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<p>Carbon-fiber reinforced polymers (CFRPs) are often used in the aerospace and automotive  industries for their high strength-to-weight ratios and corrosion resistance. A new class of  composites – known as Prepreg Platelet Molded Composites (PPMCs) – offers further  advantageous such as high forming capabilities with modest compromises in strength and stiffness.  One such property of PPMCs that have garnered interest over the years is their apparent  insensitivity to notches. Previous studies have researched the effect of specimen size and platelet  length on its effect on the open-hole performance of PPMCs. Research however has focused on  thinner samples with smaller hole sizes and neglected thicker samples with larger holes.  Additionally, while platelet sizes have been investigated for unnotched samples, platelet width on  notched samples is less clear from the literature. The present thesis offers some investigations to  aid in filling this knowledge gap. </p> <p><br></p> <p>The objective of this work is to study two parameters that could influence the performance of PPMCs under open-hole tension. First, thick (7.6 mm) specimens are subjected to large hole  sizes (up to 19.08 mm) to investigate their behavior in comparison to the smaller sample sizes  previously investigated in the literature. Through-thickness DIC measurements are taken to  investigate strain gradients in these thicker specimens. Second, various platelet widths are tested  to research their influence on notch insensitivity of open-hole tensile PPMC specimens. Lastly, a  finite element based continuum damage mechanics model is implemented to predict macro-level  structural properties using only material properties of the parent prepreg. It is found that large holes  in thick samples increase notch sensitivity compared to other samples of similar diameter-to-width  ratios. Narrower platelets were found to produce higher unnotched strengths, while wider platelets  offered more notch insensitivity. Lastly, the finite element model developed was found to  qualitatively replicate features and failure modes that are exhibited by PPMCs, though strength  predictions became inaccurate at larger specimen sizes. Recommendations are made for future  work on the basis of these findings.   </p>

This thesis investigates the effects of damage characteristics on residual compressive strength (RCS) of 4-mm thick preconditioned carbon/epoxy quasi-isotropic panels through the study of their compressive behaviour. Results of 2-mm thick preconditioned panels mostly from a previous study are also analysed. The preconditions of varying sizes include impact damage, quasi-static damage, single and multiple artificial delaminations of circular and elliptical shapes embedded at different through-the-thickness (TTT) locations, hemispherical-shaped domes of different curvature and depth and open holes. The mechanisms of impact damage and the characteristics of energy absorption were dependent on panel thickness and incident kinetic energy (IKE). A damage threshold for compressive strength (CS) reduction was found at 455-mm2 and 1257 mm2 for 2- and 4-mm thick panels, respectively. Panels affected by the presence of internal delaminations followed a sequence of prebuckling, local and global buckling (mode I) and postbuckling (mode II) in both the longitudinal and transverse directions. Their compressive failure was related to mode I to II transition. Possibility of delamination propagation was examined using response characteristics on the basis of the sequences. Evidence of delamination propagation was found only in panels with large damages and was not sensitive to RCS. For low and intermediate IKEs the effect of impact damage could be simulated with a single delamination (2-mm thick panels) and 3 delaminations of medium size (4-mm thick panels). For high IKEs, the additional effect of local curvature change was significant. The combined effect of delamination number, size and curvature change determines the RCSs. It was demonstrated that the present method of embedding artificial delaminations proves to be very useful for studying RCS of impact-damaged panels via the establishment of response characteristics and their links to the effects of the preconditions on them. This thesis also presents two analytical models, one for deflection of transversely loaded panels and the other one for the prediction of compressive strength retention factor (CSRF) based on the correlation between the ratio of maximum transverse force to initial threshold force and the CSRF, observed experimentally in thick panels.

Laminated carbon/epoxy composite structures are increasingly used in the aerospace industries. Low weight, elastic tailoring, and high durability make the composite materials well suited for replacement of conventional metallic structures. However the difficulty to capture structural failure phenomena is a significant barrier to more extensive use of laminated composites. Predictions are challenging because matrix (resin) dominated failure mechanisms such as delaminations and matrix cracking contribute to the structural failure in addition to fiber-dominated failures. A key to rigorous failure predictions for composites is availability of measurements to quantify structural model parameters including matrix-dominated stress-strain relations and failure criteria. Novel techniques for measurement of nonlinear interlaminar constitutive properties in tape composites have been recently developed at Georgia Institute of Technology. Development of methods for accurate predictions of failure in carbon/epoxy tape laminate configurations with complex lay-ups is the main focus of this work. Failures through delamination and matrix cracking are considered. The first objective of this effort is to implement nonlinear interlaminar shear stress-strain relations for IM7/8552 carbon/epoxy tape in ABAQUS finite element models and validate structural delamination failure predictions with tests. Test data for composite configurations with wavy fibers confirm that nonlinear interlaminar shear stress-strain response enables accurate failure prediction. The problem of the presence of porosity and its influence on failure was noted. The second objective is to assess the ability to simulate initiation and propagation of matrix-ply cracking. Failure models for IM7/8552 carbon/epoxy tape open-hole tensile coupons are built and validated.

As technology is developing in all automotive companies, car body designers have also investigated new materials such as composite and aluminum alloys. Designing modern car structures has also created various challenges in the production process, including formability limitations. The main purpose of this research work was to develop a test setup for an open-hole uniaxial tensile test and investigate the effect of the cutting tool on the shearing edge quality of the series 6000 aluminum alloy and materials formability as a result. To approach this significant issue, detecting the onset of necking and forming limit curves FLC using 3D digital image correlations (DIC) capabilities were studied. Two methods based on strain rate for evaluating the instability through 3D DIC and Matlab were applied. Eighteen specimens in rolling, transverse, and diagonal directions were investigated. Although the results of the tensile test machine are close for all tests, due to 3D DIC limitations, detecting the onset of necking was hard to obtain.

