Multilayer Composite Materials Research Articles

Ultrasonic detection, characterization, and simulation of delamination defects in composite laminates

Composite materials are of great importance in many industries due to their unique properties, strength and durability, but they also include disadvantages that can affect their use and must be studied. In this article, we simulate the acoustic interference field received by a delay line following an interaction between an acoustic field and a multilayer carbon fibre composite material using the ray approach. In this case, the simulation is performed using carbon fiber composite plates, where some plates have lamination defects such as delamination, while others are free of these defects. Experimental measurements are performed on carbon fiber composite plates with and without delamination defects introduced beforehand, without knowing their thickness. The thickness of each ply is 0.125 mm. The transducer used is a focusing immersion transducer type parametric (V 312) that operates at a frequency of 10 MHz The simulation results almost exactly corroborate those of the experiment. The simulation model was employed to determine the thickness of the induced delamination, which is 0.2 mm, found in the second and third layers.

Harmonizing lightweight and ablation resistance: Design and performance of multilayer composite insulation materials for solid rocket motors

AbstractThe realization of lightweight insulation materials is often accompanied by a decrease in ablation performance. Coordinating the contradiction between lightweight and ablation resistance is the key to the development of thermal protection technology. Addressing the need for high‐performance insulation materials within solid rocket motors (SRMs) combustion chambers, we designed three multilayer composite structural insulation materials and studied their properties. The results show that among these constructed multilayer composites, the bilayer structure exhibited the lowest density at a mere 0.72 g/cm3, marking a 27% reduction compared to the basic structure. Remarkably, the bilayer configuration demonstrated superior ablation resistance, showcasing a 25% decrease in the line ablation rate in contrast to the basic structure after oxygen‐acetylene test. This achievement embodies the successful harmonization of lightweight properties with ablation resistance. Furthermore, based on the performance and microstructure of the char layer, a further analysis revealed the enhancement mechanism of ablative performance by the multilayer composite structure. It was found that the synergistic effect of the compact/porous structure of the char layer grants the bilayer structure thermal insulation material optimal ablative performance. This work provides strong support for improving the performance of SRMs.Highlights Insulation materials with multilayer composite structures are designed. The materials exhibit both lightweight and superior ablation resistance. Compact/porous char layers enhance material ablation performance.

Effective elasto‐(visco)plastic coefficients of a bi‐phasic composite material with scale‐dependent size effects

We employ the theory of asymptotic homogenization (AH) to study the elasto‐plastic behavior of a composite medium comprising two solid phases, separated by a sharp interface and characterized by mechanical properties, such as elastic coefficients and “initial yield stresses” (i.e., a threshold stress above which remodeling is triggered), that may differ up to several orders of magnitude. We speak of “plastic” behavior because we have in mind a material behavior that, to a certain extent, resembles plasticity, although, for biological systems, it embraces a much wider class of inelastic phenomena. In particular, we are interested in studying the influence of gradient effects in the remodeling variable on the homogenized mechanical properties of the composite. The jump of the mechanical properties from one phase to the other makes the composite highly heterogeneous and calls for the determination of effective properties, that is, properties that are associated with a homogenized “version” of the original composite, and that are obtained through a suitable averaging procedure. The determination of the effective properties results convenient, in particular, when it comes to the multiscale description of inelastic processes, such as remodeling in soft or hard tissues, like bones. To accomplish this task with the aid of AH, we assume that the length scale over which the heterogeneities manifest themselves is several orders of magnitude smaller than the characteristic length scale of the composite as a whole. We identify both a fine‐scale problem and a coarse‐scale problem, each of which characterizes the elasto‐plastic dynamics of the composite at the corresponding scale, and we discuss how they are reciprocally coupled through a transfer of information from one scale to the other. In particular, we highlight how the coarse‐scale plastic distortions influence the fine‐scale problem. Moreover, in the limit of negligible hysteresis effects, we individuate two viscoplastic effective coefficients that encode the information of the two‐scale nature of the composite medium in the upscaled equations. Finally, to deal with a case study tractable semi‐analytically, we consider a multilayered composite material with an initial yield stress that is constant in each phase. Such investigation is meant to contribute to the constitution of a robust framework for devising the effective properties of hierarchical biological media.

