Laminate composites are commonly used for the production of critical mechanical structures and components such as wind turbine blades, helicopter rotors, unmanned aerial vehicle wings and honeycomb structures for aircraft wings. During the manufacturing process of these composite structures, zones or areas with weak bond strength are always issues, which may affect the strength and performance of components. The identification and quantification of these zones are always challenging and necessary for the mass production. Non-destructive testing methods available, including ultrasonic A, B, and C-Scan, laser shearography, X-ray tomography, and thermography can be useful for the mentioned purposes. A comparison of these techniques concerning their capacity of identification and quantification of bond defects; however, still needs a comprehensive review. In this paper, a detailed comparison of several non-destructive testing techniques is provided. Emphasis is placed to institute a guideline to select the most suitable technique for the identification of zones with bond defects in laminated composites. Experimental tests on different composite based machined components are also discussed in detail. The discussion provides practical evidence about the effectiveness of different non-destructive testing techniques.

This study introduces a unit cell-based finite element micromechanical model that accounts for correct post cure fabric geometry, in situ material properties and void content within the composite to accurately predict the effective elastic orthotropic properties of 8-harness satin weave glass fiber-reinforced phenolic composites. The micromechanical model utilizes a correct post cure internal architecture of weave, which was obtained through X-ray microtomography tests. Moreover, it utilizes an analytical expression to update the input material properties to account for in situ effects of resin distribution within yarn (the yarn volume fraction) and void content on yarn and matrix properties. This is generally not considered in modeling approaches available in literature and in particular, it has not been demonstrated before for finite element micromechanics models of 8-harness satin weave composites. The unit cell method is used to obtain the effective responses by applying periodic boundary conditions. The outcome of the analysis based on the proposed model is validated through experiments. After validation, the micromechanical model was further utilized to predict the unknown effective properties of the same composite.

Hybrid glass–carbon 2D braided composites with varying carbon contents are impacted using a gas gun by impactors of masses 12.5 and 44.5g, at impact energies up to 50J. The damage area detected by ultrasound C-scan is found to increase roughly linearly with impact energy, and is larger for the lighter impactor at the same impact energy. The area of whitening of the glass tows on the distal side corresponds with the measured C-scan damage area. X-ray imaging shows more intense damage, at the same impact energy, for a higher-mass impactor. Braids with more glass content have a modest increase in density, decrease in modulus, and reduction in the C-scan area and dent depth at the impact site, particularly at the higher impact energies. Impact damage is found to reduce significantly the compressive strength, giving up to a 26% reduction at the maximum impact energy