This paper presents a finite element (FE) analysis of an anchor for prestressing of sand-coated carbon-fiber-reinforced polymer (CFRP) tendons during the manufacturing of precast elements. This anchorage is temporary and removed after 2 to 7 days, when the pretensioning is released and the concrete is finally compressed. The investigated anchor consists of a conical metal barrel and three polymer wedges. The main tendon material properties are measured, compared with theoretical values and define the basis for the FE model. The latter considers both steps, pressing-in of the wedges and the subsequent loading of the tendon (diameter 7.5 mm). The relatively soft contact between polymer wedge and sand-coating is characterized experimentally and implemented with a pressure-overclosure condition. For the validation of the FE model, the strain distribution in the tendon is measured using fiber optical sensing. The therefore crucial process of fiber integration is described, and a novel approach is presented to uncover the optical fiber. The strain distribution of a sample with two anchors loaded in tension up to 80 kN is presented. The stress concentration at the front of the anchorage is highlighted. In addition, the finite element model is compared with the experiment, showing a good agreement of the strain distribution. A failure criterion according to Puck is finally implemented, which allows to assess potential fiber or interfiber failure.

The focus of this research is an investigation on the fatigue behaviour of unidirectional 3D-printed continuous carbon fibre-reinforced polymer (CFRP) tension straps with a polyamide matrix (PA12). Conventionally produced tension straps are becoming established components in the mechanical as well as the civil engineering sector, e.g., as rigging systems for sailing boats and cranes and—recently introduced—as network arch bridge hangers. All these structures are subjected to high fatigue loads, and although it is commonly reported that carbon fibre-reinforced polymers show excellent fatigue resistance, there is limited understanding of the behaviour of CFRP loop elements under such loads, especially in combination with fretting at the attachment points. Research on this topic was performed at Empa in the past decade on thermoset CFRP straps, but never before with 3D-printed continuous CFRP straps with a thermoplastic matrix. This paper examines an additive manufacturing and post-consolidation method for producing the straps and presents initial results on their fatigue performance, which show that the fatigue endurance limit of the investigated 3D-printed and post-consolidated CFRP strap design is acceptable, when compared to steel tendons. However, it is still 20% lower than conventionally produced CFRP straps using out-of-autoclave unidirectional carbon fibre prepregs. The reasons for these findings and potential future improvements are discussed.

In this article, a novel shear stiff, hinge-less, and truss-like structure for morphing skins is presented and investigated. Adaptive skins are an essential component of morphing wings, which enable perimeter length changes with low deformation energy requirements and increase the efficiency of the morphing system. Based on fundamental considerations for morphing skins, a high shear to morphing stiffness ratio is targeted. The underlying deformation energies for compliant structures are evaluated and provide the basis for the developed geometry of the novel structure. The sizing parameters of the structure are optimized for shear stiffness and morphing stiffness by an evolutionary multi-objective optimization algorithm. A representative geometry is manufactured and tested to verify the nonlinear simulations for shear and morphing stiffness. Furthermore, various cover options forming the aerodynamic surface were investigated and compared in terms of out-of-plane deformations and for their interaction with the underlying structure. The chosen concept, comprising of the novel substructure and sliding covers, exhibits superior performance, reaching a shear to morphing stiffness ratio up to 300, while forming a closed aerodynamic surface.

Unidirectional long fiber reinforced polymers generally exhibit unfavorable abrupt and brittle failure under mechanical stresses without pre-warning which currently limits their use in safety critical applications. The lack of ductility of such composites can be overcome by interlayer hybridization where Low Strain (LS) material is sandwiched between High Strain (HS) material. This results in complex failure mechanisms, including multiple interacting damage modes, such as ply fragmentation and delamination. All-carbon unidirectional hybrid laminates with different layup sequences were designed and manufactured to study the pseudo-ductile behavior. An available analytical model was exploited to predict the damage scenarios of the laminates, both with stress-strain diagrams and damage mode maps. Tensile tests were carried out using different measurement and observation techniques including digital image correlation (DIC), embedded distributed fiber optic sensors (dFOS) and helicoidal X-ray computed tomography (CT). A finite element model was also developed to predict the damage mechanisms. Validated by experimental results, the numerical model was found to accurately predict the tensile damage modes and their evolution in the considered unidirectional thick ply all-carbon hybrid laminates.