Adhesively bonded lap joints of pultruded GFRP shapes

The importance of Fibre Reinforced Polymers (FRPs) as a material used for civil engineering purposes has grown in the last decade. Especially the introduction of pultrusion at an industrial level as a way to produce big batches of FRP made it possible to offer the advantages – like the high strength-to-weight ratio or the good corrosion resistance – at a reasonable cost. One issue when designing with pultruded FRPs are the connections. Up to now, connections between pultruded FRPs have been designed in the same way as structural steel connections, mainly through bolts. Because of the fibrous and layered character and the anisotropy of pultruded FRPs, bolting is not a material-adapted way to connect. Adhesive bonding is by far better suited, but has not yet been investigated for the special case of pultruded FRPs. This research is intended to fill the gap by offering designing engineers a method allowing them to dimension safe and economic adhesively bonded joints of pultruded FRPs under static loads. The present Thesis is aimed to show the steps leading to this method. After a short introduction, where the objectives and methods used are listed, the actual state of the art is presented. The review of actual literature shows that not much has been done on the special field of adhesively bonded connections of pultruded FRPs, neither experimentally nor theoretically. Some publications treat the global aspect of bonded connections for special cases like the single and double lap joints, but all on idealized mechanical systems with isotropic adherents. Also, there are no detailed reports of a mechanical failure criterion for both describing and quantifying the failure of pultruded FRPs. To overcome this, experimental investigations were carried out at different levels: the basic FRP material has been investigated in both senses of revealing the fibre architecture – with the help of burn-off tests – and the material strength – using a device the Author especially developed for this purpose: the CCLab Shear-Tensile device. This device allows the determination of the material strength subjected to combinations of out-of-plane and shear stresses. The device was also used to determine an important basic material property necessary to numerically formulate the anisotropy: the out-of-plane E-Modulus. Besides the investigations on the basic material, experiments on bonded single and double lap joints were carried out where the influence of parameters like the length of the bonded overlap, the thickness of the adherents and stress reduction methods (like chamfers of fillets) on the ultimate load was investigated. All of these experimental investigations were carried out on relatively big specimens to avoid the influence of any size effects. The experimental results showed that the adhesive layer thickness and stress reduction measures like chamfers are by far less influential that former publications expected them. For selected geometric configurations, the axial strain development along the bonded splice was experimentally gathered using strain gauges. Comparisons with FEA showed that by using the right mechanical input parameters in regard to the anisotropy, it is possible to model, with sufficient accuracy the stresses inside adhesively bonded joints of pultruded FRPs. Some single and double lap joints were filmed using a high-speed camera (up to 2000 fps) to investigate the failure process. This failure process is closely linked to the fibre architecture in the sense that it has been shown that the failure is triggered inside the laminate. The entire group of experimentally investigated specimens were then modeled with the Finite Element Method using orthotropic elements. In combination with the experimentally gathered material failure criterion, it was possible to formulate a method based on the comparison of stresses in the joint and the material resistance to predict the ultimate load of single and double lap joints, which was validated for a wide range of geometrical configurations. A simplified version of this method, based on existing analytical formulae, was then developed to make the strength prediction of adhesively bonded joints of pultruded FRP shapes available for civil engineering purposes.

Finite element modeling and experimental study of brittle fracture in tempered martensitic steels for thermonuclear fusion applications

