Search Results (90)

The presence of holes in the crash boxes of vehicle parts is sometimes unavoidable to accommodate connections, cables, and maintenance access. The effect of circular cutouts on the crashworthiness of a Carbon-Fiber Reinforced Polymer (CFRP) rectangular laminate used as a crash box, consisting of identical plies with different stacking sequences, was investigated. Five tubes with different stacking sequences were prepared: an outer ply of 0°/90° twill-woven fiber and inner plies of 0°/0°, ±45°, and 0°/90° unidirectional fibers. A second set of tubes was prepared with circular cutouts of 6 mm diameter in the tube walls. A quasi-static axial crushing test was done on the tubes. Crashworthiness indicators, including initial peak load (P_ip), mean crushing load (P_m), energy absorption (EA), specific energy absorption (SEA), and crushing-force efficiency (CFE), were evaluated and statistically analyzed using ANOVA. The results show that the neat tubes generally exhibit higher energy absorption and more stable progressive crushing than the tubes with circular cutouts. The presence of cutouts reduces the initial P_ip, P_m, EA, and SEA, while also changing the failure mode from progressive splaying-dominated crushing to localized micro-buckling, segmentation, sliding, and slicing. Among the tested configurations, samples with 0°/0° plies in the mid-laminate region showed the best crashworthiness performance in both neat and with cutout tubes. These findings demonstrate that both stacking sequence and geometric discontinuity strongly influence the crash response of CFRP tubes and should be considered together in crashworthy design. Full article

Despite the low thermal conductivity that characterizes the mechanical behavior of cementitious composites like concrete, high temperatures acting for long periods could have devastating effects on the overall integrity and stability of structures. Such damage encompasses not only the structural but also the material level, manifested as a degradation of the strength and stiffness properties together with increasing porosity and the consequent cohesion loss. Adding fibers to the cementitious matrix is a strategy that increases the fire resistance of structures, improving the fracture energy release capacity beyond the peak strength. This fact has been experimentally demonstrated in numerous publications and requires the development of advanced computational constitutive models with the aim of predicting the evolution of both elastic properties and failure behavior in fiber-reinforced concrete. In this work, a temperature-dependent, thermodynamically consistent microplane material model based on the smeared crack approach is developed to simulate the mechanical behavior of preheated steel fiber-reinforced concrete (SFRC) under residual conditions. The influence of high temperatures on the material response is evaluated in terms of stress versus crack opening displacement or crack slip curves, whereas the failure analysis in the form of discontinuous bifurcation is addressed by means of numerical analysis of the acoustic tensor, identifying the critical orientation for varying temperature levels, material properties and boundary conditions. Full article

This paper innovatively employs an epoxy-free composite layer with basalt fiber-reinforced polymer (BFRP) and engineered cementitious composite (ECC) to reinforce the two-way concrete slab structure. Five strengthened slabs and one reference slab were tested under biaxial bending moments with four-side simply supported conditions. The thickness of ECC (15, 25, 35 mm) and BFRP grid (1, 2, 3 mm) were selected as two main variables in the test program. The experimental results showed that the cracking and ultimate load of the strengthened slabs were substantially improved. Notably, the cracking pattern was shifted from diagonally concentrated cracks to discontinuous short cracks, with no apparent debonding of the composite layer. As the thickness of the BFRP grid and ECC increases, both the flexural capacity and stiffness improve, with decrease in the maximum deflection and effective utilization rate of steel reinforcement and BFRP grid at mid-span. Furthermore, a theoretical model considering different positional distribution of yield line was proposed to predict the bearing capacity of the strengthened slabs, with the calculated values aligned well with the experimental results. This research highlights the FRP–ECC composite as a robust reinforcement method for two-way slabs, and offers a good design-oriented reference basis in the field. Full article

Carbon Fiber Reinforced Polymers (CFRP) are extensively utilized in high-performance engineering, yet localized structural discontinuities can severely compromise their integrity. This paper aims to achieve high-sensitivity characterization of such anomalies using a proposed acoustic shearography technique based on continuous acoustic excitation. A comprehensive finite element model (FEM) was developed to clarify the mechanical-energy coupling between the acoustic fields and localized surface strain field modulations. By exploiting ultrasonic energy coupling, the localized features of discontinuities were identified through full-field, non-contact optical measurement of localized phase distortions. Key parameters, including shearing amount, excitation frequency, driving voltage, and geometric characteristics of blind flat-bottom holes (BFBH), were systematically investigated. The results demonstrate a high correlation between FEM simulations and experimental observations quantitatively elucidating how defect diameter and hole depth modulate surface strain distributions. The proposed hybrid acoustic optical approach achieves near-instantaneous full field imaging within a millisecond timeframe typically under 200 ms. Additionally, the methodology leverages localized acoustic resonance to significantly boost the signal-to-noise ratio (SNR) resulting in highly quantified phase map contrast. Full article

