In the relentless pursuit of stronger, lighter materials, researchers at Imperial College London have unveiled a groundbreaking method to bolster composite structures, with significant implications for the energy sector. Led by Adam D. Whitehouse from the Department of Aeronautics, the team has developed a novel approach to mitigate delamination, a persistent challenge in composite materials.
Composite structures, widely used in wind turbines and other energy infrastructure, are prone to delamination, a process where layers separate, compromising the material’s integrity. With the increasing adoption of Automated Fibre Placement (AFP) in manufacturing, finding compatible delamination mitigation strategies has become crucial. Whitehouse and his team have risen to the challenge, introducing a strategy that segments plies and stacks them segment-by-segment via AFP, rather than the conventional ply-by-ply method. This innovative technique, dubbed ‘Repeated Segment Stacking (RSS)’, creates tailorable through-thickness fibre reinforcements, significantly enhancing the material’s resistance to delamination.
The RSS method allows for precise control over the fibre undulation geometry, enabling the creation of designs that mimic nature’s ingenious engineering. “Low amplitude designs provide reinforcement across all horizontal planes,” Whitehouse explains, “while increased amplitude designs can mimic the impact-resistant Herringbone structure of the Mantis shrimp’s dactyl club.” This bio-inspired approach not only enhances the material’s strength but also its ability to absorb and dissipate energy, a critical factor in high-impact scenarios.
The team’s experimental testing, including High-Velocity Impact (HVI), Low-Velocity Impact (LVI), and Compression After Impact (CAI), revealed promising results. The RSS designs showed reduced delamination footprint and containment at undulation boundaries, indicating a significant improvement in delamination resistance.
So, how might this research shape future developments in the field? The implications are vast. For the energy sector, this could mean more durable wind turbine blades, reducing maintenance costs and downtime. In the broader construction industry, it could lead to stronger, lighter structures, pushing the boundaries of what’s possible in architecture and infrastructure. Moreover, the RSS method’s compatibility with AFP opens up new avenues for automated, efficient manufacturing of high-performance composite structures.
The research, published in Composites Part C: Open Access (which translates to ‘Composites Part C: Open Access’ in English), marks a significant step forward in the quest for stronger, more resilient composite materials. As the energy sector continues to push the limits of composite technology, innovations like RSS will be instrumental in driving progress and shaping the future of construction and engineering.
