Delamination Initiation Research Articles

Effects of openings on postbuckling behavior of large‐size composite C‐beam under bending‐shear coupling load

AbstractProper design and accurate mechanical assessment of composite C‐beam after opening are of great importance in structure engineering. This paper aims to experimentally and analytically investigate the postbuckling response of large‐size C‐beam with web opening under bending‐shear coupling load. New specimen with four different open shapes were designed and tested. Strain gauges and displacement measurements were applied to monitor its buckling behavior, strain field distribution and critical failure load. Four specimens with various openings were loaded until catastrophic failure occurred. Additionally, an analytical model was introduced to predict the residual strength of circular opening. The results indicate that while the presence of an opening significantly decreases the load carrying capacity, it has minimal effect on the bending stiffness. Compared with intact specimen, the initial delamination, buckling and ultimate strength of the circular opening decreases less than those of the rectangular opening. By altering the position of the rectangular opening, improvements can be made in terms of initial delamination resistance and buckling load; however, ultimate strength remains largely unaffected. Reinforcing the edge of an opening further reduces resistance to initial delamination but other two indicators are improved. Overall, from buckling to failure stages, post‐buckling bearing capacity after opening decreases by 40%. Moreover, the shear failure mode is observed during catastrophic failures. And the analysis method employed is relatively conservative.Highlights Ten large size composite C beams are conducted under coupling loads. Deformation, strain distribution and failure mode are presented. Influence of openings on postbuckling behavior of beam is analyzed. An analysis method is employed to predict the residual strength of beam. It could provide valuable insights for assisting in designing beam openings.

Acoustic Emission based determination of delamination initiation in GFRP laminates

Acoustic Emission (AE) has the potential to identify delamination initiation in quasi-static Mode I fracture tests on glass fiber-reinforced polymer-matrix (GFRP) laminates. It had been shown that a combined AE activity and intensity criterion yields critical Mode I delamination resistance values GIC for an AS4/PEEK carbon fiber thermoplastic composite that are comparable to those from data analysis according to ASTM D5528. However, the AE historic index also allows for detection of delamination initiation under Mode I and Mode II loading of carbon fiber reinforced thermoplastics and thermosets. In the present study, these AE criteria for initiation under Mode I, Mode II and Mixed Mode I/II loading of GFRP epoxy laminates are compared with AE signal energy as additional initiation criterion. Initiation under Mode II and Mixed Mode I/II at a ratio of 4:3 was determined with two different set ups for each Mode. For some test configurations noise signals make unambiguous initiation detection difficult. Determination by means of AE energy or AE activity and intensity yields more conservative GC values compared with the AE historic index or criteria defined in the standards, however, with similar repeatability.

Progressive damage analysis of green composite laminates subjected to in-plane crashworthiness

In this paper the initiation and propagation of delamination in thin-walled green composite structures were studied. In particular, laminates of flax and hemp fibers with epoxy resin were investigated from experimental and numerical points of view, using the finite element code LS-DYNA. First, an experimental campaign was conducted using DCB and 4ENF tests to obtain the values of the interlaminar fracture modes, required for the cohesive fracture modeling. In addition, in-plane crashworthiness tests were performed on composite plates to analyze the damage of the specimens, under both quasi-static and dynamic conditions. A trigger mechanism was considered to help delamination to start and to ensure the most progressive crushing possible. The predominant damage mode was splaying, but some ply fragmentation in the middle layers and some buckling phenomena were also observed. In general, more stable progressive crushing was observed under dynamic conditions than under quasi-static ones, even if a reduction in terms of absorbed energy was obtained by moving to the dynamic condition. The numerical predictions showed a good agreement with the experimental reference results, validating the current framework for crashworthiness analysis of green composite structures.

