My work reflects the change, growth, metamorphosis, duality, and balance that exists in my life. I focus on the process of change and necessity for adaptation. I’m interested in finding balance among the chaos of everyday living. I’m an observer, an introvert, and a thinker. I see and experience opposing forces all around me. Some are simple observations, such as good versus evil, chaos versus order, organic versus geometric, while some are more personal, such as anxiety versus depression, conflict between the inner versus outer self, disorganization versus obsessive compulsive. I’m fascinated by the delicate point at which opposing forces meet to create balance. I use a variety of papers, found objects, fiber, paint, drawing, and stitching to represent things that are picked up along my journey. Using a variety of materials and imagery represents the chaos of life. Editing, rearranging, dissecting, and reassembling these materials and imagery with deliberate choice are a way to balance the chaos I see and experience to take back control.

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is characterized by through-thickness VectranTM stitching of warp-knit carbonabric prior to resin infusion. A series of novel lightning strike tests were performed on a PRSEUS panel. The panel’s lightning damage resistance was characterized as a function of peak current (50-200 kA) and strike location (mid-bay, stringer, frame). Both visual inspections and through-transmission-ultrasonic C-scans were used to investigate the damage resistance at the strike locations and to assess various damage mechanisms and morphologies. The size and severity of the damaged area depend strongly on the fiber orientation in the outermost ply, the amount of current injected into the panel, and the strike location relative to stitching lines. Increasing the current magnitude drastically increases the damaged area. Also, the presence of VectranTM structural stitches profoundly reduced the size and severity of lighting damage relative to similar strikes performed in panel regions without stitching.

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

L'objectif des travaux exposés dans cette thèse est d'identifier les différentes propriétés des constituants du sandwich cousu in-situ. Cette identification est indispensable pour simuler le comportement de ce type de matériau composite à différentes sollicitations statiques ou dynamiques. Nous proposons dans cette thèse de faire Une identification dynamique faite sur un échantillon représentatif (une plaque) qui prend en compte l'hétérogénéité et complexité de la structure. Cette identification est basée sur la corrélation ent.re un essai vibratoire et un calcul par éléments finis. La corrélation se fait en minimisant une fonction coût qui porte sur le décalage entre fréquences propres expérimentales et numériques. Cette minimisation est précédée par une identification du couple (fréquence propre/mode propre) numérique et expérimental en utilisant le MAC (Modal Assurance Criterion). Pour optimiser, nous passons, dans un premier temps; par une analyse de sensibilité qui permet de classifier les paramètres en fonction de• leur importance et ainsi ne lancer le processus d'identification que sur un nombre réduit de paramètres. Nous avons appliqué cette approche sur une poutre sandwich cousue et une plaque sandwich cousue. Dans une deuxième partie de ce travail de thèse, nous avons pu mettre au profil l'aspect périodique de ces structures composites sandwichs cousues, en utilisant le théorème de Floquet­-Bloch, et cela sur deux plans : l'aspect numérique pour la réduction du modèle et du temps de calcul et sur le plan physique par l'étude des bandes d'arrêt ('stopband') qui ont un intérêt applicatif assez intéressant. / The sandwich structures are well known for their high bending stiffness. This type of structure is also capable of including acoustic and thermal functionalities. However, they also have weaknesses such as the connection between the faceplate and the core and the weakness in the transverse direction due to the property of the core. The core is usually made of soft materials like foam for acoustic functionality. To overcome these weaknesses, it is possible to connect the different layers of the sandwich by transverse stitches. This is the concept of ‘stitched sandwich’. The stitch will deeply change the behavior of the structure and complicate the determination of its properties. The objective of this thesis is to identify the properties of the constituents of the stitched sandwich in situ. These properties are essential to simulate the behavior of this type of composite material under static or dynamic excitation. The identification of the properties of the constituents by mechanical tests is difficult for various reasons: the heterogeneity makes it complex to extract representative specimen; the behaviors of the constituents may change in non-in-situ tests; several different types of mechanical test, such as tensile-compression and torsion, are necessary to determine all the engineering constants in the case of orthotropic material which is common for composite materials. To overcome all these difficulties, we propose in this thesis a dynamic identification method conducted on the structure (the whole plate for example). Compared to mechanical test which is based on a sample, this method takes into account the heterogeneity and complexity of the structure. This method is based on the correlation between the vibration test and a finite element model of stitched sandwich. The parameters are identified by minimizing a cost function which can measure the gap between the experimental frequencies and the calculated frequencies. The correspondence of experimental mode and calculated mode is guaranteed by MAC (Modal Assurance Criterion). Before the optimization, we propose firstly a sensitivity analysis to classify the parameters according to their importance. Then the identification process is only conducted on a reduced number of parameters. We have applied this dynamic identification method to both a stitched sandwich beam and a stitched sandwich plate. 9 parameters of different constituents are identified in the case of plate. In the second part of this thesis, based on the theorem of Floquet-Bloch, we have profited from the periodic characteristic of the stitched sandwich structures in two aspects: in the numerical aspect, the periodicity has served to reduce the calculation of forced response of periodic structure; in the physical aspect, we have studied the stop band of stitched structures.

