Composites Assembly for High Performance Fastener-less Structures

✍ Scribed by Hamed Yazdani Nezhad, Vijay Kumar Thakur

• Publisher: The Institution of Engineering and Technology
• Year: 2023
• Tongue: English
• Leaves: 794
• Series: IET Manifacturing Series, 15
• Category: Library

✦ Synopsis

Composites Assembly for High Performance Fastener-less Structures provides a broad and balanced span of information, covering both fundamentals and applications across academic and industrial state-of-the-art research and development on assembly, joining, inspection and repair of high-performance structures made from fibre-reinforced polymer composites and multifunctional nanocomposites. This knowledge is essential for the realisation of critical features in assembly and joining evolving procedures (across their design, development and performance analysis) in such multi-material systems, but also for the through-life maintenance of composite components used in a range of engineering applications such as those composite structures utilised for wind turbine blades, automotive parts, aircraft wings and fuselage. The book also addresses the non-destructive testing methods used to detect damage occurring in composite joints, which are essential to decide if the repair is needed.

The book begins by providing a fundamental description of the requirements for composite joining, assembly and repair. It goes on to address a variety of joining and repair procedures in composite structures from thermoset adhesive bonding to thermoplastic hybridisation, through-the-thickness reinforcement and sandwich structures. Further chapters cover the reliable assessment of structure's damage tolerance and failure assessment procedures, including non-destructive inspections and image processing based structural health monitoring, and provide understanding of the most likely deterioration mechanisms occurring in processing and assembly of composite materials and structures. The book is wrapped up with the ongoing state-of-the-arts in multifunctional nanocomposites with application for high-performance structures for self-sensing, energy harvesting and properties tailoring.

Composites Assembly for High Performance Fastener-less Structures brings together state-of-the-art practices for assembly, in-service damage and repair procedures along with the existing certification and repair regulations, followed by the futuristic opportunities for enabling and emerging polymer nanocomposites for smart structures, for an audience of academic researchers, advanced students, engineers and manufacturing professionals.