3D woven composites, due to the presence of through-thickness fibre bridging, have the potential to improve damage tolerance and at the same time to reduce the manufacturing costs. However, the ability to withstand damage depends on weave architecture as well as the geometry of individual tows. A substantial amount of research has been performed to understand in-plane properties as well as the performance of 3D woven composites exposed to impact loads, but there is limited research on the damage tolerance and notch sensitivity of 3D weaves and no work is reported on the damage tolerance of 3D weaves with a weft binding pattern. In view of the recent interest in 3D woven composites, the influence of weft binder on the tensile, open hole tensile, impact resistance and subsequent residual compressive strength properties and failure mechanisms of 3D woven composites was investigated against equivalent UD cross-ply laminate. Four different 3D woven architectures; layer-to-layer, angle interlocked, twill angle interlock and modified angle interlock structures were produced under identical weaving conditions. All the above mentioned tests were performed in both the warp and weft directions on 3D woven and UD cross-ply laminates. Stress concentration and yarn waviness due to through-thickness reinforcement led to lower mechanical properties compared with the UD cross-ply laminate. However, improved in-plane and damage tolerance properties of 3D woven composites under tensile loads were achieved by modifying the weave architecture. The influence of the weave architecture and binder yarn orientation on the notch insensitivity and damage tolerance of 3D woven composites was less significant for compressive loads. Despite the lower undamaged compression strength of 3D woven structures, their residual compressive strength was found to be superior to their equivalent UD cross-ply laminates. The lower rate of strength reduction in the 3D woven fabrics laminates was attributed to a crack bridging mechanism, effectively inhibiting delamination propagation.

Coatings utilizing the piezospectroscopic (PS) effect of alpha alumina could enable on the fly stress sensing for structural health monitoring applications. While the PS effect has been historically utilized in several applications, here by distributing the photo-luminescent material in nanoparticle form within a matrix, a stress sensing coating is created. Parallel to developing PS coatings for stress sensing, the multi-scale mechanics associated with the observed PS response of nanocomposites and their coatings has been applied to give material property measurements, providing an understanding of particle reinforced composite behavior. Understanding the nanoparticle-coating-substrate mechanics is essential to interpreting the spectral shifts for stress sensing of structures. In the past, methods to experimentally measure the mechanics of these embedded nano inclusions have been limited, and much of the design of these composites depend on computational modeling and bulk response from mechanical testing. The PS properties of Chromium doped alumina allow for embedded inclusion mechanics to be revisited with unique experimental setups that probe the particles state of stress under applied load to the composite. These experimental investigations of particle mechanics will be compared to the Eshelby theory and its derivative theories in addition to the nanocomposite coating mechanics. This work discovers that simple nanoparticle load transfer theories are adequate for predicting PS properties in an intermediate volume fraction range. With fundamentals of PS nanocomposites established, the approach was applied to selected experiments to prove its validity. In general it was observed that the elastic modulus values calculated from the PS response were similar to that observed from macroscale strain measurements such as a strain gage. When simple damage models were applied to monitor the elastic modulus, it was observed that the rate of decay for the elastic modulus was much higher for the PS measurements than for the strain gage. A novel experiment including high resolution PS maps with secondary strain maps from digital image correlation is reviewed on an open hole tension, composite coupon. The two complementary measurements allow for a unique PS response for every location around the hole with a spatial resolution of 400 microns. Progression of intermediate damage mechanisms was observed before digital image correlation indicated them. Using the PS nanocomposite model, elastic modulus values were calculated. Introducing an elastic degradation model with some plastic deformation allows for estimation of material properties during the progression of failure. This work is part of a continuing effort to understand the mechanics of a stress sensing PS coating. The mechanics were then applied to various experimental data that provided elastic property calculations with high resolution. The significance is in the experimental capture of stress transfer in particulate composites. These findings pave the way for the development of high resolution stress-sensing coatings.

Carbon Fiber / Epoxy Laminates are increasingly being used in the primary structure of aircraft. To make effective use these materials, it is necessary to consider the ability of a laminate to resist damage, as well as material strength and stiffness. A possible means for improving damage tolerance is the use of non-traditional composite laminates, in which the longitudinal 0 plies are replaced with 5 or 10 plies. The main objectives of this collaborative Georgia Tech / Boeing research was the characterization of these non-traditional laminates, and the determination of appropriate lamina-level analytical techniques that are capable of predicting the changes caused by the use of slightly off-axis longitudinal plies. A quasi-isotropic [45/90/-45/theta/45/90/-45/-theta]s and hard [45/theta/-45/theta/90/45]s lay-up, where theta =0,5 or 10, were tested in open hole tension, filled hole tension, open hole compression, single shear bearing, and unnotched tension. These coupon level tests illustrated the effects of lay-up, notch constraint, and load type on traditional and non-traditional laminates. Die penetrant enhanced in-situ radiography was performed to determine the extent of damage suppression. The use of non-traditional laminates was found to reduce longitudinal ply cracking and delamination, with significant effect on the stress distribution around the notch. The use of non-traditional laminates also resulted in a 15%-20% improvement in bearing strength of the traditional laminates. Several predictive techniques were implemented to evaluate their ability to predict the effect of slight changes in ply orientations. A progressive damage model was written to compare Tsai-Wu, Hashin, and Maximum Stress unnotched strength criterion. Additionally, several semi-empirical failure theories for notched strength prediction were compared with linear and bi-linear cohesive zone models to determine applicability to non-traditional laminates.