Composite Materials G roup Composites on meso macro level

Stepan V. Lomov

Contents

Research objectives State-of-the-art 2010 Research perspectives 2011 and beyond

Research objectives State-of-the-art 2010 Research perspectives 2011 and beyond

Hierarchy of structural levels in composite materials: nano o P icro

Chowdhury 2007

Hierarchy of structural levels in composite materials: Picro o meso

Mishnaevsky 2009

Goyal 2008

Hierarchy of structural levels composite materials: meso o Macro o ME A G

Composites on meso - Macro level: Research objective

1.

Theoretical understanding, experimental study and formalisation into models and design tools of the mechanical behaviour of (nano-engineered) fibre reinforced composites (n)FRC: during manufacturing in-service performance

2.

Optimisation of (n)FRC and development of novel materials with high mechanical properties, toughness and damage tolerance.

Composites on meso - Macro level: Subject definition

Structural levels: (nano) micro meso Macro

Materials: 1. Fibre reinforced composites (FRC) in general, including nanoengineered (nFRC) with the emphasis on: Textile composites Random fibre reinforced composites Heterogeneous materials in general, with forays towards porous and biomaterials

2.

Properties: 1. 2. Internal architecture/structure/geometry, hierarchial organisation Mechanical properties and behaviour, including: Quasi-static response (elastic properties, non-linearity) Fatigue Damage initiation, progression, resistance and tolerance
8

Composites on meso - Macro level: Materials of special interest

Material type Woven laminates Tri-axial braids 3D woven: noncrimp 3D woven: angle interlock 3D braids Non-crimp fabrics (NCF) Structurally stitched Random fibre composites Motivation Guinea pig for new developments in matrices, fibres, nano-reinforcements Quasi-isotropic Crash resistant Best realisation of fibre properties No delaminations Net shape No delaminations Energy absorption Beams Energy absorption Cheap Best realisation of fibre properties No delaminations Cheap and formable Typical structure

Composites on meso - Macro level: Research philosophy

1. 2. Focus on the material; applications via partnerships. Behaviour of a composite can be understood only if research spans several structural levels. Performance of a composite can be understood only if manufacturing is considered as well. Experimental study should lead to a descriptive, better predictive model. Model development should lead to a numerical tool. Fundamental studies should understand about real behaviour and applications. Applied studies should understand about fundamental phenomena.
10

3.

4. 5. 6.

7.

Integrated design tool for textile composites

z A Q h p z(x) Q B x d2

Internal architecture of the reinforcement

d1 Z

Production Permeability Performance Mechanical properties and damage

M

Deformation resistance and change of geometry Compr. Shear Tension Bending

R=1/ K

Drapeability and formability Impregnation Structural analysis

S.V.Lomov - Singapore - May 2010

11

Research objectives State-of-the-art 2010

1. Models of textile composites:

2. Textile reinforcements:
Internal geometry Deformability Permeability

WiseTex Method of inclusions Integration with PAM-SYSPLY meso-FE modelling: homogenisation and damage

3. Mechanical properties and damage: 4. Materials of special interest:

Methodology of damage monitoring during test and post-mortem investigation Fatigue 3D non-crimp woven composites 3D angle interlock composites Non-crimp fabrics Structurally stitched composites Random fibre reinforced composites

Research perspectives 2011 and beyond

12

WiseTex software package: Virtual textiles and textile composites

commercialised by K.U.Leuven R&D integrated in SYSPLY package of ESI Group

S.V.Lomov - Singapore - May 2010

5 industrial licenses 20+ university licenses

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Method of inclusions
Eshelby solution Mori-Tanaka homogenisation

Excellent results for complex textile composites (and random fibre composites) Iso-strain

TexComp

G. H uysma n s 2 0 0 0 G. Per ie 2 0 0 9

CC

cm Cm  cs Cs A s cm I  cs A s

14

Integration WiseTex SYSPLY

Forming: QUIKFORM Local deformation parameters (thickness, shear)

Local stiffness

[Q]

WiseTex

TexComp Internal geometry

FE analysis: SYSPLY

Stress/strain fields
15

meso-F : Road map E

Geometric modeller Geometry corrector Meshing Assign material properties Boundary conditions FE solver, postprocessor Homogenisation Damage analysis
16
N N+1 N+2

WiseTex MeshTex/ SACO commercial F packages M E

State-of-the-art numerical tool for preparation of FE models and FE analysis of textile composites on meso-structural level W i se T e x Geometric modeller Geometry corrector Meshing M e sh T e x Assign material properties Boundary conditions FE solver, postprocessor Homogenisation Damage analysis
17