EVOLUTION OF THE PRESS BONDING PROPERTIES OF Al/Cu BIMETAL BULK COMPOSITES (EXPERIMENTAL AND NUMERICAL INVESTIGATION)

Nowadays, the application of bimetallic laminates with special capabilities is increasing and has experienced high growth. These properties include high corrosion resistance, mechanical properties, thermal stability, and lightweight. In the midst of the technologies of multilayer composite materials, accumulative press bonding (APB) as a solid-phased method of welding is one of the most common techniques for the production of multilayer composites. One of the most important aims for this choice is the press pressure, which can generate a suitable mechanical connection and strong bonding between produced metal layer components. In this study, bimetal aluminum/copper bulk composites have been fabricated via the APB technique. Then, the effect of pressing parameters such as plastic strain and the number of layers on the stress distribution has been investigated. For samples with eight layers, the shear stress between the layers reached 3.1 MPa which is a suitable condition to generate a successful bonding. The stress applied on the layers has also increased with increasing the thickness reduction ratio. The interlayer shear stresses also increase with decreeing the thickness. With a higher reduction in thickness ratios, the amount of sinking layers was greater along the entire length of the sample, which led to the crushing of copper layers. During the APB process at higher pressing passes, increasing the volume of virgin material in the direction of the press led to increasing the compaction and better bonding of Al and Cu layers to each other.

Enhanced X-ray shielding efficiency and visible light degradation performance of a multilayer composite protective material

To mitigate the adverse effects of high-energy radiation, such as X-rays, on patients during medical procedures, a multifunctional composite nanofibrous membrane has been engineered to shield against low-energy X-rays. This study involves integrating processed oil-tea camellia shells (OCS) powder into molten polylactic acid (PLA) for modification. Concurrently, metallic Bi is introduced to enhance Bi2WO6, which is subsequently combined with modified PLA and electrospun into nanofibrous membranes for photocatalytic antimicrobial and organic pollutant degradation. Additionally, sodium hyaluronate (NaHA) and a silver nanoparticle solution are electrospun with PLA to form a skin-friendly protective layer. Following this, a chitosan (CS) solution containing WO3 and B4C is used as a coating on the multilayered membranes. The membranes are then freeze-dried to create sandwich-structured multilayer composite protective material. This method addresses challenges associated with polylactic acid (PLA) in electrospinning and alleviates limitations such as low light absorption and slow charge transfer in Bi2WO6. Compared to similar materials, this composite material is lightweight, flexible for cutting, and exhibits strong X-ray shielding capabilities. The composite nanofibrous membrane demonstrates a shielding efficiency of 97.75 ± 2.05 % at low X-ray energy (46 kVp). Moreover, under visible light, the membrane generates reactive oxygen species, resulting in the efficient removal of 98.03 % of methylene blue (MB), 96.35 % of rhodamine B (Rh.B), and 91.51 % of methyl orange (MO) within 180 minutes. Furthermore, it displays bactericidal activity against E. coli and S. aureus under both dark and light conditions. In natural settings, the composite membrane undergoes gradual degradation in soil, completely decomposing within 28 days due to the influence of rainfall and microorganisms. Consequently, this composite membrane holds significant promise for specialized medical protective applications.

Multi-scale structural design of multilayer magnetic composite materials for ultra-wideband microwave absorption

Broadband microwave absorbing (MA) materials have important applications in reducing electromagnetic radiation pollution and realizing low scattering characteristics. However, current MA materials with single-layer structure generally cannot meet this requirement due to the difficulty in achieving good impedance matching. Here, we design a multilayer-structured MA material, which consists of a wave transmitting layer, a carbon-magnetic material composite absorbing layer, a strong magnetic absorbing layer and a reflector layer. Hollow Co/CoFe@C composite particles prepared using CoCoPBA as templates are used as fillers to design carbon-magnetic material composite absorbing layer. The Co/CoFe bimagnetic phases enhance permeability while the hollow structure optimizes permittivity, which endows this absorbing layer with strong microwave absorption ability with a reflection loss of −47.18 dB. The introduction of a strong magnetic absorbing layer that combines FeSiAl with high permeability and SmFeB with high coercivity further significantly improves the overall impedance matching of the material. Benefitting from the multi-scale structural design, the obtained multilayer MA material achieves strong microwave absorption in both low and high frequency ranges, and the effective absorption bandwidth reaches 12.85 GHz, far superior to the traditional single-layer MA material.