On the interlaminar mode II fracture toughness evaluation of glass Fiber/Epoxy composites with cotton and kenaf natural fibers utilizing acoustic emission features

Considering the widespread use of polymer composites due to their diverse engineering properties, the incorporation of natural fibers is a novel approach to enhance their environmental properties and acquire additional engineering benefits. Applying natural fibers in composites can offer a biocompatible solution to plastic and polymer composite waste issues. Studying the overall properties of composites made with these fibers is a novel area of research. Investigating effective methods for detecting defects and measuring mechanical properties, such as integrity, resilience to failure, and fracture toughness, is particularly crucial. In the current study, the effect of adding cotton and kenaf natural fibers on the resistance to delamination, which is the most common type of failure in laminated composites, is investigated in mode Ⅱ of loading. Specimens of woven glass/epoxy composites with natural fibers were fabricated using the hand lay-up method and end notched three-point bending test was performed. Using the methods provided in the JIS K 7086 standard, the moment of initiation of delamination is determined in the samples. The results demonstrate that only using the mechanical methods provided in the mentioned standard is not sufficient to determine the initiation of delamination. Hence, the acoustic emission can be employed for an easier and more accurate determination of the initiation of delamination. According to the obtained results, cotton and kenaf fibers show a significant increase in the interlaminar fracture toughness of woven glass/epoxy composites. Using cotton fibers shows 212% − 249% and employing kenaf fibers shows 144% − 281% increase in interlaminar fracture toughness respectively. Among the different acoustic emission data analytics, the cumulative energy method shows the lowest mean percentage deviation error of %2.59 among other examined diagnosing techniques.

Quantification of delamination resistance data of FRP composites and its limits

Quantitative delamination resistance data of fibre-reinforced polymer-matrix (FRP) composites for quasi-static or cyclic fatigue loads are determined under different loading modes and load rates, respectively. Such data find use, e.g., in FRP materials’ development, materials’ selection, assessment of durability, or structural design. Round robins during test development yielded repeatability and reproducibility (coefficients of variation) of roughly 10 to 25%. This scatter has several different sources. Intrinsic material variability amounts to a few percent at best, at least for advanced manufacturing processes. This intrinsic scatter is essential for material comparisons and structural design. Measurement resolution specified in standardised test procedures yields a maximum of 4–5% variability. Most of the remaining scatter comes from other, extrinsic sources. Test operator actions, e.g., choice of test set-up, manual data acquisition or data analysis can yield extrinsic scatter. Damage mechanisms during delamination initiation and propagation act on the micro- and meso-scale, typically a few micrometer to a few hundred micrometer in size, with corresponding time-scales estimated to between a few tens of nanoseconds and a few microseconds. Defect size-scales are hence several orders of magnitudes lower than test specimen and structural scales, respectively. Predictive capability of models using such test data for structures are, therefore, limited. Major issues are up-scaling from straight beam-like specimens to larger shell-like structures, possibly with complex shape and varying thickness as well as from unidirectional fibre orientation to multidirectional lay-ups.

Experimental and Simulation Study on Failure of Thermoplastic Carbon Fiber Composite Laminates under Low-Velocity Impact.

Numerous studies have demonstrated that under low-velocity, low-energy impact conditions, although the surface damage to fiber-reinforced composite laminates may be minimal, significant internal damage can occur. Consequently, a progressive damage finite element model was specifically developed for thermoplastic carbon fiber-reinforced composite laminates subjected to low-speed impact loads, with the objective of analyzing the damage behavior of laminates under impacts of varying energy levels. The model utilizes a three-dimensional Hashin criterion for predicting intralayer damage initiation, with cohesive elements based on bilinear traction-separation law for predicting interlaminar delamination initiation, and incorporates a damage constitutive model based on equivalent displacement to characterize fiber damage evolution, along with the B-K criterion for interlaminar damage evolution. The impact response of laminates at energy levels of 5 J, 10 J, 15 J, 20 J, and 25 J was analyzed through numerical simulation, drop-hammer experiments, and XCT non-destructive testing. The results indicated that the simulation outcomes closely correspond with the experimental findings, with both the predicted peak error and absorbed energy error maintained within a 5% margin, and the trends of the mechanical response curves aligning closely with the experimental data. The damage patterns predicted by the numerical simulations were consistent with the results obtained from XCT scans. The study additionally revealed that the impact damage of the laminates primarily stems from interlaminar delamination and intralayer tensile failure. Initial damage typically presents as internal delamination; hence, enhancing interlaminar bonding performance can significantly augment the overall load-bearing capacity of the laminate.