SAC O M , ABAQ U S, AN SYS

Un iv er sit y o f Osa k a , Pr of M . Z a k o

Damage in textile composites: Standard stiffness degradation scheme

Stiffness degradation scheme: generally accepted

real damage: transverse cracks, propagating along braiding yarns

leads to unphysical direction of propagation of damage: across the fibres inside the yarns

damage zone

D . Iv a n ov , L. Go r ba t ik h 2 0 0 7

18

Advanced damage model 1) Elementary damaged entity: segment Yarn segment: fibre orientation is constant 2) Orientation of the failure plane: Mohr-Hashin-Puck concept Crack plane defines the orientation of degradation 3) Degradation scheme
v12

Y2 d ~ cr Damage l energy release rate G 5) Combination: micro/plasticity and damage

4) Damage evolution law:

brings good predictions (example: 3-axial braid)

Damage development (shear degradation parameter d12) in MD tensile test

experimental damage initiation

Principal levels of applied strain and stress at failure: 1 - damage initiation; 2 crack density increase (delamination onset); 3 ultimate failure;
  

v (1 d 2 )

0 12

v 23

v (1 d 2 )

0 23

E2

0 E 2 (1 d 2 ) 2

G12

0 G12 (1 d12 )

d2

2(1  1  d12 ) (2  1  d12 )

d2

d12

D . Iv a n ov , 2 0 0 9

19

D . Iv a n ov , 2 0 0 9

20

Research objectives State-of-the-art 2010

1. Models of textile composites:

2. Textile reinforcements:
Internal geometry Deformability Permeability

WiseTex Method of inclusions Integration with PAM-SYSPLY meso-FE modelling: homogenisation and damage

3. Mechanical properties and damage: 4. Materials of special interest:

Methodology of damage monitoring during test and post-mortem investigation Fatigue 3D non-crimp woven composites 3D angle interlock composites Non-crimp fabrics Structurally stitched composites Random fibre reinforced composites

Research perspectives 2011 and beyond

21

Internal geometry of textile reinforcements: WiseTex

z

A Q h p z(x) Q B x d2


d1 Z

minimum of bending energy + compressibility of yarns

"

i ,k

j ,l , k

decomposition of the problem + characteristic functions

S.V.Lo mov , 1 9 9 9

We jlk

p We jlk

"

Wa Wa Bik ik h Wa F ik Wa Wa p ik p ik


B We jlk

We jlk

h We jl

min

22

Internal geometry of textile reinforcements: E xperimental studies

Nesting, yarn dimensions and distribution of the fibres

D . Iv a n ov , 2 0 0 7

23

Materials studied 2000 2010: internal geometry

Fibres/matrix carbon/epoxy

Reinforcement NCF 0/90, 45 NCF tufted with carbon yarn Bi- and tri-axial braids 3D woven 3Tex

Publication Comp A 33: 1171 (2002) Adv Comp Lett 15: 87 (2006) Text Res J 72: 706 (2002) Comp A 41: 1301 (2010) Comp Sci Techn 60: 2083 (2000) Comp Sci Techn 63: 993 (2002) Comp Sci Techn 65: 1920 (2005)

glass/epoxy

Plain weave 3D woven 3Tex

24

Deformability of textile reinforcements: WiseTex models

(un)bending + compression of yarns work of compressive force Q on change of thickness db = change of bending energy of yarns dW
Qij q d1We

Compression
p h QW a

d1Wa d2Wa

d2We

T T

Uniand Biaxial tension

T T
S.V.Lo mov , 2 0 0 1

Friction between the yarns Lateral compression of the yarns (Un) bending of the yarns Torsion of the yarns Vertical displacement of the yarns

Shear
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Deformability of textile reinforcements: E xperimental studies

0.014

Shear force, N/mm

Biaxial tensile tester

0.012 0.01 0.008 0.006 0.004 0.002 0 0 10 20

shear
30 40 50 Shear angle,

0.016

Force [kN/mm]

0.012

1:2
0.008

1:1

2:1 5:1

1:5

optical (DIC) registration of the fabric shear

0.004

0 0 0.5

Elong [%]

1.5

S.V.Lo mov , A. W il l ems 2 0 0 4

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Shear: Benchmarking exercise

picture frame

plain weave Twintex

27

Draping, formability and modelling

kinematic

FE

K. V a n c l o o st er 2 0 0 8

28

F orming diagram for multi-layered preforms Formability of multi-layered composites