Detection of Debonding Defects in Carbon Fiber-Reinforced Polymer (CFRP)-Rubber Bonded Structures Based on Active Lamb Wave Energy Analysis.

Carbon fiber-reinforced polymers (CFRPs) are widely used in the fabrication of solid rocket motor casings due to their exceptional performance. However, the bonding interface between CFRP and viscoelastic materials (rubber) is prone to debonding damage during service and storage under complex environmental conditions, which poses a significant threat to the structural integrity and reliability of the engine. Existing nondestructive testing (NDT) methods, such as X-ray imaging, infrared thermography, and ultrasonic testing, although somewhat effective, exhibit significant limitations in detecting interfacial defects in deep or multilayered composite materials, particularly under the challenging conditions of service and storage. This study proposes an innovative method based on active Lamb wave energy analysis and introduces the Damage Evolution Factor (DEF), specifically designed to detect and evaluate interfacial debonding defects in CFRP-rubber bonded structures within solid rocket motors during service and storage. Through numerical simulations and experimental validation, we selected the A0 mode Lamb wave, which is more sensitive to interfacial damage, as the incident wave and excited it on the surface of the structure. Displacement time-history response signals at observation points under different damage models were extracted and analyzed, and DEF values were calculated. The results show that DEF values increase with the size of the interfacial debonding damage. Similar trends were observed in experimental studies, further validating the effectiveness of this method and demonstrating that DEF can be used for the quantitative evaluation of interfacial debonding defects in CFRP-rubber bilayer bonded structures.

Study of Structure Formation in Multilayer Composite Material AA1070-AlMg6-AA1070-Titanium (VT1-0)-08Cr18Ni10Ti Steel after Explosive Welding and Heat Treatment

Multilayer composite materials, consisting of layers of aluminum alloy and steel, are used in the manufacturing of large engineering structures, including in the shipbuilding and railcar industries. Due to the different properties of aluminum alloys and steels, it is difficult to achieve high-strength joints by conventional welding. Therefore, these joints are produced by explosive welding. In the present work, the structure of a multilayer material, AA1070-AlMg6-AA1070 (aluminum alloys)-VT1-0-08Cr18Ni10Ti (steel), was investigated after explosive welding and heat treatments were performed under different conditions. The microstructure of the AlMg6 layer at the AlMg6-AA1070 interface consists of shaped anisotropic grains extending along the weld interface. The AA1070 layer is enriched with magnesium due to its diffusive influx from AlMg6. In the AlMg6 and VT1-0 layers, adiabatic shear bands are found that start at the weld interface and propagate deep into the material. The optimal temperature for the heat treatment is 450–500 °C, as internal stresses are reduced at this temperature and the grain structure of the AlMg6 layer is not coarse. Tear strength testing revealed that the tear strength of the composite material after explosive welding was 130 ± 10 MPa, which exceeded the strength of the AA1070 alloy.

Ultrasonic signal classification for composite materials via deep convolutional neural networks

ABSTRACT Ultrasonic testing (UT) is the most commonly used non-destructive testing method in the aerospace field. However, for the detection of delamination defect in multi-layer composite adhesive materials with metal and non-metal bonding, traditional energy statistics methods are limited and cannot achieve high-precision automatic signal classification. This article proposes a signal classification model based on hybrid neural networks. By studying the classification accuracy of convolutional neural networks (CNN) and long short-term memory networks (LSTM) for different types of signals, a relatively balanced classification is achieved, which effectively improves the classification accuracy. By integrating attention mechanisms, the ability of the detection model to identify key features is further enhanced. Experimental results demonstrate that the proposed model achieves an accuracy of 98.57%. Bayesian Optimisation (BO) can effectively and automatically select the optimal hyperparameters, and achieve global optimisation. In the experiment, the accuracy increased by 0.73% compared to the benchmark value. Comparative experiments show that the signal classification model established in this paper has good performance.

