Unidirectional Fiber Research Articles

Experimental and numerical investigation of the modal parameters for thin laminated composite plates

In the present work, glass fiber-reinforced (GFR) composite specimens were fabricated using the vacuum-bag molding process. The properties related to the vibrational response of the fabricated composite plates, such as natural frequency, modal density, and damping loss factor (DLF), were investigated through both experimental and numerical approaches. The effects of different parameters, including boundary conditions (BCs), fiber orientations, laminate layer numbers, and aspect ratios, were comprehensively studied. It was found that the experimental and numerical results were in close agreement. For each case, finite element analysis was performed to determine the natural frequencies and mode shapes. Regarding the various BCs, the DLF was observed to be highest (0.47) for fully clamped BC and lowest (0.12) for free-free BC, whereas the modal density was highest (0.068) for cantilever BC and lowest (0.037) for fully clamped BC. In terms of different lamination schemes, the DLF was highest (0.42) for a plate with quasi-isotropic fibers and lowest (0.25) for a plate with unidirectional fibers, while the modal density was highest (0.068) for quasi-isotropic fibers and lowest (0.047) for unidirectional fibers. Regarding the plates with different laminate layers, the highest DLF (0.47) was observed for a plate with 16 layers, while the lowest DLF (0.33) was found in a plate with 8 layers. Conversely, the highest modal density (0.067) was observed for a plate with 8 layers, and the lowest (0.057) was noted for a plate with 16 layers. Lastly, considering aspect ratios, the highest DLF (0.48) was observed for an aspect ratio of 0.5, and the lowest (0.26) for an aspect ratio of 1.5. The highest modal density (0.09) was also observed for an aspect ratio of 0.5, while the lowest modal density (0.045) was for an aspect ratio of 1.5.

A multiscale modeling for progressive failure behavior of unidirectional fiber-reinforced composites based on phase-field method

The effective macroscopic properties of composites are determined by the intricate interactions among the individual components within their microstructure. Preserving these microscopic details during the failure simulation of macrostructures presents significant challenges. This work proposes a multiscale modeling framework to numerically predict the macroscopic fracture properties of unidirectional fiber-reinforced composites based on micromechanical analysis. In this study, 2D representative volume elements (RVEs) combined with the phase-field method are utilized to simulate fiber-reinforced composites under transverse loadings. A series of representative loading conditions are employed to investigate cracking patterns and to construct failure strength envelopes of the composites subjected to different multiaxial proportional loadings. By extracting the softening curve from the uniaxial tensile simulation of the RVE and fitting it with a tenth-order polynomial, the homogenized cohesive law, combined with the phase-field method, is applied to the damage analysis of macroscopic heterogeneous materials. The homogenized model of unidirectional fiber reinforced composites is numerically validated through simulations of a 2D flat plate. The simulation results demonstrate the excellent potential of the proposed multiscale modeling framework to accurately and efficiently predict the progressive failure and fracture behavior of fiber-reinforced composites in engineering applications.

Progressive failure analysis of woven and non‐woven CFRP composite/steel bolted joints

AbstractDue to recent advancements in textile fabrication, woven fabric reinforcements are used in composite structures as an alternative to traditional unidirectional fiber reinforcing layups. In this paper, experimental work was performed to study the behavior of multiple bolt‐lapped joints under uniaxial tension. Different bolt numbers, composite layups, and fabric configurations were studied. Single‐ and double‐lap configurations were used to investigate the effect of secondary stresses. It was found that the P‐δ curves of lapped joints exhibit four primary stages: a linear elastic stage, followed by a nonlinear hardening stage, then linear hardening leading up to the peak, and finally a softening stage. For double‐lapped non‐woven joints, the curves encompass only the first three stages; however, for woven composites, the last stage is very small. In addition, among the laminates, the non‐woven laminate sustains the highest normalized failure load, except in the staggered case, where the quasi‐isotropic woven laminate exhibits higher strength. Conversely, the bidirectional woven laminate demonstrates the lowest loads and the highest deformation.Highlights A study compared bolted joint performance of woven and uni‐based composites. Lapped joints with different bolt arrangements were experimentally studied. P‐δ curves showed elastic, nonlinear, linear hardening, and softening stages. Woven laminates showed higher displacements compared to non‐woven laminates. Secondary bending induced additional stress with less impact on woven samples. Bearing failure predominated, with variations in extent of bearing damage.

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.

