Stringer Foot Research Articles

Experimental study of post-buckled single-stringer composite specimens under fatigue loads with different load levels and load ratios

This study aims at better understanding the damage tolerance of stiffened composite panels subjected to fatigue loads in the post-buckling regime. Ten single-stringer hat-stiffened specimens with an initial delamination between the skin and the stringer foot were manufactured, and then tested under quasi-static and fatigue loads in post-buckling conditions, with different load levels and load ratios. The tests were monitored with digital image correlation and an ultrasonic system, providing data on the displacements, strains, and extension of the delamination length. The quasi-static results showed that the delamination onset, when the initial delamination begins propagating, occurred at loads over twice the buckling load, while collapse occurred for values almost 20% higher than the delamination onset. During fatigue testing at load levels below the delamination onset, the specimens were able to sustain 150000 cycles and then, when tested statically after fatigue, the average load at collapse was reduced by less than 10% with respect to the quasi-static benchmark. When the maximum load during fatigue was increased to 5% over the delamination onset load, the specimens still withstood between 8000 and 16500 cycles before collapse, depending on the load ratio. It was also seen that for tests at the same load level, the specimens with high load ratio had a slower damage propagation.

Studies on the validity of the reduced bending stiffness method for eccentrically stacked laminates

AbstractThe reduced bending stiffness method is used in the framework of computational models for stringer stiffened panels. Here, the stringer foot is often stacked on top of the skin of the panel and leads to a stacked laminate with extensional bending stiffness coupling. The validity of the reduced bending stiffness method for the mentioned laminate type is investigated and assessed, as only unsymmetrical laminates without eccentricity have been considered in existing literature. In exemplary studies, the influence of the coupling effects is shown, which allows drawing conclusions on the error that is introduced in, e. g. closed‐form analytical approximate solutions for the buckling of stringer stiffened panels.

Nondestructive testing of composite T-Joints by TNDT and other methods

Detecting delaminations in the stringer foot areas of “T -joints” made of carbon fiber reinforced polymer (CFRP) composite is a challenging task for standard nondestructive testing (NDT) techniques. In this study, several methods of thermal NDT (TNDT) have been used to inspect eight CFRP T-Joint specimens with polyolefin film implants which represent subsurface defects. Both one- and two-sided TNDT procedures were used. Thermal modeling was performed to predict the results of TNDT tests.The potential of laser vibrometry was also investigated, and UT (ultrasonic) phased array C-scan was used for verification of test results. Two-sided TNDT was able to detect simulated defects throughout the entire thickness of the test material. Thermal images of defect-free T-Joints clearly establish baseline thermal patterns of “good” stringers, and subsurface defects may create an identifiable distortion to the baseline patterns. The ability of one-sided TNDT to detect defects depends strongly on their depth and size.Ultrasonic (“sonic”) infrared thermography was not successful in detecting the implants, due to the formation of standing waves and complicated thermal patterns observed on the stringers. And laser vibrometry has proven to be ineffective in the detection of the implants. Phased array ultrasonic C-scan testing has also been successful in detecting polymeric implants located outside the ultrasonic “dead zone” but the best sensitivity of UT is achieved in immersion techniques, with water between the ultrasonic transducer and a part to be tested. In all cases, the use of advanced data processing techniques has been indispensable to provide reasonable test results.

Strain-based health indicators for the structural health monitoring of stiffened composite panels

A common defect of composite-stiffened structures is the disbond at the interface between the two constituents (skin/stringer), as a result of inefficient manufacturing process or foreign object impacts in service. Generally, discontinuities within the volume of an elastic solid medium, subjected to mechanical load, cause anomalies on the strain field in the near vicinity of the discontinuity. Utilizing this observation, this work investigates the effect of artificially induced disbonds in the skin/stiffener interface of an aeronautical-grade generic element. A structural health monitoring methodology is developed, leveraging on numerically simulated strains along the stringer foot which aims to assess the health state of the panel as the size of the disbonds increases. The study is implemented using a parametric finite element model generating various disbond scenarios. Longitudinal strain values are acquired at the exact points where in reality actual fiber Bragg grating sensors will be located. Two types of commonly utilized strain-based health indicators are evaluated, and their drawbacks are revealed and discussed. A new health indicator is proposed that proves its capability to monitor growing disbonds while being both load- and baseline-independent.

On the use of selective stitching in stiffened composite panels to prevent skin-stringer debonding

Abstract Composite laminates are generally characterized by poor mechanical properties along the thickness direction, therefore they are highly susceptible to delaminations. A potential increase in structural efficiency may be obtained by using 3D reinforcements technologies. In this paper, an experimental/numerical study is presented focusing on the effects of a single reinforcement seam of stitches along the edge of a stringer foot, in a stiffened composite panel. Three-point bending tests have been performed on a skin-stringer configuration by considering variations of the skin thickness, the stitching technique, the pitch and the yarn diameter. Then, a Finite Element Model has been developed capable to simulate the mechanical behaviour of stiffened composite panels with selective stitching and to assist the design of more complex geometrical configurations by estimating the damage behaviour, as well as the onset and the propagation of delamination taking into account the effect of the selective stitching. The numerical results, in terms of load vs applied displacements, have been found in good agreement with the experimental data proving the effectiveness of the introduced numerical model. The numerical results have confirmed the potential beneficial effects of stitching in terms of delay of the crack initiation and growth, of smoother delamination profile, of increase in the stiffness of the structure with a reduction of the delamination area.

