Master of Science / Department of Architectural Engineering / Donald J. Phillippi / For this thesis, research was performed on CFRP bonded composite lap-joints with one and two continuous laminas through the lap. Composite wraps used to retrofit existing structures use lap joints to maintain their integrity. The use of composites for retrofitting structures has many advantages over traditional methods, such as steel jacketing, and is becoming more widely accepted in the structural engineering industry. While much literature exists documenting the performance of composite wraps as a whole when applied to concrete columns, less information is available on the behavior of the lap-joint of the wrap. Developing a better understanding of how the lap-joint behaves will help researchers further understand composite column wraps. This research sought to determine what affect continuous middle laminas may have on the stiffness of lap joints and whether or not stress concentrations exist in the lap-joint due to a change in stiffness.

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Different strategies can be used to repair, rehabilitate and strengthen existing structures. Techniques based on Fiber Reinforced Polymer (FRP) materials appear to be innovative alternatives to traditional solutions because of their high tensile strength, light, weight, and ease of installation. One of the most common and useful FRPs is Carbon Fiber Reinforced Polymer (CFRP) used in sheets and anchors attached on the concrete surface to strengthen the section through addition of tensile capacity. The purpose of this study was develop a technique for assesses the strength of anchors for quality control purpose. However, to transfer tensile capacity to a concrete surface, the sheets are bonded to the surface with epoxy adhesive. As tension increase, CFRP sheets lose adherence of the epoxy from the concrete surface and finally debond. To avoid this failure, CFRP anchors are applied in addition at the epoxy. The CFRP anchors allow the CFRP sheets to utilize their full tensile capacity and maximize the material efficiency of the CFRP retrofit. The number and size of anchors play a critical role. However the capacity of CFRP anchors has not been investigated extendedly. A methodology for assessing the quality of CFRP anchors was developed using plain concrete beams and reinforced externally with CFRP sheets attached with epoxy and CFRP anchors. Applying load to the beam, allowed the development a tensile force in the CFRP sheets and a shear force on the CFRP anchors. The shear forces in the CFRP anchors were defined by the load applied to the beam and compared with forces based on measured stress in CFRP sheets. / text

Carbon fiber-reinforced plastics (CFRPs) have gained widespread popularity as a lightweight, high-strength alternative to traditional materials. The unique anisotropic properties of CFRP make processing difficult, especially using conventional methods. This study investigates laser cutting by ablation as an alternative by comparing two near-infrared laser systems to a typical mechanical machining process. This research has potential applications in the automotive and aerospace industries, where CFRPs are particularly desirable for weight savings and fuel efficiency. First, a CNC mill was used to study the effects of process parameters and tool design on machining quality. Despite high productivity and flexible tooling, mechanical drilling suffers from machining defects that could compromise structural performance of a CFRP component. Rotational feed rate was shown to be the primary factor in determining the axial thrust force, which correlated with the extent of delamination and peeling. Experimental results concluded that machining quality could be improved using a non-contact laser-based material removal mechanism. Laser machining was investigated first with a Yb:YAG fiber laser system, operated in either continuous wave or pulse-modulated mode, for both cross-ply and woven CFRP. For the first time, energy density was used as a control variable to account for changes in process parameters, predicting a logarithmic relationship with machining results attributable to plasma shielding effects. Relevant process parameters included operation mode, laser power, pulse overlap, and cross-ply surface fiber orientation, all of which showed a significant impact on single-pass machining quality. High pulse frequency was required to successfully ablate woven CFRP at the weave boundaries, possibly due to matrix absorption dynamics. Overall, the Yb:YAG fiber laser system showed improved performance over mechanical machining. However, microsecond pulses cause extensive thermal damage and low ablation rates due to long laser-material interaction time and low power intensity. Next, laser machining was investigated using a high-energy nanosecond-pulsed Nd:YAG NIR laser operating in either Q-Switch or Long Pulse mode. This research demonstrates for the first time that keyhole-mode cutting can be achieved for CFRP materials using a high-energy nanosecond laser with long-duration pulsing. It is also shown that short-duration Q-Switch mode results in an ineffective cutting performance for CFRP, likely due to laser-induced optical breakdown. At sufficiently high power intensity, it is hypothesized that the resulting plasma absorbs a significant portion of the incoming laser energy by the inverse Bremsstrahlung mechanism. In Long Pulse mode, multi-pass line and contour cutting experiments are further performed to investigate the effect of laser processing parameters on thermal damage and machined surface integrity. A logarithmic trend was observed for machining results, attributable to plasma shielding similar to microsecond fiber laser results. Cutting depth data was used to estimate the ablation threshold of Hexcel IM7 and AS4 fiber types. Drilling results show that a 2.2 mm thick cross-ply CFRP panel can be cut through using about 6 laser passes, and a high-quality machined surface can be produced with a limited heat-affected zone and little fiber pull-out using inert assist gas. In general, high-energy Long Pulse laser machining achieved superior performance due to shorter pulse duration and higher power intensity, resulting in significantly higher ablation rates. The successful outcomes from this work provide the key to enable an efficient high-quality laser machining process for CFRP materials.