Pablo Federico Mueller

In this work we have studied brittle fracture in high-chromium reduced activation tempered martensitic steels foreseen as structural materials for thermonuclear fusion reactors. Developing the adequate materials that can withstand the severe irradiation conditions of the burning plasma in a future fusion reactor is one of the major challenges to be solved in order to make profit from the great advantages of thermonuclear fusion as an energy source. High-chromium tempered martensitic steels such as F82H and the most advanced version Eurofer97 are among the main candidate materials for structural applications in future fusion power plants due to low irradiation-induced swelling, good mechanical and thermal properties, and reasonably fast radioactive decay. The most concerning drawback of these kind of steels is irradiation embrittlement, which is manifested by a ductile-to-brittle transition temperature shift to higher temperatures after irradiation whose amplitude depends on the irradiation conditions (temperature, neutron flux, neutron fluence, etc). The aim of this work was to study and model brittle fracture in the ductile-brittle transition region of this kind of steels in the as-received unirradiated conditions. It is necessary to be able to transfer laboratory specimen fracture data to real components and structures in order to assess the performance of these steels in the different operating and transient conditions they could find during the operation life of a fusion reactor. In order to do so, the specimen geometry effects and specimen size effects on measured fracture toughness need to be properly understood, taken into account and predicted with an appropriate model. In particular, specimen size effect on measured toughness is a major concern for the nuclear materials research community owing to the limited irradiation volume in current and planed materials irradiation facilities. The main results of this PhD work are summarized below. The microstructure of Eurofer97 and F82H has been characterized and compared by means of optical microscopy, scanning electron microscopy, transmission electron microscopy and energy-dispersive X-ray spectroscopy in order to identify microstructural features that could play a role in the measured fracture toughness. Both steels have similar but slightly different chemical composition and final heat-treatments but the prior austenitic grain size measured in F82H is approximately 8 times larger than in Eurofer97. It was shown that the alloying element Tantalum, added to stabilize the austenite grain size, played a different role in both steels. After a careful analysis of the particles present in both steels, it was found that Tantalum in Eurofer97 formed carbides of an average size around 100 nanometers. In contrast in F82H it did not form small carbides but formed big oxide inclusions with a size up to 30 µm. These large particles do not effectively pin the grain boundaries. The different behavior of Tantalum in these steels is believed to be mainly a consequence of the larger content of Oxygen present and the smaller amount of Aluminum in F82H compared to Eurofer97. The Master-Curve ASTM-E1921 standard is a method initially developed to determine the ductile-to-brittle transition reference temperature, T0, in fission reactor ferritic steels from a small number of experiments. In this work the applicability of the Master-Curve method to reduced activation tempered martensitic steels such as Eurofer97 and F82H was studied in detail. Fracture tests with pre-cracked sub-sized compact tension specimens (three different sizes, 0.18T, 0.35T and 0.87T of Eurofer97) were carried out in the temperature range [-196 °C, -40 °C]. The toughness-temperature behavior and scatter were shown to deviate from the ASTM-E1921 standard predictions near the lower shelf. Using the method of maximum likelihood, the athermal component of the Master-Curve was calculated to better fit our fracture toughness data from the lower to the middle transition region. We showed that these Master-Curve adjustments are necessary to make the T0 values obtained near the lower shelf with 0.35T size C(T) specimens consistent with those obtained in the middle transition region with 0.87T C(T) specimens. The ASTM-E1921 specimen size limitations, setting the maximum toughness measurable with a given specimen size, were found to be too lenient for this kind of steels. This problem was especially evident in fracture toughness data of Eurofer97 and F82H obtained in the upper transition temperature range with two different specimen sizes. Thus a more stringent specimen size requirement was proposed to avoid inconsistent transition temperature determinations. A promising local fracture model with the potential of predicting cleavage fracture toughness was studied. Finite element simulations were undertaken for compact specimens, notched specimens and tensile specimens of Eurofer97 steel tested from 20 °C down to -197 °C. Three and two dimensional as well as axisymmetric simulations were run in order to calculate the stress and strain fields at the onset of brittle fracture. For each tested temperature, the calculated load-displacement curves were found to reproduce very well those of the experiments. A local approach fracture criterion was studied. This criterion states that when the maximum principal stress is larger than a critical stress within a critical volume ahead of the crack tip, notch or neck, cleavage is triggered leading to macroscopic fracture of the specimen. It was shown that this model is able to predict the minimum fracture load of the notched specimens with the same values of critical stress and critical volume that were calibrated to predict the lower bound of fracture in compact specimens. This local approach model was also successfully used to predict the strong size effect observed experimentally in pre-cracked compact tension specimens in the upper transition region. The critical fracture stress determined in the standard tensile specimens was found higher than that of the fracture specimens. It was suggested that this difference stems from a significant difference in the stress state between the different specimens (triaxiality). Finally, the comparison between the overall fracture behavior in the transition between F82H and Eurofer97 steels indicated that these two materials are quite similar. A difference in the reference temperature T0 of about 20 °C was found, with a nominal value of -100 °C and -80 °C for F82H and Eurofer97 respectively. However, some excessive scatter in the toughness data was found in F82H with more data points than expected lying below the 1% tolerance bound; this was not observed in Eurofer97. From an engineering point of view, the entire fracture databases of these two steels are encompassed practically by the same lower tolerance bound.