The effect of nanocellulose and silica filler on the mechanical properties of natural fiber polymer matrix composites

Natural fiber-reinforced polymer matrix composites recently got great attention in biomedical applications due to their inherent characteristics such as biocompatibility, lightweight, and biodegradability. However, natural fiber composites suffer from poor mechanical properties and weak interfacial adhesion. It is well documented that the addition of nanofiller has improved the mechanical properties of different synthetic fibers such as glass and carbon composites. The main objective of this paper is to study nanofillers' effect on the mechanical properties of unidirectional false banana fibers reinforced polymer composites. The filler materials, crystalline nanocellulose fibrils, and crystalline nanosilica particles were extracted from sugarcane bagasse and its byproducts. The composite samples were fabricated by adding the nanofillers in unidirectional natural fibers arranged in four fiber orientations (0°, 0o/90o ±45o, and quasi-isotropic), and their tensile, flexural, compression strength, thermal stability, and void content were measured following ASTM standards. The results revealed that adding nanofillers increased the tensile, flexural, and compressive strengths by 16 % (98.83 Mpa), 11 % (161.60 Mpa), and 23 % (114.62 Mpa), respectively. Similarly, at 0° orientation, the addition of nanoparticles enhances the tensile, bending, and compressive modulus by 30 % (15.43 Gpa), 12 % (13.52 Gpa), and 60 % (42.6 Gpa), respectively. On the other hand, the void content was reduced with the addition of nanofillers. The results also revealed that composites with crystalline nanosilica particle fillers had superior thermal stability compared to crystalline nanocellulose fibril fillers. The overall results of this research give the confidence that nano particle-filled natural fiber composites can be used for bio-based engineering applications, such as prosthetic sockets.

Investigation of buckling instabilities in fiber-reinforced DEAs

Artificial muscles, designed to replicate the movements of natural biological muscles, hold significant promise in the fields of robotics and prosthetics. Recent advancements have led to the development of fiber-reinforced actuators, drawing inspiration from biological tissues. Dielectric elastomer actuators (DEAs) are a type of electroactive artificial muscle. It is possible to enhance the uni-axial deformation of DEAs by constraining and applying pre-stretch on the actuator membrane. This can be achieved through uni-directional fibers bonded to the DEA that lead to transversely isotropic properties. However, combining membrane pre-stretch and fiber reinforcement may lead to instabilities such as fiber buckling due to the compressive load of the pre-stretched membrane or due to wrinkling during actuation. Understanding these instabilities is crucial as they can significantly impact the performance. A novel model taking into consideration these instabilities is established and experimentally validated. By calculating the force in the fiber direction, the buckling profile such as the wavelength and amplitude can be predicted. The validation of the model presented along with an extensive experimental investigation allow for a comprehensive analysis to explore the impact of fiber buckling on the performance and the force of uni-axial DEAs.

Material Homogenization of Human Femur Bone Material Using a New Weighted Approach

Abstract The design of efficient and safe biocompatible artificial implants for bone replacement and reconstructions requires a thorough understanding of natural bone material. A new homogenization approach is therefore used to predict effective material properties of the human femur bone. The bone structure is idealized as a functionally graded composite made of different quantities of a collagen protein matrix reinforced by hydroxyapatite mineral acting as the filler. Two distinct composite models were investigated, one where the mineral reinforcements were assumed to be randomly dispersed inclusions in a matrix of collagen, and a second model wherein the minerals were assumed to be unidirectional fibers. Predicted results for longitudinal and transverse elastic modulus from the models compare very well with range of values from published experimental data. It is also compared to those predicted using classical homogenization models. These material properties are then used to obtain the structural response of a bone plate section under transverse load.

MECHANICAL BEHAVIOUR OF ISTLE FIBRE COMPOSITE REINFORCED WITH EPOXY AND E-GLASS AT DIFFERENT FIBRE ORIENTATIONS

This paper was aimed to study the mechanical properties of Istle fibre composites. The process of fabrication was done by hand layup technique at three different fibre orientations i.e., unidirectional, bidirectional and 45 degrees inclined, and also its effect on tensile and flexural property that was studied in the Instron Testing Machine. The fibre volume ratio was kept uniform for the entire specimen as 50:50. The treatment of istle fibre was done with sodium hydroxide to increase the fibre matrix bonding. The effect of E-glass reinforcement has also been studied in both bending tests and flexural tests. The maximum tensile and bending modulus recorded were from unidirectional fibre specimen.

