Composites Assembly for High Performance Fastener-less Structures

794 Pages·2023·45.082 MB·English

by  Hamed Yazdani Nezhad, Vijay Kumar Thakur

Composites Assembly for High Performance
Fastener-less Structures
Composites Assembly for High Performance Fastener-less Structures provides a broad and
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balanced span of information, covering both fundamentals and applications across academic eo
and industrial state-of-the-art research and development on assembly, joining, inspection and rfm
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repair of high-performance structures made from fibre-reinforced polymer composites and rp for High Performance
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multifunctional nanocomposites. This knowledge is essential for the realisation of critical
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features in assembly and joining evolving procedures (across their design, development and anite Fastener-less Structures
performance analysis) in such multi-material systems, but also for the through-life cs
maintenance of composite components used in a range of engineering applications such as e
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those composite structures utilised for wind turbine blades, automotive parts, aircraft wings as
and fuselage. The book also addresses the non-destructive testing methods used to detect ss
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damage occurring in composite joints, which are essential to decide if the repair is needed. em
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The book begins by providing a fundamental description of the requirements for composite el
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joining, assembly and repair. It goes on to address a variety of joining and repair procedures in -le f Edited by
composite structures from thermoset adhesive bonding to thermoplastic hybridisation, o
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through-the-thickness reinforcement and sandwich structures. Further chapters cover the s r H Hamed Yazdani Nezhad and Vijay Kumar Thakur
reliable assessment of structure’s damage tolerance and failure assessment procedures, S
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including non-destructive inspections and image processing based structural health ruh
monitoring, and provide understanding of the most likely deterioration mechanisms occurring c
in processing and assembly of composite materials and structures. The book is wrapped up t
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with the ongoing state-of-the-arts in multifunctional nanocomposites with application for r
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high-performance structures for self-sensing, energy harvesting and properties tailoring. s
Composites Assembly for High Performance Fastener-less Structures brings together
state-of-the-art practices for assembly, in-service damage and repair procedures along with
the existing certification and repair regulations, followed by the futuristic opportunities for
enabling and emerging polymer nanocomposites for smart structures, for an audience of
academic researchers, advanced students, engineers and manufacturing professionals.
About the Editors E
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Hamed Yazdani Nezhad is an associate professor in aerospace structures at the Department e
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of Mechanical Engineering and Aeronautics at City, University of London, UK.

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Vijay Kumar Thakur is a professor and the founding head of the Biorefining and Advanced y