EPFL2009

Assessment of mechanical properties in unirradiated and irradiated zircaloys and steels with non-standard tests and finite element calculations

Emiliano Campitelli

Nuclear materials have been successfully employed in commercial fission reactors for many decades. Research and material development for advanced fission system and future thermo-nuclear fusion reactors have acquired maturity while great challenges remain to be taken up. The goal of the material scientist is to understand the way neutron irradiation and aggressive reactor environment alter the original material properties and to safely manage the operation conditions for each particular reactor component. In the framework of surveillance programme, the need has arisen to design experimental methods to be used with a limited amount of material for Post Irradiation Examination (PIE) of reactor components to test the integrity of those on a regular time basis. Having to deal with radioactive material, it is particularly important to devise experimental testing procedures as simple as possible but from which reliable information can be drawn. Within materials development programme, irradiations have continuously been performed either in reactors or with particle accelerators. In both cases, the irradiation volumes are usually limited. The concern was to optimize the volume of the irradiated samples in order to increase their number to obtain a good statistical representation of their mechanical behavior after irradiation, and to have a very definite and homogeneous damage dose and irradiation temperature. The concerns explained above originated the development of small-scale specimen testing methods. Advantage is taken of the fact that, within size and geometry limitations, some mechanical properties of a sample are independent of its absolute size. In this way it is possible to perform mechanical tests on samples of reduced volume that represents big advantages to face the aforementioned challenges. Non-standard test on very small specimen have also been proposed to extract mechanical properties of the bulk. If these non-standard testing methods are to be employed for PIE, it becomes necessary to develop modeling tool to understand under what circumstances they can provide useful information and specially how to obtain it. Finite element modeling (FEM) of the non-standard tests has played a key role in this sense, providing a link between standard test analysis and that of the non-standard ones. The goal of this work was to implement finite element models for non-standard tests to ultimately study the mechanical properties of Zircaloy cladding tube and tempered martensitic steels in the unirradiated and irradiated condition. One model was developed for ring tensile tests. It was first validated with a quite ductile iron-chromium ferritic alloy, for which ring and uniaxial tensile test were performed at room temperature. Using the constitutive behavior determined from the uniaxial tensile tests, the load – displacement curves of the ring tensile tests were very well reproduced. Another model was developed for the so-called small ball punch test, which consists in deforming a 3 mm diameter disk clamped between two dies with a ball puncher and to record the load – displacement curve. In order to validate the model, a series of ball punch tests and of tensile tests were carried out on the austenitic steel 316L at room temperature. In this last case, the ball punch test curves were also well reconstructed with the model. Based upon a simple analysis and simulation results, we showed that it is possible to obtain, by ring tensile tests, a quick and accurate assessment of the constitutive behavior of an unknown material, simply by processing the experimental force-elongation data in the same way as for uniaxial tests, taking half the ring perimeter as initial length and twice the ring cross section as the sample cross section. The ring tensile test method was used to determine the hoop mechanical properties of Zircaloy tubes used in fission reactors. Tensile tests were also performed in the axial direction of the Zircaloy tubes. Differences between the yield stress as well as the post-yield behaviors in the axial direction and those in the circumferential direction of the tube could be measured reflecting some component of the anisotropy of the tube. Ball punch specimens were cut also out of the tube in the radial direction and tested. Using the FE model for punch test, in which the anisotropy of the mechanical properties are taken into account through the Hill's theory, the values of the Hill's yield function parameters were estimated. The irradiation hardening of neutron irradiated Zircaloy tube was finally determined. The ball punch test model was extensively used for numerical investigations, to determine how the constitutive behavior of the materials (uniaxial true stress – true strain) employed as input acts in combination with other experimental factors (specimen thickness, friction coefficient) in mediating the shape of the experimental curves. In the light of the results, we derived calibrations between parameters of the non-standard and standard tests. For instance we proposed a new approach to determine the yield stress from the ball punch test. We also showed how the slope of the punch tests scales with the average flow stress of the material. The calibrations proposed in the past by authors and published in the open literature have been revisited and critically reviewed. Based upon the findings of the numerical studies, we propose a given methodology to unambiguously evaluate the material constitutive behavior of a material in a case where the only available data comes from various non-standard tests. Experimental ball punch test results obtained on proton-irradiated specimen (0.5 dpa and Tirr = 523 K), of the tempered martensitic steel, EUROFER97, have been obtained. The irradiation hardening was found equal to about 150 MPa, consistently with previous data on similar steels and irradiation conditions. From the simulations of the ball punch test curves of the irradiated specimens, it was concluded that the irradiation does not affect the strain hardening at relatively low fluence.

