An Open-Source ABAQUS Plug-In for Delamination Analysis of 3D Printed Composites.

This article presents the development and implementation of the Delamination Plug-in, an open-source tool for modeling delamination tests in the ABAQUS software. Specifically designed for stochastic modeling of 3D printed composites, the plug-in combines the benefits of the graphical user interface (GUI) and the programming of commercial finite element (FE) software. The Delamination Plug-in offers an effortless alternative to the time-consuming analytical modeling and GUI work involved in delamination tests and includes algorithms for several tests, such as the double cantilever beam, end-loaded split, end-notched flexure, and modified end-loaded split tests, solved using the virtual crack closure technique and the cohesive zone method. It enables the user to develop simulations for both simple symmetric laminates and generally layered laminates with additional thermal stresses. The applicability of the tool is demonstrated through its use in two distinct delamination problems, one for conventional and one for 3D printed composite laminates, and its results are compared to analytical models and experimental data from the open literature. The results demonstrate that the Delamination Plug-in is efficient and applicable for such materials. This establishes the tool as an important means of automating delamination analysis and for the development and testing of 3D printed composites, making it a valuable tool for both researchers and industry professionals.

Measuring and Predicting the Effects of Residual Stresses from Full-Field Data in Laser-Directed Energy Deposition.

This article presents a novel approach for assessing the effects of residual stresses in laser-directed energy deposition (L-DED). The approach focuses on exploiting the potential of rapidly growing tools such as machine learning and polynomial chaos expansion for handling full-field data for measurements and predictions. In particular, the thermal expansion coefficient of thin-wall L-DED steel specimens is measured and then used to predict the displacement fields around the drilling hole in incremental hole-drilling tests. The incremental hole-drilling test is performed on cubic L-DED steel specimens and the displacement fields are visualized using a 3D micro-digital image correlation setup. A good agreement is achieved between predictions and experimental measurements.

The Influence of Different Lay-Up Parameters on the Fatigue Response of Carbon/Epoxy Laminates under Internal Multiaxial Stress States.

The inherent anisotropy of composites complicates their damage response. The influence of multiaxiality, particularly in carbon-based composites, is not thoroughly understood due to obstacles related to damage monitoring during loading. In this study, the response of different carbon/epoxy laminates under fatigue is examined through dedicated in situ microscopic observations. By varying the orientation of off-axis layers, the impact of multiaxiality on the mechanical and damage response is evaluated. Furthermore, balanced and unbalanced laminates are compared, considering the limited information for the latter. The influence of the number of off-axis layers is finally assessed leading to important conclusions about optimal fatigue response. The fatigue response is evaluated in all cases considering both the mechanical properties and the damage characteristics. Significant conclusions are drawn, especially for the benefits of unbalanced laminates and the impact of shear stresses, allowing for the utilization of the obtained data as important input for the establishment of reliable fatigue damage models.

Elastic Wave Monitoring of Cementitious Mixtures Including Internal Curing Mechanisms.

The mitigation of autogenous shrinkage in cementitious materials by internal curing has been widely studied. By the inclusion of water reservoirs, in form of saturated lightweight aggregates or superabsorbent polymers, additional water is provided to the hydrating matrix. The onset of water release is of high importance and determines the efficiency of the internal curing mechanism. However, the monitoring of it poses problems as it is a process that takes place in the microstructure. Using acoustic emission (AE) sensors, the internal curing process is monitored, revealing its initiation and intensity, as well as the duration. In addition, AE is able to capture the water evaporation from saturated specimens. By ultrasonic testing, differences in the hydration kinetics are observed imposed by the different methods of internal curing. The results presented in this paper show the sensitivity of combined AE and ultrasound experiments to various fundamental mechanisms taking place inside cementitious materials and demonstrate the ability of acoustic emission to evaluate internal curing in a non-destructive and easily implementable way.

The Influence of Superabsorbent Polymers and Nanosilica on the Hydration Process and Microstructure of Cementitious Mixtures.

Superabsorbent polymers (SAPs) are known to mitigate the development of autogenous shrinkage in cementitious mixtures with a low water-to-cement ratio. Moreover, the addition of SAPs promotes the self-healing ability of cracks. A drawback of using SAPs lies in the formation of macropores when the polymers release their absorbed water, leading to a reduction of the mechanical properties. Therefore, a supplementary material was introduced together with SAPs, being nanosilica, in order to obtain an identical compressive strength with respect to the reference material without additives. The exact cause of the similar compressive behaviour lies in the modification of the hydration process and subsequent microstructural development by both SAPs and nanosilica. Within the present study, the effect of SAPs and nanosilica on the hydration progress and the hardened properties is assessed. By means of isothermal calorimetry, the hydration kinetics were monitored. Subsequently, the quantity of hydration products formed was determined by thermogravimetric analysis and scanning electron microscopy, revealing an increased amount of hydrates for both SAP and nanosilica blends. An assessment of the pore size distribution was made using mercury intrusion porosimetry and demonstrated the increased porosity for SAP mixtures. A correlation between microstructure and the compressive strength displayed its influence on the mechanical behaviour.