The use of fiber reinforced polymers (FRP's) for structural repair or retrofit has increased significantly in the last decade, with adoption for civil infrastructure occurring only in the last 20 years. These products are most often used to increase the capacity of damaged or deteriorated structures. Much research has been performed in the arena of testing of various FRP's bonded to both concrete and masonry substrates, the majority of which focusing on three areas; flexural strengthening, in-plane shear strengthening, and mechanical anchoring. Anchorage is commonly the limiting factor in the application of FRP's, due to the inability of the edge of the polymer matrix to reliably extend beyond a point of zero-interfacial stress. Where interfacial stresses exist and the FRP is terminated localized disbondment often occurs, these localized failures then propagate across the entire bond of the structural system. Various mechanical termination details have been tested to mitigate the potential failure modes near the ends of the fabric. There, however, has been very limited research performed on the behavior of dowels which are installed parallel to the FRP fabric and splayed onto the FRP fabric matrix. In this research the mechanical properties of carbon fiber reinforced polymer (CFRP) dowels with a parallel orientation to uniaxial carbon fabric are experimentally tested to determine the tensile capacity of "dowel to splay" CFRP connections and to discover any dominant failure modes.

Excellent properties of Carbon Fiber Reinforced Polymer (CFRP) composites are usually obtained in the direction at which carbon fibers are embedded in the polymeric matrix material. The outstanding properties of this material such as high strength to weight ratio, high stiffness and high resistance to corrosion can be tailored to meet specific design applications. Despite their excellent mechanical properties, application of CFRPs has been limited to more lucrative sectors such as aerospace and automotive industries. This is mainly due to the high costs involved in manufacturing of this material. Machining, milling and drilling, is a critical part of finishing stage of manufacturing process. Milling and drilling of CFRP is complicated due to the inhomogeneous nature of the material and extreme abrasiveness of carbon fibers. This is why CFRP parts are usually made near net shape. However, no matter how close they are produced to the final shape, there still is an inevitable need for some post machining to obtain dimensional accuracies and tolerances. Problems such as fiber-matrix debonding, subsurface damage, rapid tool wear, matrix cracking, fiber pull-out, and delamination are usually expected to occur in machining CFRPs. These problems can affect the dimensional accuracy and performance of the CFRP part in its future application. To improve the efficiency of the machining processes, i.e. to reduce the costs and increase the surface quality, researchers began studying machining Fiber Reinforced Polymer (FRP) composites. Studies into FRPs can be divided in three realms; analytical, experimental and numerical. Analytical models are only good for a limited range [0° – 75°] of Fiber Orientations , to be found from now on as “FO” in this thesis. Experimental studies are expensive and time consuming. Also, a wide variety of controlling parameters exist in an experimental machining study; including cutting parameters such as depth of cut, cutting speed, FO, spindle speed, feed rate as well as tool geometry parameters such as rake angle, clearance angle, and tool edge/nose radius. Furthermore, the powdery dust created during machining is known to cause serious health hazards for the operator. Numerical models, on the other hand, offer the unique capability of studying the complex interaction between the tool and workpiece as well as chip formation mechanisms during the cut. Large number of contributing parameters can be included in the numerical model without wasting