Multi-layered medium ultrasonic phased array sparse TFM imaging based on self-adaptive differential evolution algorithm

Abstract Multilayer Composite material structures have been widely used in modern engineering fields. However, defects within these materials can adversely affect mechanical properties. Ultrasonic phased array total focusing method (TFM) imaging has advantages of high precision and dynamic focusing over the entire range, achieving significant progress in homogeneous medium detection. However, heavy computational burdens of multilayer structures lead to inefficient imaging. To address this issue, a sparse-TFM imaging algorithm using ultrasonic phased arrays suitable for multilayer media is proposed in this paper. This method constructs a fitness function with constraints such as main lobe width and sidelobe peak. Its objective is to obtain the distribution of sparse array element positions using an self-adaptive differential evolution algorithm. Subsequently, the delay time of each array element in multilayer media sparse TFM is calculated using the root mean square (RMS) principle and combined with amplitude weighting, the method corrects the imaging results. Compared with the Ray-based full-matrix capture and TFM method (Ray-based FMC/TFM), the RMS-based full-matrix capture and TFM (RMS-based FMC/TFM), and the phase shift method, the experimental and simulation results demonstrate that the proposed method significantly reduces the imaging data volume, improves computational efficiency, and maintains quantitative errors within 0.2 mm.

Experimental and numerical investigation of the solid cold-welding properties of the APB process of Al/Cu bulk composites

AbstractNowadays, the use of bimetallic laminates with special capabilities is increasing and has experienced high growth. These properties include high mechanical properties, corrosion resistance, lightweight, and thermal stability. Among the technologies of multilayer composite materials, Accumulative Press Bonding (APB) as a solid-phased method of welding is one of the most common techniques for the production of multilayer composites. One of the most important aims for this choice is the press pressure, which can create a strong and suitable mechanical connection between produced metal layer components. In this study, the APB method has been used to produce bimetal aluminum/copper bulk composites as its novelty for the first time. After that, the effect of pressing parameters such as strain and number of layers on the stress distribution has been investigated. The shear stress among the layers reached 4 MPa for the samples with eight layers which is a good condition to generate a successful bonding. With increasing the thickness reduction ratio, the stress applied to the layers has also increased. As the thickness decreases, the interlayer shear stresses also increase which leads to a better bonding between layers. With increasing the thickness reduction ratio, the amount of layers sinking in each other was greater than before, which led to the crushing of copper layers along the entire length of the sample. During the process, as the number of passes increased, the volume of virgin material in the direction of the press rose, which led to increased compaction and better adhesion of Al and Cu layers to each other. The bonding strength enhances from 47 to 95 N for samples manufactured with one and four cycles of APB due to the increment of virgin metal normal to the pressing direction showing a 102% enhancement.

Polydimethylsiloxane enabled triple-action water-resistant coating with desirable relaxation rate in clear aligner

Clear aligners undergo rapid stress relaxation in warm, moist oral environments, compromising therapeutic effectiveness and longevity of treatment. To develop an innovative multilayer composite material with improved stability and reduced stress release, we have engineered an innovative coating characterized by the surface aggregation of polydimethylsiloxane (PDMS), which imparts a pronounced hydrophobic effect. In addition, the chemically and physically cross-linked structure of the coating reduces the free volume created by molecular chain rearrangement owing to the presence of water molecules, thereby minimizing water penetration into the coating. Concurrently, the coating’s internal structure is enriched with numerous polar functional groups to capture water molecules that penetrate into the inside of the coating. Through combination of these mechanisms, water molecules are effectively sequestered, thereby impeding their penetration into the polyethylene terephthalate glycol (PETG) substrate. The impact of the polydimethylsiloxane content on the triple-action water-resistance mechanisms was thoroughly examined using attenuated total reflection (ATR)-Fourier transform infrared (FTIR), water absorption rate, water swelling rate, and X-ray photoelectron spectroscopy. The low surface energy cross-linked polyurethane coating is applied to the polyethylene terephthalate glycol (PETG) substrate to create a novel composite material with specific mechanical properties and reduced stress relaxation. The composite material remains stable in simulated oral environment with linear swelling rate of 0.58 % upon water absorption. Additionally, the stress release rate of the composite material within 336 h is notably lower (23.64 %) than that of PETG (62.29 %).