The design and manufacturing of carbon-fiber-reinforced polymer (CFRP) structures in aerospace require balancing high structural performance with cost-efficient, reproducible production. Conventional design and planning methods are often fragmented across disciplines, causing data discontinuities and limited traceability. This paper introduces a graph-based design language (GBDL) information architecture that integrates CFRP design and manufacturing within a unified, model-based framework. The approach formalizes engineering knowledge through process ontologies and graph-based data models linking geometry, material, tooling, and process parameters in a consistent, machine-interpretable form. Each step, from geometry derivation and structural design to prepreg hand lay-up and automated fiber placement, is represented within a shared design graph to ensure data consistency, transparency, and automated assessment of lead time, labor, cost, waste, and energy consumption. Although current implementations address selected use cases with partially automated interfaces, the architecture establishes a scalable foundation for full interoperability. A helicopter-frame case study demonstrates the applicability and adaptability of the method. Full article

Carbon fiber reinforced polymers (CFRPs) are widely used in aerospace and wind power applications, but the complex failure mechanisms of their connection structures pose challenges for connection design. This study aims to investigate the influence of bonding interface inclination angle and connection method on the failure mechanisms of CFRP joints under bending loads. The study investigated two design parameters: the joint geometry of the bonding interface (single-slope, transition-slope, and single-step) and the connection methods (bonding, bolting, and hybrid bonding–bolting). Finite element simulations analyzed the mechanical performance and failure modes under different design parameters. Bending tests validated the mechanical properties of the joint interface, validating the effectiveness of the numerical simulation. The study found that under bonded connections, the bending load increased with the slope of the connection interface, with improvements of 21.87% and 39.75%, respectively. The main reason is stress concentration caused by sharp geometric discontinuities. The hybrid connection had the highest peak load, with improvements of 38.38% and 43.91% compared to the other connection methods. Hybrid bonding–bolting connections further optimized structural performance and damage tolerance. This study reveals the damage mechanisms of the bonding interface and provides a reliable prediction method for aerospace and wind turbine blade applications. Full article

This study investigates the design factors of stress wave barrier zones intended for manufacturing machines under impulse loading, using polymer discontinuously reinforced composites with specified internal microstructures, which effectively suppress stress at the wave front, promote uniform stress distribution, improve impact resistance, and reduce vibrations and noise. Two-dimensional representative unit cells and explicit finite element simulations were used to analyze stress wave propagation under impulse loading. The effects of inclusion shape, orientation, distribution, interlayer, and size of the interface on stress wave scattering and attenuation were examined. In our models, hollow inclusions demonstrated 20.6% higher attenuation compared to solid inclusions, with the hollow fiber inclusion showing the most significant improvement. Inclusion orientation relative to the stress wave direction affected attenuation by 18.5%, while redistribution of inclusions and addition of a compliant interlayer contributed additional increments of 3–11%. These results highlight the critical role of microscale topology in stress barrier zone designing, such that the combined adjustment of inclusion shape, orientation, interlayer presence, and spatial distribution provides an effective strategy to maximize stress wave attenuation. Full article

This study investigates an alternative methodology for incorporating polymeric and steel fibers into concrete. Conventional reinforcement approaches often require complex application techniques and face industrial limitations. In contrast, the present work evaluates the use of short, discontinuous fibers—commercial polypropylene fibers (PFRC), polypropylene fiber braid (PFBRC) and steel fibers (SFRC)—which enable improved dispersion, ease of mixing and potential mechanical benefits. The fibers were randomly oriented and evenly distributed within the cementitious matrix. Mechanical performance was assessed through four-point bending tests combined with displacement measurements, acoustic emission analysis and uniaxial compression tests, while scanning electron microscopy (SEM) confirmed fiber–matrix interaction and fragment retention. The results demonstrated significant improvements, with compressive strength exceeding that of unreinforced concrete, while hybrid fiber systems provided enhanced crack resistance and post-cracking stability. Overall, the findings highlight that the integration of discontinuous fibers may provide tangible mechanical advantages, potentially outweighing the structural benefits of continuous reinforcing bars in applications requiring high strength and reliable mechanical performance. Full article

