Digital Image Correlation System Research Articles

Research on high-temperature mechanical behaviour of carbon/phenolic composites under ultra-high heating rates

Fibre-reinforced resin matrix composites exhibit excellent resistance to ablation, thermal insulation and mechanical properties at high temperatures, making them widely used in aerospace engineering. Needle-punched reinforced carbon/phenolic composites are the most commonly used structural material for solid rocket engine nozzles. However, during the working process of the engine, the mechanical behaviour under ultra-high heating rates is difficult to characterise due to extreme loads. Therefore, in this study, specimens were carbonised before testing, and an electric heating testing machine was combined with an infrared thermal imager and digital image correlation system to characterise the mechanical behaviour of carbon/phenolic at ultra-high heating rates. The results indicate that at a heating rate of 200 °C/s, the compressive modulus increases linearly with temperature, reaching 63.1 GPa at 1400 °C. The maximum compressive strength is 61.9 MPa at 1400 °C, while the minimum is 27.4 MPa at 600 °C. Referring to the high-temperature damage constitutive model, a pyrolysis damage high-temperature strengthening constitutive model was constructed, accurately describing the in-plane compression mechanical behaviour of carbon/phenolic composites.

The Fracture Evolution Mechanism of Tunnels with Different Cross-Sections under Biaxial Loading

Biaxial compression tests based on an elliptical tunnel were conducted to study the failure characteristics and the meso-crack evolution mechanism of tunnels with different cross-sections constructed in sandstone. The progressive crack propagation process around the elliptical tunnel was investigated using a real-time digital image correlation (DIC) system. Numerical simulations were performed on egg-shaped, U-shaped, and straight-walled arched tunnels based on the mesoscopic parameters of the elliptical tunnel and following the principle of an equal cross-sectional area. The meso-crack evolution and stress conditions of the four types of tunnels were compared. The results show that (1) fractures around an elliptical tunnel were mainly distributed at the end of the long axis and mainly induce slabbing failure, and the failure mode is similar to a V-shaped notch; (2) strain localization is an important characteristic of rock fracturing, which forebodes the initiation, propagation, and coalescence paths of macro-cracks; and (3) the peak loads of tunnels with egg-shaped, U-shaped, and straight-walled arched cross-sections are 98.76%, 97.56%, and 90.57% that of an elliptical cross-section. The elliptical cross-section shows the optimal bearing capacity.

Coaxial panoramic 3D-DIC system for full inner surface deformation measurement

A coaxial panoramic three-dimensional digital image correlation (3D-DIC) system was developed for full 360o inner surface deformation measurement. The panoramic observation was realized by using a convex mirror. Two cameras were arranged coaxially to ensure the largest overlapping observation area. After the coordinate transformation and correlation calculation, the 3D displacement and strain distributions were reconstructed. The principles of the system were presented in detail, and the internal morphology and deformation of pipes subjected to compression loading were described to verify the effectiveness, practicality, and accuracy of the proposed system.

Lateral load behavior of shear connections between steel storage racks and the spine bracing with posts

High-rise steel storage racks are cold-formed thin-walled steel frames, which achieve their lateral strength and stiffness by the use of a spine bracing system in the down-aisle direction commonly located at a short horizontal distance away from the main rack frames. The shear connections between the main rack frame and the spine bracing system play a dominant role in the effectiveness of the spine bracing system. This paper experimentally investigates the behavior of the shear connections used in industrial practice between a steel storage rack and the spine bracing system with posts using four groups of three nominally identical connection specimens. By employing a digital image correlation (DIC) system, the tests generate comprehensive data and establish the real-time deformation fields of individual components of such shear connections. Based on the component-based approach, a linear-elastic analytical model is developed for the type of shear connections under consideration. The proposed analytical model explicitly captures the behavior of the individual connection components, including the three-dimensional flexural bending of endplates, as well as the distortions of the open sections of the upright and the bracing post. Based on the proposed model, this paper quantifies the contribution of each component towards the total deformation of the shear connections. The investigation establishes that the cross-sectional distortion of the bracing post and the out-of-plane bending of the upright web are the most flexible components of such shear connections. Recommendations associated with the shear connections under consideration are proposed for the rack designers and manufacturers.

