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The effect of ply thickness on the onset of intralaminar and interlaminar damage is extremely important for the structural response of laminated composite structures. This subject has gained particular interest in recent years due to the introduction in the market of spread-tow, ultra-thin carbon-fibre reinforcements with different configurations. In the present paper, an experimental test campaign was carried out to study the structural response of aerospace-grade plain weave spread-tow fabrics (STFs) of different areal weights. The results showed that, in spite of an apparent superior longitudinal tensile strength of the thick STF, the multidirectional thin-STF laminate exhibited an improved tensile unnotched strength over the thick-STF laminate, attributed to its damage suppression capability. However, damage suppression was also responsible for similar tensile notched strengths. In compression, the thin-STF laminate performed substantially better than the thick-STF laminate in both unnotched and notched configurations. Finally, a similar bearing response was obtained in both STF laminates, in spite of a slightly higher resistance of the thin-STF laminate to the propagation of subcritical damage mechanisms. [ABSTRACT FROM AUTHOR]

The gap is one of the most common defects during the AFP process, which has a nonnegligible impact on the mechanical properties of laminates. This paper proposes a novel three-dimension reconstructive gap model based on the in-process serial layer scanned point clouds, which can characterizes the gap features inside the laminate and pre-determine the mechanical performance before the subsequent procedures. The measured point cloud will be transformed into eligible and processible formats and then be used to generate a finite element grid using the element-based material property assignment method. The local material properties and fiber orientation are defined by previously assigned classes and grid geometries respectively. The effect of gap size on the in-plane tensile strength and damage evolution of laminates is investigated and both the experimental and simulation results find that the ultimate strength and stiffness show a significant decrease with the increase of gap size. [ABSTRACT FROM AUTHOR]