The growing demand from the automotive industry for lightweight, high-performance, and advanced manufacturing techniques for efficient and cost-effective production has accelerated the adoption of fiber-reinforced polymer composites. However, considering the manufacturing complexity of these materials, design remains challenging due to the intricate and interdependent relationships between the process conditions, the part geometry, and the resulting microstructure and quality. This research utilized the Autodesk Moldflow Insight software to design an injection molding process for the manufacturing of discontinuous glass fiber-reinforced polymer parts through computer modeling. A geometrically complex car fender was used as a case study. The effects of various process parameters, particularly gate locations, on the injection-molded parts’ properties (such as the fiber orientation, volumetric shrinkage, and shear rate) were investigated. Multiple injection molding process configurations were designed and simulated, including three, four, and five gates at varying locations. Based on the optimal performance (i.e., low shrinkage, a consistent fiber orientation, and a controllable shear rate), an optimal configuration with four gates at appropriate locations (corresponding to the second gate location set) was identified based on multicriteria decision-making analysis, i.e., volumetric shrinkage of ${8.5}_{-2.2}^{+1.4}\%$, a fiber orientation tensor of 0.927 ± 0.011, and a stable shear rate < 74,324 (1/s). A reduced strain closure model (modified Folgar–Tucker model) was used to predict the glass fiber orientation. A multicriteria decision-making technique, based on similarity ranking with an ideal solution, was employed to optimize the gate location. The simulation results clearly demonstrate that the gate placement is crucial for material behavior during molding and for reducing common defects. The simulation-based injection molding process design for the manufacturing of discontinuous fiber-reinforced polymer parts proposed in this paper can improve the production efficiency, reduce trial-and-error rates, and improve part quality. Full article

Spent coffee grounds represent an abundant waste resource with potential for sustainable material applications. This study investigates the use of carbonized spent coffee grounds (CSCG) as fillers in polyurethane (PU) coatings for carbon fiber-reinforced polymer (CFRP) substrates to enhance mechanical durability and anti-icing performance. SCGs were dried, sieved (<100 µm), and oxidatively carbonized in air at 100–300 °C for 60–120 min, then incorporated into PU at 1 or 5 wt.% and applied by spray-coating. A full-factorial design was employed to evaluate the effects of carbonization temperature, particle size, and filler loading. The optimized formulation (300 °C, 100 µm, 5 wt.%) showed the highest water contact angle (103.5°), lowest work of adhesion (55.8 mJ/m²), and improved thermal stability with 60% char yield. Mechanical testing revealed increased tensile modulus with reduced strain, and differential scanning calorimetry indicated an upward shift in glass-transition temperature, suggesting restricted chain mobility. Ice formation at 0 °C was sparse and discontinuous, attributed to lowered polar surface energy, rough surface texture, and porous carbon morphology. These results demonstrate that CSCGs are effective sustainable fillers for PU coatings, offering combined improvements in mechanical, thermal, and anti-icing properties suitable for aerospace, wind power, and other icing-prone applications. Full article

Fiber orientation is an important descriptor of the microstructure for short fiber polymer composite materials where accurate and efficient prediction of the orientation state is crucial when evaluating the bulk thermo-mechanical response of the material. Macroscopic fiber orientation models employ the moment-tensor form in representing the fiber orientation state, and they all require a closure approximation for the higher-order orientation tensors. In addition, various models have more recently been developed to account for rotary diffusion due to fiber-fiber and fiber-matrix interactions which can now more accurately simulate the experimentally observed slow fiber kinematics in polymer composite processing. It is common to use explicit numerical initial value problem-ordinary differential equation (IVP-ODE) solvers such as the 4th- and 5th-order Dormand Prince Runge–Kutta (RK45) method to predict the transient and steady-state fiber orientation response. Here, we propose a computationally efficient method based on the Newton-Raphson (NR) iterative technique for determining steady state orientation tensor values by evaluating exact derivatives of the moment-tensor evolution equation with respect to the independent components of the orientation tensor. We consider various existing macroscopic-fiber orientation models and several closure approximations to ensure the robustness and reliability of the method. The performance and stability of the approach for obtaining physical solutions in various homogeneous flow fields is demonstrated through several examples. Validation of our orientation tensor exact derivatives is performed by benchmarking with results of finite difference techniques. Overall, our results show that the proposed NR method accurately predicts the steady state orientation for all tensor models, closure approximations and flow types considered in this paper and was relatively faster compared to the RK45 method. The NR convergence and stability behavior was seen to be sensitive to the initial orientation tensor guess value, the fiber orientation tensor model type and complexity, the flow type and extension to shear rate ratio. Full article

