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This study provides an analysis of patch repair for cracked aircraft structures. Delamination is a type of damage that affects the patch's behavior. The purpose of this study is to assess the influence of delamination on repair performance.

An analytical and numerical study using the finite element method was conducted for a cracked plate repaired with a patch containing a pre-existing delamination defect. The method for defining the contact pair surfaces and modeling the delamination interaction within the patch interface is specified using the virtual crack closure technique (VCCT) approach.

The efficiency of the repair is measured in terms of the J-integral. The effects of delamination initiation, mechanical loading, crack length and patch stacking sequences are presented. It is noted that in mode I, delamination propagation is only significant at node A. The numerical results are in good agreement with those of the analytical solution found in the literature. It is observed that the patch's behavior is strongly dependent on loading, crack size and stacking sequences in terms of reducing the structure's lifespan, especially in the presence of delamination.

The numerical modeling presented by the VCCT approach is highly valuable for studying delamination evolution. The influence of loading, crack size and stacking sequences on repair performance is discussed in this work.

This paper aims to study the interfacial delamination found in the boundary of the copper/copper-epoxy layers of a multi-layer ceramic capacitor.

The thermal reflow process of the capacitor assembly and the crack propagation from the initial micro voids presented in the boundary, and later manifested into delamination, were numerically simulated. Besides, the cross section of the capacitor assembly was inspected for delamination cracks and voids using a scanning electronic microscope.

Interfacial delamination in the boundary of copper/copper-epoxy layers was caused by the thermal mismatch and growth of micro voids during the thermal reflow process. The maximum deformation on the capacitor during reflow was 2.370 µm. It was found that a larger void would induce higher vicinity stress, mode I stress intensity factor, and crack elongation rate. Moreover, the crack extension increased with the exerted deformation until 0.3 µm, before saturating at the peak crack extension of around 0.078 µm.

The root cause of interfacial delamination issues in capacitors due to thermal reflow has been identified, and viable solutions proposed. These can eliminate the additional manufacturing cost and lead time incurred in identifying and tackling the issues; as well as benefit end-users, by promoting the electronic device reliability and performance.

To the best of the authors’ knowledge, the mechanism of delamination occurrence in a capacitor during has not been reported to date. The parametric variation analysis of the void size and deformation on the crack growth has never been conducted.

This study aims to investigate the possible defects and their root causes in a soft-termination multilayered ceramic capacitor (MLCC) when subjected to a thermal reflow process.

Specimens of the capacitor assembly were subjected to JEDEC level 1 preconditioning (85 °C/85%RH/168 h) with 5× reflow at 270°C peak temperature. Then, they were inspected using a 2 µm scanning electron microscope to investigate the evidence of defects. The reliability test was also numerically simulated and analyzed using the extended finite element method implemented in ABAQUS.

Excellent agreements were observed between the SEM inspections and the simulation results. The findings showed evidence of discontinuities along the Cu and the Cu-epoxy layers and interfacial delamination crack at the Cu/Cu-epoxy interface. The possible root causes are thermal mismatch between the Cu and Cu-epoxy layers, moisture contamination and weak Cu/Cu-epoxy interface. The maximum crack length observed in the experimentally reflowed capacitor was measured as 75 µm, a 2.59% difference compared to the numerical prediction of 77.2 µm.

This work's contribution is expected to reduce the additional manufacturing cost and lead time in investigating reliability issues in MLCCs.

Despite the significant number of works on the reliability assessment of surface mount capacitors, work on crack growth in soft-termination MLCC is limited. Also, the combined experimental and numerical investigation of reflow-induced reliability issues in soft-termination MLCC is limited. These cited gaps are the novelties of this study.

Engineering composite laminates/structures are usually subjected to complex and variable loads, which result in interlayer delamination damage. However, damaged laminate may cause the whole structure to fail before reaching the design level. Therefore, the purpose of this paper is to develop an equivalent model to effectively evaluate compressive residual strength.

In this paper, taking carbon fiber reinforced composite T300/69 specimens as the study object, first, the compressive residual strength under different impact energy is obtained. Then, zero-thickness cohesive elements, Hashin failure criteria and Camanho nonlinear degradation scheme are used to simulate the full-process simulation for compression after edge impact (CAEI). Lastly, based on an improved Whitney–Nuismer criterion, the equation of edge hole stress distribution, characteristic length and compressive residual strength is used to verify the correctness of the equivalent model.

An equivalent relationship between the compressive residual strength of damaged laminates and laminates with edge hole is established. For T300/69 laminates with a thickness of 2.4 mm, the compressive residual strength after damage under an impact energy of 3 J is equivalent to that when the hole aperture R = 2.25 mm and the hole aperture R = 9.18 mm when impact energy is 6 J. Besides, the relationship under the same size and different thickness is obtained.

The value of this study is to provide a reference for the equivalent behavior of damaged laminates. An equivalent model proposed in this paper will contribute to the research of compressive residual strength and provide a theoretical basis for practical engineering application.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

This study aims to apply for the first time in literature a new multi-objective sensor selection and placement optimization methodology based on the multi-objective Lichtenberg algorithm and test the sensors' configuration found in a delamination identification case study.

This work aims to study the damage identification in an aircraft wing using the Lichtenberg and multi-objective Lichtenberg algorithms. The former is used to identify damages, while the last is associated with feature selection techniques to perform the first sensor placement optimization (SPO) methodology with variable sensor number. It is applied aiming for the largest amount of information about using the most used modal metrics in the literature and the smallest sensor number at the same time.