Advancing the Characterization of Recycled Polyolefin Blends with a Combined Experimental and Numerical Approach to Thermomechanical Behavior.

The blending of polyolefins (POs), such as polyethylene (PE) and polypropylene (PP), is a growing area of research, particularly for recycling mixed polyolefin (MPO) waste through flotation sorting techniques. However, understanding the thermomechanical behavior of these recycled blends is challenging due to limitations in the existing characterization methods. This paper introduces a combined experimental and numerical method to accurately assess the complex mechanical behavior of high-density PE, PP, and their blends. We conducted detailed thermomechanical analyses using a high-speed stereo digital image correlation (DIC) system paired with an infrared camera to capture temperature variations alongside mechanical stress and strain. This approach allowed us to correct for distortions caused by necking and to derive accurate stress-strain relationships. We also applied a cutting-edge unified semi-crystalline polymer (USCP) model to simplify the analysis, focusing on the effects of strain rate and temperature, including self-heating and thermal softening phenomena. Our results, which closely match experimental observations of stress-strain behavior and temperature changes, offer new insights into the thermomechanical properties of PO blends, which are essential for advancing their practical applications in various fields.

Hybrid Fabrication of Cold Metal Transfer Additive Manufacturing and Laser Metal Deposition for Ti6Al4V: The Microstructure and Dynamic/Static Mechanical Properties.

The titanium alloy components utilized in the aviation field are typically large in size and possess complex structures. By utilizing multiple additive manufacturing processes, the precision and efficiency requirements of production can be met. We investigated the hybrid additive manufacturing of Ti-6Al-4V using a combination of cold metal transfer additive manufacturing (CMTAM) and laser metal deposition (LMD), as well as the feasibility of using the CMT-LMD hybrid additive manufacturing process for fabricating Ti-6Al-4V components. Microstructural examinations, tensile testing coupled with digital image correlation and dynamic compressive experiments (by the split Hopkinson pressure bar (SHPB) system) were employed to assess the parts. The results indicate that the interface of the LMD and CMTAM zone formed a compact metallurgical bonding. In the CMTAM and LMD zone, the prior-β grains exhibit epitaxial growth, forming columnar prior-β grains. Due to laser remelting, the CMT-LMD hybrid additive zone experiences grain refinement, resulting in equiaxed prior-β grains at the interface with an average grain size smaller than that of the CMTAM and LMD regions. The microstructures reveal significant differences in grain orientation and morphology among the zones, with distinct textures forming in each zone. In the CMT-LMD hybrid zone, due to interfacial strengthening, strain concentration occurs in the arc additive zone during tensile testing, leading to fracture on the CMTAM zone. Under high-strain-rate dynamic impact conditions, the LMD region exhibits ductile fracture, while the CMTAM zone demonstrates brittle fracture. The hybrid zone combines ductile and brittle fracture modes, and the CMT-LMD hybrid material exhibits superior dynamic impact performance compared to the single deposition zone.

Dynamic impact experimental and global cohesive element method to shale fracture characterization

The fracture behavior and various of mechanical mechanisms of shale are greatly influenced by the bedding surface. To study the effects of bedding angles on the crack propagation patterns and dynamic fracture properties, the shale notched semi-circular bend (NSCB) specimens were studied by the modified split Hopkinson pressure bar (SHPB) device, three-dimensional digital image correlation (3D-DIC) system with the high-speed (HS) photography and ABAQUS finite element software. The research results showed that at the same impact velocity, the 30°, 45° and 60° beddings played an obvious deflexion effect on the shale crack propagation. However, the 0° and 90° bedding did not deflect the crack propagation. The dynamic fracture toughness of shale NSCB specimens increased with the increase of impact loading rate but the increase magnitude decreased with the higher impact rate. The kinetic energy during specimen fracture was calculated by the extracting displacement data from the 3D-DIC, and it was found that the kinetic energy accounted for less than 6% of the absorbed energy during the dynamic compression of the shale. The crack propagation characteristics of ABAQUS simulation was approximately consistent with the experimental results. It is conducive to the study of shale gas fracturing and the formation of complex seam networks in shale and it is of great research significance for the efficient extraction of shale gas.