Materials Research Centre at SRUC, Edinburgh, UK.
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The Institution of Engineering and Technology u
theiet.org r
978-1-83953-149-1
IET MANUFACTURING SERIES 15
Composites Assembly
for High Performance
Fastener-less Structures
Other volumes in this series:
Volume 23 Optimal Design Exploiting 3D Printing and Metamaterials Paolo Di Barba and Sławomir Wiak (Editors)
Composites Assembly
for High Performance
Fastener-less Structures
Edited by
Hamed Yazdani Nezhad and
Vijay Kumar Thakur
The Institution of Engineering and Technology
Published by The Institution of Engineering and Technology, London, United Kingdom
The Institution of Engineering and Technology is registered as a Charity in England & Wales
(no. 211014) and Scotland (no. SC038698).
© The Institution of Engineering and Technology 2022
First published 2022
This publication is copyright under the Berne Convention and the Universal Copyright
Convention. All rights reserved. Apart from any fair dealing for the purposes of research or
private study, or criticism or review, as permitted under the Copyright, Designs and Patents
Act 1988, this publication may be reproduced, stored or transmitted, in any form or by
any means, only with the prior permission in writing of the publishers, or in the case of
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Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to
the publisher at the undermentioned address:
The Institution of Engineering and Technology
Futures Place
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Hertfordshire, SG1 2UA.
www.theiet.org
While the authors and publisher believe that the information and guidance given in this
work are correct, all parties must rely upon their own skill and judgement when making use
of them. Neither the author nor publisher assumes any liability to anyone for any loss or
damage caused by any error or omission in the work, whether such an error or omission is
the result of negligence or any other cause. Any and all such liability is disclaimed.
The moral rights of the author to be identified as author of this work have been asserted by
him in accordance with the Copyright, Designs and Patents Act 1988.
British Library Cataloguing in Publication Data
A catalogue record for this product is available from the British Library
ISBN 978-1-83953-149-1 (hardback)
ISBN 978-1-83953-150-7 (PDF)
Typeset in India by Exeter Premedia Services Private Limited
Printed in the UK by CPI Group (UK) Ltd, Croydon
Contents
Preface xvii
About the Editors xxiii
1 Overview on design and manufacturing of assembled composite
aerostructures 1
Marco Barile, Giuseppe Barile, Leonardo Lecce, and Giuseppe Petrone
1.1 Introduction 1
1.2 General philosophy for strength analysis of primary aerospace
composite structures 1
1.2.1 Overview on structural analysis methods 2
1.3 Fastened joints 6
1.3.1 Load distribution in composite joints 6
1.3.2 Composite material failure at joint 6
1.4 Bonded joints 7
1.4.1 Types of failure in adhesive bonded joints 8
1.4.2 Stress analysis of adhesive bonded lap joints 9
1.5 Fabrication of bonded joints 10
1.5.1 Joints in space industry 15
1.5.2 Joints in aviation industry 20
1.6 Joint assembly 24
1.6.1 Significance of bond-line control 25
1.6.2 The need for bond-line control 25
1.6.3 Advantages and disadvantages of adhesive bonding 26
1.7 Conclusions 26
References 27
2 Processing of polymer composites: autoclave and microwave energy
approaches 29
T Lachana Dora and Radha Raman Mishra
2.1 Introduction 29
2.2 Fundamentals 31
2.2.1 Basic principles 31
2.2.2 Mathematical models 34
2.2.3 Experimental details 36
2.3 Challenges in autoclave and microwave curing 39
2.4 Concluding remarks 40
References 40
vi Composites assembly for high performance fastener-less structures
3 Industry 4.0 for composites manufacturing 43
Miroslav Stojkovic and Cristian Lira
3.1 Introduction 43
3.2 Composites context of Industry 4.0 44
3.3 Literature review 45
3.3.1 Composites technology 46
3.3.2 Business challenges 49
3.3.3 Industry 4.0 51
3.4 Critical assessment 55
3.4.1 Key trends 55
3.4.2 Gaps and research aim refinement 56
3.5 Concluding remarks 57
References 57
4 Development of fibre- reinforced polymer composites through direct
digital manufacturing 61
Ramesh Kumar Nayak and Hamed Yazdani Nezhad
4.1 Introduction 62
4.2 Fiber-reinforced AM composites 62
4.3 Fused deposition modeling 68
4.4 Selective laser sintering (SLS) 71
4.5 Mechanical properties 74
4.5.1 Tensile strength 74
4.5.2 Fatigue strength 75
4.5.3 Creep deformation 76
4.5.4 Fracture toughness 77
4.5.5 Machine learning 77
4.6 Applications 78
4.7 Sustainability 79
4.8 Challenges and future prospective 82
References 85
5 Joining and repair of resin- infused, continuous fibre- reinforced,