Producing composite parts using low-cost processes such as resin transfer moulding (RTM) has received much interest in the aerospace industry. RTM manufactured components require near net shape preforms which closely fit mould cavities. To reduce labour costs associated with composite production, automated preforming processes must be utilized. However, obtaining reproducible high quality preforms is required for manufacturing consistent high quality parts. Stitched multilayer 3D non crimp fabric preforms are well suited for automation and an investigation into quality and performance of components manufactured from these preforms is required. This thesis provides an initial evaluation of quality and mechanical properties of components made from stitched multilayer 3D non crimp fabric preforms using RTM. Similar sized flat plates of varying fibre volume fractions were manufactured to evaluate flexural modulus and strength, short beam shear strength and drop weight impact resistance of the material. Also, integral reinforced panels (IRPs) featuring a reinforcing section joined to a flat plate of varying laminating sequences were manufactured to evaluate debonding strength between sections. Optical microscopy was performed on component samples to determine quality based on void content and was found to be within acceptable limits for production composites. Flexural moduli were found to be comparable with theoretical expected values, however flexural strength was limited by the presence of transverse stitches. Short beam shear strength results showed high consistency between specimens, however were lower than comparable values found in literature. Impact specimens showed consistency among specimens, with greater damage resistance than comparable values found in literature. Determining debonding strength proved difficult as different failure modes were observed between IRPs, however, initial baseline values were acquired.

This research aims to investigate the influence of 3D through-thickness stitching on the gas permeability and transverse microcracking of cryogenically cycled carbon/epoxy composites. 3D through-thickness stitching can be used to improve the interlaminar properties of polymer matrix composites (PMCs) and produce lightweight, unitized structures for cryogenic storage tanks. To fully utilize stitched composite structures for these applications, their inherent gas permeability challenges must be understood. Therefore, in this study, the stitched composites' damage evolution and gas permeability was experimentally characterized under a) pure thermal stress, b) thermal and uniaxial mechanical stress, and c) thermal and biaxial mechanical stress. Helium gas permeability was measured for each specimen at room or cryogenic temperatures under a mechanically strained state following the thermo-mechanical cycles. Optical microscopy was used to measure microcrack densities and monitor their evolution through the thickness of the composite specimens. Thin plies, graphene nanoplatelets (GNP) modified resin, and a hybrid barrier layer comprising of both were incorporated in the stitched specimens as barrier layers to reduce their gas permeability. The dependence of gas permeability of stitched composites on the mechanical strain, test temperature, and load history was evaluated and correlated to microcrack density. A significant reduction in permeability and damage evolution (transverse microcracks and delaminations) was obtained for all thermo-mechanical cases using the hybrid barrier layer laminate. Additionally, the permeability was several orders of magnitude lower than the allowable. Overall, the hybrid barrier layer shows tremendous promise as a viable barrier layer for stitched/unstitched composites undergoing thermo-mechanical fatigue involving a cryogenic environment.

