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DIGITAL LIBRARY: CAMX 2023 | ATLANTA, GA | OCTOBER 30-NOVEMBER 2

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Extending impact fatigue life of thermoplastic fibre-reinforced composites via multi-impact resistant nature-inspired Helicoid fibre architectures

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Title: Extending impact fatigue life of thermoplastic fibre-reinforced composites via multi-impact resistant nature-inspired Helicoid fibre architectures

Authors: Lorenzo Mencattelli, Michel Jansen

DOI: 10.33599/nasampe/c.23.0078

Abstract: Impact-fatigue and out-of-plane loads durability is critical to guarantee extended composite structures life and lower maintenance costs. Repeated low energy impacts (e.g. road gravel), can result in progressive damage accumulation and eventually lead to catastrophic failures. Achieving high durability is fundamental in transportation as crashworthiness is key to the safety of the passengers and several vehicle components (e.g. EV battery pack, hydrogen storage). Thermoplastic resins are a viable source to improve impact toughness, enable recyclability and low cost repair of composite structures. Additionally, Helicoid bio-inspired fibre architectures, consisting of helicoidal lamination sequences, are a low-cost solution to improve impact performance and delayed fibre failure for a wide range of composites. While Helicoid architectures have proven successful in further enhancing the impact resistance of thermoplastic fibre-reinforced composites (TP-FRPs), a direct evaluation of impact fatigue and repairability to evaluate the durability improvement has yet to be demonstrated. For the first time, we report on the single-impact and impact fatigue resistance of TP-FRPs (Carbon Fibre Polypropylene (CF/PP) – Tafnex, Mitsui Chemicals) in conventional (CP, cross-ply, 0°,90°) and Helicoid architectures. We used automated multilayer stacking and double-belt press consolidation to create coupons with industry standard manufacturing processing. We then characterised the Helicoid and CP samples using single-impact and impact fatigue tests. We used 4mm and 2.6mm thick samples to represent thick- and thin-walled applications. We performed detailed post-damage analyses to quantify the progressive damage accumulation and related degradation of mechanical performance in terms of residual load-bearing capability, residual stiffness, dissipated energy, and fibre failure extent. We demonstrate that at equal weight, bioinspired CF/PP Helicoid architectures achieved >90% extended impact fatigue life, +42% stiffness retention and +15% peak-load retention.

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Conference: CAMX 2023

Publication Date: 2023/10/30

SKU: TP23-0000000078

Pages: 11

Price: $22.00

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