that implementing a stepwise graded density foam core, with increasing density away from the blast, reduces the deflection of the panel and damage sustained. Furthermore, the skin material affects the extent of panel deflection and damage, the lower strain to failure of carbon-fibre reinforced polymer (CFRP) skins reduces deflection but increases skin debonding. A further two panels were subjected to a 100 kg TNT air blast loading at a 15 m stand-off to compare the effect of a graded density core and the results support the underwater blast results. Future modelling of these experiments will aid the design process and should aim to include material damage mechanisms to identify the most suitable skins

Modelling the effects of patch-plug configuration on the impact performance of patch-repaired composite laminates

The patch-plug configuration has been widely used to repair composite structures and restore the structural integrity of damaged composites. In the present research, single-sided CFRP patch-repaired panels, with different patch-plug configurations, are prepared. This is where a circular-shaped damaged area has been removed and a CFRP patch has been adhesively-bonded onto the panel. In some cases, a CFRP plug is inserted into the hole, caused by removal of the damaged area, before the patch is applied. Such patch-repaired panels, and the pristine CFRP panel, are subjected to a low-velocity impact at an energy of 7.5 J. These impacted pristine and repaired panels are then examined using ultrasonic C-scan and optical microscopy to inspect the impact-associated permanent indentation, interlaminar and intralaminar damage. A finite element analysis (FEA) model, which significantly extends a previously validated elastic-plastic (E-P) numerical damage model, has been developed to predict the impact behaviour of the pristine CFRP panel and the various designs of patch-repaired CFRP panels. The comparison between the experimental and numerical results for all the studied cases shows the maximum deviations for the loading response and the damage area are 12% and 15%, respectively. The good agreement between the experimentally-measured impact properties and those predicted using the numerical model demonstrates that the model is a useful design tool

Delamination properties of laminated glass windows subject to blast loading

Delamination processes absorb significant amounts of energy in laminated glass windows when they are subjected to blast loads. Blast tests were performed previously and their results had been used to calculate the loads imposed on the support systems. In this research, the delamination process at realistic deformation rates was studied to understand the reaction force response obtained. Laboratory tensile tests were performed on pre-cracked laminated glass specimens to investigate their delamination behaviour. The experiments confirmed the presence of a plateau in the force-deflection graphs, suggesting that the delamination process absorbed significant energy. The experimental results were then employed to calibrate FEA models of the delamination process with the aim of estimating the delamination energy of the polyvinyl butyral (PVB) membrane and glass layers and its relationship with deformation speed. The delamination energies obtained through this research, if used with the appropriate PVB material model, are a valuable new tool new tool in the modelling and design of laminated glass façade structures

Effect of melt conditioning on heat treatment and mechanical properties of AZ31 alloy strips produced by twin roll casting

In the present investigation, magnesium strips were produced by twin roll casting (TRC) and melt conditioned twin roll casting (MC-TRC) processes. Detailed optical microscopy studies were carried out on as-cast and homogenized TRC and MC-TRC strips. The results showed uniform, fine and equiaxed grain structure was observed for MC-TRC samples in as-cast condition. Whereas, coarse columnar grains with centreline segregation were observed in the case of as-cast TRC samples. The solidification mechanisms for TRC and MC-TRC have been found completely divergent. The homogenized TRC and MC-TRC samples were subjected to tensile test at elevated temperature (250-400 °C). At 250 °C, MC-TRC sample showed significant improvement in strength and ductility. However, at higher temperatures the tensile properties were almost comparable, despite of TRC samples having larger grains compared to MC-TRC samples. The mechanism of deformation has been explained by detailed fractures surface and sub-surface analysis carried out by scanning electron and optical microscopy. Homogenized MC-TRC samples were formed (hot stamping) into engineering component without any trace of crack on its surface. Whereas, TRC samples cracked in several places during hot stamping process.EPSRC – LiME, UK and Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle Structures – TARF-LCV(EP/I038616/1), Department of Mechanical Engineering, Imperial College London, UK, Mr. Steve Cook, Mr. Peter Lloyd, Mr. Graham Mitchell and Mr. Carmelo and BCAST, Brunel University London