Damage Growth in Aerospace Composites

278 Pages·2015·18.08 MB·English

by  Aniello Riccio (eds.)

Springer Aerospace Technology
Aniello Riccio E ditor
Damage
Growth in
Aerospace
Composites
Springer Aerospace Technology
More information about this series at http://www.springer.com/series/8613
Aniello Riccio
Editor
Damage Growth
in Aerospace Composites
1 3
Editor
Aniello Riccio
Department of Industrial and Information
Engineering
Second University of Naples
Aversa
Italy
ISSN 1869-1730 ISSN 1869-1749 (electronic)
Springer Aerospace Technology
ISBN 978-3-319-04003-5 ISBN 978-3-319-04004-2 (eBook)
DOI 10.1007/978-3-319-04004-2
Library of Congress Control Number: 2014957962
Springer Cham Heidelberg New York Dordrecht London
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Contents
1 Introduction ............................................... 1
Aniello Riccio and Tomas Ireman
Part I D etailed Methodologies for Damage Growth
in Aerospace Composites
2 Detailed Methodologies for Integrated Delamination
Growth and Fiber-Matrix Damage Progression Simulation ........ 9
Aniello Riccio, Elisa Pietropaoli and Antonio Raimondo
3 Delamination and Debonding Growth in Composite Structures .... 63
Javier San Millán and Iñaki Armendáriz
4 Delamination Growth in Composite Plates Under
Fatigue Loading Conditions .................................. 89
Aniello Riccio, Andrea Sellitto and Rocco Ricchiuto
5 Influence of Intralaminar Damage on the Delamination
Crack Evolution ............................................ 107
Cédric Huchette, Thomas Vandellos and Frédéric Laurin
6 Microdamage Modeling in Laminates .......................... 141
Janis Varna
Part II F ast Methodologies for Damage Growth
in Aerospace Composites
7 Finite Element Study of Delaminations in Notched Composites .... 177
Sören Nilsson, Alann André and Anders Bredberg
v
vi Contents
8 Effect of the Damage Extension Through the Thickness
on the Calculation of the Residual Strength of Impacted
Composite Laminates ....................................... 187
Sören Nilsson, Anders Bredberg and Tonny Nyman
9 A Fast Numerical Methodology for Delamination
Growth Initiation Simulation ................................. 199
Aniello Riccio and Michele Damiano
Part III Manufacturing and Testing
10 An Experimental Study on the Strength of Out
of Plane Loaded Composite Structures ......................... 223
Sören Nilsson, Alann André and Anders Bredberg
11 Buckling and Collapse Tests Using Advanced
Measurement Systems ....................................... 231
Richard Degenhardt
12 Vacuum Infusion Manufacturing of CFRP Panels
with Induced Delamination .................................. 249
Vincenza Antonucci and Mauro Zarrelli
13 Lock-in Thermography to Detect Delamination in Carbon
Fibres Reinforced Polymers .................................. 263
Carosena Meola and Giovanni Maria Carlomagno
Chapter 1
Introduction
Aniello Riccio and Tomas Ireman
1.1 State of the Art of European Projects
on Composites Damage Management
The high specific strength and stiffness of composite materials make them suitable
for use in aerospace structures. However, the high sensitivity of these materials
to the presence of damage, arising after impact with foreign objects or caused by
manufacturing defects and stress concentrators, makes designing with composites
a very challenging task.
The damage mechanisms in composites are very complex and can involve one
or more constituents at a time. Delaminations, fibre breakage and matrix cracking
can strongly reduce the load carrying capability of composite structures leading,
in general, to a premature failure. Moreover, depending on the composite inter-
nal layout and on the adopted manufacturing technique, the damage mechanisms
may interact with each other, making it difficult to predict the residual properties
of composite components.
In recent years, the inability in predicting the damage onset and its evolution in
composite structures, has led to over-conservative designs, not fully realising the
composites promised economic benefits. Hence, in order to make the composites
affordable in aerospace design, many research projects have been started in the last
A. Riccio (*)
Department of Industrial and Information Engineering, Second University of Naples,
via Roma n 29, 81031 Aversa, Italy
e-mail: [email protected]
T. Ireman
Saab, Business Area Aeronautics, SE 581 88 Linköping, Sweden
© Springer International Publishing Switzerland 2015 1
A. Riccio (ed.), Damage Growth in Aerospace Composites,
Springer Aerospace Technology, DOI 10.1007/978-3-319-04004-2_1
2 A. Riccio and T. Ireman
decade aimed to investigate the composites’ damage mechanisms and to promote
damage tolerant design approaches.
A number of GARTEUR action groups have been started on damage manage-
ment in composite structures:
GARTEUR AG 09 “Damage mechanics of composites” (1986–1994) had the focal
point on the buckling and growth of delaminated areas to gain a substantial
