Fiber and matrix-dominant properties of fiber-reinforced polymer composites are important in many advanced technological fields, such as aviation, aerospace, transportation, energy industry, etc. Still, pre-mixing the polymer matrix with nanoparticles may enhance the through-thickness or matrix-dominant properties, and surface treatment of fiber reinforcements with nanoparticles, on the other hand, may improve the in-plane or fiber-dominated properties of laminated composites, as well as interfacial adhesion. A novel manufacturing method that combines a spraying process with nanoparticle/epoxy mixture technique was introduced to incorporate carbon nanoparticles for enhancement of thermal properties of multiscale laminates. Several graphene-based nanomaterials including graphene oxide (GO), reduced graphene oxide (rGO), graphene nanoplatelets (GNPs) and multi-walled carbon nanotubes (MWCNTs) were employed to modify the epoxy matrix and the surface of glass fibers. Multiscale glass fiber-reinforced composites were fabricated from unmodified and modified epoxy, as well as fibers, using the vacuum-assisted resin transfer molding (VARTM) process. The composites obtained combined improvements in both the fiber and matrix- dominant properties, resulting in superior composites. The morphological, rheological, thermal and mechanical properties of the glass fiber-reinforced multiscale composites were investigated. The thermal properties of the epoxy/nanoparticle composites were studied through differential scanning calorimetry (DSC), thermo-gravimetric analysis (TGA) and thermal conductivity measurements. The tensile, bending, vibration, interlaminar shear strength (ILSS) and thermal characterization results indicated that the introduction of GNPs, GO, rGO, and MWCNTs enhanced the themo-mechanical properties. The fracture surfaces of the fiber-reinforced composites were examined by scanning electron microscopy (SEM) and the micrographs were analyzed to comment on the mechanical results.

In this research, through-transmission ultrasonic (TTU) Acoustography was applied to measure and quantify porosity levels in carbon fiber reinforced polymer (CFRP) composite laminates. This study employed several CFRP specimens with wide ranges of porosity prepared by altering the curing pressure during the manufacturing process. The Acoustography method, operating at 5 MHz, was able to show contrast in ultrasonic images obtained for composite laminates with varied porosity levels. Porosity levels in composite laminates were quantified using destructive methods: acid digestion and microscopy. Also, strength analysis tests were conducted to investigate the effect porosity has on the laminate’s structural integrity. From the results obtained, it was demonstrated that the mechanical properties, interlaminar shear strength (ILSS), and flexural strength of CFRP decreased with the increasing void content. In addition, Acoustography absorption coefficient measurements were related to varied porosity levels in the composite laminates. As the porosity content increased within the laminates, the acoustic absorption coefficient increased. These findings are significant because Acoustography is being developed as a faster alternative to traditional ultrasonic inspection of composites and porosity is an important anomaly to quantify utilizing NDE methods.

Resumo: O desenvolvimento da tecnologia dos compósitos híbridos, combinando laminados poliméricos reforçados com fibras longas e placas metálicas, normalmente ligas de alumínio, denominados de CHMF, tem como uma de suas finalidades formar um conjunto de materiais que combine elevados valores de resistência mecânica, resistência ao impacto, rigidez e baixa massa específica. Essa combinação de propriedades torna os CHMF particularmente atrativos como substituintes das ligas metálicas e dos compósitos termorrígidos convencionais, em aplicações aeroespaciais. O objetivo deste trabalho de pesquisa é avaliar os efeitos de diferentes condicionamentos ambientais (umidade e temperatura elevadas, salinidade e variações súbitas de temperatura) em CHMF dos tipos GLARE® (metal-fibra de vidro) e CARALL® (metal-fibra de carbono). Os efeitos dos condicionamentos estudados foram avaliados por ensaios de cisalhamento interlaminar (ILSS) e Iosipescu e ensaios de vibração livre. O estudo revela que a exposição a elevados ciclos de temperatura influencia significativamente as propriedades de cisalhamento dos laminados, devido, principalmente, à diferença dos coeficientes de expansão térmica entre os seus constituintes. Observa-se também que os módulos de perda e armazenamento são afetados, devido à possível formação de microtrincas na matriz polimérica e degradação da interface metal/compósito. Já a presença do baixo teor de umidade, por sua vez, não afeta de maneira significativa as propriedades de cisalhamento e viscoelásticas. Finalmente, a exposição em atmosfera salina mostrou-se o condicionamento mais agressivo, devido à formação de "pits" de corrosão nas camadas metálicas dos laminados / Abstract: The technological development of hybrid composites combining long-fiber reinforced polymeric laminates with metallic sheets, usually Al alloys, denominated FML, aims to obtain a range of materials with high mechanical strength values, stiffness and low weight. This combination of properties becomes the FML attractive as substitutes of both metal alloys and conventional thermosetting composites in aerospace applications. The objective of this work is to evaluate the effects of different environmental conditionings (high moisture and temperature, saline atmosphere and sudden changing of temperature) in GLARE® (glass fiber-metal laminates) and CARALL® (carbon fibermetal laminates) FML samples. Interlaminar and Iosipescu shear and free vibration tests were used to evaluate the studied environmental conditioning effects. The study shows that the exposure to high temperature cycles influences significantly the shear properties of the laminates, mainly due to the thermal expansion coefficient differences of their constituents. It is also observed that the loss and storage modules are affected due to the possible formation of microcracks in the polymer matrix and also the metal/composite interface degradation. In the other side, the presence of low moisture content does not affect so significantly the shear and viscoelastic properties. Finally, the saline atmosphere exposure showed the most aggressive conditioning, due to the formation of corrosion pits on the metal layers of the laminate / Orientador: Edson Cocchieri Botelho / Coorientador: Mirabel Cerqueira Rezende / Banca: Michelle Leali Costa / Banca: José Ricardo Tarpani / Mestre