The Contribution of Elastic Wave NDT to the Characterization of Modern Cementitious Media.

To mitigate autogenous shrinkage in cementitious materials and simultaneously preserve the material's mechanical performance, superabsorbent polymers and nanosilica are included in the mixture design. The use of the specific additives influences both the hydration process and the hardened microstructure, while autogenous healing of cracks can be stimulated. These three stages are monitored by means of non-destructive testing, showing the sensitivity of elastic waves to the occurring phenomena. Whereas the action of the superabsorbent polymers was evidenced by acoustic emission, the use of ultrasound revealed the differences in the developed microstructure and the self-healing of cracks by a comparison with more commonly performed mechanical tests. The ability of NDT to determine these various features renders it a promising measuring method for future characterization of innovative cementitious materials.

Evaluation of the Self-Healing Ability of Mortar Mixtures Containing Superabsorbent Polymers and Nanosilica.

Addition of superabsorbent polymers (SAPs) to cementitious mixtures promotes the self-healing ability of the material. When cracking occurs; SAPs present inside the crack will swell upon contact with water and subsequently release this water to stimulate the further hydration of unhydrated cement particles and the calcium carbonate crystallization. However; the inclusion of SAPs affects the mechanical performance of the cementitious material by the creation of macro-pores as water is retracted from the swollen SAP. To counteract the reduction in strength, part of the cement is replaced by nanosilica. In this research, different mixtures containing either SAPs or nanosilica and a combination of both were made. The samples were subjected to wet-dry cycles simulating external conditions, and the self-healing efficiency was evaluated by means of the evolution in crack width, by optical measurements, and a water permeability test. In samples containing SAPs, an immediate sealing effect was observed and visual crack closure was noticed. The smaller influence on the mechanical properties and the good healing characteristics in mixtures containing both nanosilica and SAPs are promising as a future material for use in building applications.

A Novel Design of Autonomously Healed Concrete: Towards a Vascular Healing Network.

Concrete is prone to crack formation in the tensile zone, which is why steel reinforcement is introduced in these zones. However, small cracks could still arise, which give liquids and gasses access to the reinforcement causing it to corrode. Self-healing concrete repairs and seals these small (300 µm) cracks, preventing the development of corrosion. In this study, a vascular system, carrying the healing agent, is developed. It consists of tubes connected to a 3D printed distribution piece. This distribution piece has four outlets that are connected to the tubes and has one inlet, which is accessible from outside. Several materials were considered for the tubes, i.e., polymethylmethacrylate, starch, inorganic phosphate cement and alumina. Three-point-bending and four-point-bending tests proved that self-healing and multiple self-healing is possible with this developed vascular system.

Fatigue of Ti6Al4V Structural Health Monitoring Systems Produced by Selective Laser Melting.

Selective laser melting (SLM) is an additive manufacturing (AM) process which is used for producing metallic components. Currently, the integrity of components produced by SLM is in need of improvement due to residual stresses and unknown fracture behavior. Titanium alloys produced by AM are capable candidates for applications in aerospace and industrial fields due to their fracture resistance, fatigue behavior and corrosion resistance. On the other hand, structural health monitoring (SHM) system technologies are promising and requested from the industry. SHM systems can monitor the integrity of a structure and during the last decades the research has primarily been influenced by bionic engineering. In that aspect a new philosophy for SHM has been developed: the so-called effective structural health monitoring (eSHM) system. The current system uses the design freedom provided by AM. The working principle of the system is based on crack detection by means of a network of capillaries that are integrated in a structure. The main objective of this research is to evaluate the functionality of Ti6Al4V produced by the SLM process in the novel SHM system and to confirm that the eSHM system can successfully detect cracks in SLM components. In this study four-point bending fatigue tests on Ti6Al4V SLM specimens with an integrated SHM system were conducted. Fractographic analysis was performed after the final failure, while finite element simulations were used in order to determine the stress distribution in the capillary region and on the component. It was proven that the SHM system does not influence the crack initiation behavior during fatigue. The results highlight the effectiveness of the eSHM on SLM components, which can potentially be used by industrial and aerospace applications.

Evaluation of SHM system produced by additive manufacturing via acoustic emission and other NDT methods.

