4327 12266 1 PB PDF
4327 12266 1 PB PDF
4327 12266 1 PB PDF
Reviews
Keywords: Carbon Fibre Composites, Laminates, Aircraft Structures, Design Allowable, Structural
Design, Impact Damage, Holes in composites, Fastener joints, Hygrothermal effect.
1 Introduction
Over the past few decades Fibre Reinforced Polymer Matrix Composites have emerged as strong
contenders for building load bearing structures
giving a tough competition to the conventional
structural materials such as aluminium alloys
and steels in several engineering sectors such as
aerospace, construction, transportation, off-shore
structures and others. In particular, in the aeronautical sector where light-weighting is a major
issue, the composite usage in aircraft structure
has graduated from just being marginal and that
too in tertiary and secondary structures in 1970s
to being the preferred material for large primary
structures in modern frontline advanced aircraft
in both combat and transport category. To quote
a few examples: Airbus 320 , Boeing 737, then
Boeing 777, 787 and Airbus 380, FA-18, Grippen,
Eurofighter, French Rafale and Indian Tejas Light
Combat Aircraftall have seen a large scale use of
composites in primary structures. See, for example, Figure 1showing use of carbon/epoxy composites in LCA.
The major form of composites that pioneered
the large scale usage in aircraft structures has been
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Consultant (NPMASS),
Aeronautical Development
Agency, PB 1718,
Vimanapura PO,
Bangalore 560017, India.
[email protected]
[email protected]
Prakash D. Mangalgiri
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predict and therefore do not inspire designers confidence. Thus, most of the useful combinations of
laminate lay-ups are restricted to being symmetric, balanced with orientations of 0, 45 and 90
with adequate plies in any one direction to ensure
integrity. Based on stress concentration considerations, Hart-Smith38,40 had proposed an envelope
of laminate configurations (see Fig. 2) around the
QI configuration ensuring at least 12.5% plies in
any direction. With improved understanding and
analytical capabilities, the industry has progressed
to relaxing some of these requirements, such as
using a somewhat larger envelope of laminate (see
Fig. 2) configurations and using unbalanced (but
not unsymmetric, due to concern about warping
during manufacturing) laminates and using other
orientations such as 30 and 60. However, for
the discussions in this paper, we will restrict to 0,
45 and 90 orientations family and symmetric
laminates.
3 Environmental Effects
3.1 Hygrothermal degradationhot-wet
effect
By far the most important effect of the environment that affects the design allowables is the
hygrothermal degradation of the properties due
the moisture absorption by the polymeric matrix,
see Figure 3. The widely used epoxy based matrices
can absorb up to 46% moisture by weight which
translates to about 1.42.0% moisture absorption in carbon fibre composites. This degrades
the matrix dominated behaviour, such as transverse strengths as well as shear and compression
strengths. High temperatures close to the glass
transition (Tg) of the matrix softens the matrix.
The plasticization of the matrix (due to moisture as well as due to high temperature) reduces
support to the fibres and thus causes an overall
degradation of mechanical properties in shear
and compression. Also, the moisture reduces Tg of
the matrix significantly (by as much as 50C) and
thus puts a limit on the service temperature of the
composite, which is usually kept to be about 20C
below Tg. Thus, the hot-wet (HTW) behaviour
of composites has become an important issue in
deciding design allowables. The moisture absorption is a diffusion process, follows largely the Ficks
law and is mostly reversible. The absorption and
desorption rates depend largely upon the temperature, and the saturation level depends largely
on the relative humidity in the environment. The
phenomenon is rather slow, and in thick laminates the time for moisture saturation can be very
long. Two major issues that crop up when deriving design allowables are: (a) what is the realistic
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Figure3: Hygrothermal effect in carbon epoxy composite. (a) Moisture ageing71, (b) Strength degradation, (c) Lowering of Tg.
