Mechanics of Composite and Multi-functional Materials, Volume 5: Proceedings of the 2019 Annual Conference on Experimental and Applied Mechanics [1st ed. 2020] 978-3-030-30027-2, 978-3-030-30028-9

Table of contents :
Front Matter ....Pages i-viii
Experimental Approach of Damage Analysis in Laminated Composite Structures Under Through-Thickness Penetration (Mark R. Gurvich, Patrick L. Clavette)....Pages 1-8
Alternative Composite Design from Recycled Aluminium (AA7075) Chips for Knuckle Applications-II (G. Katundi, D. Katundi, E. Bayraktar, I. Miskioglu)....Pages 9-14
Manufacturing of Recycled Aluminum Matrix Composites Reinforced of TiC/MoS2/Al2O3 Fiber Through Combined Method: Sintered + Forging (E. Bayraktar, I. Miskioglu, D. Katundi, F. Gatamorta)....Pages 15-25
Design of Intermetallic Mg (Recycled Ti-Al) Based Composites Through Semi Powder Metallurgy Method (D. Katundi, I. Miskioglu, E. Bayraktar)....Pages 27-34
Design, Analysis and Experimental Study of Metal-3D Printed Conformal Cooling Plastic Injection Mold (Suchana Jahan, Tong Wu, Andres Tovar, Hazim El-Mounayri)....Pages 35-40
Recycling of Aluminium-431 by High Energy Milling Reinforced with TiC-Mo-Cu for New Composites in Connection Applications (F. Gatamorta, Ibrahim Miskioglu, E. Bayraktar, M. L. N. M. Melo)....Pages 41-46
Magnetic Shape Memory Composite (MSMC) Design from Intermetallic Cu-NiTi-MnAl-Fe3O4 Alloy as an Alternative Replacement for Actuators (F. Gatamorta, Dhurata Katundi, E. Bayraktar, L. M. P. Ferreira, M. L. N. M. Melo)....Pages 47-53
10° Off-Axis Tensile Testing of Carbon Fiber Reinforced Polymers Using Digital Image Correlation (Matthias Merzkirch, Tim Foecke)....Pages 55-62
Study on Mechanical Properties of Basalt Rock Fiber Reinforced Polyester Composites (G. L. Easwara Prasad, B. S. Keerthi Gowda, R. Velmurugan)....Pages 63-68
Electromagnetic and Mechanical Behavior of Conductive Polymer Materials for Antennas (Laura J. Waldman, Peter J. Hawrylak, Michael W. Keller)....Pages 69-72
Design of a Low-Cost Aircraft Structural Material Based on Epoxy: Recycled Rubber Composites Modified with Multifunctional Nano Particles (A. B. Irez, E. Bayraktar)....Pages 73-80
Reversal of Scratches in Polymer Seals via Laminated Vascular Networks (Daniel Moses, Siamack Shirazi, Michael W. Keller)....Pages 81-84
Experimental Feasibility Study of Tunable-Stiffness Polishing Wheel via Integration of Magneto-Rheological Elastomers (Denizhan Yavas, Tianyu Yu, Ashraf F. Bastawros)....Pages 85-91
POSS-Based Fiber Carbon-Fiber Surface Treatment for Enhanced Durability of Composites (Blaze Heckert, Raman Singh)....Pages 93-96
Determination of Viscoelastic Response of Interphase Region in Carbon Fiber Reinforced Epoxy Using AFM Indentation (Libin K. Babu, Raman Singh)....Pages 97-99
Full-Field Deformation Measurement of Morphing Wings (M. M. Mennu, B. Tran, P. G. Ifju, E. Santamaria)....Pages 101-104

Citation preview

Conference Proceedings of the Society for Experimental Mechanics Series

Raman Singh Geoffrey Slipher  Editors

Mechanics of Composite and Multi-functional Materials, Volume 5 Proceedings of the 2019 Annual Conference on Experimental and Applied Mechanics

Conference Proceedings of the Society for Experimental Mechanics Series Series Editor Kristin B. Zimmerman Ph.D. Society for Experimental Mechanics, Inc., Bethel, CT, USA