Depends on the relative orientation between neighbouring plies Depends on friction between the plies (PP-interlayer thickness)

measurement of interply friction for thermoplastics and FE modelling

K. V a n c l o o st er 2 0 0 9

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Materials studied 2000 2010: Deformability

Fibres/matrix carbon/epoxy

Reinforcement NCF 0/90, 45, 0/45/-45/90 Twill weave with grafted carbon nanotubes

Publication Comp A 34: 359 (2003) Comp A 36: 1188 (2005) Comp Sci Tech, accepted TexComp 2010 J Reinf Plast Comp 19: 1329 (2000) Comp Sci Techn 66: 919 (2006) Text Res J 76: 243 (2006) Comp Sci Techn 65: 1920 (2005) Comp Sci Techn 68: 807 (2008) Comp A 39: 1037 (2008)

glass/epoxy

Plain weave

Twintex

Plain weave Twill

30

Permeability of textile preforms: Simulations

gradp
p = 'p <u> A

p=0 <u>

B. V er l eye 2 0 0 8

31

Permeability of textile preforms: International benchmark

Large scatter of permeability measured in different labs and using different techniques 2nd exercise started 2010

32

Materials studied 2000 2010: Permeability

Fibres carbon glass n/a

Reinforcement NCF 0/90, +45/-45 Plain weave NCF 0/90 Stereolithographic reference medium

Publication SAMPE Europe 2003 Comp A 35: 1407 (2004) Adv Comp Lett 18: 121 (2009) Comp A 40: 244 (2009)

33

Research objectives State-of-the-art 2010

1. Models of textile composites:

2. Textile reinforcements:
Internal geometry Deformability Permeability

WiseTex Method of inclusions Integration with PAM-SYSPLY meso-FE modelling: homogenisation and damage

3. Mechanical properties and damage:

4. Materials of special interest:

Methodology of damage monitoring during test and post-mortem investigation Fatigue 3D non-crimp woven composites 3D angle interlock composites Non-crimp fabrics Structurally stitched composites Random fibre reinforced composites

Research perspectives 2011 and beyond

34

Motivation: early damage initiation in textile composites

stress

AE

No stiffness reduction up to failure Early damage initiation Design strain at 0.3 ... 0.4% Ratio Ultimate strain / Design strain of 4...5

strain, %

35

AEand DICmonitoring of damage

objective characterisation of te progressive damage

S.V. Lomov 2 0 0 8

36

E xperimental road map

Textile preparation (shear...), measurements Impregnation(RTM...) Study of the reinforcement geometry Cutting the samples in characteristic directions X-Ray of the unloaded samples Tension test with AE, strain-mapping
# # #

Architecture of the textile Thermal/cure damage characterisation Tension diagrams AE diagrams Strain maps Damage initiation threshold Dynamics of damage extent Damage periodicity Cracks placement and orientation Crack length distribution Fine structure of damage Micro-characterisation of damage modes S.V. Lomov 2 0 0 8

Identification of Tensile tests till C-scan X-Ray

1, 1,
#

2, 2,
#

3 3
#

Cutting according to the crack pattern Analysis of the cracks on micrographs SEM at the selected positions

37

Materials studied 2005 2010: Progressive damage

Fibres/matrix carbon/epoxy Reinforcement NCF 0/90, 45, 0/-45/90/45 NCF 45, sheared NCF 0/90, 45, toughened resin NCF tufted with carbon yarn 3-axial braid Uniaxial braid Uniaxial weave tufted with carbon Automated tow placement Woven twill 2/2 3D woven 3Tex 3D braided 3Tex glass/epoxy Plain weave 3D woven 3Tex ICCM-17 (2009) Comp A submitted ECCM-14 (2010) Comp A 40: 1134 (2009) Comp A 40: 1144 (2009) Publication Comp Sci Tech 68: 2340 (2008) Comp A 36: 1207 (2005) Comp A 39: 1380 (2008) Comp A 40: 251 (2009) Comp Sci Tech 69: 2701 (2009) Comp Sci Tech 69: 1373 (2009) Comp Sci Tech 68: 2340 (2008) Plast Rubb Comp 38: 98 (2009) in writing Experimental methodology in general

38

Tension-tension fatigue: S-Ncurve and progressive damage

500 450 400 350 300 250 200 150 100 50 0 1.E+00

stress, MPa

I II III
1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07

number of cycles

Vmax stress Vmin time

K. V a l l o n s, 2 0 0 7 in c o l l a bo r a t io n w it h V . Ca r v el l i, M il a n o
39

F atigue limit vs damage initiation threshold

V_ULT: failure
carbon/epoxy braid

V_2: initiation of high energy damage events V_1: damage initiation V_min: first AE event