576
care in designing with composites. Also, often,fastener joints cannot be avoided (and, in fact, may
sometimes be preferred to bonded joints or integral parts) and one needs to work with knocked
down allowable stresses in order to cater for such
discontinuities. While in Al-alloys the stress concentration relief may be provided by local yielding,
in the case of composites one needs to look for
such relief by proper choice of lay-up. It is widely
established that the addition of 45 plies can
provide such relief. Significant amount of studies were carried out in the decades of 1980s and
90s to understand the behaviour of composites
with holes and fasteners, which formed the basis
for arriving at design methodologies and design
allowable values to be used. See for example,
Refs.3776 A good account of these efforts can be
found in AGARD report74 with a historical perspective given by Oplinger.75 Improvements over
these early studies continue to interest researchers even today as seen from several studies being
reported in literature; see, for example,77106 and
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Figure4: Bearing strengths for various laminate configurations and effect of hot-wet.71
on how much hole elongation can be acceptable and set as criterion for defining the bearing
strength. Two criteria have been put forward and
have gained some acceptance in the industry: 2%
elongation in case of the earlier generation of
epoxy resins which are relatively brittle (which
is used in the study71), and 4% elongation for the
newer, toughened resins.82
4.5 Considerations for fastener joints
In addition to selection of allowable strengths for
laminates with holes and for bearing, there are a
few significant aspects which need to be considered
for proper use of allowables when designing fastener joints. The failure modes of a fastener joints
are shown in Figure 5. As mentioned earlier, the
geometric parameters (edge distance, width, pitch
etc) are to be so chosen so as to allow full bearing
strength to be developed. In addition, following
aspects are important.
4.5.1 Effect of clamp-up pressure or lateral
constraint: It is known that the lateral constraint
provided to the laminate plies helps in preventing or delaying the micro-buckling of fibres and
thus result in higher bearing and open hole compression strengths.39,42,44,59 Such lateral constraint
may be available through clamp-up pressure in
a torqued bolted joint or may be provided by
other plies in a thick laminate.44,59,72,73,85 Bearing
strength increase from 20% to 100% has been
reported for various types of laminates. However, it is to be noted that creep and relaxation
in laminates over a long period, as well as vibrations, can reduce the effective lateral constraint
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Figure5: Failure modes of fastener joints: (a) Net tension, (b) Shear-out, (c) Transverse splitting,
(d)Cleavage, (e) Bearing, (f) Pull-out.
Smith40 has shown that for a fastener in a multiple fastener configuration with pitch p, the stress
concentration is less than that for a single fastener
in a strip of width equalling pitch. Thus, data on
single bolt tests can be applied to multiple bolts.
Matthews59,70 also suggests that data on single bolt
with w/d 4 can be applied to p/d 4.
5 Impact Damage
5.1 Impact damage behaviour
It is well recognised that due to poor strength in
normal-to-plane direction, laminated composites
are susceptible to delamination and damage due
to impact. The impact damage may involve delamination, matrix cracking, and even fibre breakage. This severely restricts the residual strength,
especially in compression. A major concern is
that the impact damage may remain invisible or
undetected. While designing, an impact threat
scenario is generally considered for the structure and a design philosophy is drawn up which
defines the impact levels that the structure should
sustain along with inspection and maintenance
intervals, in consultation with the regulatory or
certification authorities. Guidelines for such an
exercise have evolved over the years and continue
to do so. A good guideline in this connection is
provided in a study by the US office of aviation
research.107
Extensive studies have been done to understand the damage due to impact and useful
reviews on this can be found in Chap 7 of MILHDBK-17-F Vol 1 and 313,15 as well as.108112 A
low velocity impact generally incites an overall
geometry response in the structure while a high
velocity impact (such as by a projectile) brings
about only a localised mode of deformation and
energy dissipation over a small area. Also, at low
velocities, a flexible structure can absorb energy
in flexing and in flexural failures of fibres, while
for a stiff structure energy gets absorbed in interlaminar shear and consequent delamination. On
impact, compressive stress waves generated at the
point of impact travel through the thickness and
are reflected as tensile stress waves from the back
surface. Thus, most of the damage gets initiated
at the back face, causing a cone of internal damage. At very high velocities, a projectile can shear
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Prakash D. Mangalgiri
out of the laminated structure causing full or partial penetration. Thus, for generation of design
allowables, it is important to note that tests for
low velocity impact should be designed with target geometries representative of the desired structure while far field geometric effects are not very
significant for high velocity impact.