During the last decades, structural health monitoring (SHM) systems are used in order to detect damage in structures. We have developed a novel structural health monitoring approach, the so-called "effective structural health monitoring" (eSHM) system. The current SHM system is incorporated into a metallic structure by means of additive manufacturing (AM) and has the possibility to advance life safety and reduce direct operative costs. It operates based on a network of capillaries that are integrated into an AM structure. The internal pressure of the capillaries is continuously monitored by a pressure sensor. When a crack nucleates and reaches the capillary, the internal pressure changes signifying the existence of the flaw. The main objective of this paper is to evaluate the crack detection capacity of the eSHM system and crack location accuracy by means of various non-destructive testing (NDT) techniques. During this study, detailed acoustic emission (AE) analysis was applied in AM materials for the first time in order to investigate if phenomena like the Kaiser effect and waveform parameters used in conventional metals can offer valuable insight into the damage accumulation of the AM structure as well. Liquid penetrant inspection, eddy current and radiography were also used in order to confirm the fatigue damage and indicate the damage location on un-notched four-point bending AM metallic specimens with an integrated eSHM system. It is shown that the eSHM system in combination with NDT can provide correct information on the damage condition of additive manufactured metals.

Fracture of human femur tissue monitored by acoustic emission sensors.

The study describes the acoustic emission (AE) activity during human femur tissue fracture. The specimens were fractured in a bending-torsion loading pattern with concurrent monitoring by two AE sensors. The number of recorded signals correlates well with the applied load providing the onset of micro-fracture at approximately one sixth of the maximum load. Furthermore, waveform frequency content and rise time are related to the different modes of fracture (bending of femur neck or torsion of diaphysis). The importance of the study lies mainly in two disciplines. One is that, although femurs are typically subjects of surgical repair in humans, detailed monitoring of the fracture with AE will enrich the understanding of the process in ways that cannot be achieved using only the mechanical data. Additionally, from the point of view of monitoring techniques, applying sensors used for engineering materials and interpreting the obtained data pose additional difficulties due to the uniqueness of the bone structure.

Wave dispersion and attenuation on human femur tissue.

Cortical bone is a highly heterogeneous material at the microscale and has one of the most complex structures among materials. Application of elastic wave techniques to this material is thus very challenging. In such media the initial excitation energy goes into the formation of elastic waves of different modes. Due to "dispersion", these modes tend to separate according to the velocities of the frequency components. This work demonstrates elastic wave measurements on human femur specimens. The aim of the study is to measure parameters like wave velocity, dispersion and attenuation by using broadband acoustic emission sensors. First, four sensors were placed at small intervals on the surface of the bone to record the response after pencil lead break excitations. Next, the results were compared to measurements on a bulk steel block which does not exhibit heterogeneity at the same wave lengths. It can be concluded that the microstructure of the tissue imposes a dispersive behavior for frequencies below 1 MHz and care should be taken for interpretation of the signals. Of particular interest are waveform parameters like the duration, rise time and average frequency, since in the next stage of research the bone specimens will be fractured with concurrent monitoring of acoustic emission.

Shear stress sensing with Bragg grating-based sensors in microstructured optical fibers.

We demonstrate shear stress sensing with a Bragg grating-based microstructured optical fiber sensor embedded in a single lap adhesive joint. We achieved an unprecedented shear stress sensitivity of 59.8 pm/MPa when the joint is loaded in tension. This corresponds to a shear strain sensitivity of 0.01 pm/µÎµ. We verified these results with 2D and 3D finite element modeling. A comparative FEM study with conventional highly birefringent side-hole and bow-tie fibers shows that our dedicated fiber design yields a fourfold sensitivity improvement.

Investigation of contact acoustic nonlinearity in delaminations by shearographic imaging, laser doppler vibrometric scanning and finite difference modeling.

Full-field dynamic shearography and laser Doppler vibrometric scanning are used to investigate the local contact acoustic nonlinear generation of delamination-induced effects on the vibration of a harmonically excited composite plate containing an artificial defect. Nonlinear elastic behavior caused by the stress-dependent boundary conditions at the delamination interfaces of a circular defect is also simulated by a 3-D second-order, finite-difference, staggered-grid model (displacement-stress formulation). Both the experimental and simulated data reveal an asymmetric motion of the layer above the delamination, which acts as a membrane vibrating with enhanced displacement amplitude around a finite offset displacement. The spectrum of the membrane motion is enriched with clapping-induced harmonics of the excitation frequency. In case of a sufficiently thin and soft membrane, the simulations reveal clear modal behavior at sub-harmonic frequencies caused by inelastic clapping.