Laminated carbon fibre-reinforced polymer (CFRP) composites are already well established in structural applications where high specific strength and stiffness are required. Damage in these laminates is usually localised and may involve numerous mechanisms, such as matrix cracking, laminate delamination, fibre debonding or fibre breakage. Microstructures in CFRPs are non-uniform and irregular, resulting in an element of randomness in the localised damage. This may in turn affect the global properties and failure parameters of components made of CFRPs. This raises the question of whether the inherent stochasticity of localised damage is of significance for application of such materials. This PhD project is aimed at developing numerical models to analyze the effect of material randomness on delamination damage in CFRP materials by the implementation of the cohesive-zone model (CZM) within the framework of the finite-element (FE) method. Both the unidirectional and cross-ply laminates subjected to quasi-static loading conditions were studied. The initiation and propagation in delamination of unidirectional CFRP laminates were analyzed. The CZM was used to simulate the progress of that failure mechanism in a pre-cracked double-cantilever beam (DCB) specimen loaded under mode-I employing initially, a two-dimensional FE model. Model validation was then carried out comparing the numerical results with experimental data. The inherent microstructural stochasticity of CFRP laminates was accounted for in the simulations, and various statistical realizations for a half-scatter of 50% of fracture energy were performed, based on the approximation of that parameter with the Weibull s two-parameter probability density function. More detailed analyses were undertaken employing three-dimensional DCB models, and a number of statistical realizations based on variation of fracture energy were presented. In contrast to the results of two-dimensional analyses, simulations with 3D models demonstrated a lower load-bearing capacity for most of the random models as compared to the deterministic model with uniform material properties. The damaged area and the crack lengths in laminates were analyzed, and the results showed higher values of those parameters for random realizations compared to the uniform case for the same levels of applied displacement. The effect of material randomness on delamination in CFRP cross-ply laminates was also investigated. Initially, two-dimensional finite-element analyses were carried out to study the effect of microstructural randomness in a cross-ply laminate under bending with the direct introduction of matrix cracks with varying spacings and delamination zones. A considerable variation in the stiffness for cases with different crack spacings suggested that the assumption of averaged distributions of defects can lead to unreliable predictions of structural response. Three-dimensional uniform, deterministic cross-ply laminate models subjected to a tensile load were analyzed to study the delamination initiation and propagation from the tips of a pre-existing matrix crack. The material s stochasticity was then introduced, and a number of random statistical realizations were analyzed. It was observed that by neglecting the inherent material randomness of CFRP laminates, the initiation conditions for delamination as well as the character of its propagation cannot be properly detected and studied. For instance, the delamination crack length value for all the simulated random statistical realizations predicted its higher magnitudes compared to the uniform (deterministic) case for the same value of applied strain. Furthermore, the location of delamination initiation was shown to be different for different random statistical realizations. Another aspect, emphasizing the importance of microstructural randomness, was the scatter in the magnitudes of global strain at the instance of initiation and subsequent propagation of delamination. In summary, the material randomness in CFRPs can induce randomness in localised damage and it can affect the global properties of laminates and critical failure parameters. These effects can be investigated computationally through the use of stochastic cohesive-zone elements.

This thesis deals with numerical simulation of a peel test with an Aluminium foil and Low Density Poly-Ethylene (LDPE) laminate. This work investigates the effects of the substrate thickness and studies the influences of interfacial strength and fracture energy of the cohesive zone between the Aluminium and LDPE. This study evaluates the proper guidelines for defining cohesive properties. A numerical cohesive zone model was created in ABAQUS. Continuum tensile tests were performed to extract LDPE material properties. The aluminium properties were found in literature. After acquiring material parameters, the simulation continued with studying the effects of changing interfacial strength, geometric parameters and fracture energy. The results were obtained in the form of root rotations and the force displacement response was studied carefully. It was validated by comparison to the traction separation curve.

To support the trust in the design development of adhesively bonded joints, it is important to precisely predict their mechanical failure load. A numerical simulation model with a two-dimensional linear elastic cohesive zone model using a combination of a soft and a stiff adhesive is developed to optimize the strength of a lap-joint. Separation under mixed-mode conditions (normal and shear direction) is considered. By varying the length of the adhesives, the fracture load is optimized. The results obtained from the numerical experiments show an improvement in strength.

In recent decades, a significant research has been carried out towards understanding the behaviour of plated beam. Initially designed to achieve a desired capacity, the plated beams prematurely fail in undesirable modes of failure, such as debonding and peeling. The uncertainty related with such modes of failure poses a real challenge towards quantifying them. This field is far from being clearly understood. Therefore, an attempt is made in this thesis to accurately predict the behaviour of adhesively plated beams.

