Dataset with press forming results of unidirectional thermoplastic composite laminates including in-plane deformation data for validation of forming simulations.

Truncated hemisphere parts were press formed with two commercially available unidirectional thermoplastic composite materials, namely Toray TC1225 and Solvay APC. The width and layup of the laminates were varied to influence the wrinkling severity, to trigger various deformation mechanisms and to influence the amount of in-plane deformation. A total of eight layup/width combinations were selected and formed in triplicate for both materials, resulting in the analysis of 48 parts in total. The wrinkling defects are clearly observed due to an intentional gap between the forming tools at the end of forming. Further, a dot pattern with a resolution of 3 mm was applied to the laminates prior to forming using a photoresist mask, sandblasting and heat resistant spray paint. The locations of the dots before and after forming were measured using photogrammetry and are provided in the dataset as a triangular mesh including a precision metric. Matlab functions, bundled with this dataset, allow for the reproduction of the deformation calculations and averages. Lastly, a Matlab App (GUI) is provided for easy visualization of the data. This dataset can serve as a reference for validation of composite forming simulations.

The Springer Model for Lifetime Prediction of Wind Turbine Blade Leading Edge Protection Systems: A Review and Sensitivity Study.

The wind energy sector is growing rapidly. Wind turbines are increasing in size, leading to higher tip velocities. The leading edges of the blades interact with rain droplets, causing erosion damage over time. In order to mitigate the erosion, coating materials are required to protect the blades. To predict the fatigue lifetime of coated substrates, the Springer model is often used. The current work summarizes the research performed using this model in the wind energy sector and studies the sensitivity of the model to its input parameters. It is shown that the Springer model highly depends on the Poisson ratio, the strength values of the coating and the empirically fitted a2 constant. The assumptions made in the Springer model are not physically representative, and we reasoned that more modern methods are required to accurately predict coating lifetimes. The proposed framework is split into three parts-(1) a contact pressure model, (2) a coating stress model and (3) a fatigue strength model-which overall is sufficient to capture the underlying physics during rain erosion of wind turbine blades. Possible improvements to each of the individual aspects of the framework are proposed.

Mesoscale Process Modeling of a Thick Pultruded Composite with Variability in Fiber Volume Fraction.

Pultruded fiber-reinforced polymer composites are susceptible to microstructural nonuniformity such as variability in fiber volume fraction (Vf), which can have a profound effect on process-induced residual stress. Until now, this effect of non-uniform Vf distribution has been hardly addressed in the process models. In the present study, we characterized the Vf distribution and accompanying nonuniformity in a unidirectional fiber-reinforced pultruded profile using optical light microscopy. The identified nonuniformity in Vf was subsequently implemented in a mesoscale thermal-chemical-mechanical process model, developed explicitly for the pultrusion process. In our process model, the constitutive material behavior was defined locally with respect to the corresponding fiber volume fraction value in different-sized representative volume elements. The effect of nonuniformity on the temperature and cure degree evolution, and residual stress was analyzed in depth. The results show that the nonuniformity in fiber volume fraction across the cross-section increased the absolute magnitude of the predicted residual stress, leading to a more scattered residual stress distribution. The observed Vf gradient promotes tensile residual stress at the core and compressive residual stress at the outer regions. Consequently, it is concluded that it is essential to take the effects of nonuniformity in fiber distribution into account for residual stress estimations, and the proposed numerical framework was found to be an efficient tool to study this aspect.

3D Numerical Modeling of Laser Assisted Tape Winding Process of Composite Pressure Vessels and Pipes-Effect of Winding Angle, Mandrel Curvature and Tape Width.

Advanced thermoplastic composites manufacturing using laser assisted tape placement or winding (LATP/LATW) is a challenging task as monitoring and predicting nip point (bonding) temperature are difficult especially on curved surfaces. A comprehensive numerical analysis of the heat flux and temperature distribution near the nip point is carried out in this paper for helical winding of fiber reinforced thermoplastic tapes on a cylindrically shaped mandrel. An optical ray-tracing technique is coupled with a numerical heat transfer model in the process simulation tool. The developed optical-thermal model predictions were compared with experimental data available in literature to validate its effectiveness. The influences of winding/placement angle, mandrel curvature and tape width on the incident angles, the laser absorbed intensity, and the process temperature distribution are studied extensively using the validated model. Winding/placement angle has a considerable effect on the temperature distribution. Increase in winding angle results in a higher temperature for tape due to more reflections coming from the substrate. On the other hand, substrate temperature decreases as the winding angle increases due to a decrease in the laser incident angles based on the local surface curvature. An increase in mandrel curvature results in higher nip point temperatures for substrate and lower one for tape. Different mandrel sizes for 90 ∘ placement path do not have a strong effect on the substrate process temperature as for other winding angles because of less curvature change of the corresponding irradiated area. Tape width causes local temperature variations at the edges of the tape/substrate. In order to obtain the desired process temeprature during LATW or LATP processes, the laser intensity distribution on the tape and substrate surfaces should be regulated.

