This work proposes a methodology for the characterisation of complex pore features in unidirectional composite prepregs, and provides insights into the interaction between fibre architecture and pores. The method showcased allows to compare spatial distributions at a three-dimensional level, highlighting in the tape analysed a significant correspondence between regions of elevated tortuosity and increased pore fractions. Regions associated with highly tortuous meandering fibres exhibit a pronounced association with porosity located both in the bulk and at the tape surface, suggesting a strong interaction between non-collective fibre displacement and the probability of pore location. Furthermore, our study quantifies the length scale of feature propagation, shedding light on the spatial extent of microstructural pore occurrence within the composite. These findings have significant implications from a characterisation perspective to aid modelling approaches and manufacturing processes for high-performance composite prepregs tapes.

Understanding the microstructural variability in unidirectional composite prepreg tapes is relevant to investigating mechanisms of tape microstructure formation, their impact on its processability and the mechanical performance of the final composite part. It has been shown that three-dimensional microstructural variability at the single-fibre level can be resolved by X-ray microcomputed tomography (XCT). However, to define a representative microstructural fingerprint of a given tape, investigations at the required small voxel size lead to limited volumes of observation, which might not be representative. This research aims to extend these findings via a multiscale approach, considering scales of observations, from microscopic (single fibre) up to mesoscopic (dimension of tape) length scale, to generate further insight into the microstructural organisation of thermoplastic prepreg tapes. By exploring the ability of XCT imaging for carbon fibre-reinforced thermoplastic composites at different voxel sizes, the work aims to identify the limitations of the use of different scales of observations to capture features of microstructures and their propagation from micro- to mesoscale level. While structure tensor analysis appeared to correctly capture misaligned regions in XCT images with small voxel size (1/10 of the fibre diameter), the method proved ineffective for larger voxel size images (1/2 of the fibre diameter).

Finding new ways to evaluate the variability of microstructures, and its effect on macroscopic properties such as permeability and mechanical performance [1,2] is of increasing interest in the composite field. The variability of microstructural features at a three-dimensional level is not fully understood and its effect on macroscale properties is not well established, and mostly analyzed at a phenomenological level [3]. We introduced in recent work a method based on X-ray Computed Tomography for the threedimensional reconstruction of the fibrous microstructure of unidirectional tapes at a single fibre resolution [4]. A schematic of the workflow is represented in Figure 1. Three descriptors are introduced in the work to describe increasing level of complexity in the microstructural organization, from a single fiber path level with differential tortuosity, to group behavior with collective motion, to fibre network connectivity with length of contact. These descriptors and their interdependence highlight local effects like edge-core segregation in microstructural characteristics. However, in order to achieve a more complete definition of the unidirectional tape domain, understanding of matrix-based features and its interrelation with fiber architecture descriptors is needed. In this work, we expand the methodology of Gomarasca et al. [4], to account for matrix-based phenomena such as tape boundary variability, and void formation and morphology. This will be showcased on a unidirectional composite tape including both fiber-based and matrix-based analysis. These methods enable advanced characterization and modelling of microstructural formation and evolution during composite manufacturing.

The main bottleneck of using composites for cryogenic storage of clean hydrogen fuel is the permeation of gas molecules. In this work, the permeation of hydrogen gas through thermally cycled thermoplastic composite laminates with two different stacking sequence is investigated. The experimental study is based on a methodology of cryogenically cycling the composite specimen and measuring the permeability in a dedicated hydrogen permeation setup. An optical microscope and X-ray computed tomography scanner are employed to investigate the existence of cracks. The results reveal that thermal cycling does not have a profound influence on permeability, while the stacking sequence has a considerable effect. Laminates with dispersed 0° layers resulted in lower permeation values compared to the laminate with grouped 0° layers at the laminate’s core. The imaging techniques did not reveal any observable crack which supports the hypothesis that permeation is mostly driven by bulk diffusion in the polymer.

Understanding the three-dimensional variability of unidirectional composites is relevant to the material performance and the development of advanced material modelling strategies. This work proposes a new methodology for the characterization of unidirectional composites, showcased on carbon fibre/poly(ether-ether-ketone) tapes. Three microstructural descriptors were here introduced, each representing an increasing level of complexity in the fibre architecture: from a tortuosity-based single fibre trajectory analysis to fibre groups’ behaviour, to fibre network interconnectivity. The methodology was developed and validated on real material datasets acquired via X-ray computed tomography. A facile method for image analysis was used to reconstruct the three-dimensional fibrous architecture at a single fibre path resolution. The approach bridges a gap in the traditional approach and nomenclature typical of the composite field to describe and quantify complex fibre organization in unidirectional composites, highlighting micro- and mesoscopic features, such as edge-core effects in the fibre arrangement, possibly occurring in tow spreading. The study of the parameter interdependence showed relationships, which will provide further insight for future research in the study of microstructure formation of unidirectional composites, its evolution during processing or loading, and input for advanced modelling techniques based on Representative Volume Elements.

Composite materials combine the advantages of lightweight and high strength. This is in particular of interest for the development of large constructions e.g. aircraft, space applications, wind turbines etc. One of the shortcomings of using composite materials is the complex nature of the failure mechanisms which makes it difficult to predict the remaining lifetime. Therefore, condition and health monitoring are important for using composite materials for the critical parts of a construction. Different types of sensors are used to monitor composite structures. These include ultrasonic, thermography, shearography and fiber optics. Optical fiber sensors can be surface mounted or embedded in the composite construction to provide the unique advantage of in-operation measurement of mechanical strain and other parameters of interest. This is identified as a promising technology for Structural Health Monitoring (SHM) or Prognostic Health Monitoring (PHM) of composite constructions. Among the different fiber optic sensing technologies, Fiber Bragg Grating (FBG) sensors are the most mature and widely used ones. FBG sensors can be realized in an array configuration with many FBGs in a single optical fiber. In the current project, different aspects of using embedded FBG for composite wind turbine monitoring are investigated. The demonstration of using FBG sensor array for temperature and strain sensing and monitoring of a 5.8 m long scale model of a glass fiber monopile is investigated. The results indicate that the embedded FBGs successfully show the temperature increase during curing of the resin. During the static and dynamic tests, the embedded FBG sensors provided accurate monitoring.

Depending on the state of stress, material can fail in a number of different modes during a collision. Three modes are identified here as material separation in the absence of necking, material separation after the onset of necking, and localized buckling/wrinkling. Through a series of case studies, the states of stress present in a collision are analyzed. Of particular interest is leakage in a scaled fuel tank that could not have been predicted by FEA due to resolution and may have been ignored even with sufficient resolution because it was in a region of generally compressive stresses. Following the review of case studies, the aforementioned failure mechanisms are reviewed, and the corresponding states of stress are summarized. It is shown that the current state of technology for failure after the onset of necking is insufficient but quickly improving. Concepts are taken from the sheet metal industry to understand the onset of buckling/wrinkling, but there is little readily available to simulate failure after the initial onset.