material. Three main objectives of numerical models are to predict principal cutting force, thrust force and post-machining subsurface damage. Knowing these, one can work on optimization of machining process by tool geometry and path design. Previous numerical studies mainly focus on the orthogonal cutting of FRP composites. Thus, the existing models in the literature are two-dimensional (2D) for the most part. The 2D finite element models assume plain stress or strain condition. Accordingly, the reported results cannot be reliable and extendable to real cutting situations such as drilling and milling, where oblique cutting of the material occurs. Most of the numerical studies to date claim to predict the principle cutting forces fairly acceptable, yet not for the whole range of fiber orientations. Predicted thrust forces, on the other hand, are generally not in good agreement with experimental results at all. Subsurface damage is reported by some experimental studies and again only for a limited FO range. To address the lack of reliable force and subsurface damage prediction model for the whole FO range, this thesis aims to develop a 3D finite element model, in hope of capturing out-of-plane displacements during stress formation in different material phases (Fiber, Matrix and the Interface bonding). ABAQUS software was chosen as the most commonly used finite element simulation tool in the literature. In present work a user-defined material subroutine (VUMAT) is developed to simulate behavior of carbon fibers during the cut. Carbon fibers are assumed to behave transversely isotropic with brittle (perfectly elastic) fracture. Epoxy matrix is simulated with elasto-plastic behavior. Ductile and shear damage models are also incorporated for the matrix. Surface-based cohesive zone technique in ABAQUS is used to simulate the behavior of the zero-thickness bonding layer. The tool is modeled as a rigid body. Mechanical properties were extracted from the literature. The obtained numerical results are compared to the experimental and numerical data in literature. The model is capable of capturing principal forces very well. Cutting force increases with FO from zero to 45° and then decreases up to 135°. The simulated thrust forces are still underestimated mainly due to the fiber elastic recovery effect. Also, the developed 3D model is shown to capture the subsurface damage generally by means of a predefined dimensionless state variable called, Contact Damage (CSDMG). This variable varies between zero to one. It is stored at each time step and can be called out at the end of the analysis. It was shown that depth of fiber-matrix debonding increases with increase in FO. / Graduate

yes / This paper presents test results of six concrete beams reinforced with longitudinal carbon fiber reinforced polymer (CFRP) bars and without vertical shear reinforcement. All beams were tested under a two-point loading system to investigate shear behavior of CFRP reinforced concrete beams. Beam depth and amount of CFRP reinforcement were the main parameters investigated. All beams failed due to a sudden diagonal shear crack at almost 45°. A simplified, empirical expression for the shear capacity of FRP reinforced concrete members accounting for most influential parameters is developed based on the design-by-testing approach using a large database of 134 specimens collected from the literature including the beams tested in this study. The equations of six existing design standards for shear capacity of FRP reinforced concrete beams have also been evaluated using the large database collected. The existing shear design methods for FRP reinforced concrete beams give either conservative or unsafe predictions for many specimens in the database and their accuracy are mostly dependent on the effective depth and type of FRP reinforcement. On the other hand, the proposed equation provides reasonably accurate shear capacity predictions for a wide range of FRP reinforced concrete beams.

