Search Results (171)

Unreinforced masonry walls exhibit limited resistance to lateral loads and, therefore, frequently require strengthening interventions. Carbon fiber reinforced polymer (CFRP) systems provide an efficient retrofit solution; however, current design procedures defined in structural guidelines require repetitive trial calculations to determine the necessary reinforcement amount. This study introduces a hybrid computational process that integrates metaheuristic optimization with symbolic regression to generate direct analytical equations for the estimation of the required CFRP area. First, a comprehensive database containing 1300 optimal strengthening scenarios was generated using the Jaya optimization algorithm under the constraints specified in ACI 440.7R and ACI 530. The resulting dataset was subsequently processed through symbolic regression using the PySR platform to identify explicit mathematical relationships between structural parameters and the optimum CFRP area. Most traditional machine learning approaches operate as black-box predictors. In contrast, the proposed approach generates interpretable closed-form expressions that can be used directly in engineering calculations. Two models were derived from the Pareto-optimal solution set. The first model is a simplified equation emphasizing algebraic simplicity. The second model prioritizes prediction accuracy. The simplified formulation achieved a coefficient of determination of approximately 0.992. The accuracy-focused model achieved a value above 0.997 with very low prediction errors. Validation studies with independent test samples showed that the obtained equations are reliable. The average error for the simplified model is below 4%, and for the high-accuracy model, it is approximately 2%. The results demonstrate that combining the optimization-generated datasets with symbolic regression makes it possible to obtain transparent design equations. These equations eliminate iterative design processes and provide a fast and reliable estimation tool for CFRP strengthening of masonry walls. Full article

This study presents an experimental investigation into a novel hybrid strengthening system for reinforced concrete (RC) beams that combines externally bonded carbon-fiber-reinforced polymer (CFRP) sheets with a spray-applied polyurea coating (Linex XS-350). Seven beams were tested under four-point bending to evaluate the effects of two main parameters, CFRP thickness and single vs. double layers, and polymer coating configurations, i.e., none, thin with 2 mm, thick with 4 mm, and embedded. The coating was intended to act as an elastic confinement layer that mitigates peeling stresses and enhances CFRP concrete bond performance. The results demonstrated significant improvements in strength, ductility, and strain capacity for coated specimens compared with CFRP-only beams. The inclusion of Linex increased the ultimate load by up to 24% in single-layer beams and 20% in double-layer beams, while bottom-fiber strain at failure increased by more than fivefold, indicating enhanced CFRP utilization. The uncoated beams failed prematurely by CFRP peeling, whereas the coated and embedded specimens transitioned to CFRP rupture with more gradual and ductile behavior. The combined use of multiple CFRP layers and polymer coating produced the most effective performance, with the double-layer embedded configuration (B7) achieving the highest load, strain, and energy absorption. The findings confirm that integrating polyurea coatings with CFRP can effectively delay debonding and significantly improve the reliability and toughness of strengthened RC members, offering a practical solution for more resilient structural retrofitting. Full article

The development of lightweight, high-strength structural systems is a persistent pursuit in modern civil engineering. This paper presents an experimental study on a novel hybrid beam concept in which a sawn timber core is fully bonded with an externally applied Carbon Fiber-Reinforced Polymer (CFRP) laminate, fabricated through a controlled hand lay-up process. The design seeks to exploit the complementary characteristics of the two materials: timber provides compressive resistance and serves as a permanent formwork, while the CFRP carries tensile stresses with high efficiency. Fourteen hybrid beams, with variations in the number of longitudinal CFRP layers (one, two or, three), the presence or absence of longitudinal CFRP layers bonded along the top and bottom surfaces, and the presence or absence of circumferential wrapping in the pure bending region, were tested under four-point bending alongside two solid timber control beams. The results demonstrate that circumferential wrapping is a critical design detail. Wrapped beams consistently failed by tensile rupture of the CFRP—the intended failure mode—and exhibited ultimate moments 15–20% higher than their unwrapped counterparts. Beams with two longitudinal CFRP layers offered the most favorable balance between strength enhancement and material efficiency; adding a third layer shifted the failure mode to crushing of the timber core, indicating a core-limited condition. All hybrid beams showed pronounced linear-elastic behavior up to sudden brittle failure, with performance variability attributable to the inherent inhomogeneity of wood and the sensitivity of the hand lay-up process. The study provides quantitative data and mechanistic insights that support the design and application of bonded CFRP–timber hybrid beams as efficient structural members. Full article

