No abstract

Compared with standard-ply composites, thin-ply composites exhibit a superior mechanical performance under various operating conditions due to their positive size effects. Thin-ply laminate failure modes, including matrix initial damage (MID), matrix failure (MF), and fiber failure (FF), have been distinguished through a systematic acoustic emission (AE) signals analysis combined with scanning electron microscopy (SEM). First, the characteristic frequencies of various failure modes are identified based on unidirectional laminates ([90] 68 and [0] 68). Then, according to the identified frequencies corresponding to distinctive damage modes, four lay-up sequences (02[[90m/0m]ns]02, m = 1, 2, 4, 8, n × m = 16) with a constant total thickness are designed, and the effects of the number of identical plies in the laminate thickness on the damage evolution characteristics and the damage process under uniaxial tension loads are dynamically monitored. The obtained results indicate that the characteristic frequency ranges for MID, MF, and FF are identified as 0–85 kHz, 165–260 kHz, and 261–304 kHz, respectively. The thickness of identical plies has a significant effect on onset damage. With the decrease of the number of identical plies (i.e., m in the stacking sequences), the thin-ply laminates exhibit the initiation of damage suppression effects and crack propagation resistance.

Thin-ply composite failure modes also significantly differ from conventional ply composite failure modes, with the final failure mechanism switching from irregular progressive failure to direct fracture characterized by a uniform fracture with the reduction of the ply thickness. When open holes and bolt joints are involved, thin-ply-laminated composites exhibit more complex stress states, damage evolution, and failure modes. Compared to the experimental study of thin-ply-laminated composite-bolted joints, there are few reports about numerical analysis. In order to understand the damage evolution and failure mechanism of thin-ply-laminated composites jointed by single-lap bolt, a progressive damage model based on three-dimensional (3D) LaRC failure criterion combined with cohesive element is constructed. Through an energy-based damage evolution method, this model can capture some significant mechanical characteristics in thin-ply-laminated structures, such as the in situ effect, delamination inhibition, and fiber compressive kinking failure. The comparisons between the numerical predictions and experimental observations are made to verify the accuracy of the proposed model. It is found that the predicted stress-displacement curves, failure modes, damage morphologies, etc., are consistent with the experimental results, indicating that the presented progressive damage analysis method displays excellent accuracy. The predicted stress at the onset of delamination is 50% higher than that of the conventional thick materials, which is also consistent with experimental results. Moreover, the numerical model provides evidence that the microstructure of thin-ply-laminated composite performs better in uniformity, which is more conducive to inhibiting the intra-layer damage and the expansion of delamination damage between layers. This study on the damage inhibition mechanism of thin-ply provides a potential analytical tool for evaluating damage tolerance and bearing capabilities in thin-ply-laminated composite-bolted joints.