The Conference Proceedings of the Society for Experimental Mechanics Series presents early findings and case studies from a wide range of fundamental and applied work across the broad range of fields that comprise Experimental Mechanics. Series volumes follow the principle tracks or focus topics featured in each of the Society’s two annual conferences: IMAC, A Conference and Exposition on Structural Dynamics, and the Society’s Annual Conference & Exposition and will address critical areas of interest to researchers and design engineers working in all areas of Structural Dynamics, Solid Mechanics and Materials Research. More information about this series at http://www.springer.com/series/8922

Raman Singh • Geoffrey Slipher Editors

Mechanics of Composite and Multi-functional Materials, Volume 5 Proceedings of the 2019 Annual Conference on Experimental and Applied Mechanics

Editors Raman Singh School of Materials Science and Engineering Oklahoma State University Tulsa, OK, USA

Geoffrey Slipher U.S. Army Research Laboratory RDRL-VTA Aberdeen Proving Ground, Maryland, USA

School of Mechanical and Aerospace Engineering Oklahoma State University Tulsa, OK, USA

ISSN 2191-5644     ISSN 2191-5652 (electronic) Conference Proceedings of the Society for Experimental Mechanics Series ISBN 978-3-030-30027-2    ISBN 978-3-030-30028-9 (eBook) https://doi.org/10.1007/978-3-030-30028-9 © Society for Experimental Mechanics, Inc. 2020 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors, and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictional claims in published maps and institutional affiliations. This Springer imprint is published by the registered company Springer Nature Switzerland AG The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland

Preface

Mechanics of Composite, Hybrid and Multifunctional Materials represents one of six volumes of technical papers presented at the 2019 SEM Annual Conference and Exposition on Experimental and Applied Mechanics organized by the Society for Experimental Mechanics and held in Reno, NV, June 3–6, 2019. The complete proceedings also include volumes on Dynamic Behavior of Materials; Challenges in Mechanics of Time-Dependent Materials, Fracture, Fatigue, Failure and Damage Evolution; Advancement of Optical Methods & Digital Image Correlation in Experimental Mechanics; Mechanics of Biological Systems and Materials & Micro- and Nanomechanics; and Residual Stress, Thermomechanics & Infrared Imaging and Inverse Problems. The commercial market for composite continues to expand with a wide range of applications from sporting equipment to aerospace vehicles. This growth has been fueled by new material developments, greater understanding of material behaviors, novel design solutions, and improved manufacturing techniques. The broad range of applications and the associated technical challenges require an increasingly multidisciplinary and collaborative approach between the mechanical, chemical, and physical sciences to sustain and enhance the positive impact of composites on the commercial and military sectors. New materials are being developed from recycled source materials, leading to composites with unique properties and more sustainable sources. Existing materials are also being used in new and critical applications, which require a deeper understanding of material behaviors and failure mechanisms on multiple length and time scales. In addition, the unique properties of composites present many challenges in manufacturing and in joining with other materials. New testing methods must be developed to characterize the novel composite properties, to evaluate application and product life cycle performance, as well as to evaluate impacts and merits of new manufacturing methods. This volume presents early research findings from experimental and computational investigations related to the processing, characterization, and testing of composite, hybrid, and multifunctional materials. Stillwater, OK, USA Adelphi, MD, USA 