Micro-buckling resistant unidirectional glass fiber composites with excellent transverse and longitudinal flexural properties from cross-linking by nano-/micro-aramid fibers

This study aims at obtaining an effective structural design strategy for stronger and more reliable Unidirectional glass fiber (UD-GF) composites by in-situ formed cross-linking from randomly distributed nano-/micro- Aramid pulp (AP) fibers. The flexural strength and stiffness have shown substantial improvements in both the transverse and longitudinal directions due to the AP cross-linking and the “brick-slurry” structure. With AP of 8 g/m2, up to 60–70 % improvement in flexural strengths (both transverse and longitudinal directions) and up to 20–37 % improvement in “effective modulus” have been observed. The noticeable longitudinal improvements have been attributed to the resin reinforcement and interlayer cross-linking provided by ultra-thin AP interlayers, and the resultant improvement in micro-buckling resistance under compression. Since sparsely distributed nano-/micro-AP can be readily incorporated in pultrusion and pre-preg manufacturing processes, this study is not only important for micro-mechanism study, but also provides a plausible improvement in manufacturing.

Experimental investigation and micromechanical analysis of glass fiber reinforced polyamide 6

Achieving process stability in the thermoforming of fiber reinforced polymer materials (FRPs) for aerospace or automotive manufacturing is usually associated with a costly trial-and-error process, where experimental boundary conditions and other influencing factors, such as, for example, material composition, need to be adjusted over time. This is especially true when material phenomena on the microlevel, such as the crystallization kinetics of the polymer matrix or resulting stresses from temperature gradients, are the cause of the process instability. To reduce the experimental effort and reliably predict the material behavior during thermoforming, finite element simulation tools on multiple scales are a useful solution. Hereby, incorporating micromechanical phenomena into the model approaches is crucial for an accurate prediction by further reducing the deviation between simulation and experiment, in particular with regard to the underlying nonlinear material behavior. In this work, unit cell simulations on the microscale of a unidirectional glass fiber reinforced polymer (UD GFRP) are conducted to predict effective thermomechanical properties of a single material ply and ascertain the effect of individual ply constituents on the homogenized material behavior. The polymeric matrix material model used was identified in a prior publication with experimental data at various temperatures for polyamide 6 blends with varying degrees of crystallinities. Various randomization methods are tested to generate the unit cells and replicate the composites’ random fiber distribution, with a focus on process automation. The simulative results are successfully compared to an experimental study on glass fiber reinforced polyamide 6 tested at various temperatures, demonstrating the potential of the approach to reduce both time and cost required for material characterization. Finally, the unit cells are used to generate a database to predict untested load cases that will be used in future work to characterize a homogenized macroscopic material model.

Characterizing nonlinear constitutive behaviors of fiber metal laminates

Abstract This study characterized the nonlinear tensile behavior of fiber metal laminates (FMLs). FMLs comprise layers of thin metallic sheets and fiber-reinforced composite layers, and a constitutive FML model includes the constitutive relationships of the FML’s constituent materials; however, nonlinear behavior is typically only considered for the metal components of an FML. In this study, a nonlinear constitutive relationship for the unidirectional fiber composites was modeled using a one-parameter plastic model. The nonlinear constitutive law for the metal was formulated using the J2 flow rule. These relationships were summed for each layer in accordance with laminated plate theory to obtain a constitutive FML model, which was then used for numerical predictions of nonlinear stress–strain curves. The model was validated by comparing its predictions with experimental results from the literature. Moreover, the effect of the inclusion of nonlinear fiber composite behavior on the model predictions was investigated. Results revealed that the difference between the model predictions and the experimental results was less than 4%. These predictions with nonlinear fiber composite behavior were substantially more accurate than those of the model without this behavior for FMLs with angle-ply fiber composites.

Unidirectional fibre reinforcement of syntactic metal foams

Abstract Metal matrix syntactic foams are porous structures where the porosity is formed by introducing a porous filler material into the metal matrix. They have low density and absorb significant energy during compression but cannot withstand tensile stress. The main goal of this study was to apply unidirectional fibre reinforcement to syntactic metal foams. Therefore, a lightweight double-composite structure that can be utilised against tensile load and has advantageous properties during compression was created. Copper-nickel coated carbon fibre bundles were used as unidirectional long fibre reinforcement, lightweight expanded clay aggregate particles as filler material and Al99.5 aluminium as matrix material. The samples were created with vacuum infiltration and formed into cylindrical tensile specimens. Quasi-static tensile tests were carried out on the specimens and fibre trusses, and quasi-static compression was applied on specimens in the parallel and perpendicular direction to the unidirectional fibre truss.