Influence of Stitching on Skin Stringer Debonding in Stiffened Composite Panels

A potential increase of the out-of plane structural efficiency of laminated composites may be obtained by using 3D reinforcements technologies. In this paper, a numerical study is presented focusing on the effects of a single reinforcement seam of stitches (selective stitching) along the edge of a stringer foot, in a stiffened composite panel. A Finite Element Model has been developed in order to simulate the mechanical behaviour of the stiffened composite panels with selective stitching. The numerical model has been preliminary validated by comparison with experimental data on three-point bending tests on a skin-stringer configuration. The numerical results, in terms of load vs applied displacements, have been found in good agreement with the experimental data proving the effectiveness of the introduced numerical model. The numerical results have confirmed the potential beneficial effects of stitching in terms of delay of the crack initiation and growth.

Experimental Analysis of Debonding of Skin/Stringer Interfaces under Cyclic Loading and Ageing

An experimental investigation aiming to characterize the fatigue failure mechanisms and effect of ageing of skin/stringer interfaces is presented. A simplified specimen known as a “stringer foot specimen” is used. The effects of local design, of the angle of plies located at the interface and of moisture ageing are studied. Among other results, it is shown that a quasi-infinite fatigue life can be obtained under 33% of the static damage initiation load for all designs. In the framework of multi-level analysis, this study is a preliminary investigation to study cyclic buckling of composite stiffened structures.

A Study on Skin Delaminations Growth in Stiffened Composite Panels by a Novel Numerical Approach

In this paper, a study on skin delamination growth in stiffened composite panels made of carbon fibres reinforced polymers and subjected to compressive load is presented. A robust (mesh and time step independent) numerical finite elements procedure, based on the Virtual Crack Closure Technique (VCCT) and on the fail release approach, is used here to investigate the influence of skin delamination size and position on the damage tolerance of stiffened composite panels. Four stiffened panels configurations with skin delaminations differently sized and positioned are introduced. Bay delaminations and delaminations under the stringer foot are considered. The novel numerical procedure has been used to simulate the delamination growth for all the investigated panel configurations and to evaluate the influence of the delaminations’ geometrical parameters on the growth development. As a confirmation of the applicability and effectiveness of the adopted numerical tool, the numerical results, obtained for all the analysed configurations, in terms of grown delaminated area, displacements and strains measured in various panel locations, have been compared with experimental data available in literature.

Panel stiffener debonding analysis using a shell/3D modeling technique

A shear loaded, stringer reinforced composite panel is analyzed to evaluate the fidelity of computational fracture mechanics analyses of complex structures. Shear loading causes the panel to buckle. The resulting out-of-plane deformations initiate skin/stringer separation at the location of an embedded defect. The panel and surrounding load fixture were modeled with shell elements. A small section of the stringer foot, web and noodle as well as the panel skin near the delamination front were modeled with a local 3D solid model. Across the width of the stringer foot, the mixed-mode strain energy release rates were calculated using the virtual crack closure technique. A failure index was calculated by correlating the results with a mixed-mode failure criterion of the graphite/epoxy material. The objective was to study the effect of the fidelity of the local 3D finite element model on the computed mixed-mode strain energy release rates and the failure index.

Fracture mechanisms and failure processes at stiffener run-outs in polymer matrix composite stiffened elements

Abstract This paper describes the fractographic analyses of three stringer run-out designs which had been loaded to failure in tension. The main aims of the investigation were to deduce the failure processes in the elements, and to characterise the effect of local geometry of the stringer run-out on the failure process. The analysis showed that the critical failure mechanism in the elements was the development of +45° ply splitting at the skin surface, initially under mode I dominated intralaminar fracture. However, as these splits grew beneath the stringer foot, the mode II component increased. This led to mixed-mode delamination growth, extending parallel to the +45° ply, at the skin/adhesive interface. Subsequently, the delamination migrated through the skin via ply splits, ultimately reaching the interface between the second and third (−45°/0°) plies, in which it remained until catastrophic failure. Extending and tapering the stringer foot led to shifting of the site of the +45° ply splitting; this was attributed to in-plane tensile stresses in the skin being inhibited in the modified designs. The reduced out-of-plane support on the stiffener foot in the modified designs led to an increase in the mode I component at the delamination from the stringer tip. It also led to an increase in the degree of multi-plane delamination growth. Based on the fractographic observations, recommendations for modelling the elements were suggested.

The effect of defects on the performance of post-buckled CFRP stringer-stiffened panels

Abstract This paper describes the testing and failure analysis of wing relevant skin-stringer panels containing defects. Five panels containing two types of defect; embedded defects (representative of inclusions introduced during fabrication) and impact damage (representative of the damage from dropped tools), were tested under monotonic compression loading. The defects were located at two sites; within the bay between stringers and beneath the stringer foot. All the panels buckled at approximately the same applied strain (−2780 μe) and buckling mode; three-half waves in each bay. The undamaged panel failed at an applied strain of −6261 μe and the failure was attributed to skin/stiffener debonding. The presence of defects led to a reduction in the strength ranging from 7% (bay impact) to 29% (foot impact). Fractographic evidence showed that the effect of the defects on the panel strength was related to how they influenced skin/stiffener debonding. For foot defects, impact was worse than an embedded defect, whilst for bay damage this effect was reversed. The rate and extent of damage growth differed with defect type; the results indicate that modelling impact damage as a single plane embedded defect is of limited validity and may be non-conservative.

Characterisation of impact damage in skin-stringer composite structures

In studies aimed at understanding the impact performance of structures made from carbon-fibre composites, effects of structural geometry, material type and impact location have been investigated in skin-stringer panels representative of aircraft structure. Effects were investigated for low-velocity impacts to the skin in the bay between stringers, over a stringer foot, and over a stringer centreline. Detailed studies of the impact damage at these locations were investigated using ultrasonic techniques, and optical and electron microscopy. The damage characteristics were explained in terms of the proportion of energy absorbed through damage, such as delamination, and elastic effects, such as structural response of the panel.