Raman Singh Geoffrey Slipher

v

Contents

1 Experimental Approach of Damage Analysis in Laminated Composite Structures Under Through-Thickness Penetration �������������������������������������������������������������������������������������������������������������������  1 Mark R. Gurvich and Patrick L. Clavette 2 Alternative Composite Design from Recycled Aluminium (AA7075) Chips for Knuckle Applications-II���������������������������������������������������������������������������������������������������������������������������������������  9 G. Katundi, D. Katundi, E. Bayraktar, and I. Miskioglu 3 Manufacturing of Recycled Aluminum Matrix Composites Reinforced of TiC/MoS2/Al2O3 Fiber Through Combined Method: Sintered + Forging ��������������������������������������������������������������������������������������������������� 15 E. Bayraktar, I. Miskioglu, D. Katundi, and F. Gatamorta 4 Design of Intermetallic Mg (Recycled Ti-Al) Based Composites Through Semi Powder Metallurgy Method����������������������������������������������������������������������������������������������������������������������������������������������������� 27 D. Katundi, I. Miskioglu, and E. Bayraktar 5 Design, Analysis and Experimental Study of Metal-3D Printed Conformal Cooling Plastic Injection Mold������������������������������������������������������������������������������������������������������������������������������������������������� 35 Suchana Jahan, Tong Wu, Andres Tovar, and Hazim El-Mounayri 6 Recycling of Aluminium-431 by High Energy Milling Reinforced with TiC-Mo-Cu for New Composites in Connection Applications����������������������������������������������������������������������������������������������������� 41 F. Gatamorta, Ibrahim Miskioglu, E. Bayraktar, and M. L. N. M. Melo 7 Magnetic Shape Memory Composite (MSMC) Design from Intermetallic Cu-NiTi-MnAl-Fe3O4 Alloy as an Alternative Replacement for Actuators ��������������������������������������������������������������������������������������������������������� 47 F. Gatamorta, Dhurata Katundi, E. Bayraktar, L. M. P. Ferreira, and M. L. N. M. Melo 8 10° Off-Axis Tensile Testing of Carbon Fiber Reinforced Polymers Using Digital Image Correlation������������������������������������������������������������������������������������������������������������������������������������������������������� 55 Matthias Merzkirch and Tim Foecke 9 Study on Mechanical Properties of Basalt Rock Fiber Reinforced Polyester Composites ��������������������������������� 63 G. L. Easwara Prasad, B. S. Keerthi Gowda, and R. Velmurugan 10 Electromagnetic and Mechanical Behavior of Conductive Polymer Materials for Antennas����������������������������� 69 Laura J. Waldman, Peter J. Hawrylak, and Michael W. Keller 11 Design of a Low-Cost Aircraft Structural Material Based on Epoxy: Recycled Rubber Composites Modified with Multifunctional Nano Particles����������������������������������������������������������������������������������� 73 A. B. Irez and E. Bayraktar 12 Reversal of Scratches in Polymer Seals via Laminated Vascular Networks��������������������������������������������������������� 81 Daniel Moses, Siamack Shirazi, and Michael W. Keller

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13 Experimental Feasibility Study of Tunable-Stiffness Polishing Wheel via Integration of Magneto-Rheological Elastomers������������������������������������������������������������������������������������������������������������������������� 85 Denizhan Yavas, Tianyu Yu, and Ashraf F. Bastawros 14 POSS-Based Fiber Carbon-Fiber Surface Treatment for Enhanced Durability of Composites ������������������������������������������������������������������������������������������������������������������������������������������������������������� 93 Blaze Heckert and Raman Singh 15 Determination of Viscoelastic Response of Interphase Region in Carbon Fiber Reinforced Epoxy Using AFM Indentation ��������������������������������������������������������������������������������������������������������������������������������� 97 Libin K. Babu and Raman Singh 16 Full-Field Deformation Measurement of Morphing Wings �����������������������������������������������������������������������������������101 M. M. Mennu, B. Tran, P. G. Ifju, and E. Santamaria

Chapter 1

Experimental Approach of Damage Analysis in Laminated Composite Structures Under Through-Thickness Penetration Mark R. Gurvich and Patrick L. Clavette

Abstract  This study is focused on development of experimental capabilities to (a) understand and (b) quantify progressive damage processes (PDP) in thick composite structures; as well as (c) generate experimental outputs sufficient for confident validation of corresponding modeling solutions. It specifically addresses crucially important, yet relatively unexplored, load scenario of through-thickness penetration. This scenario is associated with quite complex patterns of damage which present obvious challenges for both characterization and modeling. Based on developed internal analytical modeling capabilities, clear expectations of inter- and cross-laminar damage patterns are generated as functions of composite lay-up, thickness (number of layers), and specific implementations of boundary conditions. For experimental assessment of these patterns, a general testing rig is developed with high level of flexibility to accommodate key variables of load conditions and material design. The rig provides a clear through-thickness view of the damage process as function of monotonically increased quasi­2D load. Also, coupling with Digital Image Correlation (DIC) allows one to monitor through-thickness strain distributions before and during PDP up to complete penetration through tested composite samples. Experimental demonstration of the rig is considered on examples of nine different thick composites with distinct failure processes. Details of experimental implementation and observed patterns of multi-step PDP are systematically discussed. Keywords  Composite · Damage process · Through-thickness · Penetration · Impact