Carbon fiber-reinforced plastics (CFRPs) offer excellent in-plane mechanical performance, but their relatively low interlaminar fracture toughness makes them vulnerable to delamination, particularly around intralaminar discontinuities such as resin-rich regions or fiber gaps. This study investigates the effectiveness of polyamide (PA) mesh inserts in improving interlaminar toughness and suppressing delamination in CFRP laminates with such features. Two PA mesh configurations were evaluated: a fully embedded continuous layer and a 20 mm cut mesh strip placed between continuous and discontinuous plies near critical regions. Fracture toughness tests showed that PA mesh insertion improved interlaminar toughness approximately 2.4-fold compared to neat CFRP, primarily due to a mechanical interlocking mechanism that disrupts crack propagation and enhances energy dissipation. Uniaxial tensile tests with digital image correlation revealed that while initial matrix cracking occurred at similar stress levels, the stress at which complete delamination occurred was approximately 60% higher in specimens with a 20 mm mesh and up to 92% higher in specimens with fully embedded mesh. The fully embedded mesh provided consistent delamination resistance across the laminate, while the 20 mm insert localized strain redistribution and preserved global mechanical performance. These findings demonstrate that PA mesh is an effective interleaving material for enhancing damage tolerance in CFRP laminates with internal discontinuities. Full article

Discontinuous fibers are commonly added to matrix materials in additive manufacturing to enhance properties, but such benefits may be constrained by print and fiber orientation. The additive processes of forming rasters and layers in powder bed fusion inherently cause anisotropy in printed parts. Many print parameters, such as laser, temperature, and hatch pattern, influence the anisotropy of tensile properties. This study characterizes fiber orientation attributed to recoating non-encapsulated fibers and the resulting anisotropic tensile properties. Tensile and fracture properties of polyamide 12 reinforced with 0%, 2.5%, 5%, and 10% discontinuous carbon fibers by volume were characterized in two primary print/tensile loading orientations: tensile loading parallel to the recoater (“horizontal specimens”) and tensile load along the build axis (“vertical specimens”). Density and fractographic analysis indicate a homogeneous mixture with low porosity and primary fiber orientation along the recoating direction for both print orientations. Neat specimens (zero fiber) loaded in either direction have similar tensile properties. However, fiber-reinforced vertical specimens have significantly reduced consistency and tensile strength as fiber content increased, while the opposite is true for horizontal specimens. These datasets and results provide a mechanism to tune material properties and improve the functionality of selectively laser-sintered fiber-reinforced parts through print orientation selection. These datasets could be used to customize functionally graded parts with multi-material selective laser-sintering manufacturing. Full article

Fused filament fabrication of thermoplastic composites has grown exponentially owing to its efficiency, thereby meeting numerous engineering demands. However, these materials have limitations owing to their structural vulnerability to elevated temperatures. To address this drawback, this study aims to investigate the tensile behavior of 3D-printed composites in a broad thermal domain from ambient temperature to the crystallization point. For this purpose, a commercial high-temperature-resilient polyamide carbon fiber was selected. To assess the optimal bead configuration and application range, the methodology includes tensile testing of five infill orientations across the four principal thermal domains of the polymers. The results highlight different bead arrangements under constant thermal conditions and demonstrate how temperature effects the tensile performance at similar raster angles, as further correlated with fracture mechanism analysis via scanning electron microscopy. The key findings indicate that raster orientation has a minor influence compared to temperature change. In accordance with the literature, a significantly decreased strength and an abrupt increase in plasticity is observed above the glass transition temperature. Nevertheless, the material retains one-third of its ambient tensile strength at 150 °C, demonstrating its potential for high-temperature applications. Full article

Flax fiber reinforcements weaken with aging and microstructural changes, limiting their applications. Here, we examine the effects of microstructure and aging on flax fiber elements’ performance by using 4000-year-old and modern Egyptian flax as references through multi-scale numerical modeling. This study introduces a novel investigation into the tensile stress distribution behavior of archaeological and modern flax yarns. The finite element (FE) model is derived from 3D volumes obtained via X-ray microtomography and tensile testing in the elastic domain. At the microscale, fibers exhibit higher axial stress concentrations around surface defects and pores, particularly in regions with kink bands and lumens. At the mesoscale, fiber bundles show increased stress concentrations at inter-fiber voids and lumen, with larger bundles exhibiting greater stress heterogeneity, especially around pores and surface roughness. At the macroscale, yarns display significant stress heterogeneity, especially around microstructural defects like pores and fiber–fiber cohesion points. Aged fibers from ancient Egyptian cultural heritage in particular demonstrate large fiber discontinuities due to long-term degradation or aging. These numerical observations highlight how porosity, surface imperfections, and structural degradation increase stress concentration, leading to fiber rupture and mechanical failure. This insight reveals how aging and defects impact flax fiber performance and durability. Full article