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Characterisation and Modelling of Continuous-Discontinuous Sheet Moulding Compound Composites for Structural Applications

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Characterisation and Modelling of Continuous-Discontinuous Sheet Moulding Compound Composites for Structural Applications Anna Trauth omposites C C ico SM ico CHARACTERISATION AND MODELLING D o OF CONTINUOUS-DISCONTINUOUS SHEET C MOULDING COMPOUND COMPOSITES FOR STRUCTURAL APPLICATIONS SCHRIFTENREIHE DES INSTITUTS FÜR ANGEWANDTE MATERIALIEN BAND 83 haracterisation and Modelling of of and Modelling haracterisation C H T U A A. TR Anna Trauth Characterisation and Modelling of Continuous- Discontinuous Sheet Moulding Compound Composites for Structural Applications Schriftenreihe des Instituts für Angewandte Materialien Band 83 Karlsruher Institut für Technologie (KIT) Institut für Angewandte Materialien (IAM) Eine Übersicht aller bisher in dieser Schriftenreihe erschienenen Bände finden Sie am Ende des Buches. Characterisation and Modelling of Continuous-Discontinuous Sheet Moulding Compound Composites for Structural Applications by Anna Trauth Karlsruher Institut für Technologie Institut für Angewandte Materialien Characterisation and Modelling of Continuous-Discontinuous Sheet Moulding Compound Composites for Structural Applications Zur Erlangung des akademischen Grades eines Doktor s der Ingenieurwissenschaften von der KIT-Fakultät für Maschinenbau des Karlsruher Instituts für Technologie (KIT) genehmigte Dissertation von M.Sc. Anna Trauth Tag der mündlichen Prüfung: 1. Oktober 2018 Hauptreferent: Prof. (apl.) Dr.-Ing. Kay André Weidenmann Korreferenten: William Altenhof, Ph.D., P.Eng. Prof. Dr.-Ing. Peter Elsner Impressum Karlsruher Institut für Technologie (KIT) KIT Scientific Publishing Straße am Forum 2 D-76131 Karlsruhe KIT Scientific Publishing is a registered trademark of Karlsruhe Institute of Technology. Reprint using the book cover is not allowed. www.ksp.kit.edu This document – excluding the cover, pictures and graphs – is licensed under a Creative Commons Attribution-Share Alike 4.0 International License (CC BY-SA 4.0): https://creativecommons.org/licenses/by-sa/4.0/deed.en The cover page is licensed under a Creative Commons Attribution-No Derivatives 4.0 International License (CC BY-ND 4.0): https://creativecommons.org/licenses/by-nd/4.0/deed.en Print on Demand 2020 – Gedruckt auf FSC-zertifiziertem Papier ISSN 2192-9963 ISBN 978-3-7315-0950-9 DOI 10.5445/KSP/1000097160 Für meine Großeltern "Damit das Mögliche entsteht, muss immer wieder das Unmögliche versucht werden." Hermann Hesse Acknowledgements The research within this doctoral dissertation was performed at the Institute of Applied Materials at the Karlsruhe Institute of Technology, during the period of April 2015 through August 2018. It was part of the International Research Training Group (IRTG), which focusses on the integrated engineering of continuous-discontinuous long fibre reinforced polymer structures (GRK 2078). I would like to thank a number of people for their support and valuable help, throughout the last few years, in completing this doctoral dissertation. The supervisor of this work, Prof. Kay André Weidenmann, deserves my gratitude for his continuous and always encouraging support, helpful advice and hours of conversations and discussions. I would like to express my sincere appreciation to Prof. William Altenhof for his support during my time conducting research at the University of Windsor, for this doctoral dissertation. Thank you the opportunity to be part of your research group and to conduct experi- mental testing. This opportunity enriched my research significantly. I would also like to thank Prof. Peter Elsner for his valuable input in finalising this manuscript and for being a member of my committee. Much gratitude goes as well to Prof. Thomas Böhlke for chairing the committee. i Acknowledgements Many thanks to all my colleagues at the Institute of Applied Mate- rials, especially to the group of Hybrid and Lightweight Materials. Thank you for every discussion and critique of my work, but most importantly, thank you for making the work environment so enjoy- able. My grateful thanks go to Pascal Pinter for providing the m-CT scans and valuable input for data and image processing, as well as to Miriam Bartkowiak, who supported me particularly within the last few weeks of this dissertation. Further, thanks to the technicians at the Institute of Applied Materials. In particular, Ralf Rößler, Arndt Hermeneit and Marc Brecht, for their irreplaceable support in technical problems and questions. David Bücheler’s support and endless endurance while manufactur- ing the materials investigated within this dissertation was crucial in this research: thank you. To Loredana Kehrer of the Institute of Engineering Mechanics (ITM) at Karlsruhe Institute of Technology (KIT), my warm thanks for support in modelling and