Assessment of the Possibilities of Ultrasound Tomographic Imaging of Multi-Layer Composite Materials

Assessment of the Possibilities of Ultrasound Tomographic Imaging of Multi-Layer Composite Materials

Characteristic investigation of carbon/ceramic-based functionally graded multilayered composite materials

Characteristic investigation of carbon/ceramic-based functionally graded multilayered composite materials

Enhanced broadband sound absorption of multi-layer composite material based on three-dimensional warp-knitted spacer fabric

Compared with other sound-absorbing materials, spacer fabric with a “sandwich” structure has many advantages, such as light weight, an environmentally friendly production process, recyclability, versatility, low production cost and high efficiency, and strong designability of the organizational structure. However, as a porous sound-absorbing material, the effective sound-absorbing frequency band of the spacer fabric is concentrated at high frequencies, so the sound-absorbing performance needs to be improved. This paper establishes a Johnson–Champoux–Allard theoretical model by using a genetic algorithm to characterize the sound absorption performance of the three-dimensional (3D) warp-knitted spacer fabric. The theoretical model is validated through finite element analysis and experimental methods. Based on this model, two composite materials are designed to improve the sound absorption performance: (1) multi-layer spacer fabric composite material and (2) multi-layer spacer fabric-aluminum foil composite material. Numerical simulation and experimental results show that the sound absorption performance is significantly improved by widening the effective frequency band and increasing the sound absorption coefficient. The contribution of this paper is twofold. Firstly, the theoretical acoustic model of 3D warp-knitted spacer fabric is established. Secondly, the superior sound absorption performance is achieved by proposing multi-layer and multi-material composite material. The spacer fabric-based composite material has broad application prospects in the field of noise reduction and sound insulation. The paper provides a theoretical basis and more strategies for the acoustic and multifunctional design of spacer fabric in the future.

Cu/Mo/NGs composites: Multilayer interconnected spatial net structure enhanced the mechanical properties

This study addresses the urgent problem of developing high-performance metal-based conductor materials capable of adapting to complex working environments. A novel method, called Accumulative Hot Pressing Roll Bonding (AHRB), is proposed for fabricating Cu/Mo/NGs multilayer composite materials. Through repetitive cold rolling and hot-pressing operations, nanoscale metal-based layered materials with thicknesses in the range of hundreds of nanometers are successfully obtained. This material features a multilayered interconnected net structure with Mo2C as the core and CuMo alloy as the framework. The layers are dislocated and connected to each other. The mechanical properties of the materials are significantly improved due to heterogeneous strengthening and grain refinement. The material achieves a tensile strength of 854 MPa, while the conductivity remains stable between 55% ∼ 60% IACS. The reaction between NGs and Mo leads to the formation of an Mo2C interface, while the hot-pressing operation promotes the formation of a CuMo diffusion interface. These two interfaces enhance the interlayer forces of the composites, thereby improving the material's integrity. The investigation of Cu/Mo/NGs multilayer composite materials presents a novel approach for alloying refractory metals Mo and Cu, offering promising prospects for future engineering applications.

Hamiltonian/Stroh formalism for reversible poroelasticity (and thermoelasticity)

Stroh’s sextic formalism represents the equilibrium equations of anisotropic elasticity in a particularly attractive form, that is most suitable for studying interface-dominated multilayered solids, composite materials and time-harmonic problems. Taking advantage of the fact that the Stroh formalism really amounts to the canonical form of the equations in the Hamiltonian sense, the case of Biot’s reversible (i.e. no fluid dissipation) poroelasticity is here addressed, in the absence of a fluid pressure gradient. This framework is the same as thermoelasticity of perfect conductors. Two Hamiltonian formulations are developed: the first describes both the solid and the fluid phases and it exhibits, besides energy conservation, momentum conservation, as a result of pressure uniformity (perfectly drained conditions). The second is restricted to the solid skeleton and perfectly parallels anisotropic elasticity, where the Stroh matrices refer to the effective stress tensor. The case of weak fluid–solid coupling is also considered and it produces a perturbation from anisotropic elasticity with the same structure as incompressibility, although in an “opposing” manner. This comparison suggests that the incompressibility limit introduced by Biot should be revised. The energy conservation integral and the edge impedance matrix are also illustrated.