Efficient and optimal use of composites in structures requires tools to monitor and capture the complex degradation that can occur within the laminates over time. Structural health monitoring (SHM) techniques uses sensors/actuators on the structure to progressively monitor the health of the structure with minimal manual intervention. Electrical tomography (ET) is a SHM technique that uses voltage measurements from the surface of the laminate to reconstruct a conductivity map of the structure. Since damage has been shown to modify the conductivity of the laminate, the conductivity map can provide an indirect measure of the damage within the material. Studies have shown the capability of ET to identify macroscale damage due to impact. But, little has been done to quantitatively assess damage using ET. In this work, we present a theoretical framework to link degradation mechanisms occuring at the microscale to the conductivity at the mesoscale through damage indicators. The mesoscale damage indicators are then shown to be intrinsic to the ply. Next, we use the knowledge obtained through mesoscale homogenization to study the detectability of transverse cracks. Last, we show how the mesoscale homogenization participates in regularization of the inverse problem and in the quantitative assessment of the reconstructed conductivity map. This is as such the first step towards turning ET into a viable quantitative health monitoring technique.

Abstract Layered composite materials consisting of thin orthotropic layers offer for a designer many possibilities to tailor the structure: the behaviour and properties of the structure can be influenced not only by varying the geometry and thicknesses of the structure but also by varying the lay-up of the laminate. As new orthotropic materials having high specific strength and stiffness are used in structures, the tailoring is essential to utilize all the benefits of these materials. In this thesis tailoring and optimization of thermomechanical properties of layered composite structures are considered. The tailoring problemis formulated and solved as a constrained nonlinear optimization problem. Different types of global thermomechanical properties, such as stiffnesses, coefficients of thermal expansion and natural frequencies and buckling loads of composite plates, as well as layer-wise properties, such as stresses and strains in a certain lamina, are considered. Also, coupled thermalstructural problems are studied. When lay-up parameters, i.e. number of layers, and their orientations and thicknesses, are employed as design variables, global as well as layer-wise properties of the laminate can be considered. As relations between thermomechanical properties and lay-up parameters are highly nonlinear, optimization may suffer from various local optima. However, in tailoring the global minima or maxima are not the points of interest but rather the points of design space, where appropriate values for considered properties are achieved. In the thesis optimization of global thermomechanical properties is presented also by applying so-called lamination parameters as design variables. The lamination parameters are defined as integrals of the functions, which consist of sines and cosines of the lay-up angles of different layers multiplied by the powers of the thickness co-ordinate z, through the thickness of the laminate. Thus, information of the lay-up of the laminate can be compressed into these parameters and only twelve lamination parameters are needed to describe the behaviour of a common laminate. The use of these parameters as design variables is advantageous, because the number of parameters needed is small and often formulating a convex optimization problem is possible. After finding optimal lamination parameters, a procedure is needed to generate a lay-up corresponding to these parameters. Explicit equations are derived for generating lay-ups having optimal bending lamination parameters. For creating a laminate having both optimal in-plane and bending lamination parameters, a new optimization problem searching laminates having lamination parameters as close as possible to the optimal ones is formulated. In that problem, also layer-wise properties and restrictions of manufacturing are taken into account. Agenetic algorithmsearch is employed for solving that later problem as the value of the objective function can be computed efficiently. Also, often the thicknesses and orientations of different layers can have only discrete values, which can be handled easily in the GA search, where all design variables are discrete in character.