Disc-cutter induced rock breakage mechanism for TBM excavation in rock masses with different joint shear strengths

When tunnel boring machines (TBMs) excavate through jointed rock masses, the cutting efficiency is strongly affected by the shear strength of joints, the mechanism of which, however, remains poorly understood. In this study, a series of disc-cutter indentation tests were conducted on granite rock mass specimens with different joint shear strengths. During the indentation, the cracking process was recorded by a digital image correlation (DIC) system. The deformation and strength of specimens, cracking behavior, rock breakage mode and cutting efficiency were quantitatively investigated. In addition, to investigate the combined effects of joint shear strength, orientation and spacing on the rock breakage mechanism, numerical rock mass models were established based on a particle flow code PFC2D. Experimental results reveal that the cracking of primary and secondary cracks changes from the mixed shear-tensile to tensile mode in the initial stage, while the joint shear strength does not affect the cracking mode in the subsequent propagation process. The rock breakage mode is classified to an internal block breakage mode, a cross-joint breakage mode and a cutters-dependent breakage mode. The cross-joint breakage mode is optimal for improving the cutting efficiency. Numerical simulation results reveal that the increase in the joint shear strength changes the internal block breakage mode to cross-joint breakage mode for rock masses of particular ranges of joint orientation and spacing. These findings provide basis for improving the TBM cutting efficiency through jointed rock masses.

Experimental investigation on the low‐velocity impact response and the residual strength of CFRP tubes

AbstractWith the help of the high‐speed camera and self‐designed fixture, it was investigated that the effects of the impactors in a variety of shapes on the mechanical behavior and failure mode of carbon fiber‐reinforced polymer (CFRP) tubes with a range of inner diameter during the low‐velocity impact (LVI) of four impact energies. Then, the three‐dimensional digital image correlation (3D‐DIC) system was carried out to monitor the damage evolution of the LVI‐damaged specimens under compressive and flexural loading. In addition, the residual compressive and flexural strength of all kinds of cases were compared and discussed. The results show that the increase in wall thickness can improve the LVI, compression‐after‐impact (CAI), and flexure‐after‐impact performance. The failure mode of compression changes to brittle fracture failure at the impact circumferential region. The CAI strength of the specimen damaged by a flat impactor is 23.89% less than that of a hemispherical one, but there is little difference in flexural loading.Highlights Mechanical behavior on in & post LVI of CFRP tubes varying wall thickness and impactor. Due to point‐line contact for flat impactor, two peak forces are in the F‐D curves. LVI property and residual strength are improved with the increase of wall thickness. Compressive failure mode is brittle fracture at the impact circumferential area. Flexure‐after‐impact strength mainly depends on the no‐impact surface of tubes.

Stereo Camera Setup for 360° Digital Image Correlation to Reveal Smart Structures of Hakea Fruits.

About forty years after its first application, digital image correlation (DIC) has become an established method for measuring surface displacements and deformations of objects under stress. To date, DIC has been used in a variety of in vitro and in vivo studies to biomechanically characterise biological samples in order to reveal biomimetic principles. However, when surfaces of samples strongly deform or twist, they cannot be thoroughly traced. To overcome this challenge, different DIC setups have been developed to provide additional sensor perspectives and, thus, capture larger parts of an object's surface. Herein, we discuss current solutions for this multi-perspective DIC, and we present our own approach to a 360° DIC system based on a single stereo-camera setup. Using this setup, we are able to characterise the desiccation-driven opening mechanism of two woody Hakea fruits over their entire surfaces. Both the breaking mechanism and the actuation of the two valves in predominantly dead plant material are models for smart materials. Based on these results, an evaluation of the setup for 360° DIC regarding its use in deducing biomimetic principles is given. Furthermore, we propose a way to improve and apply the method for future measurements.

