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.