The proposed method was not only able to find a sensor configuration for each sensor number and modal metric but also found one that had full accuracy in identifying delamination location and severity considering triaxial modal displacements and minimal sensor number for all wing sections.

This study demonstrates for the first time in the literature how the most used modal metrics vary with the sensor number for an aircraft wing using a new multi-objective sensor selection and placement optimization methodology based on the multi-objective Lichtenberg algorithm.

The industrial application of continuous glass fabric-reinforced polymer composites (GFRPCs) is growing; however, the manufacturing boundedness of complex structures and the high cost of molds restrict their use. This research proposes a three-dimensional (3 D) printing process for GFRPCs that allows low-cost and rapid fabrication of complex composite parts.

The composite is manufactured using a digital light processing (DLP) based Vat-photopolymerization (VPP) process. For the composites, suitable resin material and glass fabrics are chosen based on their strength, stiffness, and printability. Jacob's working curve characterizes the curing parameters for adequate adhesion between the matrix and fabrics. The tensile and flexural properties were examined using UTM. The fabric distribution and compactness of the cured resin were analyzed in scanning electron microscopy.

The result showed that the object could print at a glass fabric content of 40 volume%. In DLP-based VPP printing technology, the adequate exposure time was found to be 30 seconds for making a GFRPC. The tensile strength and Young's modulus values were increased by 5.54 and 8.81 times, respectively than non-reinforced cured specimens. The flexural strength and modulus were also effectively increased to 2.8 and 3 times more than the neat specimens. In addition, the process is found to help fabricate the functional component.

The experimental procedure to fabricate GFRPC specimens through DLP-based AM is a spectacular experimental approach.

The tensile behavior of additively manufactured nylon-based carbon fiber-reinforced composites (CFRP) is an important criterion in aerospace and automobile structural design. So, this study aims to evaluate and validate the tensile stiffness of printed CFRP composites (low- and high-volume fraction fiber) using the volume average stiffness (VAS) model in consonance with experimental results. In specific, the tensile characterization of printed laminate composites is studied under the influence of raster orientations and process-induced defects.

CFRP composite laminates of low- and high-volume fraction carbon fiber of different raster orientations (0°, ± 45° and 0/90°) were fabricated using the continuous fiber 3D printing technique, and tensile characteristics of laminates were done on a universal testing machine with the crosshead speed of 2 mm/min. The induced fracture surface of laminates due to tensile load was examined using the scanning electron microscopy technique.

The VAS model can predict the tensile stiffness of printed CFRP composites with different raster orientations at an average prediction error of 5.94% and 10.58% for low- and high-volume fiber fractions, respectively. The unidirectional CFRP laminate composite with a high-volume fraction (50%) of carbon fiber showed 50.79% more tensile stiffness and 63.12% more tensile strength than the low-volume fraction (26%) unidirectional composite. Fiber pullout, fiber fracture and ply delamination are the major failure appearances observed in fracture surfaces of laminates under tensile load using scanning electron microscopy.

This investigation demonstrates the novel methodology to study specific tensile characteristics of low- and high-volume fraction 3D printed CFRP composite.

The effect of different service parameters on the current-carrying tribological properties of CF-Al₂O₃/Cu composites was investigated, and the damage behavior of the composites under different service parameters was probed. The purpose of this study is to provide a theoretical basis for the application of CF-Al₂O₃/Cu composites.

The composites were fabricated by internal oxidation combined with powder metallurgy. The current-carrying tribological properties of CF-Al₂O₃/Cu composites were investigated on an electrical damage test system at different loads and currents.

As the load increases, the wear mechanism of the composite changes from abrasive wear to delamination wear. As the current increases, the oxidation wear and arc erosion of the composites gradually intensified. Under the service parameters of 0–25 A and 30–40 N, the composite has relatively stable current-carrying tribological properties.

This paper could provide a theoretical basis for the practical application of CF-Al₂O₃/Cu composites.

The purpose of this paper is to examine the mechanical characteristics and optimization of wear parameters of hybrid (TiO₂ + Y₂O₃) nanoparticles with Al matrix using squeeze casting technique.

The hybrid aluminium matrix nanocomposites (HAMNCs) were fabricated with varying concentrations of titanium oxide (TiO₂) and yttrium oxide (Y₂O₃), from 2.5 to 10 Wt.% in 2.5 Wt.% increments. Dry sliding wear test variables were optimized using the Taguchi method.

The introduction of hybrid nanoparticles in the aluminium (Al) matrix was evenly distributed in contrast to the base matrix. HAMNC6 (5 Wt.% TiO₂ + 5 Wt.% Y₂O₃) reported the maximum enhancement in mechanical properties (tensile strength, flexural strength, impact strength and density) and decrease in porosity% and elongation% among other HAMNCs. The results showed that the optimal combination of parameters to achieve the lowest wear rate was A3B3C1, or 15 N load, 1.5 m/s sliding velocity and 200 m sliding distance. The sliding distance showed the greatest effect on the dry sliding wear rate of HAMNC6 followed by applied load and sliding velocity. The fractured surfaces of the tensile sample showed traces of cracking as well as substantial craters with fine dimples and the wear worn surfaces were caused by abrasion, cracks and delamination of HAMNC6.

Squeeze-cast Al-reinforced hybrid (TiO₂+Y₂O₃) nanoparticles have been investigated for their impact on mechanical properties and optimization of wear parameters.