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During production or service life, lightweight components made of fibre-reinforced polymers (FRP) may suffer from different types of defects such as cracks or delamination, which may be detected, amongst others, with the help of ultrasonic lamb waves (LW). The study intends to illustrate the potentials of numerical models to assist the design of LW-based non-destructive testing (NDT) processes. For that, the complete NDT chain of an LW driven inspection system was supported by a Finite Element Analysis (FEA) using stringer-stiffened C FRP panels as an exemplary component. The study was divided in two publications: The first part focused on the description of the numerical model, illustration of its functionalities and – most importantly – the determination of LW related effects that were needed to design the inspection system (dispersion characteristics, excitation frequency, propagating modes etc.). In this part, the FEA driven design approach was first validated with self measured experimental data as well as experiments provided in literature. In the second step, the numerical model was applied for the performance of parameter studies in order to identify component specific aspects that proved important for the NDT process. Finally, general advices and FEA related working steps were derived from all findings to assist practitioners in the implementation of the technique. [ABSTRACT FROM AUTHOR]

Components made of fibre-reinforced polymers (FRP) may suffer from various types of damages, such as cracks or delamination. In order to monitor the structures' material condition, non destructive testing (NDT) methods have emerged – among them, the use of ultrasonic waves. Inter alia, research focused on Lamb waves (LW), which offer promising conditions for NDT processes. However, prior implementation in a specific production environment, practitioners are faced with many open questions such as excitation frequencies to be used or which mode to select for defect identification. Therefore, the study aimed at demonstrating how a finite element analysis (FEA) can assist the experimental design of an LW driven NDT process. For that, a numerical model was developed, capable of computing LW propagations in an exemplary component: Stringer-stiffened C-FRP panels. The study was divided into two parts: In this part, all information regarding the model building is presented and principal functionality demonstrated. In the second part, the FEA is validated and then used to perform parameter studies, highlighting important conditions for practical application. The results of the present paper showed that stiffeners provoke varying interactions with LW modes – effects that increase wave field complexity but do not limit defect identification within or behind the stringer. [ABSTRACT FROM AUTHOR]

The constantly growing demand for cost-intensive lightweight structures is accompanied by an increased demand for reliable non-destructive testing (NDT) methods. Previous investigations have shown that Lamb Waves (LW) are very well suited for the use in Structural Health Monitoring (SHM) due to their relatively undamped propagation over long distances. Therefore the numerical modelling of a non-contact and automated system for non-destructive testing of C-FRP laminates was investigated in the present study. The method is based on the propagation of LW, which are excited by an actuator-driven piezo transducer and interact with defects in the structure. In contrast to classical Structural Health Monitoring, a scanning inspection system is used instead of a sensor permanently integrated into the structure to detect the measurement signals. For the representation of the wave propagation a three-dimensional simulation model with the commercial FEM software PZFlex was modelled. The wave interactions in defective C-FRP coupons are investigated and visualized through different output formats like A-, B- and C-Scans. Additionally the model allows the determination of the dispersion characteristics of the LW in the examined laminate. The validation of the numerical results was successfully carried out at different levels with the help of experimental investigations. [ABSTRACT FROM AUTHOR]

The use of natural fibres for components subjected to higher mechanical requirements tends to be limited by the high price of high-quality semi-finished products. Therefore, the present study deals with the development of more cost-effective staple fibre yarns made from flax tow. In the subsequent processing stage, the yarns were processed into quasi-unidirectional (UD) fabrics. The results of the fibre characterisation along the process chain have shown that no significant mechanical fibre damage occurs after slivers' production. Fibres prepared from yarns and fabrics show comparable characteristics. The yarns were processed to composites by pultrusion to verify the reinforcement effect. The mechanical properties were comparable to those of composites made from a high-quality UD flax roving. The fabrics were industrially processed into composite laminates using a vacuum infusion and an autoclave injection process (vacuum injection method in an autoclave). While impact strength compared to a reference laminate based on the UD flax roving was achieved, tensile and flexural properties were not reached. An analysis showed that the staple fibre yarns in the fabric show an undulation, leading to a reorientation of the fibres and lower characteristic values, which show 86–92% of the laminate made from the flax roving. Hybrid laminates with outer glass and inner flax layers were manufactured for the intended development of a leaf spring for the bogie of a narrow-gauge railroad as a demonstrator. The hybrid composites display excellent mechanical properties and showed clear advantages over a pure glass fibre-reinforced composite in lightweight construction potential, particularly flexural stiffness. [ABSTRACT FROM AUTHOR]