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The failure mode is a dominant factor of mechanical performance of braided composite tube subjected to axial compression. The failure mode was modified by tailoring stack-up sequence of composite tubes hybridized by bi/tri-axial braided laminate. The thermal photographing and micro-CT scanning methods were employed to monitor the in-situ damage progression and post-mortem specimen, respectively. The results show that the delamination was easy to be induced at the interface nearby tri-axial braided laminate. It attributes to the combination between the crack caused by local buckling of the axial yarns and the crack caused by shear deformation of braiding yarns. By the illumination of this behavior, delamination is controlled to occur at the different position along thickness direction of braided tube by adjusting the stacking sequence of braided laminates. When delamination position transfer from the inner/outer sides to the middle of tube wall, the failure mode transfer from the progressive folding to splaying, which increase the specific energy absorption by 45.77%. [ABSTRACT FROM AUTHOR]

• The usage of correlation between maximum temperature and peak load. • The reconstruction of CT images identifies the debonding distribution and degree. • A novel inspection way of combing infrared imaging and micro CT reconstruction methods. • The role of axial yarns in axial crushing. In this work, the effect of axial yarns on damage behavior of two-dimensional triaxially braided composite(2DTBC) tubes subjected to axial compression was investigated. A novel damage detection method combining infrared thermography and CT scanning was presented. In the area without axial yarns, yarn crossovers were separated from each other due to interlacing patterns. Axial compression caused the braiding yarns to shear deformation like scissors. Inter-yarn de-bonding appeared in crossovers and could not connect. Consequently, it caused a progressively folding failure mode. In contrast, local buckling occurred on axial yarns because of their primary loading behavior. Cracks along the axial yarns formed, which would combine with debonding crossovers caused by the sheared braiding yarn. It resulted in significant inter-layer delamination and consequently splaying failure mode. The energy absorption of composites tube with 18 axial yarns increased by 79.9% at the cost of 27.8% fiber usage more than 3 axial yarns. [ABSTRACT FROM AUTHOR]

• The delamination damage distribution induced by multi-impact was identified. • The sensitivity of axial compression performance to impact damage was studied. • Proposed FE model provided accurate predication for CAI scenario of braided tube. In this study, damage behaviors and residual crashworthiness characteristics of braided composite tube with transverse pre-impact damages subjected to axial compression were investigated by experimental and numerical methods. The compression tests were conducted on intact, single impact and repeated impact tubes at identical, adjacent and opposite positions to analyze the effects of impact damages. A multi-step finite element model considering the progressive damage characteristics was developed in ABAQUS/Explicit to predict the failure behaviors of braided tube. It was found that the damage behavior and residual performance of braided tube subjected to axial compression were dominated by impact induced delamination distribution with respect to area and position. A relatively small delamination area induced by single impact resulted in similar progressive folding damage mode and energy absorption capacity as in intact tube. For repeated impact, delamination with increased area at identical position leaded to local buckling damage mode, while small delamination areas distributed at adjacent and opposite positions caused U-shape and W-shape fracturing damage modes, respectively. Consequently, the transformation of damage mode resulted in significantly reduced residual crashworthiness characteristics in repeated impact tubes compared to intact and single impact tubes. [ABSTRACT FROM AUTHOR]

Braided composite laminates allow a reinforcement architecture design method of varying ply-to-ply braided structure instead of rotating fiber orientation in traditional unidirectional laminates. The stacking sequence sensitivities of braided laminates subjected to low-velocity impact were experimentally studied. Uniform ([±45° 6 ]) and non-uniform ([±30° 2 /±45° 2 /±60° 2 ]) architectures were designed to evaluate the effect of braided structure on impact performance. In addition, non-uniform laminate was impacted on both sides to identify the role of impact side on the failure mode. Quasi-static indentation was conducted to understand the damage initiation and propagation of braided laminates. The experimental results show that braided ply with high crimp level in impact side induced the main cracks along the load-carrying yarn, causing that the laminate failed in a kink-band dominated mode. For braided ply with low crimp level, a micro-buckling damage was found in the impact side, leading to the delamination dominated failure mode. It was also found that uniform braided laminate presents inferior impact resistance with respect to lower peak load and more concentrated damage because the kink-band can propagate into the specimen along braiding yarn easily. [ABSTRACT FROM AUTHOR]