The purpose of this research is to evaluate the influence of through-the-thickness reinforcements on the fracture behavior of stitched sandwich composites and to develop predictive methodologies to aid in simulating their damage-tolerant capability. Sandwich composites are widely used for their high stiffness-to-weight ratio due to their unique material architecture, which is composed of two rigid, outer facesheets that are bonded to a light-weight internal core. However, sandwich composites are limited by their low interlaminar strengths and can develop core-to-facesheet separation when subjected to low out-of-plane loads. In this study, sandwich composites were manufactured with through-the-thickness reinforcements, or stitches, to act as crack-growth inhibitors and to improve interlaminar properties. Stitch processing parameters, such as the number of stitches per unit area (stitch density) and stitch diameter (linear thread density), have considerable influence on the in-plane and out-of-plane behavior of composite structures. A design of experiments (DoE) approach is used to investigate stitch processing parameters and their interaction on the fracture behavior of stitched sandwich composites. Single cantilevered beam (SCB) tests are performed to estimate the required energy to propagate crack growth, or Mode I fracture energy, during the separation of the facesheet from the core. Additionally, embedded optical fibers within the SCB test articles are used to determine the internal crack front variation. During testing, unique fracture morphologies are obtained and show dependency on stitch processing parameters. Furthermore, embedded optical fibers indicate that the internal crack front is approximately 10% greater than visual edge measurements, which is primarily attributed to Poisson’s effect. The DoE approach is then used to develop a statistically informed response surface model (RSM) to optimize stitch processing parameters based on a maximum predicted fracture energy. Novel analytical formulations are developed for estimating the mode I fracture energy using the J-integral approach. The DoE approach is then used to inform and validate finite element models that simulate the facesheet-to-core separation using a discrete cohesive zone modeling approach. The predicted load and crack growth response show good agreement to experimental measurements and highlights the capability of stitching to arrest delamination in stitched sandwich composites.

Les nouveaux renforts NCF (Non Crimp Fabrics) sont adaptés aux procédés RTM (Resin Transfer Moulding) ou RIM (Resin Infusion Moulding) et permettent d’élaborer des structures aéronautiques complexes et de grande taille. Cependant, la présence de la couture peut conduire à une morphologie spécifique hétérogène du matériau avec un réseau 3D de zones riches en résine. Ces dernières, sous cycles de vieillissement hygrothermiques, sont à l’origine d’un état spécifique de fissuration. Ainsi, le présent travail se concentre sur la caractérisation morphologique et la fissuration d’une famille particulière des NCF - NC2 (Non Crimp New Concept), soumis au vieillissement hygrothermique cyclique. Pour cela, des cycles accélérés de vieillissement sont définis, diverses méthodes de caractérisation sont utilisées et différentes variables représentatives sont introduites. Au sujet de la morphologie du matériau, une hétérogénéité multi-échelles a été visualisée en surface et dans l’épaisseur en effectuant des coupes sous microscope 2D et de la reconstruction volumique sous tomographie 3D à RX. En ce qui concerne la fissuration hygrothermique, son initiation et son développement ainsi que sa morphologie ont été étudiés. L’influence de la morphologie et des paramètres de chargement au cours des cycles a été identifiée. De plus, afin de maîtriser le comportement des zones riches en résine, un couplage thermique/hygrothermique-mécanique à différents états de vieillissement du matériau a été décrit finement par des mesures de champs. Enfin, la tenue mécanique du matériau vieilli a été étudiée. / Stitched multiaxial laminates NCF (Non-Crimp Fabric) are potential candidate materials as new high performance preforms for manufacturing complex and large aeronautical composite structures by RTM (Resin Transfer Moulding) or infusion processes. Stitching within the preform leads to a particular morphology including 3D resin-rich regions and to a specific crack network developed in the bulk of the laminate when this is subjected to hygrothermal ageing cycles. The present work focuses on the characterization of the morphology and the crack development in a particular family of NCF - NC2 (Non Crimp New Concept) subjected to hygrothermal cycling. For this purpose, different accelerated thermal/hygrothermal ageing cycles were defined, various characterisation methods were adopted and representative variables were introduced. Regarding the structural morphology, a multi-scale heterogeneity of the NC2 could be visualized on the surface and through the thickness by optical microscopy as well as by the non-destructive volumetric analysis of X-Ray tomography. Regarding hygrothermal cracking, its initiation, its development and its morphology were studied. The influence of the morphology and the role of loading parameters on crack development were identified. Furthermore, for a better control of resin-rich region behaviour, the thermal/hygrothermal-mechanical coupling at different ageing states was investigated by full-field image correlation. Finally, the mechanical strength of the aged material was determined.