NCF carbon/epoxy, 3D carbon/epoxy stitched NCF carbon/epoxy, unstitched NCF carbon/epoxy

plain weave glass/epoxy 3D glass/epoxy

40

Materials studied 2007 2010: F atigue

Fibres/matrix carbon/epoxy

Reinforcement NCF 0/90 NCF 0/90, 45, toughened resin NCF 0/90 NCF tufted with carbon yarn Woven twill 2/2 3D woven 3Tex 3D braided 3Tex

Publication Comp A 38: 1603 (2007) Comp A 40: 251 (2009) Comp Sci Tech 70: 2216 (2010) ICCM-17 (2009) Comp A submitted ECCM-14 (2010) Comp Sci Tech 70: 2216 (2010)

glass/epoxy

Plain weave 3D woven 3Tex

41

Research objectives State-of-the-art 2010

1. Models of textile composites:

2. Textile reinforcements:
Internal geometry Deformability Permeability

WiseTex Method of inclusions Integration with PAM-SYSPLY meso-FE modelling: homogenisation and damage

3. Mechanical properties and damage: 4. Materials of special interest:

Methodology of damage monitoring during test and post-mortem investigation Fatigue 3D non-crimp woven composites 3D angle interlock composites Non-crimp fabrics Structurally stitched composites Random fibre reinforced composites

Research perspectives 2011 and beyond

42

3Dwoven non-crimp composites: G lass/ epoxy

comparative study: plain weave laminate vs 3D woven composite

2D

3D

in c o l l a bo r a t io n w it h A. Bo g da n o v ic h , 3 Tex a n d V. C a r v el l i, M il a n o

43

3Dwoven non-crimp composites: Carbon/ epoxy

detailed study of internal geometry

non-Hookean tensile behaviour

1000 900 800 700 stress, MPa 600 500 400 300 200 100 0 0 0.2 0.4 0.6 0.8 strain, % 1 1.2 1.4 1.6 stress, fill E, fill 100 90 80 70 60 50 40 30 20 10 0 E, GPa

damage progression and fatigue

S-N AE

in c o l l a bo r a t io n w it h A. Bo g da n o v ic h , 3 Tex, M . Ka r a h a n , Bur sa a n d V . C a r v el l i, M il a n o

44

3Dwoven non-crimp composites: F modelling E

correct modelling of degradation of stiffness reasonable evaluation of damage initiation threshold qualitative representation of intensity of damage

45

3Dangle interlock composites

1m

WiseTex model: excellent predictions of the stiffness

G. Per ie, 2 0 1 0

46

3Dtextiles 1995 2010

Material General 3D weave 3D woven, carbon/epoxy 3Tex, glass/epoxy Properties Coding of the weave Stiffness Internal geometry Stiffness, strength Damage Fatigue 3Tex, carbon/epoxy Internal geometry Stiffness, strength Damage Fatigue 3D angle interlock, carbon/epoxy Internal geometry Stiffness Publication Technische Text 38: 20 (1995) Comp Sci Tech 60: 2083 (2000) Comp Sci Tech 65: 1920 (2005) Comp A 40: 1134 (2009) Comp A 40: 1144 (2009) Comp Sci Tech, in print Comp A 41: 1301 (2010) Comp A, submitted Comp A, submitted Comp A, submitted ICCM-17 (2009) Text Res J 81: 1 (2011)

47

NCF Internal geometry :

Distortions of fibrous plies due to stitching

change of geometry in a sheared fabric

S.V. Lomov, 2 0 0 2 ; R. Lo en der sl o o t , 2 0 0 5
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NCF Deformability and permeability :

forming

shear (picture frame) and biaxial tension

Biaxial -45/+45 MD/CD
0.02

0.016

Force [kN/mm]

0.012

0.008

0.004

permeability

0 0 0.5

Elong [%]

1.5

S.V. Lomov, 2 0 0 2 , 2 0 0 5

49

NCF Mechanical properties, damage and fatigue :

MD

Damage initiation and development is linked to the stitching sites S-N fatigue curves and development of cracks during fatigue

Tr uon g , 2 0 0 5 , 2 0 0 8 ; M ik h a l uk 2 0 0 8 ; V a l l o n s 2 0 0 8 , 2 0 0 9 , 2 0 1 0