The aim of this study is to characterize and assess the effect of fabric structure on the damage resistance subjected to low velocity impact. Composite panels reinforced by layered unidirectional (LU), layered woven (LW) and 3D orthogonal woven (OW) fabric were prepared respectively and the impact tests were carried out on a low-velocity testbench. Finite element models at yarn-level were established to numerically investigate the material deformation and failure mechanism. The impact tests showed that the OW composite possessed better impact resistance with respect to impact-induced deformation and inelastic energy absorption. The roles of the z-binder have also been identified through comparison of impacted morphology and numerical results. The z-binder serves as cracking trigger due to the weak debonding with resin pocket around it and its zig-zag configuration impedes the growth of delamination by damage deflection. Therefore, the discontinuous resin damage in 3D composite allows the enhancement of impact resistance instead of delamination failure in the 2D panel. In addition, the in-plane interlacement of woven fabric causes that primary yarn breaks in the high stress region and forms a circle damage area, whereas the penetrating cracking along the fiber orientation of superficial layer is induced in the unidirectional composite. [ABSTRACT FROM AUTHOR]

Nonlinear stiffness composite helical spring has gained considerable attention due to its significant lightweight effect and reliable nonlinear stiffness function. Those performance of helical spring is of great significance to the energy saving and comfort improvement of automobiles. In this paper, the design method of nonlinear stiffness composite helical spring using typical materials and ply scheme was put forward. The FEM models of different ply schemes were established. Combined with ABAQUS software and the secondary development subroutine, the strength and fatigue simulation analysis of circular tubes with typical ply schemes was carried out. Then the samples using different ply schemes were prepared. The failure type, stiffness attenuation rate, and height attenuation rate of springs were obtained through the strength test under extreme condition (compression state) and the fatigue test under the full-load condition. Finally, the best ply scheme and typical damage types were obtained. Comparing the test results with the simulation results, a method that can accurately predict the strength and fatigue failure of the nonlinear stiffness composite helical spring was verified. This study can provide a systematic ply scheme design method for the fatigue reliability design of composite structures with circular tube shape. [ABSTRACT FROM AUTHOR]

Numerical simulation is a key means to evaluate the forming performance of 3D woven preforms (3DWPs). However, the macroscopic continuous model of 3DWPs cannot predict the orientation and deformation of yarns, while the microscopic discrete model is unsuitable for large-size samples forming simulation due to computational constraints. A novel mesoscopic hybrid element yarn model is thus proposed to establish a large-size 3D woven virtual yarn preform (VYP) model and the L-shaped virtual forming simulation model. The L-shaped forming experiment of the 3DWP is designed and executed, and the accuracy of the numerical simulation models is verified from three aspects: the mechanical curve, the sample's macroscopic morphology, and the local meso -structure features. Subsequently, the deformation behavior of the yarn structure inside the 3DWP during the L-shaped forming process is analyzed by combining experimental and simulation results. Furthermore, the effects of the L-shaped angle and chamfer radius on the deformation behavior of the 3DWP are studied, which helps guide the structural design of 3DWPs. [ABSTRACT FROM AUTHOR]

• Advantages of asymmetric hybridization on impact resistance and resilience. • Rules of external damage area and internal crack volume distribution. • Damage mechanism of carbon/Kevlar hybridization laminates. The ply structure has a significant effect on the impact resistance and failure behavior of composite laminates. In this paper, carbon/Kevlar hybrid fabric reinforcements were prepared with different Kevlar ratio (0%, 25%, 50%, 75%, 100%) by replacing carbon fabric plies on the non-impact side by Kevlar plies. The low-velocity impact tests for all configurations were carried out under 15 J and 25 J energy respectively. The results show that the maximum deflection, impact duration, impact absorption energy and absorption energy efficiency of hybrid laminates increased with the Kevlar hybrid ratio, whereas the peak force presented a decreasing trend, which indicates that the adding of Kevlar layer makes the laminates more ductile than non-hybrid carbon structure. The damage mechanism of the carbon fiber ply was brittle fiber fracture, resin cracking and resin shedding, while the fibers pull-out and tows splitting was found in Kevlar ply. The critical structural damages start from the non-impact side and evolve to the impact side. And the rules of internal crack volume distribution with Kevlar plies are consistent with the trend of external damage area on the non-impact side. It is suggested that in order to take into account the peak strength and excellent structural resilience, Kevlar asymmetric-hybrid ratio of 25% is the most appropriate. The reason is that an appropriate small ratio of Kevlar cushion ply can not only effectively avoid the tensile fracture at non-impact side happened in the non-hybrid carbon structure, but also withstand enough impact load by maintaining a high carbon fiber content. [ABSTRACT FROM AUTHOR]