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The characteristics of carbon fiber composites have enabled these materials to be accepted as replacements for metal parts in industry. However, due to their unsymmetrical material properties, carbon fiber composites are susceptible to damage, such as a delamination, which can cause premature failure in the structure. This has resulted in the need for nondestructive testing methods that can provide quick, reliable results so that these parts can be tested while in service. In this study, an approach was examined that involved a pencil lead break to excite multiple wave modes in a composite plate in an effort to identify key characteristics based on the wavespeed and frequency. These characteristics were then compared to models based on boundary conditions to generate dispersion curves using the transfer matrix method for whole composite plates that were either undamaged or damaged. To first test this approach, experiments were performed on multilayer isotropic plates and then on a composite plate. The results for all cases showed that modes could be excited by the pencil lead break in the undamaged region of the plates that were not theoretical possible in a delaminated region. Also modes that were specific to the delaminated region were excited and this allowed for a clear comparison between the two regions. This approach could be placed into practice to provide routine testing to detect delamination for in-service, carbon fiber composite parts. / Master of Science / The physical properties of high strength and low weight and the economic benefits of carbon fiber composites has resulted in these materials replacing metals in several industries. It is important, however, to be aware that the change in materials used impacts the different types of damage composites experience compared to conventional metals. One type of damage that could cause a composite part to fail is a delamination or a separation of layers. In order to identify if this damage has occurred, it is beneficial to have an inspection technique that will not damage the part. In this study, a technique was tested that involved breaking a piece of pencil lead on a plate in order to generate multiple wave modes that would propagate in the plate. Based on boundary conditions caused by the damage in the plate, the speed of the wave and frequency content could be compared to an undamaged plate to identify a delamination. A model was created to compare experimental results and demonstrated that using wavespeed and frequency could identify a delamination. The experimental results compared well with the model dispersion curves for a plate with and without a delamination suggesting this approach could be placed into practice to provide routine testing to detect delamination for in-service, carbon fiber composite parts.

The PhD thesis evaluates the mechanical properties and damage tolerance of aerospace carbon/epoxy laminates containing long, narrow interlaminar galleries. The term 'galleries' refers to thin and long holes in a laminate used for the installation of small measuring devices, such as structural health monitoring (SHM) sensors. The galleries considered in this study are similar to those used in a novel SHM system known as 'Comparative Vacuum Monitoring (CVM)'. CVM was developed by the Australian company - Structural Monitoring Systems (SMS) - for damage detection in aircraft structures. CVM is a SHM system that utilises pressure differentials between a parallel series of galleries at atmospheric or low pressure to detect damage initiation and propagation. Thus far, CVM has been used for the monitoring of surface cracks in metallic structures using surface mounted sensors. Recent research has also demonstrated that it may be possible to monitor damage along the bond- line of both metallic and composite joints using CVM. The ability of CVM sensors to detect delamination damage inside composite structures is less well understood. It is envisaged that CVM can be used for the through-life health monitoring of composite aircraft structures prone to delamination damage. However, a major concern with applying CVM to composite laminates is the open-hole design of the galleries that may initiate damage growth under external loading. Material property data, structural tests, and models for predicting the properties of laminates containing galleries is needed before CVM technology can be certified for use in aircraft composite structures. The primary objectives of this PhD thesis are the development of an optimum process method for introducing multiple interlaminar CVM galleries in composite laminates; the development of a validated model for calculating changes to the mechanical properties of laminates containing CVM galleries; and the determination of optimum CVM gallery shape, size and orientation combinations for minimising the effect of the galleries on the mechanical properties of laminates. The effects of the shape, size and orientation of CVM galleries on the mechanical properties of carbon/epoxy laminates are evaluated by an extensive experimental research program, and the results are presented in the thesis. The properties investigated include the in-plane tensile and compressive properties, tensile and compressive fatigue life, through-thickness tensile strength, interlaminar shear strength, mode I and mode II interlaminar fracture toughness, and impact damage resistance. The results from tensile tests on lap-joints and T-joints containing CVM galleries are also presented.

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