✦ Table of Contents

Contents
Preface
About the Editors
1 Overview on design and manufacturing of assembled composite aerostructures
1.1 Introduction
1.2 General philosophy for strength analysis of primary aerospace composite structures
1.2.1 Overview on structural analysis methods
1.3 Fastened joints
1.3.1 Load distribution in composite joints
1.3.2 Composite material failure at joint
1.4 Bonded joints
1.4.1 Types of failure in adhesive bonded joints
1.4.2 Stress analysis of adhesive bonded lap joints
1.5 Fabrication of bonded joints
1.5.1 Joints in space industry
1.5.2 Joints in aviation industry
1.6 Joint assembly
1.6.1 Significance of bond-line control
1.6.2 The need for bond-line control
1.6.3 Advantages and disadvantages of adhesive bonding
1.7 Conclusions
References
2 Processing of polymer composites: autoclave and microwave energy approaches
2.1 Introduction
2.2 Fundamentals
2.2.1 Basic principles
2.2.2 Mathematical models
2.2.3 Experimental details
2.3 Challenges in autoclave and microwave curing
2.4 Concluding remarks
References
3 Industry 4.0 for composites manufacturing
3.1 Introduction
3.2 Composites context of Industry 4.0
3.3 Literature review
3.3.1 Composites technology
3.3.2 Business challenges
3.3.3 Industry 4.0
3.4 Critical assessment
3.4.1 Key trends
3.4.2 Gaps and research aim refinement
3.5 Concluding remarks
References
4 Development of fibre-reinforced polymer composites through direct digital manufacturing
4.1 Introduction
4.2 Fiber-reinforced AM composites
4.3 Fused deposition modeling
4.4 Selective laser sintering (SLS)
4.5 Mechanical properties
4.5.1 Tensile strength
4.5.2 Fatigue strength
4.5.3 Creep deformation
4.5.4 Fracture toughness
4.5.5 Machine learning
4.6 Applications
4.7 Sustainability
4.8 Challenges and future prospective
References
5 Joining and repair of resin-infused, continuous fibre-reinforced, thermoplastic acrylic-matrix composites for extended applicability
5.1 Introduction
5.2 Liquid acrylic resin-based composites
5.2.1 Manufacturing
5.2.2 Comparison with conventional thermoset composites
5.3 Joining of acrylic-matrix composites
5.4 Thermoplastic acrylic-matrix fibre-metal laminates
5.5 End-of-life opportunities with acrylic-based composites
5.5.1 Applicability of recyclate matrix
5.5.2 Repairability of acrylic-matrix composites
5.5.3 Reshapability of acrylic-matrix composites
5.6 Future opportunities
5.7 Conclusion
References
6 Aerospace composites' repair: integrated processes' feasibility
6.1 Introduction
6.1.1 Aim of the project
6.2 Structure and methodology
6.2.1 Methodology
6.2.2 Literature review
6.2.3 Damage in composite structures
6.2.4 Main causes and associated costs of damages
6.2.5 Typical damages in composites
6.3 NDI techniques
6.3.1 Ultrasonic testing (UT)
6.3.2 Thermography
6.3.3 Shearography
6.3.4 Combination of thermography and shearography
6.3.5 Other NDI techniques
6.3.6 Post repair inspection
6.3.7 Material removal
6.3.8 Surface preparation
6.3.9 Surface treatments
6.4 Material and conditions
6.4.1 Hard and soft patch
6.4.2 To bond or to bolt?
6.4.3 Quality control
6.4.4 Structural health monitoring
6.4.5 Repair certification
6.5 Needs assessment
6.5.1 Available systems
6.5.2 Gap analysis
6.5.3 Situation of the composite industry in the UK
6.6 Feasibility
6.6.1 NDI system
6.6.2 Commercial options
6.6.3 Machinable area
6.6.4 Material removal
6.6.5 Conventional machining
6.6.6 Laser system
6.6.7 3D scanning
6.6.8 Commercial options
6.6.9 Patch
6.6.10 Patch design
6.6.11 Patch production
6.6.12 Adhesives
6.6.13 On-site curing
6.7 Implementation
6.7.1 Experimental testing
6.8 Conclusion
References
7 Augmented reality-equipped composites bonded repair
7.1 Introduction
7.1.1 Project background
7.1.2 Previous group project outcome
7.1.3 Gap analysis
7.1.4 Aim and objectives
7.2 Methodology
7.3 Literature review
7.3.1 Defects and damages in composite materials and structures
7.3.2 Manufacturing defects
7.3.3 Common service-life damages
7.3.4 Alternative classification of composite impact damage
7.3.5 Composite material repairing technique
7.3.6 Classification of composite material repairing method
7.3.7 Scarf-based repair process
7.4 Augmented reality
7.4.1 Augmented reality technique
7.4.2 Application of augmented reality into aircraft industry
7.5 Concept design
7.5.1 Project scope selection
7.5.2 Reparation method
7.5.3 Target process
7.5.4 Scenario design
7.5.5 Panel
7.5.6 Patches
7.5.7 Bagging layers design