Study on the superposition effect of stress waves and crack propagation law between blastholes at different angles

The drilling and blasting method is extensively employed in various industries such as mining and infrastructure construction. In the majority of blasting operations, strip-charges are predominantly utilized, while blastholes often exhibit an angled orientation in practical engineering scenarios. To investigate the stress wave superposition effect and the crack propagation law among blastholes at varying angles, this study employs a high-speed digital image correlation system to conduct blasting model experiments. The results indicate that: the fractal dimension of the crack propagation trajectory decreases progressively as the angle increases. the von Mises strain-time curve of the specimen initially increases and then decreases. As the angle between the blastholes widens, the fractal dimension of the crushing zone and blasting crack among the blast borehole decreases accordingly, suppressed the blasting effect of the blasted medium. On the central axis between the two holes, the stress superposition becomes more obvious in the direction away from the initiation point, and the peak value of strain is the highest at the bottom of the blastholes. When the angle between the blastholes is 30°, the strain in the specimen takes the longest to decline from peak to valley, and the blasting stress wave sustains its influence for an extended duration, thus maximizing the use of blasting energy. Conversely, when the angle between the blastholes is 0°, the specimen experiences the shortest duration of blasting action and the least efficient energy utilization.

Experimental study on exterior precast concrete beam-to-CECFST column joints with wet connections under cyclic loading

Concrete-encased concrete-filled steel tube (CECFST) structural system has gained popularity in recent years due to its several advantages over conventional structures. Additionally, precast technology has become an effective way of improving construction efficiency and environmental performance. Therefore, it is essential to investigate the structural behaviour of precast concrete (PC) beam-to-CECFST column joints to ensure their optimal performance in applications. In this regard, this paper presents an experimental study of 4 precast exterior joints subjected to lateral cyclic loading. The study investigated the effect of replacing normal concrete with steel fibre-reinforced concrete at the joint region and the presence of axial load on PC composite joints. Based on the test results, cyclic load-carrying resistance, failure modes and crack patterns of the PC specimens were recorded and analysed. In addition, a Digital Image Correlation (DIC) system was adopted to show the crack evolution of joint specimens and calculate shear strains of concrete encasement at the joint region. Further comparisons were conducted in terms of ductility, energy dissipation, stiffness and strength degradation to investigate the joint performance. Finally, existing American and European design code provisions were modified and used to predict joint shear strength. Their predictions were reasonably close to the test results.

The Influence of Flame Exposure and Solid Particle Erosion on Tensile Strength of CFRP Substrate with Manufactured Protective Coating.

This paper presents the results of laboratory tests for new materials made of a carbon fibre-reinforced polymer (CFRP) composite with a single-sided protective coating. The protective coatings were made of five different powders-Al2O3, aluminium, quartz sand, crystalline silica and copper-laminated in a single process during curing of the prepreg substrate with an epoxy matrix. The specimens were subjected to flame exposure and solid particle erosion tests, followed by uniaxial tensile tests. A digital image correlation (DIC) system was used to observe the damage location and deformation of the specimens. All coatings subjected to solid particle erosion allowed an increase in tensile failure force ranging from 5% to 31% compared to reference specimens made of purely CFRP. When exposed to flame, only three of the five materials tested, Al2O3, aluminium, quartz sand, could be used to protect the surface, which allowed an increase in tensile failure force of 5.6%.

Fabrication of one-piece high-strength glass cenospheres/aluminum core sandwich by pressure infiltration process

In this study, one-piece glass cenospheres/aluminum core sandwich is prepared using a pressure infiltration method. In comparison to adhesive bonding, the layers combined by metallurgical bonding are straight and smooth, and the sandwich shows high shear stress of 80.4 MPa. The failure mode is analyzed through a combination of mises stress distribution simulated using the finite element analysis and in-situ strain distribution obtained from a digital image correlation system. After cracks initiated at interfaces, they propagate to nearby layers in the sandwich structure, which can delay the shear failure by avoiding significant damage of core layer.

