Finite Element Simulation of Acoustic Emissions from Different Failure Mechanisms in Composite Materials

Abstract

Damage in composite laminates evolves through complex interactions of different failure modes, influenced by load type, environment, and initial damage, such as from transverse impact. This paper investigates damage growth in cross-ply polymeric matrix laminates under tensile load, focusing on three primary failure modes: transverse matrix cracks, delaminations, and fiber breaks in the primary loadbearing 0-degree laminae. Acoustic emission (AE) techniques can monitor and quantify damage in real time, provided the signals from these failure modes can be distinguished. However, directly observing crack growth and related AE signals is challenging, making numerical simulations a useful alternative. AE signals generated by the three failure modes were simulated using modified step impulses of appropriate durations based on incremental crack growth. Linear elastic finite element analysis (FEA) was applied to model the AE signal propagating as Lamb waves. Experimental attenuation data were used to modify the simulated AE waveforms by designing arbitrary magnitude response filters. The propagating waves can be detected as surface displacements or surface strains depending upon the type of sensor employed. This paper presents the signals corresponding to surface strains measured by surface-bonded piezoelectric sensors. Fiber break events showed higher-order Lamb wave modes with frequencies over 2 MHz, while matrix cracks primarily exhibited the fundamental S0 and A0 modes with frequencies ranging up to 650 kHz, with delaminations having a dominant A0 mode and frequency content less than 250 kHz. The amplitude and frequency content of signals from these failure modes are seen to change significantly with source–sensor distance, hence requiring an array of dense sensors to acquire the signals effectively. Furthermore, the reasonable correlation between the simulated waveforms and experimental acoustic emission signals obtained during quasi-static tensile test highlights the effectiveness of FEA in accurately modeling these failure modes in composite materials.