In recent years, the prevalence and application of composite materials has exploded. Due to the demands of commercial transportation, the aviation industry has taken a leading role in the integration of composite structures. Among the leading concepts to develop lighter, more fuel-efficient commercial transport is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. The highly integrated structure of PRSEUS allows pressurized, non-circular fuselage designs to be implemented, enabling the feasibility of Hybrid Wing Body (HWB) aircraft. In addition to its unique fabrication process, the through-thickness stitching utilized by PRSEUS overcomes the low post-damage strength present in typical composites. Although many proof-of-concept tests have been performed that demonstrate the potential for PRSEUS, efficient computational tools must be developed before the concept can be commercially certified and implemented. In an attempt to address this need, a comprehensive modeling approach is developed that investigates PRSEUS at multiple scales. The majority of available experiments for comparison have been conducted at the coupon level. Therefore, a computational methodology is progressively developed based on physically realistic concepts without the use of tuning parameters. A thorough verification study is performed to identify the most effective approach to model PRSEUS, including the effect of element type, boundary conditions, bonding properties, and model fidelity. Using the results of this baseline study, a high fidelity stringer model is created at the component scale and validated against the existing experiments. Finally, the validated model is extended to larger scales to compare PRSEUS to the current state-of-the-art. Throughout the current work, the developed methodology is demonstrated to make accurate predictions that are well beyond the capability of existing predictive models. While using commercially available predictive tools, the methodology developed herein can accurately predict local behavior up to and beyond failure for stitched structures such as PRSEUS for the first time. Additionally, by extending the methodology to a large scale fuselage section drop scenario, the dynamic behavior of PRSEUS was investigated for the first time. With the predictive capabilities and unique insight provided, the work herein may serve to benefit future iteration of PRSEUS as well as certification by analysis efforts for future airframe development. / PHD

Ce travail de thèse s’est déroulé dans le cadre du projet de nanolanceur à propulsion hybride PERSEUS du CNES. La performance de ce concept est influencée par l’allègement de la structure du lanceur. La voie de développement qui a été choisie est de supprimer le liner du réservoir composite cryogénique. Elle repose sur trois exigences fonctionnelles : la compatibilité du matériau composite avec l’oxygène liquide (LOX), l’étanchéité du réservoir, et la résistance aux sollicitations thermomécaniques.L’étude de la compatibilité LOX des matériaux composites met en évidence l’importance du transfert de chaleur au sein du composite et plus précisément de la conductivité thermique des fibres. Ce résultat théorique est conforté par l’expérimentation.Le verrou scientifique principal du travail de thèse concerne l'influence de l’endommagement du composite sur la perméabilité de ce dernier. La conception de dispositifs expérimentaux a permis de déterminer l’évolution des endommagements (fissuration transverse, micro-délaminage, ouverture de fissure) et celle de la perméabilité. Un modèle complet de prévision de la perméabilité d’une paroi composite sollicitée thermo-mécaniquement est proposé. Il s’articule autour d’un modèle d’endommagement à l’échelle du pli, d’un modèle de prédiction de l'ouverture des fissures, et d’un modèle d’écoulement en milieu poreux. La pertinence du modèle développé est testée à travers la réalisation d’un démonstrateur technologique sans liner et d’une campagne d’essais d’endommagement et de mesure de perméabilité. / This thesis deals with hybrid propulsion launcher systems studied by the CNES (Centre National d'Etudes Spatiales). The performance of the launcher implies its lightening and in this work, the use of a cryogenic composite linerless tank is evaluated. Three functional requirements must be satisfied: the compatibility between the composite material and the liquid oxygen (LOX), the tank gas-tightness and the strength under pressure.The LOX compatibility of composite materials implies high thermal conductivity of the composite, and consequently of the fiber reinforcement. This theoretical result is confirmed by experiments.The main scientific challenge concerns the damage influence on the composite permeability. Specific experimental devices allow determining the damage evolution (transverse cracking, delamination, opening crack) and the composite permeability. A predictive composite permeability model is applied to a composite wall under thermomechanical load: this model includes a ply-scale damage model, a predictive opening crack model and a model of flow through porous media. The relevance of the model is validated through the realization of a linerless prototype tank and the associated tests which correlate damage and permeability.