Les revêtements de couches minces soumis à de fortes contraintes de compression peuvent subir un phénomène de flambage et de délaminage simultané appelé « cloquage ». Le mécanisme de formation et de propagation des cloques en forme de rides droites et des cloques circulaires a largement été étudié dans la littérature en considérant un comportement élastique linéaire pour le film. Cependant, l’effet de la plasticité sur la propagation et l’équilibre de telles cloques, bien que constaté expérimentalement, n’avait pas encore été vraiment étudié à ce jour.Dans ce travail nous nous intéressons tout d’abord à l’observation et à la caractérisation des structures de flambement observées sur des film d’or déposés sur des substrats en silicium. Des effets de la plasticité sur la morphologie ou la charge critique de flambage des structures cloquées sont mis en évidence de manière quantitative grâce à des techniques d'observation morphologique comme l'AFM, ainsi que des tests mécaniques par nano-indentation et des mesures de contrainte.Un modèle mécanique est développé, permettant de modéliser le film comme une plaque non-linéaire géométrique au comportement élasto-plastique en contact unilatéral sur un support rigide représentant le substrat. De plus, un modèle de zone cohésive est introduit entre la plaque et le support de manière à prendre en compte le délaminage du film, avec un travail de séparation dépendant de la mixité modale du chargement.Ce modèle nous a permis de mettre en évidence l’effet de la plasticité sur les profils d’équilibres résultant du cloquage élasto-plastique, pour des morphologies de cloques en ride droite et de cloque circulaire. L'effet sur le décalage de la charge critique de flambage a également été étudié. Enfin, l'influence de la déformation plastique sur le mécanisme de propagation de la rupture interfacial lui même a été étudiée. En particulier, un effet de stabilisation de la forme de cloque circulaire, qui avait été observé expérimentalement dans diverses études, a pu être démontré par le calcul. / Thin film coatings submitted to high compressive stresses may experience a simultaneous buckling and delamination phenomenon called "blistering". The mechanism of formation and propagation of blisters in the form of straight wrinkles and circular blisters has been extensively studied in the literature considering a linear elastic behavior for the film. However, the effect of plasticity on the propagation and mechanical equilibrium of such blisters, although experimentally observed, had not been systematically studied to date.In this work, we are interested in the observation and characterization of buckling structures observed on gold films deposited on silicon substrates. The effects of plasticity on the morphology or critical buckling load of buckled structures are quantitatively demonstrated using small scale surface observation techniques such as AFM, as well as mechanical testing by nanoindentation tests and stress measurement methods.A mechanical model is developed in order to model the film as a geometric nonlinear plate with elastic-plastic behavior in unilateral contact with a rigid support representing the substrate. In addition, a cohesive zone model is introduced between the plate and the support in order to take into account the delamination of the film, with a separation work depending on the mode mix of the interface loading.This model allowed us to highlight the effect of plasticity on the equilibrium profiles resulting from elastic-plastic blistering, for both straight and circular blisters morphologies. The effect on the offset of the critical buckling load has also been studied. Finally, the influence of plastic deformation on the propagation mechanism of the interfacial fracture itself has been studied. In particular, a stabilizing effect of the circular blister form, which has been observed experimentally in various studies, has been demonstrated through calculation.

<p>Fracture of silicon solar cells in photovoltaic (PV) modules are widely reported and a wellknown issue in the PV industry, since it is exposed to adverse climatic conditions and varying temperature loads. A commercial silicon solar cell is mainly composed of four different layers. This thesis investigates delamination failure and thermal fatigue failure due to alternating temperature loads using finite element method (FEM) simulation.</p> <p><br></p> <p>The delamination of the encapsulant (EVA) layer and the cell interface was simulated using</p> <p>finite element (FE) simulations in the COMSOL Multiphysics software. The adhesion between the</p> <p>layers were modeled using the cohesive zone model (CZM). The CZM parameters such as normal</p> <p>strength and penalty stiffness were used for the bilinear traction-separation law for the cohesive</p> <p>model in a 90-degree configuration. The critical energy release rate (𝐺𝐺𝑐𝑐) was experimentally calculated as one of the CZM parameters. A uniaxial tensile test of the upper layer of the cell was conducted to determine the material properties of the solar cell layers, and that information was</p> <p>later used for FE simulations. To validate the simulation, we compared the peeling force graph</p> <p>from the experiment and FE simulation, and it was found both graphs showed a maximum peeling</p> <p>force of 120 N.</p> <p><br></p> <p>Finite element simulations were also conducted to predict the stress variations in the silicon</p> <p>solar cell layer due to alternating temperatures. An alternating temperature function was developed</p> <p>using triangular waveform equations in the COMSOL Multiphysics software. For this simulation,</p> <p>a 3D model of the cell with a 90-degree peel arm was used, like in the peeling simulation. A</p> <p>maximum stress of 7.31 x 10−3 𝑁/𝑚𝑚2 was observed on the encapsulant (EVA)/cell layer, but no</p> <p>delamination was observed for the given temperature range. In future work, we plan to explore the</p> <p>calculation of fatigue life using thermal simulation to predict the reliability of a solar cell.</p>

