COMPOSITES 2025

Exploring Stacking Sequences for Enhanced Damage Tolerance in Thin-Ply CFRP Bouligand Laminates: A Numerical and Experimental Approach

  • Touni, Farida (TUHH)
  • Neubacher, Marcel (TUHH)
  • Fiedler, Bodo (TUHH)

In session: CT - Thin Ply

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CFRP laminates often suffer from interlaminar delamination under out-of-plane loading, leading to a reduction in residual strength. To address this issue, bio-inspired lamination sequences, such as Bouligand structures, have been explored. A notable example is the dactyl clubs of the mantis shrimp, which feature a helicoidal Bouligand arrangement with pitch angles ranging from 1.6° to 6.2°, providing enhanced resistance to high-energy impacts. Such bio-inspired CFRP designs have shown that lower pitch angles can improve residual strength, even with fewer 0° fibers. These structures offer significant improvements in damage tolerance and impact resistance for composite materials. In this work, the influence of different pitch angles (θ) in helical laminates on the performance of thin ply CFRP structures is investigated. Four Bouligand structures with varying pitch angles were fabricated with 40 gsm Thin-Ply material to explore the effect of angle variation on mechanical properties, including interlaminar shear strength and damage tolerance. ILSS tests were conducted to assess the interlaminar properties, while open-hole tension and compressive after-impact (CAI) tests were performed to evaluate the damage tolerance and residual strength under different loading conditions. The results indicate that the structural performance of helical laminates is significantly influenced by the pitch angle, with lower pitch angles contributing to a change in failure modes from interlaminar delamination to helical matrix cracking. Additionally, numerical simulations of these structures were performed using Abaqus with a user-defined material, designed to model the damage and failure behavior of composite materials. To improve computational efficiency, multiple plies were combined in the simulations while keeping key layers separate. This strategy maintains accuracy in critical regions, resulting in faster computations and enabling quicker design iterations for multi-layered structures.