Introduction A problem of through thickness penetration of composite structures is motivated by several practical engineering issues with high-velocity damage resistance among them. In real service conditions, high-velocity load conditions can be quite unpredictable and are often [1, 2] associated with variability in speed, energy, orientation, shape, size density, frequency, etc. of foreign objects (Fig. 1.1a). To minimize effects of such variability, standardized tests are usually used for practical engineering purposes to generate experimental results for either certification or validation of modeling capabilities or indirect characterization of unknown dynamic material parameters that control the damage process. The most obvious approach in this direction is a dynamic statement (Fig. 1.1b) with pre-defined simplified impactor to mimic actual foreign body, pre-defined load conditions (e.g., normally applied impactor with known speed and kinetic energy) and either actual or simplified 3D representation of considered structure. To minimize the cost of such dynamic statements, an additional simplification in a form of static load is often suggested (Fig. 1.1c). In this case, the dynamic impact is substituted with quasi-static load as either a displacement- or force-controlled very low-speed event. Major outputs of the 3D static statement are usually (a) generated force-displacement diagrams and (b) post-damage inspections, either destructive or non-destructive. Here, distribution of damage patterns across a tested composite structure during the loading process remain largely undetected and are primarily quantified by averaging global metrics, e.g., total force under displacement-controlled load or accumulated noise using the acoustic emission technique. There is, however, significant progress in 2D characterization of damage at open surfaces of composite structures using the Digital Image Correlation (DIC) technique. Representative successful examples of DIC-based damage characterization at the visible surfaces of composite structures or samples were shown, among others, for rotorcraft main rotor blade spars [1, 2], M. R. Gurvich (*) · P. L. Clavette United Technologies Research Center, East Hartford, CT, USA e-mail: [email protected]; [email protected]

© Society for Experimental Mechanics, Inc. 2020 R. Singh and G. Slipher (eds.), Mechanics of Composite and Multi-functional Materials, Volume 5, Conference Proceedings of the Society for Experimental Mechanics Series, https://doi.org/10.1007/978-3-030-30028-9_1

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Fig. 1.1  Potential statements of through-thickness damage analysis from (a) impact load in real conditions; (b) impact load in controlled conditions as a 3D problem; (c) static load in controlled conditions as a 3d axisymmetric problem; and (d) developed static load in controlled conditions as 2D (or quasi-2D) problem

Fig. 1.2  Parametric definition of 2D implementation

cylindrical rods [3], statically determinate or indeterminate beams [4, 5] and complex shaped specimens [6]. The major advantage here is in understanding and quantification of spatially distributed damage patterns along with an understanding of actual pre-damage strain distributions. The motivation of this study, therefore, is development of a similar 2D experimental variant of through-thickness damage penetration in thick laminated composites (Fig.  1.1d) and demonstration of its efficiency, robustness and flexibility on examples of typical carbon-fiber reinforced materials.

Concept A proposed concept suggests a multi-parametric experimental implementation of through-thickness 2D penetration applicable to a broad range of laminated composite materials and geometries of impactors. As illustrated at Fig. 1.2, key parameters of the implementation are the span length L (or the aspect ratio L/H assuming the fixed composite thickness H), the radius of the impactor corner R, the radius of the support corner r, and applied pressure σ. Variation of aspect ratio L/H allows one to control mutual effects of shear and longitudinal normal stresses with corresponding damage modes and their interaction. Also, consideration of composite samples of the same periodic lay-ups, but with different thickness H, can be used for understanding and quantification of potential size effects and, if needed, corresponding scaling factors for practical design. Corner radii R and r provide a convenient opportunity to modify the “sharpness” of penetration from clear-cut scenarios (at R and/or r → 0) to almost bending mode of deformation and damage at relatively large radii. Applied transversal pressure σ (or similarly applied transversal deformation) allows one to control a horizontal movement of the composite sample through friction with the supports. Note that for composite layups, with ply orientation different than 0 or 90°, the proposed concept is not strictlyspeaking 2D, but rather a quasi-2D due to the edge effect phenomenon (see for example, [7]). However, sensitivity of the edge effect depends on composite width (i.e., out-of-plane dimension of the composite sample W) and, therefore, can be easily quantified by running identical tests on samples with different widths.