Buckling Analysis of Variable Stiffness Composite Cylindrical Shells Under Axial Compression Considering Imperfection Sensitivity

Thin-walled composite cylindrical shells are nowadays widely used as primary structures in the aerospace industry. The so-called variable stiffness (VS) composite cylindrical shells with flexible stiffness tailoring characteristics have been made possible by existing AFP techniques. Considering the inherent imperfection sensitivity property of axially compressed thin-walled cylindrical shells, the buckling behaviors of the axially compressed VS composite cylindrical shells with initial geometric imperfections and delamination imperfections are investigated respectively in this paper. The design buckling loads of the axially compressed VS composite cylindrical shells are first determined by the probing method, which is verified by comparing with the existing test data and numerical simulation results. Additionally, a parametric study is conducted to investigate the effects of delamination imperfections on the buckling loads. The constraint delamination sizes of the VS composite cylindrical shells based on the design buckling load in this paper are given. Furthermore, the effects of continuously variable fiber angles on the buckling loads are investigated considering the imperfection sensitivity. The specific VS composite cylindrical shells with both high- buckling loads and low-imperfection sensitivity are obtained. Results indicate that the effects of imperfection sensitivity need to be carefully considered in buckling design of the axially compressed VS composite cylindrical shells.

Adhesive strength improvement by providing steps in joints and differentiating initial and final debonding stresses

Step adhesive joints have a special characteristic quite different from other joints. When initial delamination occurs in other joints such as butt, lap and scarf joints, final failure always occurs. In these cases, the external stress causing initial delamination σcInitial is equal to the final failure stress as σcFinal = σcInitial. However, in step joints, the final failure stress σcFinal can be greater than the initial delamination stress σcInitial < σcFinal. To clarify the adhesive improvement mechanism, first, this paper discusses the ISSF (Intensity of Singular Stress Fields) for fully bonded step joint by varying the number of steps NS. Second, the singular stress field causing 2nd debonding is discussed by analyzing partially delaminated step joint. The results show that 2nd debonding requires larger external load than the initial debonding as σcInitial < σcFinal. This is because under the same external load the singular stress causing the 2nd deboning is smaller than the one causing the initial debonding. When NS≥6 and suitable overlap length, the final bond strength σcFinal can be more than 3.6 ∼ 4.4 times larger than the initial delamination stress σcInitial≪σcFinal resulting in much larger bond strength.

Experimental and analytical investigations on single and repetitive impact failure responses of composite sandwich panels with orthogonal woven GFRP facesheets and PVC foam cores

Due to the unique design requirements for high load-bearing capacity of ship structures, composite materials used in the marine industry are gradually being developed with the characteristics of multi-layer sandwich structures with large thickness and cross-section, which are different from thin-walled composite materials widely applied in the aeronautical industry. However, sandwich composite materials used in marine structures have high susceptibility to impact event during in-service applications. The impact induced damage may seriously affect their mechanical performance and structural safety. Therefore, a comprehensive investigation in this paper on the failure mechanisms of composite sandwich panels with orthogonal woven GFRP facesheets and a PVC foam core layer is carried out with a series of single and repetitive low-velocity impact tests. The variations of impact force, dent depth, structural stiffness, failure modes, energy absorption and so on of composite sandwich panels against impact energy levels and impact numbers were explored. The results demonstrate that the delamination damage threshold at the first impact, the sudden drop of peak force and the slow descent process of impact force are the three typical characteristics of impact responses that corresponded to delamination initiation and fibre breakage of the upper panel, and compression damage of the core layer, respectively. The accumulated impact-induced damage has a significant negative effect on load-bearing and energy-absorption capabilities of composite sandwich panels. Moreover, an approximate theoretical analytical method is presented to solve the impact resistance of composite sandwich panels. The analytical results are compared well with experimental results. This research provides a detailed understanding of the damage mechanisms of composite sandwich panels under impact loadings and a guidance for impact resistant design of ship protective structures.