Effect of the Glass Fiber Orientation on Mechanical Performance of Epoxy based Composites

Composites are one of the most advanced and adaptable engineering materials. The strength of any composite depends upon volume/weight fraction of reinforcement, orientation angle and other factors. The present work focuses on the determination of the mechanical properties of pure epoxy and unidirectional glass fiber reinforced epoxy. Nowadays, glass fibers are being used in several engineering applications like electronics, aviation, automobile, sport industry etc. Glass fibers are having excellent properties like high strength, flexibility, stiffness, and resistance to chemical attack. With an increase in the content of unidirectional glass fiber volume the properties of unidirectional glass Fiber Reinforcement Polymer (GFRP) composite were improved. It may be used in different forms like chopped, woven mat, short fibers and long fibers etc. Each type of glass fiber has unique properties and is used for different applications. The mechanical and thermal properties of various polymer composites reinforced with glass fibers when subjected to mechanical loading have been studied and reported.

Development of sandwich test coupons with continuous protective layers for accurate determination of the tensile failure strain of unidirectional carbon fibre reinforced composites

Recently introduced unidirectional (UD) carbon fibre reinforced epoxy (CF/EP) tensile test coupons with continuous protective layers were developed further by comparing three coupon designs with different layer integration techniques. Consistent experimental data was generated with high sample number and low scatter. Thermal residual strains were considered in case of two coupon designs where the layers were integrated at elevated temperature. A curve-fitting-based strength evaluation method is proposed for the sandwich coupons since this parameter cannot be evaluated directly. The sandwich type coupons yielded statistically significant increase in their average failure strain compared to that of the baseline tabbed coupons. In contrast, the three sandwich coupon types did not show significant differences. Therefore, the sandwich coupon type made by bonding cured UD composite layers together at room temperature is proposed for further application as they allow for full delamination at CF/EP layer fracture and do not require thermal strain correction during the evaluation.

Damage indicators in unidirectional natural fibre composites under fatigue loading

This paper investigates the occurrence of failure under fatigue loading of unidirectional flax fibre composites with different matrices. Various parameters, such as dissipated energy, residual strain, and stiffness, were measured to evaluate fatigue damage and the fatigue life of composites. The results indicate that absolute dissipated energy may not be the most suitable indicator for assessing damage in natural fibre composites when they are subjected to fatigue before reaching failure. The research proposes to rather consider the “loss factor”, defined as the ratio of dissipated energy to total energy stored in each cycle. This indicator appears to provide a more effective means of evaluating fatigue life of the studied composites, especially when compared to the dissipated energy observed during fatigue tests at low stress levels. Fatigue and acoustic emission results indicate that biocomposites with better fibre–matrix adhesion show a delayed damage initiation and propagation, as well as longer fatigue life.

Study of Interlaminar Fracture Toughness and Flexural Properties of Carbon Fibre Composites Reinforced with Polyethersulfone/Graphene Oxide Films

Unidirectional carbon fibre reinforced plastic (CFRP) composites were prepared by inserting polyethersulfone (PES) films or polyethersulfone/graphene oxide (GO) films into the composites and used to improve the interlaminar fracture toughness as well as the flexural properties. The effect of low-temperature cycling (35, 70, 105, and 140 cycles between −55 °C and room temperature (25 °C)) on the flexural properties of the specimens was also investigated, and the damage caused to the reinforcement layer was directly detected by comparing the interlaminar images. The results of the double cantilever beam (DCB) test and the end notched flexure (ENF) test were used to verify the optimisation of the interlaminar fracture toughness and flexural properties of the new composite film (PES/GO film). The results show that the performance of PES/GO film under both DCB test and ENF test is superior to that of PES film. Regarding the effect of low-temperature cycling on the specimens, the flexural properties of the specimens containing PES/GO films were improved. Finally, the matrix interface and failure mechanism of the interlayer reinforcement were investigated by scanning electron microscopy (SEM).