1  Experimental Approach of Damage Analysis in Laminated Composite Structures Under Through-Thickness Penetration

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Experimental Implementation The actual implementation was performed using a custom-developed rig and a range of typical laminated composite materials. Overall view of the rig is shown in Fig. 1.3a. Details of 2D deformation and damage were monitored for a symmetric half of composite samples, highlighted by a red domain at Fig. 1.3b. A systematic test-matrix of nine different composite lay-ups was executed with, at least, two specimens per lay-up. The considered lay-ups were with orientations [0], [90], [0/90], [90/45/−45], [0/45/−45] and with different thicknesses and sequences of individual plies (here, 0-orientation corresponds to the horizontal in-plane direction in Fig. 1.2). Number of plies in these samples varied from 20 (the thinnest) to 55 (the thickest). The 25 × 150 mm coupons were constructed from commercially available carbon-fiber reinforced composites based on IM7 fibers (12,000 filament count tow uni-directional carbon tape from Hexcel) impregnated with Cycom 977-3 resin (ply thickness = 0.127 mm (0.005 in); the volume fraction = 63%). Penetration tests were conducted on a 530 kN servohydraulic Tinius Olsen load frame. A displacement rate of 2.5 mm/min was applied to the impactor. The displacement was increased at a constant rate until specimen failure. Through-thickness strain and damage distributions were visualized and characterized by DIC technique. During the test, full field DIC-based measurement was conducted to observe the composite behavior under incrementally increased displacement-­controlled load. The DIC characterization was performed with a GOM Aramis 5M (5 megapixel) stereo system. The DIC imaging frame rate was 4 frames per second (fps). The imaged region was an area of 15 mm wide by 12.5 mm high, centered in one of the two shear regions. For the purposes of the analysis, a coordinate transformation was imposed to align (a) the y-axis direction with the impactor action line; (b) the x-axis with the bottom of the impactor and (c) the z-axis normal to the plane of the visible impactor surface. Speckle pattern for DIC was applied to the specimen edge and all visible tool surfaces. Benefits of DIC-based characterization are illustrated at Fig. 1.4 on example of a representative thick composite. DIC-­ based distributions of shear strains (the left column, Fig. 1.4a, c, e) are shown in comparison with actual images of deformation (the right column, Fig. 1.4b, d, f). At the very beginning of deformation, a clear domain of shear strain concentration can be seen along the line of expected through-thickness cut (Fig. 1.4a). With increased load, clear indications or interlaminar shear can be observed as characteristic red lines between the plies (Fig. 1.4c). Upon catastrophic damage (Fig. 1.4e), growth and interaction of inter- and cross-laminar strains can be noted along with actual damage. Here, areas of damage are shown in white, due to loss of the speckle patterns. In contrast with DIC, direct visualization of damage can only be seen in Fig. 1.4f where damage is already quite significant, while no damage is apparent (Fig. 1.4b, d) at lower levels of load.

Parametric Studies As a more detailed illustration of the multi-step damage process, distributions of measured shear strains and damage patterns are shown in Fig. 1.5 under gradual load increment, from “a” (low) to “h” (high load level). Clear indications of the first visible damage (Fig. 1.5e), multiple damage (Fig. 1.5f), growing damage network (Fig. 1.5g) and catastrophic damage (Fig. 1.5h) can be noted. In addition, pre-damage strain concentrations (Fig. 1.5a–d) can be observed as well. Some loss of DIC correlation is also noted in Fig. 1.5c, d: the white areas indicate the barely visible damage condition. Generated patterns

Fig. 1.3  Details of developed experimental implementation showing (a) overall and (b) closeup views of the implementation

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Fig. 1.4  Demonstration of DIC-based capabilities to capture pre- and post-damage strain distributions under increased load: (a, c, e) DIC and (b, d, f) actual photo views

can be used for validation of FEA predictions in a 2D form, i.e., providing justification of predicted local strain due to through-thickness effects. An example of the effect of impactor sharpness is shown in Fig. 1.6 for three illustrated cases with R = 3.175 mm (1/8 in) (Fig. 1.6a–c), R = 1.5875 mm (1/16 in) (Fig. 1.6d–f), and the sharpest edge with R → 0 (Fig. 1.6g, h). Composite lay-up [90]20 is used in this illustration (matrix dominated damage behavior). In all considered cases, pre-damage strain concentrations (Fig.  1.6a, d, g), the first damage (Fig.  1.6b, e, h), and catastrophic damage (Fig.  1.6c, f) have some differences explained by the sharpness of the impactor. Note that in case of the sharpest impactor, the first damage was sufficient for