High Aspect Ratio Composite Wings: Geometrically Nonlinear Aeroelasticity, Multi-Disciplinary Design Optimization, Manufacturing, and Experimental Testing

In the field of aerospace engineering, the design and manufacturing of high aspect ratio composite wings has become a focal point of innovation and efficiency. These long, slender wings, constructed with advanced materials such as carbon fiber and employing efficient manufacturing methods such as vacuum bagging, hold the promise of significantly lighter aircraft, reduced fuel consumption, and enhanced overall performance. However, to fully realize these benefits, it is imperative to address a multitude of structural and aeroelastic constraints. This research presents a novel aeroelastically tailored Multi-objective, Multi-disciplinary Design Optimization (MMDO) approach that seamlessly integrates numerical optimization techniques to minimize weight and ensure structural integrity. The optimized wing configuration is then manufactured, and a Ground Vibration Test (GVT) and static deflection analysis using the Digital Image Correlation (DIC) system are used to validate and correlate with the numerical model. Within the fully automated in-house Nonlinear Aeroelastic Simulation Software (NAS2) package (version v1.0), the integration of analytical tools offers a robust numerical approach for enhancing aeroelastic and structural performance in the design of composite wings. Nonlinear aeroelastic analyses and tailoring are included, and a population-based stochastic optimization is used to determine the optimum design within NAS2. These analytical tools contribute to a comprehensive and efficient methodology for designing composite wings with improved aeroelastic and structural characteristics. This comprehensive methodology aims to produce composite wings that not only meet rigorous safety and performance standards but also drive cost-efficiency in the aerospace industry. Through this multidisciplinary approach, the authors seek to underscore the pivotal role of tailoring aeroelastic solutions in the advanced design and manufacturing of high aspect ratio composite wings, thereby contributing to the continued evolution of aerospace technology.

Digital Fracture Surface Morphology and Statistical Characteristics of Granite Brazilian Tests after Non-Steady-State Thermal Disturbance

With the widespread advent of digital technologies, traditional perspectives in rock mechanics research are poised for further expansion. This paper presents a Brazilian test conducted on granite after non-steady-state thermal disturbance at 25 °C, 200 °C, 400 °C, and 600 °C, with detailed documentation of the damage process and failure response using an acoustic emission (AE) apparatus and a digital image correlation (DIC) system. Subsequently, utilizing point cloud data captured by a three-dimensional (3D) laser scanning system, a digital reconstruction of the failed specimen’s fracture surface was accomplished. The 3D fractal characteristics and roughness response of the digitized fracture surface were studied using the box-counting method and least squares approach. Furthermore, texture information of the digitized fracture surface was calculated using the Gray Level Co-occurrence Matrix (GLCM), and statistical characteristics describing the elevation distribution were analyzed. The results elucidate the influence of thermal disturbance temperature on the mechanical parameters of the specimen, acoustic emission behavior, surface strain field evolution, and digital fracture morphology characteristics. The findings indicate a non-linear degradation effect of temperature on the specimen’s tensile strength, with a reduction reaching 80.95% at 600 °C, where acoustic emission activity also peaked. The rising thermal disturbance temperature inhibited the crack initiation load at the specimen’s center but expanded the high-strain concentration areas and the growth rate of horizontal displacement. Additionally, varying degrees of linear or non-linear relationships were discovered between thermal disturbance temperature and the 3D fractal dimension of the fracture surface, average roughness (Ra), peak roughness (Rz), and root mean square roughness (Rq), confirming the potential of Rsm in predicting the 3D fractal dimension of Brazilian test fracture surfaces. The study of the GLCM of the digitized 3D fracture surface demonstrated a high dependency of its four second-order statistical measures on thermal disturbance temperature. Finally, the statistical parameters of the fracture surface’s elevation values showed a significant non-linear relationship with thermal disturbance temperature, with a critical temperature point likely existing between 400 and 600 °C that could precipitate a sudden change in the fracture surface’s elevation characteristics.

A Modified DF2016 Criterion for the Fracture Modeling from Shear to Equibiaxial Tension.

