This paper presents an experimental demonstration and validation of high-resolution three-dimensional experimental strain measurement using Digital Volume Correlation (DVC) on Carbon Fibre-Reinforced Polymers, via through-thickness strain analysis under a state of pure bending. To permit the application of DVC to displacements and/or strain measurements parallel to the fibre direction in well-aligned unidirectional materials at high volume fractions, a methodology was developed for the insertion of sparse populations of 400 nm BaTiO3 particles within the matrix to act as displacement trackers (i.e. fiducial markers). For this novel material system, measurement sensitivity and noise are considered, along with the spatial filtering intrinsic to established DVC data processing. In conjunction with Micro-focus Computed Tomography, the technique was applied to a simple standard specimen subjected to a four-point flexural test, which resulted in a linear strain distribution through the beam thickness. The high-resolution, fibre-level strain distributions (imaged at a voxel resolution of ∼0.64 µm) were compared against the classical beam theory (Euler–Bernoulli) in incrementally decreasing averaging schemes and different sub-set sizes. Different sampling and averaging strategies are reported, showing that DVC outputs can be obtained that are in very good agreement with the analytical solution. A practical lower limit for the spatial resolution of strain is discerned for the present materials and methods. This study demonstrates the effectiveness of DVC in measuring local strains parallel to the fibre direction, with corresponding potential for calibration and validation of micromechanical models predicting various fibre-dominated damage mechanisms.

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Carbon Fibre Sheet Moulding Compounds (CF-SMCs) are lightweight materials very suitable for automotive parts. So far, their use was limited to thin components. This work presents a feasibility study on the compression moulding of a thick-walled SMC component, with a compound of randomly oriented chopped carbon fibre tapes.Bending tests were used to evaluate the effects of the manufacturing conditions on the mechanical performance. The choice of the charge pattern configuration played the paramount role in the final part performance, especially via the creation of weld surfaces, leading to a maximum strength difference of over 400%. The moulding temperature, pressure and cooling method showed no statistically significant influence on both strength and stiffness of the part. The results of this work can be used as a starting point in the design of manufacturing processes for thick SMC components.

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This paper presents the development of novel Carbon-Fibre Reinforced Polymer (CFRP) laminates, tailored for the application of Digital Volume Correlation (DVC) and Computed Tomography (CT) to experimental mechanics analyses of these materials. Analogous to surface-based Digital Image Correlation (DIC), DVC is a relatively novel volumetric method that utilizes CT data to quantify internal three-dimensional (3D) displacements and implicit strain fields. The highly anisotropic and somewhat regular/self-similar microstructures found in well-aligned unidirectional (UD) materials at high fibre volume fractions are intrinsically challenging for DVC, especially along the fibre direction at microstructural length-scales on the order of a few fibre diameters. To permit the application of DVC to displacement and/or strain measurements parallel to the fibre orientation, the matrix was doped with a sparse population of sub-micrometre particles to act as displacement trackers ( i.e. fiducial markers). Barium titanate particles (400 nm, ∼1.44 vol. %) were found to offer the most favourable compromise between contrast in CT images and the ability to obtain a homogeneous distribution in 3D space with sufficient particle compactness for local DVC analyses. This property combination was selected following an extensive Micro-focus Computed Tomography (µCT)-based qualitative assessment on a wide test matrix, that included 38 materials manufactured with a range of possible particle compositions, mean sizes and concentrations. By comparing the tensile behaviour of the particle-adapted material alongside its particle-free counterpart, we demonstrate through the application of in situ Synchrotron Radiation Computed Tomography (SRCT) that the macro- and micromechanical responses of the newly developed CFRP are consistent with standard production materials indicating its suitability as a model system for mechanistic investigations.