1  Experimental Approach of Damage Analysis in Laminated Composite Structures Under Through-Thickness Penetration

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a

b

c

d

e

f

εxy 0.170 0.150 0.125

g

h

0.100 0.075 0.050 0.025 0.000 -0.025

Fig. 1.5  Damage patterns and corresponding shear strain distributions for 55-layer composite [+45/−45/0] under increased load levels from (a) till (h)

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R

a

b

c

d

e

f

R

εxy 0.016 0.012 0.008

g

h

0.004 0.000 -0.004 -0.008 -0.012 -0.016

Fig. 1.6  Representative progressive damage processes as functions of impactor sharpness at R = 1/8″ (a–c); R = 1/16″ (d–f); and R → 0 (g–h) showing indication of shear strain concentrations (a, d, g), the first damage (b, e, h), and catastrophic failure (c, f)

1  Experimental Approach of Damage Analysis in Laminated Composite Structures Under Through-Thickness Penetration

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the catastrophic behavior in a form of almost straight cut (Fig. 1.6h). Such parametric studies can be extremely helpful for ­comparison with potential FEA predictions, at least, due to the following two reasons. Firstly, it may provide convincing 2D validations for a much broader range of cases (e.g., under different values of R). Secondly, it can be used for much more adequate characterization of unknown material parameters by test/model interpolation, by using a set of several cases instead of a single one. Also, test/model comparison for purposes of either validation or/and material characterization can be performed through analysis of force/displacement diagrams. Figure 1.7 illustrates such experimental diagrams for considered nine composite lay-ups, normalized per unit with (W = 25.4 mm). Clear indications of the first damage and damage network formation can be noted as corresponding peaks. In case of available similar FEA predictions, the modeled damage process can be validated and assessed with respect to the predictive accuracy. Also, good repeatability of separate samples of the same layup (shown at Fig. 1.7 with the same color) can be noted as indication of the robustness of the developed experimental approach. Fig. 1.7 Representative load-displacement patterns of multi-step progressive damage process for different composite layups (signs ∗, ∗∗, ∗∗∗ indicate different thicknesses and/or sequences of plies)

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Conclusions An efficient experimental approach of through-thickness damage characterization is developed using a quasi-2D statement of analysis. Implementation of the approach is shown on examples of nine representative carbon-fiber composite lay-ups with different ply orientations, thicknesses and/or ply sequences. Robustness of the approach, repeatability of generated data, and flexibility with respect to parameters of implementation are demonstrated. Advantages of DIC to capture in 2D form pre-damage strain distributions and details of multi-step damage process are shown. The developed approach seems to be a very convenient experimental way for validation of potentially available corresponding FEA predictions. It can also be helpful for indirect characterization of unknown material properties by test/model comparison and minimization of the observed differences. The developed 2D implementation can also potentially reduce cost of test/model validation as compared to corresponding 3D test programs under static and dynamic loading conditions. Acknowledgements  The authors thank the United Technologies Research Center (UTRC) for support and permission for publication.

References 1. M.R. Gurvich, P.L. Clavette, B.D. Bouquillon, P.M. Rao, An approach for experimental characterization of damage processes in thick rotorcraft composite components. American Helicopter Society 69th Annual Forum, Phoenix, 21–23 May 2013 2. M.R. Gurvich, P.M. Rao, P.L. Clavette, B.D. Bouquillon, M.W. Davis, Analysis of impact behavior of thick rotorcraft composite components: Approach and implementation. American Helicopter Society 70th Annual Forum, Montreal, 19–22 May 2014 3. M.R. Gurvich, M.D. Mordasky, P.L. Clavette, R. Ganis, Experimental method of interlaminar characterization in filament wound thick composite structures. Proceedings of SAMPE 2014 Tech Conference, Seattle, 2–5 June 2014 4. M.R. Gurvich, P.L. Clavette, M.E. Robeson, Approach of interlaminar characterization for thick aircraft composite structures. AIAA SciTech, 57th AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, 4–8 Jan 2016, San Diego, 2016. Paper AIAA 2016–1235 5. M.R. Gurvich, S.B. Kim, P.L. Clavette, M.E. Robeson, Approach of probabilistic characterization of progressive damage process in laminated composite materials. Proceedings of the American Society for Composites: Thirty-Second Technical Conference, Purdue University, West Lafayette, 23–25 Oct 2017, p. 2582–2596 6. M.R. Gurvich, P.L. Clavette, S.B. Kim, G.S. Zafiris, N.D. Phan, A. Rahman, Effect of geometrical imperfections on structural integrity of laminated composite structures: Experimental approach and characterization. Proceedings of the American Society for Composites: Thirty-Third Technical Conference, Seattle, 24–26 Sept 2018, p. 1979–1992 7. R.B. Pipes, N.J. Pagano, Interlaminar stresses in composite laminates under uniform axial extension. J. Compos. Mater. 4(4), 538–548 (1970)