With increasing climate change the automotive industry is facing increasing demands regarding emissions and environmental impact. To lower emissions and environmental impact the automotive industry strives to increase the efficiency of vehicles by for example reducing the weight. This can be achieved by the implementation of lightweight products made of composite materials where different materials must be joined. A key technology when producing lightweight products is adhesive joining. In an effort to expand the implementations of structural adhesives Volvo Buses wants to increase their knowledge about adhesive joining techniques. This thesis is done in collaboration with Volvo Buses and aims to increase the knowledge about numerical simulations of adhesively bonded joints. A numerical model of an adhesively bonded T-joint is presented where the adhesive layer is modelled using the Cohesive Zone Model. The experimental extraction of cohesive laws for adhesives is discussed and implemented as bi-linear traction-separation laws. Experiments of the T-joint for two different load cases are performed and compared to the results of the numerical simulations. The experimental results shows a similar force-displacement response as for the results of the numerical simulations. Although there were deviations in the maximum applied load and for one load case there were deviations in the behavior after the main load drop. The deviations between numerical and experimental results are believed to be due to inaccurate material properties for the adhesive, the use of insufficient bi-linear cohesive laws, the occurrence of a combination of adhesive and cohesive fractures during the experiments and dissimilar effective bonding surface areas in the numerical model and the physical specimens.

Ce travail concerne des expériences mécaniques, des analyses numériques et des modélisations analytiques de la rupture cohésives (Mode I), vis-à-vis de l’étude du comportement mis en évidence par la courbe de Résistance (Courbe-R) et l’effet d’échelle de structures entaillées en bois massif. Des expériences de fissuration sont combinées à des analyses numériques pour déterminer les propriétés de rupture au moyen d’une procédure appelée Théorie de la Mécanique de la Rupture Linéaire Élastique équivalente (TMRLE), basée sur la complaisance de la structure. La courbe-R, obtenue à partir des expériences, selon une méthode de correction du poids propre, montre l’existence d’un domaine endommagé (Zone de Processus de Rupture) de taille non négligeable se développant en fond de fissure. Dans des conditions de fissuration stationnaire, ce domaine atteint une taille critique, et l’énergie nécessaire pour faire propager la fissure avec ce domaine endommagé (par unité de surface de rupture), reste constante. Le taux de libération de l’énergie de fissuration ainsi attendu, joue un rôle important en Mécanique de la Rupture, car il est possible simuler le comportement quasi-fragile du matériau en combinaison avec les autres propriétés de cohésion. La loi d’effet d’échelle de Bažant, utilisée pour prévoir l’influence de la taille sur la contrainte nominale, est estimée à partir de la réunion de deux comportements asymptotiques réalisés sur de petites tailles (Analyse limite ou RdM) et des grandes tailles. Une procédure analytique est présentée pour évaluer le comportement asymptotique additionnel exhibé par la contrainte nominale dans le régime intermédiaire, de façon plus exacte. Une validation numérique est présentée, et l’information expérimentale vient confirmer ce comportement asymptotique. / This work concerns the mechanical testing, numerical analysis and modelling of cohesive fracture (Mode I) on the purpose to study the Resistance-curve behaviour and the size effect in wooden notched structures. The mechanical testing is combined with the numerical analysis to evaluate fracture properties by means of an equivalent LEFM approach based on the structure compliance. The Resistance-curve being revealed from the experiments, by means of a self-weight compensation method, correction puts into evidence that a non-negligible damaged domain (Fracture Process Zone) is under development in the crack front during the loading process. This being the case, among other fracture parameters issued from the Resistance-curve, the critical (asymptotic) energy release rate is determined, turning possible to use it in combination with other cohesive crack properties in the crack modelling (in Mode I). Thus, for a given geometry it is possible to monitor the critical dimension being revealed by the Fracture Process Zone (FPZ) during the crack propagation. The well known Bažant’s size effect law provides the scaling of the nominal strength through the asymptotic matching performed both on the small (Strength Theory) and on the large (LEFM) structure sizes. An analytical procedure is proposed to determine an additional asymptotic regime in the intermediate size range through a more accurate manner. Numerical validations of the proposed procedure are made and experimental data is presented revealing the scaling of the nominal strength through an envelop of values.