Neste trabalho avaliou-se a influência da forma da seção transversal e da excentricidade do carregamento sobre o efeito de confinamento em pilares de concreto encamisados com polímeros reforçados com fibras (PRF). Para estas avaliações foi utilizada a análise experimental, por meio de ensaios de pilares sob flexo-compressão, e a análise numérica com o método dos elementos finitos. Observou-se que ocorreram reduções significativas dos efeitos de confinamento em pilares de seção quadrada e retangular quando a relação entre o raio de arredondamento dos cantos e o maior lado da seção transversal diminuiu. A influência da relação entre o lado maior e menor, no caso de pilares de seção retangular, não foi tão significativa se comparada ao efeito redutor do raio de arredondamento mencionado anteriormente. Ocorreram ganhos de resistência em todos os pilares ensaiados, indicando que o encamisamento com PRF pode ser utilizado mesmo em situações em que a força de compressão seja aplicada com pequenas excentricidades. O efeito da excentricidade sobre o confinamento dependeu da forma da seção transversal considerada. Em pilares de seção circular a excentricidade reduziu levemente os efeitos de confinamento. Nos pilares de seção quadrada a excentricidade não reduziu significativamente os efeitos de confinamento, sendo que para os menores raios de arredondamento o efeito de confinamento foi até maior na presença da excentricidade. Nos pilares de seção retangular observou-se que aplicando a excentricidade na direção da menor inércia o comportamento foi semelhante ao dos pilares de seção quadrada. Porém, aplicando a excentricidade na direção da maior inércia observou-se um grande efeito de confinamento, maior inclusive que no pilar centrado. / In this work the influence of the cross section shape and eccentricity of the compressive load on the confinement of concrete columns wrapped by fiber reinforced polymer (FRP) was evaluated. Experimental analysis, through flexural compression tests of columns, and numerical analysis developed through the finite element method were used to study these effects. Significant reductions of confinement effects were noticed in square and rectangular cross sections when the ratio of the round off radius to the major side of the column was reduced.The ratio between the major and minor side in rectangular columns was not so important to define the effectiveness of confinement as was the fore mentioned factor. Increases of strength were noticed in all columns tested, showing that FRP wrapping can be successfully used even with small eccentricities of loading. The effect of the eccentricity on the confinement showed to be dependent on the cross section shape. In circular columns the eccentricity of loading reduced the confinement effects. For the square cross section columns tested the confinement was not significantly affected by the eccentricity. In fact, for square columns with low round off radius, the eccentricity increased the confinement effects. Rectangular columns subjected to eccentric loading in the direction of the minor inertia showed a behavior similar to square columns. On the other hand, with the eccentricity applied in the direction of the major inertia, an important confinement effect was observed, more important than in the case of concentric loading.

The performance of reinforced concrete (RC) columns during recent earthquakes has clearly demonstrated the possible failures associated with inadequate confining reinforcement. The confinement reinforcement requirements of older codes were less stringent than present standards. Many studies were conducted by applying different retrofitting techniques for RC columns that have inadequate confinement reinforcement. A new retrofitting technique by means of Carbon Fiber Reinforced Polymer (CFRP) was developed and tested in many countries in the last decade. This technique is performed by CFRP wrapping the critical region of columns. The effectiveness of CFRP retrofitting technique was shown in many studies conducted worldwide. In Turkey, the frame members are considerably deficient from the seismic detailing point of view. Therefore, in order to use the CFRP retrofitting technique effectively in Turkey, experimental evidence is needed. This study investigates the performance of CFRP retrofitted RC columns with deficient confining steel and low concrete strength. It was concluded by experimental and analytical results that the CFRP retrofitting method can be implemented to seismically deficient columns. Moreover, two design approaches were proposed for CFRP retrofit design of columns considering safe design regulations.

Due to their practical application, flat-plates have been commonly used slab type in constructions in recent years. According to the investigations that were performed since the beginning of the 20th century, the vicinity of the slab-column connection is found to be susceptible to punching failure that causes serious unrepairable damage leading to the collapse of the structures. The objective of this study is to enhance the punching shear strength of slab-column connections in existing deficient flat plate structures. For this purpose, an economical and easy to install strengthening method was applied to &frac34 / scale flat-slab test specimens. The proposed strengthening scheme employs the use of in house-fabricated Carbon Fiber Reinforced Polymer (CFRP) dowels placed around the column stubs in different numbers and arrangements as vertical shear reinforcement. In addition, the effect of column aspect ratio on strengthening method was also investigated in the scope of this study. Strength increase of at least 30% was obtained for the CFRP retrofitted specimens compared to the companion reference specimen. Three-dimensional finite element analyses of test specimens were conducted by using the general purpose finite element analyses program. 3-D finite element models are successful in providing reasonable estimates of load-deformation behavior and strains. The experimental punching shear capacities and observed failure modes of the specimens were compared with the estimations of strength and failure modes given by punching shear strength provisions of ACI 318-08, Eurocode-2, BS8110-97 and TS500. Necessary modifications were proposed for the existing provisions of punching shear capacity in order to design CFRP upgrading.