Printing "Smart" Inks of Redox-Responsive Organometallic Polymers on Microelectrode Arrays for Molecular Sensing.

Printing arrays of responsive spots for multiplexed sensing with electrochemical readout requires new molecules and precise, high-throughput deposition of active compounds on microelectrodes with spatial control. We have designed and developed new redox-responsive polymers, featuring a poly(ferrocenylsilane) (PFS) backbone and side groups with disulfide units, which allow an efficient and stable bonding to Au substrates, using sulfur-gold coupling chemistry in a "grafting-to" approach. The polymer molecules can be employed for area selective molecular sensing following their deposition by high-precision inkjet printing. The new PFS derivatives, which serve as "molecular inks", were characterized by 1H NMR, 13C NMR, and FTIR spectroscopies and by gel permeation chromatography. The viscosity and surface tension of the inks were assessed by rheology and pendant drop contact angle measurements, respectively. Commercial microelectrode arrays were modified with the new PFS ink by using inkjet printing in the "drop-on-demand" mode. FTIR spectroscopy, AFM, and EDX-SEM confirmed a successful, spatially localized PFS modification of the individual electrodes within the sensing cells of the microelectrode arrays. The potential application of these devices to act as an electrochemical sensor array was demonstrated with a model analyte, ascorbic acid, by using cyclic voltammetry and amperometric measurements.

Steering the propagation direction of a non-linear acoustic wave in a solid material.

In this research non-collinear wave mixing is used as a non-destructive testing method where the amplitude of the scattering wave contains information on the condition of a material. The practical implementation of non-collinear wave mixing as a non-destructive testing technique is limited by many factors such as the geometry and shape of the structure, the accessibility to the specimen's surfaces and the ultrasonic sensors available to perform measurements. A novel approach to steer the propagation direction of a generated wave from the mixing of two incident acoustic waves is proposed. The angle of the scattering wave is controlled by the frequencies of the two interaction waves, rather than by the angle between these waves. The scattering amplitude was analytically solved for the longitudinal plus shear interaction process. The analytical solution was validated with experiments. The model qualitatively agrees with the experiments. Furthermore, the possibility to use a wider range of excitation frequencies of the incident waves was found. This is a great advantage in applications where the space and access to the specimen under test is limited.

A Methodology Based on Pulse-Velocity Measurements to Quantify the Chemical Degradation Levels in Thin Mortar Specimens.

In this research, ultrasonic pulse echo measurements are used to quantify through thickness chemical degradation in thin mortar specimens. The degradation level is predicted using the time of travel of the acoustic wave through the thickness of the structure. The front and back wall interaction reflections are used to obtain additional information from very early stage degradation. The pulse-velocity of sound waves as a function of the thickness of the layers within the structure is described. With knowledge of the pulse-velocity in pristine and fully degraded conditions, it is possible to determine the complete range of degradation length over the layer thickness. The method is applicable for leaching of calcium and acidic attack. The acoustic measurements were verified with destructive testing. The correlation between the acoustic and non-acoustic experiments agree with the described pulse-velocity and degraded depth function. The method based on ultrasonic measurements can be implemented in other thin-layered structures.

A Review on the Mechanical Modeling of Composite Manufacturing Processes.

The increased usage of fiber reinforced polymer composites in load bearing applications requires a detailed understanding of the process induced residual stresses and their effect on the shape distortions. This is utmost necessary in order to have more reliable composite manufacturing since the residual stresses alter the internal stress level of the composite part during the service life and the residual shape distortions may lead to not meeting the desired geometrical tolerances. The occurrence of residual stresses during the manufacturing process inherently contains diverse interactions between the involved physical phenomena mainly related to material flow, heat transfer and polymerization or crystallization. Development of numerical process models is required for virtual design and optimization of the composite manufacturing process which avoids the expensive trial-and-error based approaches. The process models as well as applications focusing on the prediction of residual stresses and shape distortions taking place in composite manufacturing are discussed in this study. The applications on both thermoset and thermoplastic based composites are reviewed in detail.