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In an attempt to increase resource efficiency and reduce carbon emissions, the development of lightweight designs in structural applications is essential. In addition, the lightweight structures often follow complex topologically optimized designs which are more suitable for the application of additive, in contrast to conventional manufacturing techniques. Within the additive manufacturing (AM) process, constituents may be combined to design and produce durable and lightweight materials with predefined mechanical, electrical, and thermal properties, while also accounting for their sustainability and recyclability. Regretfully, due to the lack of research in material behavior, the AM technology implementation in engineering applications is still limited in comparison to traditional manufacturing methods. While the potential of additively manufactured continuous fiber composites has already been recognized in the scientific community, constitutive modeling and damage resistance are seldom reported. Since fiber-reinforced composite structures are rarely designed as unidirectional (UD), this study is focused on numerical analysis of failure for multi-directionally reinforced composite laminates loaded in a uniaxial direction. Specimens are modeled and evaluated using a progressive damage model, proposing guidelines for safer design and application.

Structural hierarchies are universal design paradigms of biological materials, e.g., several materials in nature used for carrying mechanical load or impact protection such as bone, nacre, dentin show structural design at multiple length scales from the nanoscale to the macroscale. Another example is the case of diatoms, microscopic mineralized algae with intricately patterned silica-based exoskeletons, with substructure from the nanometer to micrometer length scale. Previous studies on silica nano-honeycomb structures inspired from these diatom substructures at the nanoscale have shown a great improvement in plasticity, ductility and toughness through these designs over macroscopic silica, though along with a substantial reduction in stiffness. Here, we extend the study of these structural designs to the micron length scale by introducing additional hierarchy levels to implement a multilevel composite design. To facilitate our computational experiments we first develop a mesoscale particle-spring model description of the mechanics of bulk silica/nano-honeycomb silica composites. Our mesoscale description is directly derived from constitutive material behavior found through atomistic simulations at the nanoscale with the first principles-based ReaxFF force field, but is capable of describing deformation and failure of silica materials at tens of micrometer length scales. We create several models of randomly-dispersed fiber-composite materials with a small volume fraction of the nano-honeycomb phase, and analyze the fracture mechanics using J-integral and R-curve studies. Our simulations show a dominance of quasi-brittle fracture behavior in all cases considered. For particular materials with a small volume fraction of the nano-honeycomb phase dispersed as fibers within a bulk silica matrix, we find a large improvement (≈4.4 times) in toughness over bulk silica, while retaining the high stiffness (to 70%) of the material. The increase in toughness is observed to arise primarily from crack path deflection and crack bridging by the nano-honeycomb fibers. The first structural hierarchy at the nanometer scale (nano-honeycomb silica) provides large improvements in ductility and toughness at the cost of a large reduction in stiffness. The second structural hierarchy at the micron length scale (bulk silica/nano-honeycomb composite) recovers the stiffness of bulk silica while substantially improving its toughness. The results reported here provide direct evidence that structural hierarchies present a powerful design paradigm to obtain heightened levels of stiffness and toughness from multiscale engineering a single brittle — and by itself a functionally inferior material — without the need to introduce organic (e.g., protein) phases. Our model sets the stage for the direct simulation of multiple hierarchical levels to describe deformation and failure of complex biological composites.

The quasi-static and dynamic compression responses and failure of fiber-reinforced syntactic foams were investigated. The role of fiber volume fraction on the compression response of syntactic foams was examined in terms of mechanical behavior and energy absorption under both quasi-static and dynamic conditions. Results showed that the mechanical behavior and energy absorption of the reinforced specimens increased with increasing fiber volume fraction. The syntactic foams exhibited distinct strain rate sensitivity; and their yield strength and elastic modulus increased by 41.1% and 85.1%, respectively, as strain rate increased from 0.0011 s${}^{\mathrm{\text{-1}}}$ to 1070 s${}^{\mathrm{\text{-1}}}$. The deformation and failure processes of the syntactic foams were also examined, and the underlying mechanisms were discussed.

This paper proposes a theoretical approach to predict the failure behavior of laminated carbon fiber reinforced polymer (CFRP) under combined thermal and mechanical loadings. Two types of CFRP Laminates, i.e., CCF300/BA9916 and T700/BA9916, are investigated, and TGA tests in both nitrogen and oxidation environments at different heating rates are carried out to obtain the thermal decomposition kinetic parameters of polymer matrix and carbon fiber. Based on the thermal decomposition behavior and a multi-level structure model, the thermal physical properties, mechanical properties and thermal deformations of the laminated composites at high temperatures are obtained. Then substituting thermally degraded properties into constitutive equations of composite materials as macroscopic defects, the damage mode and failure strength of the laminated composite under thermo-mechanical loadings is obtained. Predicted elastic properties and failure strength are compared with experimental results as well as previous models. Effects of heating rates and heating environments through rigorous physical model are considered in the present work. It is found that the heating rate significantly affects the thermal and mechanical properties, the higher the heating rate, the less degraded are the thermo-mechanical properties and failure strength at a given temperature. Young’s modulus and failure strength of T700/BA9916 are higher than those of CCF300/BA9916 at high temperatures, due to the higher volume fraction of carbon fibers, which are less weakened in thermal environment.

This research focuses on generating the plastic collapse load boundaries of a cylindrical vessel with a radial nozzle via employing three different plastic collapse load techniques. The three plastic collapse load techniques employed are the plastic work curvature (PWC) criterion, the plastic work (PW) criterion, and the twice-elastic-slope (TES) method. Mathematical based determination of plastic collapse loads is presented and employed concerning both the PWC and the PW criteria. A validation study is initially conducted on a pressurized 90-degree pipe bend structure subjected to in-plane closing bending via finite element analyses along with an elaborate explanation of the mathematical approaches for determining the plastic collapse loads via the PWC and the PW criteria. Outcomes of the validation study revealed very good outcomes for the three techniques. Accordingly, the aforementioned three techniques are utilized to determine the plastic collapse load boundaries of a pressurized cylindrical vessel/nozzle structure subjected to in-plane (IP) and out-of-plane (OP) bending loadings applied on the nozzle one at a time. The TES method revealed considerate limitations when applied within the medium to the high internal pressure spectra. It is shown that both the PWC and the PW criteria outperform the TES method in computing the plastic collapse loads. The vessel/nozzle structure revealed relatively higher plastic collapse moment boundaries under IP bending as compared to OP bending. Conclusively, methodical steps are devised for determining the plastic collapse loads via the PWC and the PW criteria for the ease of systematic application on pressurized structures in general.

A coupled model of aeroservoelasticity and hydraulic actuator used for failure simulation is presented. The mathematical model composites rigid-body modes, elastic modes, control surface modes, unsteady aerodynamic forces and failure models (jam, loss of control (LOC), oscillatory failure, and hydraulic fluid leakage). A clear framework of coupling method of airplane aeroelastic equation and control surface dynamic equation is provided to study the impacts of surface failures on rigid-elastic motion of airplane. The coupled model is shown to be effective in evaluation of gust response in both discrete gust and continuous turbulence conditions compared with results obtained from the 3-order simplified actuator. Examples of gust load alleviation (GLA) system with LOC of ailerons are given. Results show that total loss of function of GLA system is caused by the LOC. With continuous turbulence excitation, the failure loads is several times larger than that without GLA system.