Tension and Shear Behaviour of Basalt Fiber Bio-Composites with Digital Image Correlation and Acoustic Emission Monitoring

This research investigates the mechanical behavior and damage evolution in cross-ply basalt fiber composites subjected to different loading modes. A modified Arcan rig for simultaneous acoustic emission (AE) monitoring was designed and manufactured to apply quasi-isotropic shear, combined tensile and shear loading, and pure tensile loading on specimens with a central notch. Digital image correlation (DIC) was applied for high-resolution strain measurements. The measured failure strengths of the bio-composite specimens under different loading angles are presented. The different competing failure mechanisms that contribute to the local reduction in stress concentration are described. Different damage mechanisms trigger elastic waves in the composite, with distinct AE signatures that closely follow the sequence of fracture mechanisms. AE monitoring is employed to capture signals associated with structural damage initiation and progression. The characteristic parameters of AE signals are correlated with crack modes and damage mechanisms. The evolution of AE parameters during the peak load transition is presented, which enables the timely AE detection of the maximum load transition. The combination of DIC and AE monitoring improves understanding of the mechanical response and failure mechanisms in cross-ply basalt fiber composites, offering valuable insights for possible performance monitoring and structural reliability in diverse engineering applications.

Moisture Effects on Acoustic Emission Characteristics and Damage Mechanisms of Balsa Wood Core Composite Sandwich under 4-Point Bending

To contribute to the development of sustainable composites, this work investigates the effects of moisture on the key AE characteristics related to the damage mechanisms of a bio-based balsa wood core sandwich in 4-point bending tests, including cumulative counts, amplitude, peak frequency, and duration. Novel triple dog-bone balsa wood core sandwich specimens with different MC (moisture content) were studied by comparing microscopic observations and a proposed two-step clustering approach in AE analysis. Three MC states, i.e., dry, 50% MC, and 120% MC, are discussed. GFRP (glass-fiber-reinforced polymer) laminate skin damages were found to be predominant in most GFRP-balsa sandwich specimens, but balsa wood core damages play a more important role as MC increases. The degradation of the bending stiffness of the sandwich was proven to be faster in the first linear stage of the moisture absorption curve, while the decrease in bending strength was more pronounced at the MC saturation level. Finally, for all of the dry and wet sandwich specimens, peak frequency and duration were proven to be more helpful in identifying damages associated with the lighter bio-based balsa wood core, such as balsa core damages and skin/core debonding.

Hydrogen Impact: A Review on Diffusibility, Embrittlement Mechanisms, and Characterization

Hydrogen embrittlement (HE) is a broadly recognized phenomenon in metallic materials. If not well understood and managed, HE may lead to catastrophic environmental failures in vessels containing hydrogen, such as pipelines and storage tanks. HE can affect the mechanical properties of materials such as ductility, toughness, and strength, mainly through the interaction between metal defects and hydrogen. Various phenomena such as hydrogen adsorption, hydrogen diffusion, and hydrogen interactions with intrinsic trapping sites like dislocations, voids, grain boundaries, and oxide/matrix interfaces are involved in this process. It is important to understand HE mechanisms to develop effective hydrogen resistant strategies. Tensile, double cantilever beam, bent beam, and fatigue tests are among the most common techniques employed to study HE. This article reviews hydrogen diffusion behavior, mechanisms, and characterization techniques.

