Damage initiation and evolution of three-dimensional (3D) orthogonal woven carbon fibre composite (3DOWC) is investigated experimentally and numerically. Meso-scale homogenisation of the representative volume element (RVE) is utilised to predict the elastic properties, simulate damage initiation and evolution when loaded in tension. The effect of intra-yarns transverse cracking and shear diffused damage on the in-plane transverse modulus and shear modulus is investigated while one failure criterion is introduced to simulate the matrix damage. The proposed model relies on two major assumptions. First, the effect of the binder yarns, on the in-plane properties, is neglected, so the 3DOWC unit cell can be approximated as a (0°/90°) cross-ply laminate. Second, a micro-mechanics based damage approach is used at the meso-scale, so damage indicators can be correlated, explicitly, to the density of cracks within the material. Results from the simulated RVE are validated against experimental results along the warp (0° direction) and weft (90° direction). This approach paves the road for more predictive models as damage evolution laws are obtained from micro mechanical considerations and rely on few well-defined material parameters. This largely differs from classical damage mechanics approaches in which the evolution law is obtained by retrofitting experimental observations.@en

Three different architectures of 3D carbon fibre woven composites (orthogonal, ORT; layer-to-layer, LTL; angle interlock, AI) were tested in quasi-static uniaxial tension. Mechanical tests (tensile in on-axis of warp and weft directions as well as 45° off-axis) were carried out with the aim to study the loading direction sensitivity of these 3D woven composites. The z-binder architecture (the through-thickness reinforcement) has an effect on void content, directional fibre volume fraction, mechanical properties (on-axis and off-axis), failure mechanisms, energy absorption and fibre rotation angle in off-axis tested specimens. Out of all the examined architectures, 3D orthogonal woven composites (ORT) demonstrated a superior behaviour, especially when they were tested in 45° off-axis direction, indicated by high strain to failure (∼23%) and high translaminar energy absorption (∼40MJ/m3). The z-binder yarns in ORT architecture suppress the localised damage and allow larger fibre rotation during the fibre “scissoring motion” that enables further strain to be sustained by the in-plane fabric layers during off-axis loading.@en

The effect of circular notch has been evaluated for three different architectures of three-dimensional (3D) carbon fibre woven composites (orthogonal, ORT; layer-to-layer, LTL; angle interlock, AI) through open-hole quasi-static tension and double-lap bearing strength tests in the off-axis (45textdegree) direction. Damage characterisation is monitored using Digital Image correlation (DIC) for open-hole testing and X-ray Computed Tomography (CT) for double-lap bearing strength test. The off-axis notched 3D woven composites exhibits minor reduction (less than 10 %) of the notched strength compared to the un-notched strength. DIC strain contour clearly show stress/strain localisation regions around the hole periphery and stress/strain redistribution away from the whole due to the z-binder existence, especially for ORT architecture. Up to 50 % bearing strain, no significant difference in the bearing stress/bearing strain response is observed. However when ORT architecture was loaded up to failure, it demonstrates higher strain to failure (textasciitilde140 %) followed by AI (textasciitilde105 %) and lastly LTL (textasciitilde85 %). X-ray CT scans reveal the effect of the z-binder architecture on damage evolution and delamination resistance. The study suggests that off-axis loaded 3D woven composites, especially ORT architecture, has a great potential of overcoming the current challenges facing composite laminates when used in composite joints' applications.@en