With the rapid growth and use of wearable devices over the last decade, the advantages of using portable wearable devices are now been utilised for day to day activities. These wearable devices are designed to be flexible, low profile, light-weight and smoothly integrated into daily life. Wearable transmission lines are required to transport RF signals between various pieces of wearable communication equipment and to connect fabric based antennas to transmitters and receivers; the stitched transmission line is one of the hardware solutions developed to enhance the connectivity between these wearable devices. Textile manufacturing techniques that employ the use of sewing machines alongside conductive textile materials can be used to fabricate the stitched transmission line. In this thesis the feasibility of using a sewing machine in fabrication of a novel stitched transmission line for wearable devices using the idea of a braided coaxial cable have been examined. The sewing machine used is capable of a zig-zag stitch with approximate width and length within the range of 0-6 mm and 0-4mm respectively. The inner conductor and the tubular insulated layer of the stitched transmission lines were selected as RG 174, while the stitched shields were made up of copper wires and conductive threads from Light Stiches®. For shielding purpose, the structure is stitched onto a denim material with a conductive thread with the aid of a novel manufacturing technique using a standard hardware. The Scattering Parameters of the stitched transmission line were investigated with three different stitch angles 85°, 65° and 31° through simulation and experiments, with the results demonstrating that the stitched transmission line can work usefully and consistently from 0.04 to 4GHz. The extracted Scattering parameters indicated a decrease in DC loss with increased stitch angle and an increase in radiation loses, which tends to increase with increase in frequency. The proposed stitched transmission line makes a viable transmission line but a short stitch length is associated with larger losses through resistance. The DC losses observed are mainly influenced by the resistance of the conductive threads at lower frequencies while the radiation losses are influenced by the wider apertures related to the stitch angles and increase in frequency along the line. The performances of the stitched transmission line with different stitch patterns, when subjected to washing cycles and when bent through curved angles 90° and 180° were also investigated and results presented. Also, the sensitivity of the design to manufacturing tolerances was also considered. First the behaviour of the stitched transmission line with two different substrates Denim and Felt were investigated with the results indicating an insignificant increase in losses with the Denim material. Secondly, the sensitivity of the design with variations in cross section dimensions was investigated using numerical modelling techniques and the results showed that the impedance of the stitched transmission line increases when the cross sectional dimensions are decreased by 0.40mm and decreases when the cross sectional dimensions are increased by 0.40mm. Equally, repeatability of the stitched transmission line with three different stitch angles 85°, 65° and 31° were carried out. The results were seen to be consistent up to 2.5GHz, with slight deviations above that, which are mainly as a result of multiple reflections along the line resulting in loss ripples. The DC resistance of the stitched transmission line with three different stitch angles 85°, 65° and 31° corresponding to the number of stitches 60,90 and 162 were computed and a mathematical relationship was derived for computing the DC resistance of the stitch transmission line for any given number of stitches. The DC resistance computed results of 25.6Ω, 17.3Ω and 13.1Ω, for 31°, 65° and 85° stitch angles, indicated an increase in DC resistance of the stitch with decrease in stitch angle which gives rise to an increase in number of stitches. The transfer impedance of the stitched transmission line was also computed at low frequency (< 1GHz) to be ZT=(0.24+j1.09)Ω, with the result showing the effectiveness of the shield of the stitched transmission line at low frequency (< 1GHz).

The purpose of this research is to investigate the influence of stitching architectures by using different stitching periodic patterns on the in-plane and out-of-plane mechanical properties. By using the inherent periodic architecture of these composites, their mechanical properties may be tailored for specific applications. Composite structures are extensively used in several industries such as aerospace, automotive, sports, and construction due to their many advantages, which include tailorable mechanical properties, high strength-to-weight ratios, and high specific stiffness. However, due to their low interlaminar tensile strength, composites are prone to delaminations, which can degrade the overall mechanical performance of the structure. Through-thickness stitching provides the third-direction reinforcement to enhance the interlaminar tensile and shear strengths. In this study, quasi-isotropic composite test articles were manufactured and stitched through-thickness using different chain stitch patterns. Full-field surface strain measurements were collected through the non-contact digital image correlation (DIC) technique. A design of experiments (DoE) approach was used to investigate the stitch parameters, such as stitch density (number of stitches per unit area), stitch angle (stitch seam orientation), and linear thread density (thread diameter), and their interactions on the in-plane and out-of-plane mechanical properties. Experimental results are then used to develop a statistically informed response surface model (RSM) to find optimal stitching parameters based on a maximum predicted tensile strength, tensile modulus and flexural strength.