degree of understanding of delamination growth mechanism.
GARTEUR AG 14 “Fractography of composites” (1991–1995) wanted to establish
a series of standards to follow in the field of non-destructive tests.
GARTEUR AG 16 “Damage propagation in Composites” (1994–1997) was focused on
the delaminations in composites. Most of the work done was addressed to the devel-
opment and validation of basic methods for the delamination growth simulation.
GARTEUR AG 20 “Fractographic aspects of fatigue failure in composites” (1994–
2001) had the objective to develop analysis methods contributing to the failure
prediction of composite wing panel and to validate them with experimental data.
GARTEUR AG 22 “Design Methodology for Damage Tolerant Composite Wing
Panels” (1998–2000) was aimed to the development of methodologies for the
failure prediction of composite wing panels.
GARTEUR AG 28 “Impact Damage and Repair of Composites” (2002–2006) was
addressed to the development of methodologies for the prediction and charac-
terisation of the impact damage. Relevant effort was also put on the analysis of
impacted post-buckling designed composite structures.
Additionally, several EU funded projects have been carried out to improve the
knowledge about composites fracture mechanisms:
EDAVCOS “Efficient Design and Verification of Composite Structures” (1998–
2001) was addressed to the development of methods for design of composite
structures with damage tolerance constraints.
BOJCAS “Bolted Joint in Composite Aircraft Structures” (2000–2003) was
focused on the development of methodologies for the prediction of final fail-
ure of composite joints. Delamination, fibre breakage and matrix cracking have
been taken into account.
FALCOM “Failure, Performance and Processing Prediction for Enhanced Design
with Non-crimp-Fabric Composites” (2001–2004) aimed to the development of
methodologies for predicting the mechanical behaviour including failure of non-
crimp fabric composites.
Finally, being composites widely adopted for military scopes, their structural
behaviour including damage evolution has been studied under MoD funded
projects:
DAMOCLES “Damage Management of Composite Structures for Cost Effective
Life Extensive Service” (1999–2005). DAMOCLES programmes were finalised
to the development of design numerical tools able to perform a cost oriented
1 Introduction 3
optimisation taking into account damage resistance and damage tolerance con-
straints. Applications to composite stiffened panels and composite wing-box
proved the validity of the developed approaches.
All these projects have contributed to increasing the knowledge of the composites
structural response and failure mechanisms. However, since GARTEUR AG 16,
which represented the first attempt to analyse the composites damage evolution,
in the last fifteen years, big steps forward have been made in the field of com-
putational technologies and new “composites oriented” non-destructive inspection
tools have been introduced. These innovative numerical/experimental features can
be considered as relevant driving factors for the development of newer effective
numerical approaches oriented to the prediction of damage on-set and growth in
composites.
Furthermore, fifteen years of research and growing applications in industries
have brought to life new needs, to be addressed by Research and Development, for
example related to the presence of new composites typologies (textile composites)
and new manufacturing techniques (RFI, RTM, fibres placement).
The lesson learned from the majority of the mentioned research projects also
suggests trying to introduce more general approaches able to deal with different
failure mechanisms (delamination, fibres breakage, matrix cracking, etc.) at a time
and to take into account their interaction, independently from the damage causes
(impact, manufacturing defect etc.).
Finally the emerging tendency to adopt composite materials for primary struc-
tures opens new scenarios involving new safety issues which imply considering
damage tolerance design approaches from the earlier phases of the design process
(including optimisation) rather than limiting the use of damage on-set and growth
numerical techniques to complex/expensive non-linear verification analyses.
From the above considerations, the GARTEUR Action Group AG 32:
C.I.R.A. (Centro Italiano Ricerche Aerospaziali)—Italy (Chairman)
QinetiQ—United Kingdom
DLR (The German Aerospace Center)—Germany
INTA (Instituto Nacional de Tecnica Aerospacial)—Spain
SWEREA-SICOMP—Sweden
EADS-M—Germany
ALENIA—Italy
Imperial College of London—United Kingdom
CNR (Centro Nazionale Ricerche)—Italy
Lulea University of Technology—Sweden
SAAB—Sweden
ONERA (The French Aerospace Lab)
University of Nantes—France
University of Naples “Federico II”—Italy
carried out between year 2006 and year 2011 a joint research work focused on
“DAMAGE GROWTH IN COMPOSITES”.