7.5.8 Other assisting materials and equipment
7.5.9 Overall vacuum bagging system
7.5.10 Functionality design
7.6 Implementation and result
7.6.1 Hardware configuration
7.6.2 Developing environment configuration
7.6.3 Coding language
7.6.4 Developing process
7.6.5 Program validation
7.7 Discussion
7.7.1 Strengths
7.7.2 Challenges
7.7.3 Future work
7.7.4 Prospect
7.8 Conclusion
References
8 3D printing of multi-material polymer composite systems
8.1 Introduction
8.2 Theoretical background
8.2.1 Material science
8.2.2 Polymer blends
8.2.3 Fillers and reinforcements
8.2.4 Particulates
8.2.5 Metallic polymer composites
8.2.6 Ceramic polymer composites
8.2.7 Carbon polymer composites
8.2.8 Fibres and whiskers
8.2.9 Final impressions
8.3 Objectives
8.4 Numerical simulation
8.4.1 Schematic
8.4.2 Parameters
8.4.3 Boundary conditions
8.4.4 Mesh discretisation
8.4.5 Estimating thermo-physical properties
8.5 Results and discussion
8.5.1 Estimated thermo-physical properties of specimens
8.5.2 Slicing
8.6 Conclusion
References
9 3D printing of composites for space applications
9.1 Introduction
9.2 3D-printed structures
9.2.1 Heat shields for suborbital flight
9.2.2 Radiation shields in low-Earth orbits or deep space
9.2.3 Issues in printing and assembling structural parts
9.3 3D-printed electronics
9.3.1 Traces and substrates
9.3.2 Passive components
9.3.3 Active components
9.4 3D-printed batteries
9.5 3D-printed devices for medical and life support purposes
9.6 Conclusion
Acknowledgements
References
10 Development and manufacturing of thermoplastic composite booms for drag augmentation system of a small satellite
10.1 Introduction
10.1.1 Background
10.1.2 Cranfield University's de-orbit mechanism
10.1.3 Project's aims and objectives
10.2 Designs of booms
10.2.1 TRAC boom
10.2.2 STEM boom
10.2.3 CTM booms
10.3 Additive manufacturing
10.3.1 Markforged's FDM printer and materials
10.4 Design of the CTM boom
10.4.1 Onyx and CuBe
10.4.2 Cross-section geometry
10.4.3 Finite element analysis of CTM boom
10.4.4 Three-point bending test methodology
10.5 Manufacturing of the CTM booms
10.5.1 Horizontal, half profile
10.5.2 Vertical, full profile
10.5.3 Horizontal, full profile
10.6 Conclusion and future work
References
11 Adhesively bonded polymer composite joints
11.1 Introduction
11.2 Bonding of composite materials
11.3 Composite adherend modifications
11.3.1 Transverse toughened and reinforced adherends
11.3.2 Functionally graded substrates
11.4 Bi-adhesive joints
11.4.1 Manufacturing techniques
11.4.2 Bi-adhesive SLJs
11.4.3 Other types of joints
11.5 Composite adhesives with natural fibres
11.5.1 Surface preparation
11.5.2 Cork particles
11.5.3 Date palm tree fibres
References
12 Design principles and recent developments in adhesively bonded joints of fibre-reinforced plastic composite structures
12.1 Introduction
12.2 Design considerations and effective parameters in ABJs in FRP composites
12.2.1 Basics of adhesive bonding design and manufacturing considerations
12.2.2 Joint configuration: geometries and dimensions
12.2.3 Stress distribution and failure modes
12.2.4 Adhesive type
12.2.5 Surface preparation
12.2.6 Environmental parameters
12.2.7 Ease of assembly and costs
12.3 Characterisation methods for adhesively bonded composite-to-composite joints
12.3.1 Tensile test
12.3.2 Shear test
12.3.3 Peel test
12.3.4 Wedge cleavage test
12.3.5 Double cantilever beam (DCB), end-notched flexure (ENF) and mixed-mode tests
12.4 Analytical and finite element models for analysis of adhesively bonded composite-to-composite joints
12.4.1 Analytical analysis
12.4.2 Finite element analysis
12.5 Design principles and recent developments in high-performance composite-to-composite ABJs
12.6 Conclusions
References
13 Mechanical degradation of composite bonded joints subjected to environmental effects
13.1 Introduction
13.1.1 Objectives
13.2 Literature review
13.2.1 Adhesive joints
13.2.2 Design aspects
13.2.3 Manufacture process
13.2.4 Durability
13.2.5 Non-destructive testing
13.2.6 Damage prediction
13.2.7 Overview
13.3 Methodology, materials and methods
13.3.1 Research methodology
13.3.2 Adhered manufacturing
13.3.3 SJL manufacturing
13.3.4 Hygrothermal cycles
13.3.5 Bulk adhesive specimens manufacturing
13.3.6 Materials' characterization
13.3.7 Mechanical properties
13.4 Experimental results
13.4.1 Introduction
13.4.2 Moisture characterization
13.4.3 Adhesive bonded SLJ test