EPFL2005

Stochastic analysis of clear timber as a structural material

Alireza Farajzadeh Moshtaghin

Wood/timber has been widely used for house and bridge construction. It is a widely available natural material that necessitates low energy for the production, following simple processes. The environmentally friendliness, together with the low cost of raw material makes it an efficient building material. Moreover, timber possesses attractive mechanical properties such as high specific strength and stiffness. In contrast, timber constructions have, to a large extent, been based on experience and craftsmanship, which prevents taking full advantage of this material. There are several reasons for this. Timber has a complex mechanical behavior being a natural highly anisotropic fiber composite, with properties that are also affected by moisture content. For specific species, geographical location, local growth conditions and moisture content, the material properties depend, among others, on the age, the structural imperfections, the location of timber within the tree, and load history. Consequently, the mechanical properties of timber are, inherently, highly variable. Variability of timber properties includes statistical and spatial variabilities, referred to as random spatial variability (RSV). This entails adopting a probabilistic/stochastic approach to analysis of timer structures. The aim of this research is to understand and model the effect of the RSV on the clear timber mechanical properties, as well as the experimental characterization of RSV for clear timber, and also to develop a stochastic finite element framework for random response assessment of clear timber components. A size effect model was developed which takes into account the RSV in the strength field. The theory of random fields was used for this purpose. Using the spectral representation scheme, realizations of strength field in each specimen were generated. The stochastic response was obtained via the Monte Carlo method. The model results was compared to the existing experimental data in the literature. Also, an analytical expression was provided to facilitate the application of the model. Clear timber specimens of different lengths were fabricated for longitudinal tensile tests. Local deformations along the lengths of the specimens were recorded during the tests in order to characterize the RSV in longitudinal properties. A connection between the mesostructure of the clear wood and its local elastic modulus was observed. Statistics concerning the elastic modulus, strength and strain to failure and the effect of length change on these properties were extracted. The correlations between the strength, the elasticity and the density were obtained. Transverse properties were also investigated which are of particular importance in some applications such as mechanical and adhesively-bonded timber joints. Regularly positioned and randomly positioned specimens were cut from different timber boards. Statistics and size effects concerning the elastic modulus, strength and strain to failure as well as the correlation between the properties were studied. The spatial variability in the transverse elastic modulus, the tensile strength and the failure strain was also experimentally studied. Mesostructural patterns of clear timber were shown to have a direct effect on the local elastic modulus. Finally, a stochastic finite element framework was established by combining the spectral representation scheme for RSV modelling and the finite element software ABAQUS in a non-intrusive manner. This framework can be used for the stochastic structural response assessment of timber structural components made of clear timber. To show the applicability of the model in real applications, the failure of adhesively bonded double-lap timber joints were simulated under tensile loading. The effect of size on the strength was also taken into account. The results were in a fairly well agreement with the available experimental data in the literature.

EPFL2016