Acoustic Emission-Based Analysis of Damage Mechanisms in Filament Wound Fiber Reinforced Composite Tubes

This study investigates the mechanical behavior and damage mechanisms of thin-walled glass/epoxy filament wound tubes under quasi-static lateral loads. The novelty is that the tubes are reinforced in critical areas using strip composite patches to provide a topology-optimized tube, and their damage mechanisms and mechanical performance are compared to that of un-reinforced (reference) tubes. To detect the types of damage mechanisms and their progression, the Acoustic Emission (AE) method is employed, accompanied by data clustering analysis. The loading conditions are simulated using the finite element method, and the results are validated through experimental testing. The findings confirm that the inclusion of reinforcing patches improves the stress distribution, leading to enhanced load carrying capacity, stiffness, and energy absorption. Compared to the reference tubes, the reinforced tubes exhibit a remarkable increase of 23.25% in the load carrying capacity, 33.46% in the tube's stiffness, and 23.67% in energy absorption. The analysis of the AE results reveals that both the reference and reinforced tubes experience damage mechanisms such as matrix cracking, fiber-matrix debonding, delamination, and fiber fracture. However, after matrix cracking, delamination becomes dominant in the reinforced tubes, while fiber failure prevails in the reference tubes. Moreover, by combining the AE energy and mechanical energy using the Sentry function, it is observed that the reinforced tubes exhibit a lower rate of damage propagation, indicating superior resistance to damage propagation compared to the reference tubes.

The Effect of Various Environmental Conditions on the Impact Damage Behaviour of Natural-Fibre-Reinforced Composites (NFRCs)-A Critical Review

Studies into environmental conditions and their effects on the properties of renewable materials are gaining significant attention in the research field, particularly for natural fibres and their resultant composites. However, natural fibres are prone to water absorption because of the hydrophilic nature of the fibres, which affects the overall mechanical properties of natural-fibre-reinforced composites (NFRCs). In addition, NFRCs are based mainly on thermoplastic and thermosetting matrices, which could be used in automobile and aerospace components as lightweight materials. Therefore, such components have to survive the maximum temperature and humid conditions in different parts of the world. Based on the above factors, through an up-to-date review, this paper critically discusses the effects of environmental conditions on the impact performance of NFRCs. In addition, this paper critically assesses the damage mechanisms of NFRCs and their hybrids by focusing more on moisture ingress and relative humidity in the impact damage behaviour of NFRCs.

The Typical Damage Form and Mechanism of a Railway Prestressed Concrete Sleeper

Prestressed concrete sleepers are an important track component that is widely used in railway ballast track. Prestressed concrete sleepers have high strength, strong stability, and good durability; thus, their operation and use in railways are beneficial. However, in different countries and regions, certain damage to sleepers typically appears. Existing research on concrete sleepers focuses primarily on the structural design method, the application of new materials, theoretical analysis, and bearing strength test research, while ignoring sleeper damage. There are a few sleeper damage studies, but they look at only one type of damage; thus, there is no comprehensive study of prestressed concrete sleeper damage. The damage forms of prestressed concrete sleeper damage are thus summarized in this study, and the theory of the causes of prestressed concrete sleepers is analyzed based on the limit state method for the first time. The findings indicate that sleeper structure design is the primary cause of its operation and use status, and that special measures should be considered based on sleeper use conditions. In addition to meeting design requirements, materials, curing systems, product inspection, and other factors must be considered during manufacturing to improve the sleepers' long-term performance. Keeping the track in good condition, including but not limited to the state of fasteners, ballast bed, and track geometry is also an important aspect of preventing sleeper damage. The outcomes of this study provide better insights into the influences of damage to railway prestressed concrete sleepers and can be used to improve track maintenance and inspection criteria.

Analysis of the Damage Mechanism around the Crack Tip for Two Rubber-Toughened PLA-Based Blends

The toughening mechanisms of poly(lactic acid; PLA) blended with two different elastomers, namely poly (butylene adipate-co-terephtalate; PBAT) and polyolefin elastomers with grafted glycidyl methacrylate (POE-g-GMA), at 10 and 20 wt.%, were investigated. Tensile and Charpy impact tests showed a general improvement in the performance of the PLA. The morphology of the dispersed phases showed that PBAT is in the form of spheres while POE-g-GMA has a dual sphere/fibre morphology. To correlate the micromechanical deformation mechanism with the macroscopical mechanical behaviour, the analysis of the subcritical crack tip damaged zone of double-notched specimens subjected to a four-point bending test (according to the single-edge double-notch four-point bend (SEDN-4PB) technique) was carried out using several microscopic techniques (SEM, polarized TOM and TEM). The damage was mainly generated by shear yielding deformation although voids associated with dilatational bands were observed.