This work presents a detailed predictive modeling methodology for comprehensive crashworthiness analysis of advanced jet engine forward sections, containing hybrid and composite structures, when subjected to soft impact. Bird strike onto the fan assembly is chosen as the impact event to be studied. The aim is to develop a numerical methodology capable of accurately capturing the full range of multifaceted damage in hybrid and composite structures as they evolve throughout the forward section of a propulsion system. Effective strategies are developed within an explicit finite element framework for modeling a bird, an engine forward section, intra-ply and inter-ply composite damage, and hybrid structural failure. The accuracy of each approach and their numerical modeling considerations are thoroughly investigated. These techniques are then combined to form the full crashworthiness methodology. It is demonstrated that the complete methodology effectively captures progressive hybrid fan blade fracture, leading edge de-bonding, composite casing delamination, and other significant progressive damage effects caused by direct impact and subsequent engine component interactions. The full damage prognosis capabilities demonstrated by this approach encompass aspects which have remained mainly unaddressed in soft impact analysis. A methodology for assessing the complete extent of impact damage for advanced structural engine designs represents a breakthrough that can contribute greatly to the rapid development of these systems in the future. / Master of Science

Three dimensional (3D) woven composites have attracted the interest of academia and industry thanks to their damage tolerance characteristics and automated fabric manufacturing. Although much research has been conducted to investigate their out-of-plane "through thickness" properties, still their in-plane properties are not fully understood and rely on extensive experimentation. The aim of this work is to study the electromechanical behaviour of three different fibre architectures of 3D woven composites "orthogonal (ORT), layer-to-layer (LTL) and angle interlock (AI)" loaded, in three different orientations "warp (0º), weft (90º) and off-axis (45º)", in quasi-static tension. Stress/strain response is captured as well as damage initiation and evolution up to final failure. The ORT architecture demonstrated a superior behaviour, in the off-axis direction, demonstrated by high strain to failure (~23%) and high translaminar energy absorption (~40 MJ/m3). The z-binder yarns in ORT suppress delamination and allow larger fibre rotation during the fibre "scissoring motion" that enables further strain to be sustained. In-situ electrical resistance variation is monitored using a four-probe technique to correlate the resistance variation with the level of damage induced while loading. Monotonic and cyclic "load/unload" tests are performed to investigate the effect of piezo-resistivity and residual plasticity on resistance variation while damage is captured by X-ray scanning during interrupted tests at predefined load levels. In addition, this study investigates the potential of using 3D woven composites in joint assemblies through open-hole tension and "single fastener double-lap joint" bearing strength tests. 3D woven composites in the off-axis orientation, especially ORT, demonstrate a potential for overcoming some of the major challenges for composite joints' applications which are the pseudo-ductility, stress redistribution away from the notch and notch insensitivity. Finally, the study proposes a micro-mechanics based damage model to simulate the response of 3D orthogonal woven composites loaded in tension. The proposed model differs from classical damage mechanics approaches in which the evolution law is obtained by retrofitting global experimental observations.

The future of the aerospace industry in large part relies on two factors: (i) development of advanced damage tolerant materials and (ii) development of advanced smart sensors with the ability to detect and evaluate defects at very early stages of component service life. Laminated composite materials, such as carbon fibre reinforced plastics (CFRP), have emerged as the materials of choice for increasing the performance and reducing the cost and weight of aircrafts, which leads to less fuel consumption and therefore lower CO2 emissions. However, it is well known that these materials exhibit fragile behaviour, poor resistance to impact damage caused by foreign objects and require a relatively slow and labour intensive manufacturing process. These factors prevent the rapid expansion of composite materials in several industrial sectors at the current time. Inspired by the use of rope throughout history and driven by the necessity of creating a lean manufacturing process for composites and enhancing their impact properties, the first part of this work has shown that enhanced damage tolerance and pseudo-ductile behaviour can be achieved with standard CFRP by creatively arranging the fibres into a 3D twisted helical configuration. Through an extensive experimental campaign a new method to arrange fibre reinforcement was presented and its effect investigated. The second part of this PhD work focused on developing a new smart sensor. A spiral passive electromagnetic sensor (SPES) for damage detection on CFRP and glass fibre reinforced plastics (GFRP) is presented in this work. A range of defect types in glass and carbon composite has been considered, such as delamination, perforated holes and cracks. Furthermore, throughout this work, the SPES has been exploited as a multi-sensing device allowing the ability to detect temperature and humidity variation, presence of ice and act as an anti/de-icing device.

Aerospace research for next-generation travel increasingly focuses on the use of advanced composites to reduce weight and cost while retaining strength. One subset of materials with great potential is based on the combination of resin matrix and glass-fiber reinforcement. This research explores the application of a candidate nanopaper coating with a given composite. Prior research applied a set of given heat fluxes to the top surface of the composite for a set of given periods of time, and subsequently performed a 3-point flexural test to determine the elastic modulus for both the coated and uncoated composite for all of the combinations of heat flux and time. A finite element (FE) model is developed using the ANSYS general purpose finite element analysis (FEA) software that models the degradation in strength/stiffness properties based on heating condition and with the goal of predicting cracking using the element death feature in ANSYS. This thesis describes the prior research suggesting both the need for and novelty of this model, and the procedures used to form the model. The loading conditions of the 3-point flexural test are replicated, and four measures of accuracy are developed based on the force versus displacement curve of the test and the FE model. It is envisioned that continuum-level models developed as a part of these research be applied for design of next-generation space components These measurements are used to verify the FE model, and this model is then employed to extrapolate beyond the context of experimental conditions.