In this research, conduction welded C-struts, part of a thermoplastic composite fuselage designed and manufactured in the framework of the Clean Sky 2 STUNNING project, are investigated. Five specimens made of two C-section profiles are manufactured and welded using conduction welding in three different configurations with variations in the direction and distance of the two welded joints. Preliminary numerical analysis using the virtual crack closure technique are conducted to obtain an initial evaluation of the specimens behavior, in preparation of the tests. Experiments are performed under quasi-static loading conditions to measure the strength of the welds. Comparisons with the preliminary numerical analyses show a good agreement in terms of the predicted maximum load, while a clear difference is observed in the initial stiffness, due to the compliance of the support structure. The numerical model is updated, leading to results that closely match the experimental behavior. For all the analyzed specimens, the separation occurs suddenly and no signs of propagation are observed. Experimental and numerical data show no relevant difference in the joint strength among the different conduction welding configurations.

This study aims at better understanding the damage tolerance of stiffened composite panels subjected to fatigue loads in the post-buckling regime. Ten single-stringer hat-stiffened specimens with an initial delamination between the skin and the stringer foot were manufactured, and then tested under quasi-static and fatigue loads in post-buckling conditions, with different load levels and load ratios. The tests were monitored with digital image correlation and an ultrasonic system, providing data on the displacements, strains, and extension of the delamination length. The quasi-static results showed that the delamination onset, when the initial delamination begins propagating, occurred at loads over twice the buckling load, while collapse occurred for values almost 20% higher than the delamination onset. During fatigue testing at load levels below the delamination onset, the specimens were able to sustain 150000 cycles and then, when tested statically after fatigue, the average load at collapse was reduced by less than 10% with respect to the quasi-static benchmark. When the maximum load during fatigue was increased to 5% over the delamination onset load, the specimens still withstood between 8000 and 16500 cycles before collapse, depending on the load ratio. It was also seen that for tests at the same load level, the specimens with high load ratio had a slower damage propagation.

This paper evaluates the capabilities of the recently developed CF20 cohesive fatigue model, which can predict crack initiation as well as the rates of crack propagation by relying on intrinsic relationships between a stress-life diagram and its corresponding Paris law. The model is validated here using a partially reinforced double cantilever beam (R-DCB) benchmark proposed in literature. The two parameters needed for the CF20 cohesive fatigue model were obtained by performing preliminary analyses of a conventional DCB. The analysis results indicate that the CF20 cohesive fatigue model can accurately reproduce the complex evolution of the delamination observed in the R-DCB.

In this paper, a comparison between six finite element models of a representative wing structural component performed in the context of Optimised Design for Inspection (ODIN) project of the European Cooperation in Science and Technology (COST) is presented. Six partners from six different countries involved in the project received the drawing of the structure, the material properties, the loading and boundary conditions. Each partner, based on their background and experience in numerical analyses, developed a finite element model with different levels of details and accuracy and performed a blind prediction of the structural behaviour of the wing component. The numerical results are presented and compared with the experimental test data conducted at Cardiff University.

The standard experimental procedures for determining the interlaminar fracture toughness are designed for delamination propagation in unidirectional specimens. However, in aerospace structural components, delamination usually occurs between plies at different orientations resulting in different damage mechanisms which can increase the value of the fracture toughness as the delamination propagates. Generally, numerical analyses employ the value measured at the delamination onset, leading to conservative results since the increase resistance of the delamination is neglected. In this paper, the fracture toughness and the R-curves of carbon/epoxy IM7/8552 are experimentally evaluated in coupons with delamination positioned at 0°/0° and 45°/−45° interfaces using Double Cantilever Beam (DCB) and Mixed-Mode Bending (MMB) tests. A simplified numerical approach based on the Virtual Crack Closure Technique (VCCT) is developed to simulate variable fracture toughness with the delamination length within a Finite Element code using a predefined field variable. The results of the numerical analyses compared with the experimental data in terms of load-displacement curves demonstrate the effectiveness of the proposed technique in simulating the increase resistance in delamination positioned between plies at 45°/−45° interface.

The fatigue life prediction of post-buckled composite structures represents still an unresolved issue due to the complexity of the phenomenon and the high costs of experimental testing. In this paper, a novel numerical approach, called “Min-Max Load Approach”, is used to analyze the behavior of a composite single-stringer specimen with an initial skin-stringer delamination subjected to post-buckling fatigue compressive load. The proposed approach, based on cohesive zone model technique, is able to evaluate the local stress ratio during the delamination growth, performing, in a single Finite Element analysis, the simulation of the structure at the maximum and minimum load of the fatigue cycle. The knowledge of the actual value of the local stress ratio is crucial to correctly calculate the crack growth rate. At first, the specimen is analyzed under quasi-static loading conditions, then the fatigue simulation is performed. The results of the numerical analysis are compared with the data of an experimental campaign previously conducted, showing the capabilities of the proposed approach.

In this work, an approach based on the Virtual Crack Closure Technique, included in the commercial finite element code ABAQUS, is adopted to study the propagation of delamination in composite structures under quasi-static and fatigue loads. The methodology, originally capable of simulating only delamination under quasi-static loads, has recently been extended introducing the possibility to analyze damage progression under fatigue load condition. The approach is assessed on simple specimens, Double Cantilever Beam and Mixed Mode Bending test, comparing the results with literature data. Afterwards, the behavior of a single-stringer specimen with an initial delamination is numerically investigated considering compressive loading conditions. At first, the single-stringer specimen is analyzed under quasi-static compressive load showing a clear correlation between local buckling phenomena and delamination growth. Then, a cyclic compressive load is applied such that the specimen switches between pre- and post-buckling conditions in a single load cycle. The outcomes of the numerical analyses are compared with the experimental data obtained from an experimental test campaign previously performed, showing the advantages of the adopted numerical technique but also the limitations that need to be addressed to properly analyze this phenomenon.