Prediction of fatigue life in composite materials using thermoelastic stress analysis

Thermoelastic Stress Analysis (TSA) is developed to provide a prediction of fatigue life in glass reinforced polymers. A test specimens has been designed to promote cracking and a methodology is defined that allows the measurement of the strain in the damaged region. It is shown that a TSA approach can evaluate fibre breakage, matrix cracking and delamination damage. A strain based metric is established based on calibrated data obtained from the TSA, which can be used to assess the condition of a component throughout its fatigue life

Modelling and evaluation of pulsed and pulse phase thermography through application of composite and metallic case studies

A transient thermal finite element model has been created of the pulsed thermography (PT) and pulse phase thermography (PPT) experimental procedure. The model has been experimentally validated through the application of four case studies of varying geometries and materials. Materials used include aluminium, carbon fibre reinforced plastic (CFRP) and adhesively bonded joints. The same four case studies have also formed a basis for comparison between three experimental techniques: PT, PPT and the more established ultrasonic (UT) c-scan.Results show PPT to be advantageous over PT due to its deeper probing as it is less influenced by surface features. Whilst UT is able to reveal all the defects in these case studies, the time consuming nature of the process is a significant disadvantage compared to the full field thermography methods.Overall, the model has achieved good correlation for the case studies considered and it was found that the main limiting factor of the PT model accuracy was knowledge of thermal material properties such as conductivity and specific heat. Where these properties were accurately known the model performed very well in comparison with experimental results. PPT modelling performed less well due to the method of processing the PT data which aims to emphasise small differences. Hence inaccuracies in inputted values such as material properties have a much greater influence on the modelled PPT data. The model enables a better understanding of PT and PPT and provides a means of establishing the experimental set-up parameters required for different components, allowing the experimental technique to be appropriately tailored to more complex situations including bonded joints or structures where several materials are present.The paper ends with a section on defect detectability based on thermal diffusivity contrast between the defect and the bulk material. It shows that in aluminium, because of its higher conductivity, greater thermal contrast is achieved for small differences in diffusivity. Regions where the diffusivity ratio between defect and bulk materials was insufficient to provide thermal contrast for defect identification were found. PPT phase data is shown to reduce the extent of such regions increasing the detectability of defects. Effusivity is introduced as a means of determining the thermal contrast between the defect and non-defective areas and hence establishing the defect detectability

Material heterogeneity or stress concentration: the thermoelastic response from woven composite materials subjected to cyclic fatigue

A study of the growth of fatigue damage in 2 x 2 twill woven composite materials, subjected to cyclic tensile loading are described. Thermoelastic stress analysis (TSA) is used to monitor the stress field. As a result of the damage, a net reduction in the thermoelastic signal is observed. Laminates are found to be more resistant to fatigue

Design and commission of an experimental test rig to apply a full-scale pressure load on composite sandwich panels representative of aircraft secondary structure

This paper describes the design of a test rig, which is used to apply a representative pressure load to a full-scale composite sandwich secondary aircraft structure. A generic panel was designed with features to represent those in the composite sandwich secondary aircraft structure. To provide full-field strain data from the panels, the test rig was designed for use with optical measurement techniques such as thermoelastic stress analysis (TSA) and digital image correlation (DIC). TSA requires a cyclic load to be applied to a structure for the measurement of the strain state; therefore, the test rig has been designed to be mounted on a standard servo-hydraulic test machine. As both TSA and DIC require an uninterrupted view of the surface of the test panel, an important consideration in the design is facilitating the optical access for the two techniques. To aid the test rig design a finite element (FE) model was produced. The model provides information on the deflections that must be accommodated by the test rig, and ensures that the stress and strain levels developed in the panel when loaded in the test rig would be sufficient for measurement using TSA and DIC. Finally, initial tests using the test rig have shown it to be capable of achieving the required pressure and maintaining a cyclic load. It was also demonstrated that both TSA and DIC data can be collected from the panels under load, which are used to validate the stress and deflection derived from the FE model

Assessment of foam fracture in sandwich beams using thermoelastic stress analysis

Thermoelastic Stress Analysis (TSA) has been well established for determining crack-tip parameters in metallic materials. This paper examines its ability to determine accurately the crack-tip parameters for PVC foam used in sandwich structures

Development of thermoelastic stress analysis as a non-destructive evaluation tool

A modified methodology is proposed in which only a single transient load is used for the TSA measurement. Specimens with different damage severities are tested and it is shown that the modified TSA method has the potential to be applied in the field as a non-destructive evaluation tool

Derivation of the stress concentrations at holes in orthotropic plates using thermoelastic stress analysis

An experimental study of the stress distribution around holes in orthotropic composite laminates has been conducted using thermoelastic stress analysis (TSA). Quantitative thermoelastic studies of stress concentrations in metallic plates is a straightforward matter, all that is required is the ratio of the response from the hole and a far-field reading. For orthotropic materials the situation is more complex as the response is not simply proportional to the sum of the principal stresses. In general the thermoelastic response of an orthotropic laminate is a function of the stresses in the principal surface material directions and the associated coefficient of thermal expansion. The approach in this paper is to obtain ‘stress factors’ at the hole and identify the maxima in the plot. Specimens manufactured from a variety of different laminate lay-ups (unidirectional (UD), cross-ply (CP), angle-ply (AP) and quasi-isotropic (QI)) are considered. In all these cases the principal stress directions at the hole are not coincident with the principal material directions and it is a challenging proposition to derive meaningful stress data from these configurations. To validate the approach the experimental data are compared to analytical models. To better understand the nature of the response finite element models are produced that mimic the thermoelastic response

Identification of the source of the thermoelastic response from orthotropic laminated composites

In previous work, a series of theoretical considerations have been made aimed at identifying the source and assessing prominent factors influencing the thermoelastic response from laminated composites. In this paper four different methods of interpreting the data are investigated and the theoretical thermoelastic response is compared to experimental data to identify the source of the thermoelastic response

Sub-surface damage location and identification using infra-red techniques

The paper presents a new methodology for identifying sub-surface damage in composite components using a combination of Pulse Phase Thermography (PPT) and Thermoelastic Stress Analysis (TSA)

Full-scale performance assessment of aircraft secondary sandwich structure using thermoelastic stress analysis

The use of resin film infusion (RFI) has been proven to reduce the cost of production of aircraft secondary sandwich structure. In this paper thermoelastic stress analysis (TSA) is used to assess the performance of full scale aircraft sandwich structure panels produced using both the conventional autoclave process and RFI. Finite element (FE) models of both panel types are developed and TSA is used to validate the models