manufacturing the pure resin sheets required for this work. Valuable assistance was furthermore provided by all technicians at the University of Windsor, especially Matt St.Louis and Andrew Jenner during my time in Canada, which is greatly appreciated. In addition, I would like to thank Matthias Merzkirch and Tim Foecke of the National Institute of Standards and Technology in Washington, DC, for offering to me a research visit at their institute, which offered me valuable insights for my dissertation. Let me extend my thanks also to all students who contributed im- portantly to the success of this work, especially Kai Kirchenbauer, Patrick Blinzer, Sascha Zeizinger, Robin Kopp, Moritz Seidler, André Schubert and Leopold Giersch. ii Acknowledgements My gratitude is owed, too, to my friends, who succeeded in taking my mind off this work when necessary, and didn’t take it amiss when I was occupied working so often. I wish to express my sincere thanks to Stefan for being there as important support, when I began to doubt everything. Your words strongly encouraged me to keep believing in my ability to reach my goal. Lastly, I would like to thank my family. Words cannot express how grateful I am for your endless support and encouragement throughout my studies. Thank you Michael for always believing in me, more than I ever did. I am really fortunate that I had you on my side during the completion of this dissertation. Thank you especially for being worried about my eating habits when I forgot to worry about them myself. This dissertation would not have been possible without your endless support and words of encouragement. Karlsruhe, October 2018 Anna Trauth iii Abstract A novel approach in hybridisation of composites focusses on the combination of a discontinuous (Dico) glass fibre reinforced sheet moulding compound (SMC) with continuous (Co) carbon fibre SMC, manufactured in an adapted SMC process. The hybrid continuous- discontinuous (CoDico) SMC aims to enhance load-bearing capacities due to a possible local reinforcement of components. The main ob- jective of this work is to significantly deepen the understanding of the material and structural behaviour of CoDico SMC composites, follow- ing a holistic approach to investigate microscopic aspects and macro- scopic mechanical behaviour at the coupon, structure and component level. For this purpose, the mechanical properties of the hybrid SMC and modelling approaches are presented and discussed. Criteria to evaluate the effect of hybridisation are also introduced. In general, a hybrid CoDico SMC composite is an interesting hybrid material that allows tailorable material properties in structural components through local reinforcements; it thereby achieves a property profile superior to the sum of the properties of the individual materials. In comparison to a discontinuous glass fibre SMC, hybrid CoDico SMC composites stood out due to their superior mechanical perfor- mance at coupon, structure and component level. However, the effect of hybridisation strongly depended on loading case. The continuous component determined elastic material properties. At the coupon level, tensile and compressive moduli of elasticity were more than v Abstract doubled by a continuous reinforcement. A rule of hybrid mixtures based on the volume-averaged elastic material properties of the two individual materials was suitable to predict the tensile and compres- sive moduli of elasticity. The laminate layup, with two continuous carbon fibre SMC surface layers, most importantly increased the flexural modulus of elasticity, to more than four times higher than that of the discontinuous glass fibre SMC. An adaption of the classical laminate theory (CLT), which enabled consideration of the specific layup of the hybrid laminate as well as the tension-compression anisotropy of the continuous carbon fibre SMC, precisely predicted the flexural modulus of elasticity. Evolving damage, hence the strength of the hybrid CoDico SMC com- posite, was strongly linked to the continuous reinforcement. Inter- fibre failure and (inter- as well as intralaminar) delamination were the most important failure mechanisms. Tensile and flexural strength could be tripled and doubled, respectively, due to hybridisation. Hybridisation significantly enhanced performance at the structure level in terms of maximum force and puncture energy, if exposed to quasi-static puncture. In addition, an optimised local continuous reinforcement of a discontinuous glass fibre SMC component signi- ficantly increased stiffness and load at failure. vi Kurzfassung Ein innovativer Ansatz verfolgt das Konzept diskontinuierliche glasfaserbasierte Sheet Moulding Compound (SMC) Verbunde lokal mit kontinuierlichem kohlenstofffaserbasiertem SMC zu verstärken, um die mechanischen Eigenschaften von strukturellen Komponen- ten gezielt an ein Anforderungsprofil anpassen zu können. Die vorliegende Arbeit basiert auf einem
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