Compositional analysis of multilayered plastic constituents and constituent mixtures using benchtop 1H NMR spectroscopy.

Multilayered plastics are widely used in food packaging and other commercial applications due to their tailored functional properties. By layering different polymers, the multilayered composite material can have enhanced mechanical, thermal, and barrier properties compared to a single plastic. However, there is a significant need to recycle these multilayer plastics, but their complex structure offers significant challenges to their successful recycling. Ultimately, the use and recycling of these complex materials requires the ability to characterize the composition and purity as a means of quality control for both production and recycling processes. New advances and availability of low-field benchtop 1H NMR spectrometers have led to increasing interest in its use for characterization of multicomponent polymers and polymer mixtures. Here, we demonstrate the capability of low-field benchtop 1H NMR spectroscopy for characterization of three common polymers associated with multilayered packaging systems (low-density polyethylene [LDPE], ethylene vinyl alcohol [EVOH], and Nylon) as well as their blends. Calibration curves are obtained for determining the unknown composition of EVOH and Nylon in multilayered packaging plastics using both the EVOH hydroxyl peak area and an observed peak shift, both yielding results in good agreement with the prepared sample compositions. Additionally, comparison of results extracted for the same samples characterized by our benchtop spectrometer and a 500-MHz spectrometer found results to be consistent and within 2wt% on average. Overall, low-field benchtop 1H NMR spectroscopy is a reliable and accessible tool for characterization of these polymer systems.

Characterization of the layer, direction and time-dependent mechanical behaviour of the human oesophagus and the effects of formalin preservation.

The mechanical characterization of the oesophagus is essential for applications such as medical device design, surgical simulations and tissue engineering, as well as for investigating the organ's pathophysiology. However, the material response of the oesophagus has not been established ex vivo in regard to the more complex aspects of its mechanical behaviour using fresh, human tissue: as of yet, in the literature, only the hyperelastic response of the intact wall has been studied. Therefore, in this study, the layer-dependent, anisotropic, visco-hyperelastic behaviour of the human oesophagus was investigated through various mechanical tests. For this, cyclic tests, with increasing stretch levels, were conducted on the layers of the human oesophagus in the longitudinal and circumferential directions and at two different strain rates. Additionally, stress-relaxation tests on the oesophageal layers were carried out in both directions. Overall, the results show discrete properties in each layer and direction, highlighting the importance of treating the oesophagus as a multi-layered composite material with direction-dependent behaviour. Previously, the authors conducted layer-dependent cyclic experimentation on formalin-embalmed human oesophagi. A comparison between the fresh and embalmed tissue response was carried out and revealed surprising similarities in terms of anisotropy, strain-rate dependency, stress-softening and hysteresis, with the main difference between the two preservation states being the magnitude of these properties. As formalin fixation is known to notably affect the formation of cross-links between the collagen of biological materials, the differences may reveal the influence of cross-links on the mechanical behaviour of soft tissues.

Multi-layer material combination for manufaturing stab-proof life jackets

In modern times, individuals working in aquatic environments such as fishermen, fishery inspectors, customs officers, and others require a device that offers protection against punctures and drowning. As a result, a multi-layer composite material consisting of para-aramid 200de woven fabric, Dyneema® SB31 coated plates, and foam was evaluated for the creation of a life jacket that combines stab-proof capabilities with anti-drowning features (stab-proof life jacket). The objective of the research was to determine the optimal number of layers and arrangement of the multi-layer composite materials that would meet the NIJ standard level 1 protection against punctures. The study findings demonstrated that utilizing both types of woven fabric and coated plates yielded the most desirable puncture resistance, considering the thickness and weight of the composite materials. The effectiveness of using only woven fabric ranked second, while relying solely on coated plates produced less satisfactory results. Placing the puncture-resistant material above the foam layer proved to be more effective than placing it beneath the foam layer in all three scenarios. These findings lay the groundwork for the design and development of stab-proof life jackets tailored to the needs of professionals in specific aquatic industries. Keywords: Puncture-resistant life vest, puncture-resistant, multi-layer composite, aramid, UHMWPE