Damage mechanisms in thermoplastic structural composites: characterization and modeling

Damage mechanisms in thermoplastic structural composites: characterization and modeling

Details

Continuous fiber thermoplastic composites have gained a growing interest in automotive industry due to their weight-saving potential, recyclability, fast processing time and excellent mechanical response in accommodating damage and plasticity. We work together with SABIC (Saudi Arabia Basic Industries Corporation) in developing multiscale finite element models for predicting the behavior of continuous fiber reinforced thermoplastic composites. The models are developed based on a strong understanding of static and dynamic responses and, particularly, damage mechanisms (damage initiation, propagation and failure) of thermoplastic composites. To this end, we fully characterize the thermal and mechanical properties of the thermoplastic polymer (of different formulations); the morphology (e.g. spherulite), degree of crystallinity and property of the neat thermoplastic polymers; damage mechanisms of thermoplastic composites under in-plane tension and out-of-plane loads (quasi-static indentation and low-velocity impact). We developed in situ technique utilizing fiber Bragg gratings to monitor the processing of thermoplastic composites. The experimental part feeds the model with material data, and validates the developed models. The models should be able to capture various damage types (e.g. fiber/matrix debonding, transverse cracking, delamination) and the synergistic mechanisms between these types. Rigorous models are developed based on micro- and meso-mechanical schemes. The models must have the capability of being transferred to form part of a framework that is suitable for industrial counterpart. The homogenization strategies to fully define damage mechanics models that can be easily integrated in commercial software are performed. This simplifies the knowledge transfer to our partners and makes these new strategies universally available.
 
Four research themes covering the modeling and experimental parts are as follows:
  • Predictive micro- and meso-scale damage mechanics models for thermoplastic composites LINK
  • Macroscopic evaluation of damage in glass-fiber reinforced polypropylene laminates under quasi-static indentation and low-velocity impact
  • In situ strain monitoring of glass-fiber reinforced polypropylene laminates using fiber Bragg gratings
  • Microscopic evaluation of damage in glass-fiber reinforced polypropylene laminates at low and high speeds LINK



 
 
 

Researcher(s):
  • Prof. Gilles Lubineau (PI)
  • Dr. Arief Yudhanto (KAUST Project Manager)
  • Dr. Matthieu Mulle (Research scientist)
  • Ditho Pulungan (PhD candidate - modeling)
  • Husam Wafai (PhD candidate - experiment)
  • Shiva Kumar (Visiting student)

Collaborators

SABIC Europe (ir. Recep Yaldiz - SABIC Project Manager, Dr. Nikhil Verghese, ir. Warden Schijve)




Publications

Journal paper
  1. D. Pulungan et al. Identifying design parameters controlling damage behaviors of continuous fiber-reinforced thermoplastic composites using micromechanics as a virtual testing tool​, International Journal of Solids and Structures, April 2017.
  2. H. Wafai et al. Effects of the cooling rate on the shear behavior of continuous glass fiber/impact polypropylene composites (GF-IPP). Composites Part A, Volume 91(1), pp. 41-52, December 2016 
  3. A. ​Yudhanto et al. Monotonic and cyclic responses of impact polypropylene and continuous glass fiber-reinforced impact polypropylene composites at different strain rates. Polymer Testing, Volume 51, pp. 93–100, May 2016.
  4. M. Mulle et al. Process monitoring of glass reinforced polypropylene laminates using fiber Bragg gratings, Composites Science and Technology, Volume 123, pp. 143-150, February 2016.

Conference proceeding

  1. D. Pulungan et al. Micromechanics as a virtual testing tool to understand damage behaviours of continuous fiber-reinforced thermoplastic composites. Proc. ECCM17, Munich, Germany, 26-30 June 2016
  2. A. Yudhanto et al. Experimental investigation of damage transition in thermoplastic composites at the microscale. Proc. ECCM17, Munich, Germany, 26-30 June 2016
  3. A. Yudhanto et al. Damage and failure of thermoplastic laminates with stratified and clustered fibers, Proc. ICCM-20, Copenhagen, Denmark, 19-24 July 2015
  4. H. Wafai et al. Effect of constrain ratio and cooling rate on transverse cracking in thermoplastic cross-ply laminates, Proc. ICCM-20, Copenhagen, Denmark, 19-24 July 2015
  5. M. Mulle et al. Process monitoring of glass reinforced polypropylene laminates using fiber Bragg gratings,  Proc. ICCM-20, Copenhagen, Denmark, 19-24 July 2015