Deep neural network homogenization of multiphysics behavior for periodic piezoelectric composites

We present a physically informed deep neural network homogenization theory for identifying homogenized moduli and local electromechanical fields of periodic piezoelectric composites. The theory employs a multi-network model to represent solutions to stress equilibrium and electrostatic partial differential equations in the inclusion and the matrix phases, leading to a more accurate depiction of field variables. Satisfaction of periodicity conditions for hexagonal and cubic symmetries are efficiently tackled using a series of sinusoidal functions with known periods and adjustable parameters. Additionally, the theory applies fully trainable weights to the collocation points. These trainable weights, trained concurrently with the neural network weights, compel the neural networks to enhance their performance when faced with large local stress/deformation gradients. The predictive capability of the proposed theory is illustrated by comparison with finite-element solutions for composites reinforced with unidirectional fiber, spherical particle, or weakened by an ellipsoidal cavity over a wide range of volume fractions.

Tensile and low-cycle fatigue failure of carbon fiber reinforced aluminium laminates

Fiber metal laminates (FMLs) have emerged as advanced materials for engineering applications due to their high strength-to-weight ratio. This study aims to understand the mechanical response and failure mechanisms of carbon-fiber reinforced aluminium laminates (CARALL) under monotonic and cyclic loading, specifically uniaxial tensile and low-cycle fatigue (LCF) conditions. CARALL, fabricated with alternating (3/2) layers of AA2024-T3 and unidirectional carbon fiber composite, exhibits superior ultimate tensile strength (UTS) compared to AA2024-T3 sheets, with a distinctive three-zone stress-strain curve. The first zone shows elastic strain in both the aluminium alloy and laminate. The second zone features elastic strain in the laminate and plastic strain in the aluminium alloy. In the third zone, surface modifications enhance adhesion, leading to a sudden load drop due to fiber fracture or delamination. Fractographic analysis indicates no significant necking in the laminate, contrasting with the ductile failure of AA2024-T3. The carbon fiber layer exhibits a pure brittle fracture with visible delamination at the interphase of carbon fiber layer and aluminium alloy sheet. Under LCF conditions, the laminate’s cyclic stress response remains stable, with fatigue cracks initiating in the aluminium layers but mitigated by the carbon fibers, leading to cyclic softening. High-magnification images reveal striation marks and transverse micro-cracks in the aluminium, highlighting the complex interaction between aluminium and carbon fiber layers during fatigue.

Tensegrity FlaxSeat: Exploring the Application of Unidirectional Natural Fiber Biocomposite Profiles in a Tensegrity Configuration as a Concept for Architectural Applications

Material selection is crucial for advancing sustainability in the building sector. While composites have become popular, biocomposites play a pivotal role in raising awareness of materials deriving from biomass resources. This study presents a new linear biocomposite profile, fabricated using pultrusion technology, a continuous process for producing endless fiber-reinforced composites with consistent cross-sections. The developed profiles are made from flax fibers and a plant-based resin. This paper focuses on the application of these profiles in tensegrity systems, which combine compression and tension elements to achieve equilibrium. In this study, the biocomposite profiles were used as compression elements, leveraging their properties. The methods include geometrical development using physical and digital models to optimize the geometry based on material properties and dimensions. A parametric algorithm including physics simulations was developed for this purpose. Further investigations explore material options for tension members and connections, as well as assembly processes. The results include several prototypes on different scales. Initially, the basic tensegrity principle was built and explored. The lessons learned were applied in a final prototype of 1.5 m on a furniture scale, specifically a chair, integrating a hanging membrane serving as a seat. This structure validates the developed system, proving the feasibility of employing biocomposite profiles in tensegrity configurations. Furthermore, considerations for scaling up the systems to an architectural level are discussed, highlighting the potential to enhance sustainability through the use of renewable and eco-friendly building materials, while promoting tensegrity design applications.

Multiscale verification method for prediction results of mechanical behaviors in unidirectional fiber reinforced composites

At present, there is almost no reliable multiscale experiment method that can be used to verify the multiscale mechanical behaviors of unidirectional (UD) fiber reinforced composites (FRC). Therefore, a multiscale method was developed for verifying the prediction results of the macro-mechanical properties and micro-damage modes in UD FRC. Firstly, the fiber volume fractions were determined using the fiber content test for three different FRC. Secondly, the random fiber distributed representative volume elements (RFDRVEs) were generated corresponding to these fiber volume fractions. Moreover, the RFDRVEs were used to predict the macro-mechanical properties and micro-damage modes of UD FRC. Ultimately, the standard mechanical tests and scanning electron microscopy (SEM) were applied to verify the accuracy of the prediction for the macro-mechanical properties and micro-damage modes of UD FRC. The results show that the proposed multiscale method is feasible for the verification of the multiscale prediction results based on RFDRVEs.