An ANSYS user cohesive element for the modelling of fatigue initiation and propagation of delaminations in composite structures

A deeper understanding of delamination growth under fatigue loading in composite wind turbine blades is required. A new cohesive model for delamination fatigue initiation, which uses initiation S-N curve data to calculate the number of cycles to the introduction of delaminations, is developed and tailored to a state-of-the-art model for fatigue propagation. Both models are implemented in a novel user-defined cohesive element for ANSYS Mechanical APDL. In fatigue propagation-dominated test cases, including with multiple delaminations, the crack growth rate evolution is accurately predicted. In fatigue initiation-dominated cases, a satisfactory prediction is achieved, also showcasing the ability to model fatigue propagation after initiation.

Finite Element Analysis of Delamination Initiation in Wind Turbine Blade Spar Caps: Role of Compression, Strain Energy, and Principal Stresses

In wind turbine blades, utilizing the finite element method (FEM) to identify potential failure modes before production provides considerable value and cost savings in contrast to conventional structural tests. This paper focuses on examining the factors leading to delamination in spar caps and exploring the initiation of this delamination using the finite element method. Compression, total strain energy density, and principal stresses are significant among the variables examined to determine the effects on model deformation and crack formation. Examining these variables may contribute to understanding the mechanisms involved in initiating and progressing delamination. This study examined the effects of compression, total strain energy density, and principal stresses on model deformation and crack formation. This study focuses on the effects of principal stresses on displacement, the effects of compression on delamination and crack formation, and the effects of total strain energy density on fracture tendency and failure modes due to delamination.

Finite element simulations on delamination-induced local stress shielding effects on aseptic loosening behavior by bone remodeling

Interfacial damages (wear, delamination) and bone damage (remodeling, micro-cracks) can significantly affect the local bone deterioration and loosening of the acetabular cup. However, limited research has been conducted on both delamination and bone remodeling. This study aims to analyze the loosening behavior of an acetabular cup caused by the interaction of both interfacial damages and bone remodeling under different boundary conditions. A three-dimensional model of the acetabular cup was developed, and mechanically-induced remodeling behavior was implemented for the surrounding bone while the interfacial delamination between the cup and bone was modeled using the fracture mechanics approach. The delamination in the low initial bone mineral density (BMDs) cases encompasses almost the entire cup surface, which significantly affects the local bone remodeling process. The bone density near the top edge could be reduced to 20% in the lowest BMDs case which exaggerates the local strain accumulation and causes it to approach the micro-breaking limit. The loosening risk of the 45∘ fixation was reported in the low BMDs case which is a major limitation in conventional operation procedures for elderly patients. The interactive effect of the low BDMs, inclination angle, and loading amplitude can reduce the aseptic loosening life by half. This can be attributed to the amplified embedding of the acetabular cup caused by the delamination-induced reduction of the bone density. In future works, we aim to further consider anisotropic bone remodeling, microstructure of the bone, and delamination initiation behavior of surface coating.

Influence of fatigue damage on the impact performance of toughened-interleave carbon fibre epoxy composite laminates

The impact performance of mechanically fatigued carbon fibre-reinforced polymer (CFRP) composite laminates with and without thermoplastic toughening particles has been investigated through a joint experimental and numerical campaign. Prismatic carbon fibre/epoxy specimens with added toughening particles at the ply interfaces were mechanically fatigued with different load amplitudes leading to a loss in apparent stiffness of 10% to 15%. Following the fatigue loading, high resolution computed tomography (CT) has been performed, revealing varying degrees of delamination starting from the free edges along the length of the specimens. In addition, transverse matrix cracks are observed in all fatigued specimens regardless of the amount of delamination. The residual ballistic impact performance of the damaged specimens has been investigated in a dynamic three-point bending configuration at three different velocities, showing a significant detrimental effect of even barely visible initial delamination. In addition, post-mortem CT scans and detailed finite element simulations are used to gain further insight into the mechanisms by which the two types of initial damage affected the impact resistance of the laminates. Finally, repeating the same experiments on a similar CFRP system without discrete toughening particles showed that their inclusion significantly increased the impact resistance both with and without prior fatigue damage.