thermoplastic acrylic- matrix composites for extended applicability 93
Winifred Obande and Dipa Ray
5.1 Introduction 93
5.2 Liquid acrylic resin-based composites 94
5.2.1 Manufacturing 94
5.2.2 Comparison with conventional thermoset composites 96
5.3 Joining of acrylic-matrix composites 96
5.4 Thermoplastic acrylic-matrix fibre-metal laminates 102
5.5 End-of-life opportunities with acrylic-based composites 103
5.5.1 Applicability of recyclate matrix 106
5.5.2 Repairability of acrylic-matrix composites 107
5.5.3 Reshapability of acrylic-matrix composites 107
Contents vii
5.6 Future opportunities 109
5.7 Conclusion 110
References 111
6 Aerospace composites’ repair: integrated processes’ feasibility 117
Dileep Yaswanth Pasupuleti, Gopalakrishnan Kamalakannan,
Guillermo Garcia Del Valle, Larissa Reuter, Laurine Dehée,
Lucas Mestre, and Hamed Yazdani Nezhad
6.1 Introduction 118
6.1.1 Aim of the project 120
6.2 Structure and methodology 120
6.2.1 Methodology 121
6.2.2 Literature review 123
6.2.3 Damage in composite structures 123
6.2.4 Main causes and associated costs of damages 125
6.2.5 Typical damages in composites 127
6.3 NDI techniques 128
6.3.1 Ultrasonic testing (UT) 129
6.3.2 Thermography 130
6.3.3 Shearography 132
6.3.4 Combination of thermography and shearography 133
6.3.5 Other NDI techniques 134
6.3.6 Post repair inspection 135
6.3.7 Material removal 135
6.3.8 Surface preparation 137
6.3.9 Surface treatments 138
6.4 Material and conditions 140
6.4.1 Hard and soft patch 141
6.4.2 To bond or to bolt? 145
6.4.3 Quality control 146
6.4.4 Structural health monitoring 147
6.4.5 Repair certification 149
6.5 Needs assessment 151
6.5.1 Available systems 151
6.5.2 Gap analysis 152
6.5.3 Situation of the composite industry in the UK 152
6.6 Feasibility 153
6.6.1 NDI system 153
6.6.2 Commercial options 154
6.6.3 Machinable area 155
6.6.4 Material removal 156
6.6.5 Conventional machining 157
6.6.6 Laser system 157
6.6.7 3D scanning 158
6.6.8 Commercial options 159
6.6.9 Patch 160
viii Composites assembly for high performance fastener-less structures
6.6.10 Patch design 161
6.6.11 Patch production 162
6.6.12 Adhesives 163
6.6.13 On-site curing 163
6.7 Implementation 165
6.7.1 Experimental testing 165
6.8 Conclusion 186
References 189
7 Augmented reality- equipped composites bonded repair 197
Xi Wang, Hamed Yazdani Nezhad, Samuel Court, Bikram Thapa,
and John Erkoyuncu
7.1 Introduction 198
7.1.1 Project background 198
7.1.2 Previous group project outcome 198
7.1.3 Gap analysis 198
7.1.4 Aim and objectives 199
7.2 Methodology 199
7.3 Literature review 200
7.3.1 Defects and damages in composite materials and structures 200
7.3.2 Manufacturing defects 200
7.3.3 Common service-life damages 200
7.3.4 Alternative classification of composite impact damage 202
7.3.5 Composite material repairing technique 202
7.3.6 Classification of composite material repairing method 202
7.3.7 Scarf-based repair process 202
7.4 Augmented reality 210
7.4.1 Augmented reality technique 210
7.4.2 Application of augmented reality into aircraft industry 211
7.5 Concept design 212
7.5.1 Project scope selection 212
7.5.2 Reparation method 213
7.5.3 Target process 213
7.5.4 Scenario design 214
7.5.5 Panel 214
7.5.6 Patches 214
7.5.7 Bagging layers design 214
7.5.8 Other assisting materials and equipment 215
7.5.9 Overall vacuum bagging system 216
7.5.10 Functionality design 216
7.6 Implementation and result 217
7.6.1 Hardware configuration 217
7.6.2 Developing environment configuration 217
7.6.3 Coding language 218
Contents ix
7.6.4 Developing process 218
7.6.5 Program validation 221
7.7 Discussion 224
7.7.1 Strengths 224
7.7.2 Challenges 224
7.7.3 Future work 225
7.7.4 Prospect 225
7.8 Conclusion 226
References 227
8 3D printing of multi- material polymer composite systems 231
Feroz Khan and Hamed Yazdani Nezhad
8.1 Introduction 231
8.2 Theoretical background 233
8.2.1 Material science 240
8.2.2 Polymer blends 241
8.2.3 Fillers and reinforcements 242
8.2.4 Particulates 245
8.2.5 Metallic polymer composites 248
8.2.6 Ceramic polymer composites 252
8.2.7 Carbon polymer composites 254
8.2.8 Fibres and whiskers 254
8.2.9 Final impressions 260
8.3 Objectives 261
8.4 Numerical simulation 262
8.4.1 Schematic 262
8.4.2 Parameters 264
8.4.3 Boundary conditions 266
8.4.4 Mesh discretisation 272
8.4.5 Estimating thermo-physical properties 273
8.5 Results and discussion 275
8.5.1 Estimated thermo-physical properties of specimens 275
8.5.2 Slicing 275
8.6 Conclusion 277
References 278
9 3D printing of composites for space applications 283
Sung Wook Paek and Sivagaminathan Balasubramanian
9.1 Introduction 283
9.2 3D-printed structures 284
9.2.1 Heat shields for suborbital flight 284
9.2.2 Radiation shields in low-Earth orbits or deep space 287
9.2.3 Issues in printing and assembling structural parts 291