Rheological Model to Describe the Cyclic Load-Bearing Behaviour of Strain-Hardening Cement-Based Composites (SHCC)

The mechanical behaviour of strain-hardening cement-based composites (SHCC) under monotonic tensile loading has been the subject of research for many years. The recent research on the SHCC’s performance under cyclic loading has enabled the identification of a wide variety of damage phenomena different to those observed under monotonic loading. The article at hand first summarises the experimental evidence of such phenomena in the context of the material performance observed. On this basis, the mechanisms behind these phenomena are discussed and explained using rheological modelling.

3D Microstructure-Based Finite Element Simulation of Cold-Sprayed Al-Al2O3 Composite Coatings Under Quasi-Static Compression and Indentation Loading

This study developed microstructure-based finite element (FE) models to investigate the behavior of cold-sprayed aluminum-alumina (Al-Al2O3) metal matrix composite (MMC) coatings subject to indentation and quasi-static compression loading. Based on microstructural features (i.e., particle weight fraction, particle size, and porosity) of the MMC coatings, 3D representative volume elements (RVEs) were generated by using Digimat software and then imported into ABAQUS/Explicit. State-of-the-art physics-based modeling approaches were incorporated into the model to account for particle cracking, interface debonding, and ductile failure of the matrix. This allowed for analysis and informing on the deformation and failure responses. The model was validated with experimental results for cold-sprayed Al-34 wt.% Al2O3 and Al-46 wt.% Al2O3 metal matrix composite coatings under quasi-static compression by comparing the stress versus strain histories and observed failure mechanisms (e.g., matrix ductile failure). The results showed that the computational framework is able to capture the response of this cold-sprayed material system under compression and indentation, both qualitatively and quantitatively. The outcomes of this work have implications for extending the model to materials design and for applications involving different types of loading in real-world application (e.g., erosion and fatigue).

In Situ Characterization of Polycaprolactone Fiber Response to Quasi-Static Tensile Loading in Scanning Electron Microscopy

Microstructural responses to the mechanical load of polymers used in tissue engineering is notably important for qualification at in vivo testing, although insufficiently studied, especially regarding promising polycaprolactone (PCL). For further investigations, electrospun PCL scaffolds with different degrees of fiber alignment were produced, using two discrete relative drum collector velocities. Development and preparation of an adjusted sample geometry enabled in situ tensile testing in scanning electron microscopy. By analyzing the microstructure and the use of selected tracking techniques, it was possible to visualize and quantify fiber/fiber area displacements as well as local fractures of single PCL fibers, considering quasi-static tensile load and fiber alignment. The possibility of displacement determination using in situ scanning electron microscopy techniques for testing fibrous PCL scaffolds was introduced and quantified.

Predictive Computational Model for Damage Behavior of Metal-Matrix Composites Emphasizing the Effect of Particle Size and Volume Fraction

In this paper, an integrated numerical model is proposed to investigate the effects of particulate size and volume fraction on the deformation, damage, and failure behaviors of particulate-reinforced metal matrix composites (PRMMCs). In the framework of a random microstructure-based finite element modelling, the plastic deformation and ductile cracking of the matrix are, respectively, modelled using Johnson–Cook constitutive relation and Johnson–Cook ductile fracture model. The matrix-particle interface decohesion is simulated by employing the surface-based-cohesive zone method, while the particulate fracture is manipulated by the elastic–brittle cracking model, in which the damage evolution criterion depends on the fracture energy cracking criterion. A 2D nonlinear finite element model was developed using ABAQUS/Explicit commercial program for modelling and analyzing damage mechanisms of silicon carbide reinforced aluminum matrix composites. The predicted results have shown a good agreement with the experimental data in the forms of true stress–strain curves and failure shape. Unlike the existing models, the influence of the volume fraction and size of SiC particles on the deformation, damage mechanism, failure consequences, and stress–strain curve of A359/SiC particulate composites is investigated accounting for the different possible modes of failure simultaneously.