This study introduces a modified DF2016 criterion to model a ductile fracture of sheet metals from shear to equibiaxial tension. The DF2016 criterion is modified so that a material constant is equal to the fracture strain at equibiaxial tension, which can be easily measured by the bulging experiments. To evaluate the performance of the modified DF2016 criterion, experiments are conducted for QP980 with five different specimens with stress states from shear to equibiaxial tension. The plasticity of the steel is characterized by the Swift-Voce hardening law and the pDrucker function, which is calibrated with the inverse engineering approach. A fracture strain is measured by the XTOP digital image correlation system for all the specimens, including the bulging test. The modified DF2016 criterion is also calibrated with the inverse engineering approach. The predicted force-stroke curves are compared with experimental results to evaluate the performance of the modified DF2016 criterion on the fracture prediction from shear to equibiaxial tension. The comparison shows that the modified DF2016 criterion can model the onset of the ductile fracture with high accuracy in wide stress states from shear to plane strain tension. Moreover, the calibration of the modified DF2016 criterion is comparatively easier than the original DF2016 criterion.

Tensile properties of welded joints with delayed hydride crack

In this work, a procedure for producing tensile coupon specimens with naturally delayed hydride cracks was proposed, and the tensile properties of the specimens were studied. Firstly, a delayed hydride crack was prefabricated on the welded plate according to the relevant specification, and the crack type was determined by microstructure and macrostructure observation and analysis. Secondly, the tensile coupon specimens of welded joints with or without delayed hydride cracks were cut from the welded plate. Finally, tensile tests of welded joints were carried out, and the strain and displacement were monitored by a digital image correlation system. The test phenomena, fracture mode and the tensile properties of the welded joint were analysed according to the stress-strain curve, the strain cloud map and the tensile property parameters. When the specimen fractured at the base metal, the effect of delayed hydride crack on the strength and deformation of the welded joints was insignificant. The cracked area ratio was relatively small (e.g. 1.91% to 22.5%). When the specimen fractured at the cracked region, the cracked area ratio was relatively large (e.g. 16.77% to 39.62%). The fracture modes could be divided into two types: the full-sectional yield fracture and the low stress fracture. The remaining ultimate strength, yield-to-tensile ratio and elongation of low stress fracture specimens showed a linear decline with the increase of cracked area ratio. For specimens with cracked area ratio between 16.77% and 22.5%, the differences in fracture locations might be caused by the pattern and angles of the crack.

Industrial application of a low-cost structural health monitoring system in large-scale airframe tests

A small, novel, integrated SHM system has been deployed during full-scale testing of a wing fatigue test for several weeks and a fuselage pressurisation test for several months. Complementary NDE measurement techniques were combined, with inputs from visible and infrared optical sensors, as well as resistance strain gauges. Sensor units were deployed at regions of interest and integrated board computers permitted near real-time data processing. The outputs were full-field measurement datasets from digital image correlation and thermoelastic stress analysis systems. Changes in these datasets in the regions of interest were successfully quantified using orthogonal decomposition and were indicative of changes in the condition of the structure. The results from these case studies demonstrate that this system can be successfully deployed in spatially restricted areas within airframe structures to monitor crack growth. The low cost and small footprint of the system presents the opportunity for installation of arrays of similar sensors for both test and in-service data collection. Near real-time data processing would allow timely reporting to service engineers, informing maintenance or operational decisions.

Resistance of natural stone masonry wallettes under centred and eccentric compressive loading: Experimental and numerical approaches

Masonry walls are typically subjected to eccentric compressive loadings in common buildings. However, the design of walls towards this type of solicitation remains very empirical, often leading to oversizing the structure. This is especially true for natural stone masonry, for which experimental data are quite scarce. This paper presents an experimental campaign on 15 natural stone masonry wallettes subjected to centred and eccentric compression until failure. Different values of the eccentricity of the load, ranging from h/12 to h/4 (where h is the thickness of the wallette) were investigated, highlighting the noticeable effect of such a value on the compressive failure load. During the tests, the displacements were recorded by a Digital Image Correlation system, providing insights into the different failure mechanisms that depend on the value of the eccentricity. The so-obtained experimental failure loads are then compared to the predictions of Eurocode 6. Finally, a finite-element yield-design analysis of these tests is proposed which shows that this modelling framework is suitable to find the ultimate bearing capacity of a masonry wallette.