Chapter 2

Alternative Composite Design from Recycled Aluminium (AA7075) Chips for Knuckle Applications-II G. Katundi, D. Katundi, E. Bayraktar, and I. Miskioglu

Abstract  In this work, an alternative aluminium matrix composite (AMCs) was designed from the recycled chips of the aluminium series of AA7075 (90 wt %) and Al-Zn-Mg-Si-Ni (10 wt %) given by French aeronautic company to prepare a typical matrix after that we have designed a composite through combined method of powder metallurgy followed by Sintering + Forging. Basically, B2O3 (4 wt %, 8 wt %), TiC (5 wt %), fine Al2O3 Fibre (5 wt %), Zn (4 wt %) and Nb2Al (4 wt %) were added as the main reinforcements. To increase wettability of the reinforcements, we doped them through a thermomechanical treatment. The main idea of this research is to propose an alternative low cost composite for the application in a mechanism to transfer motion for the connection links, for example; between the two railways wagons etc. and also some connecting link in aeronautical pieces as an alternative replacement for conventional alloys used in this area. Mechanical properties, static compression 3-Point Bending (3PB) and dynamic drop weight tests and also micro-hardness results of these composites have been carried out. The microstructure analyses were evaluated by Scanning Electron Microscope (SEM). Keywords  Knuckle-joint composites · Sinter + forging · Damage analyses · Static-dynamic tests · SEM analyses

Introduction Design of the metal matrix and/or hybrid composites should develop their mechanical properties of the pieces used in engineering applications. The present work was done in the frame of the research project that is going on to propose an alternative design of aluminium matrix composites for the mechanical joints such as the knuckle/pin joint components, as rod-­couplings, recently a wind shield wipers for automotive industries as transmitting pieces. Here, the basic idea is to create a heterogeneous structure actually for the pin joint. In fact some of the industrial partners use extensively knuckle component as pin joint, etc. As well known, heterogeneous and anisotropic materials are useful structures for decreasing damage zone. It means that the behaviour of the materials can be changed by the heterogeneous structures [1–6]. In this work, a new innovative method was used as low cost to produce tough, the high strength and resistant materials. Here, a simple idea was developed on the production of knuckle joint pieces from the fresh scrap–recycled aluminium series of AA7075 (90 wt %) and Al-Zn-Mg-Si-Ni (10 wt %) given by French aeronautic company (AA7075) based composites reinforced with hard particles ceramic and intermetallic reinforcements [1, 7–14]. As an alternative replacement for conventional alloys used for the application for the connection link in a mechanism to transfer motion, for example; between the two railways wagons etc. and also some connecting link in aeronautical pieces in this area. These composites were produced through the combined method of powder metallurgy followed by Sintering + Forging [1–3, 5, 8–10, 13, 14]. These composites contain two levels of variable B2O3 (4–8 wt %) and also constant hard powders were

G. Katundi Nexteer-Automotive, Villepinte, France e-mail: [email protected] D. Katundi · E. Bayraktar (*) Supmeca-Paris, School of Mechanical and Manufacturing Engineering, Paris, France e-mail: [email protected]; [email protected] I. Miskioglu ME-EM Department, Michigan Technological University, Houghton, MI, USA e-mail: [email protected] © Society for Experimental Mechanics, Inc. 2020 R. Singh and G. Slipher (eds.), Mechanics of Composite and Multi-functional Materials, Volume 5, Conference Proceedings of the Society for Experimental Mechanics Series, https://doi.org/10.1007/978-3-030-30028-9_2

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used as TiC (5 wt %), fine Al2O3 Fibre (5 wt %), Zn (4 wt %) and Nb2Al (4 wt %) further reinforcements. To accelerate and improve the mutual chemical diffusion of certain reinforcements in the matrix, and mechanical properties of the structure, 2 wt % very fine nickel (d