Ballistic Impact Behaviour of Glass/Epoxy Composite Laminates Embedded with Shape Memory Alloy (SMA) Wires

This paper aims to estimate the enhancement in the energy absorption characteristics of the glass fiber reinforced composites (GFRP) by embedding prestrained pseudo-elastic shape memory alloy (SMA) that was used as a secondary reinforcement. The pseudo-elastic SMA (PE-SMA) embedded were in the form of wires and have an equiatomic composition (i.e., 50%-50%) of nickel (Ni) and titanium (Ti). These specimens are fabricated using a vacuum-assisted resin infusion process. The estimation is done for the GFRP and SMA/GFRP specimens at four different impact velocities (65, 75, 85, and 103 m/s) using a gas-gun impact set-up. At all different impact velocities, the failure modes change as we switch from GFRP to SMA/GFRP specimen. In the SMA/GFRP specimen, the failure mode changed from delamination in the primary region to SMA-pull out and SMA deformation. This leads to an increase in the ballistic limit. It is observed that energy absorbed by SMA/GFRP specimens is higher than the GFRP specimens subjected to the same levels of impact energy. To understand the damping capabilities of SMA embedment, vibration signals are captured, and the damping ratio is calculated. SMA dampens the vibrations imparted by the projectile to the specimen. The damping ratio of the SMA/GFRP specimens is higher than the GFRP specimens. The damping effect is more prominent below the ballistic limit when the projectile got rebounded (65 m/s).

Study on the Microstructure of Polyether Ether Ketone Films Irradiated with 170 keV Protons by Grazing Incidence Small Angle X-ray Scattering (GISAXS) Technology

Polyether ether ketone (PEEK) films irradiated with 170 keV protons were calculated by the stopping and ranges of ions in matter (SRIM) software. The results showed that the damage caused by 170 keV protons was only several microns of the PEEK surface, and the ionization absorbed dose and displacement absorbed dose were calculated. The surface morphology and roughness of PEEK after proton irradiation were studied by atomic force microscope (AFM). GISAXS was used to analyze the surface structural information of the pristine and irradiated PEEK. The experimental results showed that near the surface of the pristine and irradiated PEEK exists a peak, and the peak gradually disappeared with the increasing of the angles of incidence and the peak changed after irradiation, which implies the 170 keV protons have an effect on PEEK structure. The influences of PEEK irradiated with protons on the melting temperature and crystallization temperature was investigated by differential scanning calorimetry (DSC). The DSC results showed that the crystallinity of the polymer after irradiation decreased. The structure and content of free radicals of pristine and irradiated PEEK were studied by Fourier transform infrared spectroscopy (FTIR) and electron paramagnetic resonance (EPR). The stress and strain test results showed that the yield strength of the PEEK irradiated with 5 × 10¹⁵ p/cm² and 1 × 10¹⁶ p/cm² was higher than the pristine, but the elongation at break of the PEEK irradiated with 5 × 10¹⁵ p/cm² and 1 × 10¹⁶ p/cm² decreased obviously.

Data Merging of AE Sensors with Different Frequency Resolution for the Detection and Identification of Damage in Oxide-Based Ceramic Matrix Composites

In this paper, acoustic emission data fusion based on multiple measurements is presented for damage detection and identification in oxide-based ceramic matrix composites. Multi-AE (acoustic emission) sensor fusion is considered with the aim of a better identification of damage mechanisms. In this context, tensile tests were conducted on ceramic matrix composites, fabricated with 3M™ Nextel™ 610 fibers and aluminosilicate matrix, with two kinds of AE sensors. Redundant and complementary sensor data were merged to enhance AE system capability and reliability. Data fusion led to consistent signal clustering with an unsupervised procedure. A correlation between these clusters and the damage mechanisms was established thanks to in situ observations. The complementarity of the information from both sensors greatly improves the characterization of sources for their classification. Moreover, this complementarity allows features to be perceived more precisely than using only the information from one kind of sensor.