Among the common impact threats that are
considered for design allowable generation are
tool (including some service boxes or equipment)
drops, runway debris thrown by tires, hail-stones
and some bullet strikes. The two major issues to
be addressed through proper tests are: one, the
detectibility threshold (for visual inspection and
for other NDE) and the other, the loss in strength.
In most cases of the current design practice, the
design philosophy has been built around the concept of Barely Visible Impact Damage (BVID).
Any damage which cannot be seen (BVID or less)
must be tolerated by the structure (with Design
Ultimate Load) through the life time (or any other
specified period). However, for thick laminates
and laminates with impact resistant matrices, the
impact energies to cause BVID can be very large
and the threat of such high impact may be improbable. An energy cut-off is therefore defined for the
structure to sustain, see Figure 6(a). Thus, a common practice is to base the design on the Visibility
cut-off and the Energy cut-off.15,107,113 In terms of
damage sustenance, apart from the BVID, Allowable Damage Limit (ADL) and Critical Damage
Threshold (CDT) are generally specified which
need to sustain the design ultimate load and the
Figure6: Visibility and energy cut-off for Impact damage with laminate thickness t.
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Figure7: Compression after impact. Failure strains for quasi-isotropic laminates. Laminates L1, L2, L3
are 6mm thick with various stacking sequence. Laminate C is 3.6mm thick, Ref.145
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Figure8: Strain energy release rate for a delamination in the shoulder radius of a T-joint in skin-stiffener
connection. The deformation under internal pressure causes peel stresses on the delamination. The criticality of a size of delamination can be assessed by comparing max SERR (GI, GII) to its critical value (GIc,
GIIc). Source Ref.189
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under repeated impact is outlined in.194 Simulation of impact events is used to study strain-rate
effects for toughened composites in,195 whereas a
possibility of increasing CAI by exploring nonsymmetric laminates is explored in.196
7 Concluding Remarks
Choice of design allowable strengths for composite materials has an important bearing on the
entire design process of an aircraft and the final
product and its certification and performance.
We have outlined some important considerations while arriving at design allowable values. In
doing so, we have examined the effort that has
gone into developing underlying understanding
of composite behaviour and its implication for
the allowable values. In particular, we looked into
the hot-wet effect, holes and fasteners and impact
damage. The literature on these issues is really vast
and the references quoted here should be taken as
only representative of the entire effort. No claim is
made to being exhaustive, nor is any claim made
towards relative importance of cited literature
over the omitted ones.
At the present design allowable values, the
potential of composites as aircraft structural
materials remains vastly unrealised. Future efforts
need to be and will be directed towards expanding
the current envelope of usage, such as for example, exploring post-buckling strengths, strength
beyond first-ply-failure, use of non-symmetric
lay-ups and through-thickness reinforcements.
For, this to happen, it is important to develop better understanding of the material behaviour in
those regimes and develop better predictive capability. Better material systems would be explored
and toughness and resistance to hot-wet would be
the target directions. Newer developments such
as Structural Health monitoring can bring in new
thinking about allowable damage which also will
hopefully allow higher design allowables and better utilisation of the potential of composites.
Acknowledgements
Much of my understanding and knowledge of
designing with composites is derived from the
work carried out for the LCA programme during
1980s and 1990s and this forms the cornerstone of
the discussions in this paper reflecting a view from
a practising engineer rather than a research scientist. Many colleagues and collaborators, too numerous to name, from ADA, HAL, NAL, IISc, IITs and
other collaborating institutions have helped me in
learning about composites and their contribution
is gratefully acknowledged. In particular, thanks are
due to Dr. KN Raju, head of the erstwhile National
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