Fracture toughness resistance curves for a delamination in CFRP MD laminate composites, Part II: Mixed-mode deformation

The use of composite laminates continues to increase, especially in the aerospace industry, due to their high strength-to-weight ratio, resistance to corrosion, and surface degradation. However, in such materials, separation of plies, referred to as delamination, is common. Characterization of the driving forces causing delamination initiation and propagation is different in the case of mode I, mode II, or mixed-mode I/II deformations. This paper is Part II of a two-paper series. Results from calibrated end-loaded split specimens, producing nearly mode II deformation, were presented in Part I. Here, mixed-mode end-loaded split, quasi-static tests were performed. Two multi-directional carbon fiber reinforced polymer material systems are considered and are referred to as the ’wet-layup’ and ’prepreg’, which is attributed to their manufacturing process. Based upon results from three-dimensional finite element analyses in conjunction with the displacement extrapolation method, as well as with the conservative interaction energy or M-integral, stress intensity factors were determined. Based upon the obtained stress intensity factors, the in-plane and out-of-plane mode mixities were evaluated by means of phase angles as a function of the delamination extension through the specimen width. In addition, fracture toughness resistance curves, or R-curves, were generated as a function of delamination extension. The critical interface initiation and fracture resistance interface energy release rate values were determined based on the obtained stress intensity factors and compared with values obtained from the J-integral. Both methods are considered local. Additionally, the global experimental compliance method was employed.Differences of less than 4% for the prepreg and 12% for the wet-layup were observed between the results obtained using the global and local methods. Moreover, it was found that although the materials and interfaces tested are different, the average in-plane mode mixity, as measured by the in-plane phase angle, was found to range between 0.645 rad and 0.668 rad. This implies that the opening mode is dominant for these specimens. In addition, the critical values of the interface energy release rate for initiation Gic and steady state propagation Giss of the two materials were found to be relatively close although the failure mechanisms are not the same.

Quantitative evaluation of PI-RDL interfacial delamination in fan-out wafer-level packaging during unbiased highly accelerated stress test

Fan-Out Wafer-Level Packaging (FOWLP) is increasingly utilized for its superior performance, facilitated by flexible heterogeneous integration. Despite its advantages, the interface between Polyimide (PI) and Redistribution Layers (RDL) is susceptible to significant vulnerabilities, notably delamination. This study introduces a quantitative method to assess PI-RDL interface delamination in FOWLP under unbiased Highly Accelerated Stress Tests (uHAST), a standard approach in accelerated reliability testing characterized by high humidity and temperature. Central to our methodology is the development of a time–temperature-moisture equivalence-based creep constitutive model, which significantly enhances our understanding of the impact of temperature and moisture on creep behavior. Furthermore, we have developed an innovative “open moisture absorption” method for preparing samples for four-point bending tests, enabling precise quantification of the time-induced degradation of PI-RDL interfacial fracture toughness under saturated conditions. Our comprehensive finite element model integrates moisture diffusion, the newly developed creep constitutive model, and solid mechanics to accurately simulate the accumulation of strain energy release rate during uHAST, facilitating precise predictions of delamination initiation times in FOWLP. Experimental validation under two uHAST conditions—130 °C/85 %RH for 96 h and 110 °C/85 %RH for 264 h—demonstrates the effectiveness of our approach, predicting the delamination initiation time at the PI-RDL interface with over 80 % accuracy. This predictive methodology is pivotal in enhancing the structural optimization and extending the service life of FOWLP in varied environmental conditions.

Failure process of bidirectional J-stiffened composite cockpit floors under unidirectional compression

The bidirectional J-stiffened composite panels exhibit high compressive stability and outstanding load-carrying capacity after buckling, thus being currently utilized in the cockpit floor design of a new aircraft in China. The failure process under unidirectional compression was numerically and experimentally investigated. The bidirectional stiffeners are arranged in a “tic-tac-toe” pattern, and no initial delamination or debonding is detected upon ultrasonic scanning. Both experiments and numerical analysis indicate that employing a bidirectional J-stiffener arrangement effectively disperses loads, enabling the stiffened panels to retain significant load-bearing capacity after the skin buckled, with the failure load being five times the buckling load.