<p dir="ltr">In structural metallic components, a material’s lifecycle begins with the processing route, to produce a desired structure, which dictates the in-service performance. The variability of microstructural features as a consequence of the processing route has a direct influence on the properties and performance of a material. In order to correlate the influence processing conditions have on material performance, large test matrices are required which tend to be time consuming and expensive. An alternative route to avoid such large test matrices is to incorporate physics-based process modeling and lifing paradigms to better understand the performance of structural materials. By linking microstructural information to the material’s lifecycle, the processing path can be modified without the need to repeat large-scale testing requirements. Additionally, when a materials system is accurately modeled throughout its lifecycle, the performance predictions can be leveraged to improve the design of materials and components.</p><p dir="ltr">Ni-based superalloys are a material class widely used in many critical aerospace components exposed to coupling thermal and mechanical loads due to their increased resistance to creep, corrosion, oxidation, and strength characteristics at elevated temperatures. Many Ni-based superalloys undergo high-temperature forging to produce a desired microstructure, targeting specific strength and fatigue properties in order to perform under thermo-mechanical loads. When in-service, these alloys tend to fail as a consequence of thermo-mechanical fatigue (TMF) from either inclusion- or matrix- driven failure. In order to produce safer, cheaper and more efficient critical aerospace components, the micromechanical deformation and damage mechanisms throughout a Ni-based superalloy’s lifecycle must be understood. This research utilizes process modeling as a tool to understand the damage and deformation of inclusions in a Ni-200 matrix throughout radial forging as a means to optimize the processing conditions for improved fatigue performance. In addition, microstructural sensitive performance modeling for a Ni-based superalloy is leveraged to understand the influence TMF has on damage mechanisms.</p><p dir="ltr">The radial forging processing route requires both high temperatures and large plastic deformation. During this process, non-metallic inclusions (NMIs) can debond from the metallic matrix and break apart, resulting in a linear array of smaller inclusions, known as stringers. The evolution of NMIs into stringers can result in matrix load shedding, localized plasticity, and stress concentrations near the matrix-NMI interface. Due to these factors, stringers can be detrimental to the fatigue life of the final forged component. By performing a finite element model of the forging process with cohesive zones to simulate material debonding, this research contributes to the understanding of processing induced deformation and damage sequences on the onset of stringer formation for Alumina NMIs in a Ni-200 matrix. Through a parametric study, the interactions of forging temperature, strain rate, strain per pass, and interfacial decohesion on the NMI damage evolution metrics are studied, specifically NMI particle separation, rotation, and cavity formation. The parametric study provides a linkage between the various processing conditions parameters influence on detrimental NMI morphology related to material performance.</p><p dir="ltr">The microstructural characteristics of Ni-based superalloys, as a consequence of a particular processing route, creates a variability in TMF performance. The micromechanical failure mechanisms associated with TMF are dependent on various loading parameters, such as temperature, strain range, and strain-temperature phasing. Insights on the complexities of micromechanical TMF damage are studied via a temperature-dependent, dislocation density-based crystal plasticity finite element (CPFE) model with uncertainty quantification. The capabilities of the model’s temperature dependency are examined via direct instantiation and comparison to a high-energy X-ray diffraction microscopy (HEDM) experiment under coupled thermal and mechanical loads. Unique loading states throughout the experiment are investigated with both CPFE predictions and HEDM results to study early indicators of TMF damage mechanisms at the grain scale. The mesoscale validation of the CPFE model to HEDM experimental data provides capabilities for a well-informed TMF performance paradigm under various strain-temperature phase profiles. </p><p dir="ltr">A material’s TMF performance is highly dependent on the temperature-load phase profile as a consequence of path-dependent thermo-mechanical plasticity. To investigate the relationship between microstructural damage and TMF phasing effects, the aforementioned CPFE model investigates in-phase (IP) TMF, out-of-phase (OP) TMF, and iso-thermal (ISO) loading profiles. A microstructural sensitive performance modeling framework with capabilities to isolate phasing (IP, OP, and ISO) effects is presented to locate fatigue damage in a set of statistically equivalent microstructures (SEMs). Location specific plasticity, and grain interactions are studied under the various phasing profiles providing a connection between microstructural material damage and TMF performance.</p>