Influence of Aluminum Surface Treatment on Tensile and Fatigue Behavior of Thermoplastic-Based Hybrid Laminates

Hybrid laminates consist of layers of different materials, which determine the mechanical properties of the laminate itself. Furthermore, the structure and interfacial properties between the layers play a key role regarding the performance under load and therefore need to be investigated in respect to industrial applicability. In this regard, a hybrid laminate comprised of AA6082 aluminum alloy sheets and glass and carbon fiber-reinforced thermoplastic (polyamide 6) is investigated in this study with a focus on the influence of aluminum surface treatment application on tensile and fatigue behavior. Four different aluminum surface treatments are discussed (adhesion promoter, mechanical blasting, phosphating, and anodizing), which were characterized by Laser Scanning Microscopy. After the thermal consolidation of the hybrid laminate under defined pressure, double notch shear tests and tensile tests were performed and correlated to determine the resulting interfacial strength between the aluminum sheet surface and the fiber-reinforced plastic, and its impact on tensile performance. To investigate the performance of the laminate under fatigue load in LCF and HCF regimes, a short-time procedure was applied consisting of resource-efficient instrumented multiple and constant amplitude tests. Digital image correlation, thermography, and hysteresis measurement methods were utilized to gain information about the aluminum surface treatment influence on fatigue damage initiation and development. The results show that fatigue-induced damage initiation, development, and mechanisms differ significantly depending on the applied aluminum surface treatment. The used measurement technologies proved to be suitable for this application and enabled correlations in between, showing that the hybrid laminates damage state, in particular regarding the interfacial bonding of the layers, can be monitored not just through visual recordings of local strain and temperature development, but also through stress-displacement hysteresis analysis.

Dynamic Mechanical Response and Damage Mechanism of HTPB Propellant under Impact Loading

The dynamic mechanical behaviors of Hydroxyl-terminated polybutadiene (HTPB) propellant was studied by a split Hopkinson pressure bar apparatus (SHPB) at strain rates ranging from 10³ to 10⁴ s⁻¹. The obtained stress–strain curves indicated that the mechanical features, such as ultimate stress and strain energy, were strongly dependent on the strain rate. The real time deformation and fracture evolution of HTPB propellant were captured by a high-speed digital camera accompanied with an SHPB setup. Furthermore, microscopic observation for the post-test specimen was conducted to explore the different damage mechanisms under various conditions of impact loading. The dominated damage characteristics of HTPB propellant were changed from debonding and matrix tearing to multiple cracking modes of ammonium perchlorate (AP) particles, along with the increase of the strain rate. For the first time, the influence of AP particle density on the dynamic response of HTPB propellant was studied by analyzing the strain-rate sensitivity (SRS) index of HTPB propellant with two different filler content (80 wt.% and 85 wt.%), which deduced from a power function of ultimate stress and strain energy density. The result of this study is of significance for evaluating the structural integrity and security of HTPB propellant.