Buckling of steel-composite cylindrical pressure hulls with initial delamination

This study investigated the buckling behavior of steel–composite cylindrical pressure hulls with initial delamination. Hydrostatic tests were conducted on three groups of steel–composite cylindrical pressure hulls with different delamination parameters, and the study determined the relationships between the delamination parameters and buckling behavior of delaminated pressure hulls. Numerical analyses were conducted using linear subspace and nonlinear Riks methods, followed by a comprehensive comparison of the numerical and experimental results. Numerical and response surface analyses were conducted, and two sets of practical equations were proposed to evaluate the linear and nonlinear buckling loads of steel–composite cylindrical pressure hulls. The results indicated that initial delamination reduced the buckling loads by 50 %, with the ratio of delamination length to total length being the key factor determining the nonlinear buckling loads of delaminated steel–composite cylindrical pressure hulls.

Delamination Initiation Identification of Mode II Based on AE Characterization of Composite Damage Mechanism

Delamination Initiation Identification of Mode II Based on AE Characterization of Composite Damage Mechanism

A Numerical Assessment of the Influence of Local Stress Ratio in the Fatigue Analysis of Post-Buckled Composite Single-Stringer Specimen

This paper presents a numerical approach for investigating fatigue delamination propagation in composite stiffened panels loaded in compression in the post-buckling field. These components are widely utilized in aerospace structures due to their lightweight and high-strength properties. However, fatigue-induced damage, particularly delamination at the skin–stringer interface, poses a significant challenge. The proposed numerical approach, called the “Min–Max Load Approach”, allows for the calculation of the local stress ratio in a single finite element analysis. It represents the ratio between the minimum and maximum values of the stress along the delamination front, enabling accurate evaluation of the crack growth rate. The methodology is applied here in conjunction with the cohesive zone model technique to evaluate the post-buckling fatigue behavior of a composite single-stringer specimen with an initial delamination. Comparisons with experimental data validate the predictive capabilities of the proposed approach.

Reliability evaluation for shot-peening conditions affecting durability life of automotive suspension coil springs

Shot peening (SP) is a cold working method used to improve the fatigue life and corrosion resistance of metallic materials subjected to repeated loading. However, optimal SP conditions can only be found through experiments with actual operating parts. In addition, studies on the effective SP conditions and ensuring safety for improving the durability of parts are lacking. In this study, SP of various conditions were applied to automobile suspension coil springs (ASCS). Consequently, the process factors, damage assessment, and microstructure were analyzed to determine the factors that exerted a dominant effect on durability life. The durability life of springs applied with stress SP (SSP) was evaluated to be approximately 3.8–4.8 times higher compared to that of springs applied with other SP conditions. In addition, by analyzing the process factors affecting the durability life, the absence of a direct effect of the arc height and Vickers hardness was observed. Moreover, the effect of surface roughness was observed to be small. However, the durability life in response to the change in maximum compressive residual stress (MCRS) exhibited a tendency to change linearly, and this relationship was expressed in an equation through regression analysis. The fracture surface of spring with a high durability life tended to have a large number of spiral shapes, and that of spring with a low durability life tended to have a large number of flat shapes. Before conducting the durability test, a circumferential metal flow was observed in the work-hardened layer below the spring surface upon shot peening. After conducting the durability test, partial crack initiation and propagation and delamination were observed in these areas. Despite the varying SP conditions, the surface microstructure of each spring was observed to be similar before and after the durability test. In this study, it was confirmed that SSP is the most effective method to improve the durability life of ASCS, and it was possible to understand through damage evaluation and microstructure analysis that MCRS affects the durability life by delaying the initiation of cracks in the spring. The analysis method and results of this study are expected to be useful for improving the reliability of not only ASCS but also SP-applied components in the future.