13.5 Degradation modelling of adhesively bonded SLJ
13.5.1 Finite-element analysis
13.6 Discussion
13.6.1 Introduction
13.6.2 Moisture absorption
13.6.3 Moisture effect adhesive mechanical properties
13.6.4 Mechanical test results
13.6.5 Non-destructive inspection adhesive bonded joints
13.6.6 Degradation modelling
13.7 Conclusions and contribution
References
14 Performance of aerospace composites in the presence of process-induced defects
14.1 Introduction
14.1.1 Aim
14.1.2 Objectives
14.2 Materials and manufacturing
14.2.1 Materials
14.2.2 Manufacturing
14.3 Testing
14.3.1 Lap shear test
14.3.2 NDI
14.4 Results and discussion
14.4.1 Lap shear test
14.4.2 NDI
14.4.3 Optical microscopy
14.5 Conclusions
References
15 Interleaving in composites
15.1 Introduction
15.2 Measuring interleaving properties
15.3 Interleaving types and performance
15.3.1 Self-same matrix resin
15.3.2 Summary
15.3.3 Interleaving applied to stiffeners and adhesive joints
15.3.4 Selective interface interleaving
15.3.5 Summary
References
16 A deep learning-based tool to predict delamination induced interlaminar stresses in composite structures
16.1 Introduction
16.2 Methodology
16.2.1 Design of experiments
16.2.2 Database development
16.2.3 Machine learning modelling
16.3 Results
16.3.1 Stress distributions within the composite panel
16.3.2 Performance measure plot
16.3.3 Training state plot
16.3.4 Error histogram
16.3.5 ML predictions and regression plot
16.4 Discussion
16.5 Conclusions
References
17 Damage assessment of composites based on non-destructive pulsed thermographic inspection
17.1 Introduction
17.2 Experimental data
17.2.1 Specimen
17.2.2 Data collection
17.2.3 Temperature decay curve
17.3 Coefficient clustering analysis
17.4 Results and discussion
17.4.1 Damage detection
17.4.2 Damage measurement
17.5 Conclusions
Acknowledgements
References
18 Augmented reality-equipped composite monitoring
18.1 Introduction
18.2 Theory: measurement, simulation, and visualization
18.2.1 Review of literature and research
18.2.2 Stress and strain calculation through surface data
18.2.3 Image data processing and 3D modelling
18.3 Methodology
18.3.1 Deformation type
18.3.2 Composite laminates specifications
18.3.3 Photogrammetry measurements
18.3.4 LIDAR measurements
18.3.5 Point cloud denoising and distance measurements
18.3.6 Abaqus and MATLAB® simulation
18.3.7 AR Visualization
18.4 Results and discussion
18.4.1 Photogrammetry results
18.4.2 C2C from LIDAR and Abaqus results
18.4.3 Difficulties with MATLAB® code
18.4.4 Recommendations and future work
18.4.5 Scope of application
Appendix A
References
19 Energy harvesting and self-sensing multi-functional polymer composites
19.1 Energy harvesting and self-sensing
19.2 Piezoelectric effect
19.2.1 Piezoelectric materials
19.3 Energy harvesting polymer composites
19.3.1 Energy harvesting fibre-reinforced polymer composites
19.3.2 Energy harvesting polymer nanocomposites
19.4 Self-sensing and health monitoring polymer composites
19.5 Conclusions
References
20 Tailoring thermo-mechanical properties of hybrid composite-metal bonded joint
20.1 Introduction
20.1.1 Aim
20.1.2 Objectives
20.2 Literature review
20.2.1 Carbon nanotube
20.2.2 Composite-metal adhesively bonded joint
20.2.3 Effects of CNTs on thermo-mechanical performance
20.2.4 CNTs dispersion
20.2.5 Mechanism of joint failure by CTE mismatch
20.2.6 Analytical calculations
20.2.7 Methods of thermal strain measurement
20.3 Specimens manufacturing
20.3.1 Material
20.3.2 Specimens manufacturing
20.4 Testing
20.4.1 Thermal strain measurement
20.4.2 Scanning electron microscopy
20.4.3 Raman spectroscopy
20.5 Results and discussion
20.5.1 Coefficient of thermal expansion
20.5.2 Scanning electron microscopy
20.5.3 Raman spectroscopy
20.5.4 Bond deficiency on specimens
20.6 Conclusion and further work
References
21 High-performance nanocomposites for strain self-sensing applications in composite joints
21.1 Introduction
21.1.1 Structure of carbon nanotubes
21.1.2 Electromechanical properties
21.1.3 CNTs for strain sensing
21.2 Materials and methods
21.2.1 CNT fabrication
21.2.2 Sample manufacturing
21.2.3 Tensile and electrical resistance testing
21.2.4 Scanning electron microscopy
21.2.5 Raman spectroscopy
21.3 Results and discussion
21.3.1 Carbon nanotubes characterisation
21.3.2 Strain sensing
21.4 Conclusion
21.5 Future work
Appendix A: Tensile tests
Appendix B : Load vs displacement curves
References
Index