Accurate 3D representations of multiphase layered composite fabric, including distinguish and label the pores, matrices, warp and weft yarns, can assist in understanding and ultimately improving composite material design performance. In this work, a new data enhancement algorithm is proposed to generate realistic-looking artificial learning datasets for expanding the datasets. Then, we demonstrate how supervised, the Swin Transformer approach can help to realize accurate segmentation of low-resolution and poor-contrast fabric datasets by populating databases with real and artificial learning datasets. Most of the pixels were correctly identified and the boundaries of the yarn could be identified clearly, except for some spots and a few merged boundaries. The work presented here provides an effective tool that can be widely used in semantic segmentation for various composite materials (woven composites, fiber-reinforced composites, short-fiber materials, etc.), which enables higher-precision reconstruction of fiber-composites and significant reduction in dataset processing time, and provides a route to generating artificial learning dataset. [ABSTRACT FROM AUTHOR]

Hybrid structures are increasingly important in joints of composite components. For carbon, glass, and bilateral carbon/glass hybrid composites, a thermal-mechanical characterization experimental study was implemented to explore the hybrid effect on the drilling temperature evolutions and damage mechanism. Infrared thermography was applied to analyze the temperature distribution from the side and exit surface of the composites. The results indicate that the hybrid structure generated an abrupt change of thrust force during drilling the carbon/glass interfacial region and the maximum peak force was induced in 5C5G specimen. The temperature isothermal on the side surface of hybrid composites gradually evolved into a trapezoidal shape. The variations of hole positions on the plain fabric structure can affect the temperature generation and heat transfer. The carbon layer can prevent bending deformation and act as a support in drilling the last layer of 5G5C and showed better performance. Severe damage was induced for the less mechanical strength in the glass layer and low heat dissipation of exit material leading to concentrated heat. Accumulated high temperature reduced the bonding strength between the fiber and resin, and thus the debonding, matrix smearing and resin strips occurred. [ABSTRACT FROM AUTHOR]

• Advantages of symmetric intercalation hybridization on impact strength and resilience. • Correlation of apparent damage area index and internal damage volume data. • Damage mechanism of symmetric and asymmetric carbon/Kevlar structures. Hybrid fiber composite laminates with the same materials, manufacturing methods and molding processes may present different mechanical behaviors. In this paper, the effect of intercalation sequence on the mechanical performance of carbon/Kevlar plain laminates were studied. According to different intercalation methods, the hybrid layout was divided into symmetric and asymmetric configurations. It is found that the symmetric intercalation structures (KCCK and CKKC) possess better load-bearing and resilience capacity compared with asymmetric structures (CCKK and CKCK), even better than pure carbon structure (CCCC) under high energy impact. The impact damage volume of symmetric specimens was significantly smaller than that of asymmetric specimens by quantitative micro-CT analysis. The apparent damage index (d f and d r) can be used to estimate the internal damage data (d CT , H and V). KCCK, a typical symmetric sandwich-like structure, presented the most slight damage among all symmetric and asymmetric configurations, with shear cracks observed at the brittle carbon fiber core layers, while the delamination cracks between Kevlar-carbon interlayers were away from the central damaged region. In CKCK, interlaminar cracks were formed at each carbon-Kevlar interlayers, which shared and relieved the primary interlaminar crack at the core layers compared with CCKK. [ABSTRACT FROM AUTHOR]

Low-velocity impact and flexure-after-impact (FAI) tests were performed on 2D plain woven fabric (PWF) and 3D orthogonal woven fabric (OWF) reinforced carbon fibers/epoxy composite beams while the electrical resistance measurement was applied during impact and FAI tests via four-probe technique to study the relations between resistance variation (RV) and residual mechanical properties. The impact tests (from 3 J to 9 J) showed that OWF specimens have better suppression of delamination than PWF, which was also evaluated through thermography and cross-sectional imaging method. Then FAI tests were implemented on impacted specimens while acoustic emission signals were captured. The residual flexural strength and modulus from the FAI tests were normalized by the values of intact specimens and compared with the RV from impact tests. The relations between electrical and mechanical properties revealed that the rise of resistance after the impact is an effective sign that indicates the reduction in the residual flexural strength and modulus of the composite beam. Moreover, the relation between RV and residual modulus is more effective than that with residual strength. [ABSTRACT FROM AUTHOR]

Interlayer friction is an important factor in producing rolls of glass-fiber woven fabric and strongly depends on the fabric structure and fabric interlayer contact mechanism. This paper investigates the effect of the initial contact state on the fabric/fabric friction coefficient by adjusting dislocations along circumferential and axial directions with a Capstan-based test setup. Results reveal that the maximal friction coefficient is approximately proportional to the height gradient between two adjacent yarns, while the minimal friction coefficient is less sensitive to the fabric structure. Moreover, a dislocation between fabric layers reduces both the maximal static and dynamical friction coefficients, and actively reciprocating a dislocation along the axial direction is an effective way of avoiding the interlayer friction from remaining at a low level. A dislocating mechanism is developed and introduced to a commercial fabric winding machine to verify the effectiveness of the proposed method in improving winding quality. [ABSTRACT FROM AUTHOR]