50

Structurally stitched reinforcements

internal geometry and WiseTex model

correlation between damage and stitching sites

Ko issin 2 0 0 6 , 2 0 0 9

51

Abook @Woodhead Publishers, 2011

52

NCFand structurally stitched 2000 2010

Material Carbon/epoxy NCF Properties Internal geometry Deformability Permeability Mechanical properties, damage Fatigue Publication Comp A 33: 1171 (2002) Comp A 37: 103 (2006) Comp A 34: 359 (2003) Comp A 36: 1188 (2005) SAMPE-Europe 2003 Comp A 36: 1207 (2005) Comp A 39: 1380 (2008) Comp A 38: 1633 (2007) Comp A 40: 261 (2009) Comp A 42: 16 (2011) Comp A 41: 1019 (2010) Eng Fract Mech 75: 2751 (2008) Comp A 39: 1380 (2008) Adv Comp Lett 15: 87 (2006) Plast Rubb Comp 38: 98 (2008) Comp Sci Tech 69: 2701 (2009) Comp Sci Tech 70: 2216 (2010)
53

Impact and post-impact FE modelling Structurally stitched Internal geometry Mechanical properties, damage, FE damage Fatigue

Random fibre reinforced composites

Successful use of inclusions method for prediction of stiffness and onset of debonding
1 2 3 4 5%

Ja o Jul es 2 0 0 5

54

Research objectives State-of-the-art 2010 Research perspectives 2011 and beyond

1. Integrated Design Tool:
WiseTex: integrations meso-FE modelling Fatigue Compression Deformability Permeability Damage and fatigue

2. Manufacturing

3. Performance 4. 3D composites 5. Nano-engineered fibre reinforced composites 6. Steel fibre composites

55

WiseTex integrations
XML input-output and scripting Custom software XML textile data

Further integration with PAM software

XML description of WiseTex model

Custom software in collaboration with

56

meso-F modelling: New cases; dry fabrics; numerical tools E

Textile composites: New FE models: 3K vs 12K carbon/epoxy woven composites 3D woven non-crimp composites: exact representation of VF inside yarns and yarn shapes Models of NCF: glass/epoxy quasi-UD (wind applications) Full implementation of objective strain UMATs Implementation of compression model Models of shear and biaxial tension Models of knitted fabrics Convertor WiseTex Meshtex Abaqus Interpenetration tool

Dry fabrics:

Numerical tools:

57

F atigue modelling: F atigue jump approach

max
$

Applied to: Textile composites Random fibre composites

58

Compression of nano-grafted carbon fabrics

Compressibility of a fabric after grafting of CNT is seriously decreased Possible problems in LCM processes

59

Deformability: New experimental tools

On-line: thickness measurements of thickness of the fabric during shear or tension deformation change of yarn width during compression

Direct identification of tension/ compression model of Boisse

60

Deformability: Steel knitted fabrics for glass forming

Steel fibres/yarns Bekaert Draping of knitted fabric over a glass-forming mould

61

Permeability: Second benchmarking exercise

Decided during FPCM-10 (Ascona, Switzerland) Coordinated by EP Montreal K.U. Leuven: Geometrical characterisation of the fabrics presented fro the benchmark 2010 2012

62

Damage: carbon woven; G lass NCF nF ; RC

Different damage scenario depending on the tow size/ crimp/ Shift of the damage initiation in nFRC; change of mechanism?

Position glass NCF for wind applications vis--vis damage behaviour and fatigue life
63

F atigue: E xperimental studies

Relation between the fatigue life and static damage

Reliable input data for fatigue modelling: new experiments and literature data

64

3Dcomposites: F modelling; Voids in C/ Ccomposites E

FE models with: correct VF inside yarns correct yarn shapes numerical tools for interpenetrations Inclusion and FE 3D models of C/C composites with voids

Analysis of damage and fatigue experimental data on 3D braids

65

Nano-engineered fibre reinforced composite

1. Toughness and damage resistance of nFRC: 2. 3. Explanation and theoretical models for the delayed damage in nFRC Fatigue damage delay Micro-models of damage, including gradient layers in matrix Further investigation of compression of CNT-grafted fabrics/yarns Permeability of nFRC

Processing of nFRC:

Macro-damage effects in nFRC

66

Steel fibre reinforced composites

1. 2. 3.

Specific effect of plasticity of steel on the composite behaviour Specific effects of the reinforcement architecture (crimp), related to high transversal stiffness of steel Toughness of the interface: gradients of the interface

67