In Situ Characterization of Damage Development in Cottonid Due to Quasi-Static Tensile Loading

Cottonid is a layered material based 100% on cellulose that holds excellent material properties by being completely sustainable. The finite nature of petroleum-based resources nowadays makes these properties significant for technical applications again. To understand how Cottonid reacts to application-oriented mechanical loads and how it fails, development of microstructural damage on the surface and in the volume of Cottonid was studied using innovative in situ testing techniques for the first time. Quasi-static tensile tests were comparatively performed in a scanning electron microscope as well as a microfocus computer tomograph, and the development of defects present in the initial condition of the material was investigated. In the elastic region, no visible damage initiation on the surface and a decrease of overall void volume within the gauge length could be detected. When reaching the yield strength, crack initiation on the surface starts at critical areas, like pores and microcracks, which propagation and assembly could be visualized via scanning electron micrographs. In the plastic region, an increase in void volume could be shown in the gauge length until final failure of the specimen. Innovative material testing techniques presented in this study support lifetime estimation in technical applications and understanding of process–structure–property relations. Particularly, characterization of microstructural damage development due to a mechanical load, which leads to final failure of the specimen, is essential to be able to create material models for lifetime prediction in respect to variable manufacturing or application parameters.

Water Droplet Erosion of Wind Turbine Blades: Mechanics, Testing, Modeling and Future Perspectives

The problem of erosion due to water droplet impact has been a major concern for several industries for a very long time and it keeps reinventing itself wherever a component rotates or moves at high speed in a hydrometer environment. Recently, and as larger wind turbine blades are used, erosion of the leading edge due to rain droplets impact has become a serious issue. Leading-edge erosion causes a significant loss in aerodynamics efficiency of turbine blades leading to a considerable reduction in annual energy production. This paper reviews the topic of water droplet impact erosion as it emerges in wind turbine blades. A brief background on water droplet erosion and its industrial applications is first presented. Leading-edge erosion of wind turbine is briefly described in terms of materials involved and erosion conditions encountered in the blade. Emphases are then placed on the status quo of understanding the mechanics of water droplet erosion, experimental testing, and erosion prediction models. The main conclusions of this review are as follow. So far, experimental testing efforts have led to establishing a useful but incomplete understanding of the water droplet erosion phenomenon, the effect of different erosion parameters, and a general ranking of materials based on their ability to resist erosion. Techniques for experimentally measuring an objective erosion resistance (or erosion strength) of materials have, however, not yet been developed. In terms of modelling, speculations about the physical processes underlying water droplet erosion and consequently treating the problem from first principles have never reached a state of maturity. Efforts have, therefore, focused on formulating erosion prediction equations depending on a statistical analysis of large erosion tests data and often with a combination of presumed erosion mechanisms such as fatigue. Such prediction models have not reached the stage of generalization. Experimental testing and erosion prediction efforts need to be improved such that a coherent water droplet erosion theory can be established. The need for standardized testing and data representation practices as well as correlations between test data and real in-service erosion also remains urgent.

Comparison of Microstructure and Mechanical Properties of Scalmalloy® Produced by Selective Laser Melting and Laser Metal Deposition

The second-generation aluminum-magnesium-scandium (Al-Mg-Sc) alloy, which is often referred to as Scalmalloy^®, has been developed as a high-strength aluminum alloy for selective laser melting (SLM). The high-cooling rates of melt pools during SLM establishes the thermodynamic conditions for a fine-grained crack-free aluminum structure saturated with fine precipitates of the ceramic phase Al₃-Sc. The precipitation allows tensile and fatigue strength of Scalmalloy^® to exceed those of AlSi10Mg by ~70%. Knowledge about properties of other additive manufacturing processes with slower cooling rates is currently not available. In this study, two batches of Scalmalloy^® processed by SLM and laser metal deposition (LMD) are compared regarding microstructure-induced properties. Microstructural strengthening mechanisms behind enhanced strength and ductility are investigated by scanning electron microscopy (SEM). Fatigue damage mechanisms in low-cycle (LCF) to high-cycle fatigue (HCF) are a subject of study in a combined strategy of experimental and statistical modeling for calculation of Woehler curves in the respective regimes. Modeling efforts are supported by non-destructive defect characterization in an X-ray computed tomography (µ-CT) platform. The investigations show that Scalmalloy^® specimens produced by LMD are prone to extensive porosity, contrary to SLM specimens, which is translated to ~30% lower fatigue strength.