Carbon-fiber-reinforced polymer (CFRP) composites possess outstanding specific stiffness and strength but typically exhibit low intrinsic damping, which limits vibration attenuation in lightweight dynamic structures. Herein, a hybrid toughening strategy combining carboxyl-terminated butadiene nitrile rubber (CTBN) and hexagonal boron nitride (h-BN) is developed to enhance the damping of CFRP laminates while preserving cure feasibility and thermomechanical stability. An E51/DICY/accelerator epoxy system (100:6.5:1.2, mass ratio) is used as the baseline matrix. Differential scanning calorimetry shows that both CTBN and h-BN shift the cure peak temperature upward (Tp: 160.6 → 170.3 °C) and reduce the reaction enthalpy (ΔH: 386.5 → 255.1 J/g), indicating dilution/transport effects and altered cure kinetics. Dynamic mechanical analysis (DMA) reveals that CTBN exhibits an optimum damping enhancement at 25 phr (tan δ_max = 0.300), whereas h-BN provides a stronger monotonic increase up to 25 phr (tan δ_max = 0.437). Notably, the CTBN/h-BN hybrid (25/25 phr) delivers a high tan δ_max of 0.468 together with the broadest effective damping window (ΔT_half = 28.6 °C), exceeding 85% of the linear additivity criterion proposed herein. When the materials are transferred into CFRP laminates, free-vibration tests (using the logarithmic decrement method) demonstrate a clear structural damping improvement (ζ: 0.021 → 0.035; δ: 0.132 → 0.221; t₁/₂: 0.48 → 0.27 s). Overall, the results suggest that the damping enhancement arises from a combination of EPBN-mediated ductile energy dissipation and h-BN-related interfacial/interlayer frictional losses, which can be jointly tuned to balance processability, thermal response, and damping performance in CFRPs. Full article

This study presents a hybrid experimental–numerical methodology for the preliminary design and optimization of a CFRP crash box intended for high-performance automotive applications. An initial experimental campaign was conducted on frustum-shaped crash boxes manufactured by Pagani Automobili S.p.A., comparing constant and variable thickness configurations through drop tower impact tests to evaluate energy absorption, crushing stability, and failure mechanisms. A lightweight finite element model was developed in Abaqus/Explicit using shell elements and Hashin-based damage criteria, achieving calibration errors below 10% for most parameters and under 15% for peak forces. Geometric enhancements, including continuous flanges, removal of the top surface, and an internal cruciform reinforcement, significantly improved energy absorption (up to 110%) but introduced trade-offs in stroke efficiency and mean force levels. To mitigate these effects, a genetic algorithm was employed to optimize laminate layup by varying ply orientations, resulting in improved stroke efficiency and reduced peak and average forces while maintaining crushing stability. The proposed approach demonstrates that integrating experimental validation with efficient numerical modeling and optimization accelerates the development of lightweight, high-performance crash absorbers, offering a robust framework for motorsport and automotive applications that balances safety, efficiency, and manufacturability. Full article

Carbon fiber-reinforced polymer (CFRP) composites modified with alumina (Al₂O₃) and silicon carbide (SiC) nanoparticles were developed to produce hybrid nanocomposites with improved mechanical and thermal characteristics. This study investigates the hot drilling behavior of unidirectional CFRP and hybrid nanocomposites by examining the effects of spindle speed, feed rate, drill diameter, and drill geometry (step, core, and twist). Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) were used to identify the most influential parameters governing drilling-induced damage. ANOVA results revealed that drill geometry was the most dominant factor, contributing more than 89% to delamination, burr formation, and surface roughness, followed by drill diameter with over 7% contribution. For temperature rise, drill geometry accounted for more than 50% of the total variation, while drill diameter contributed over 17%. Among the tools evaluated, the step drill produced the minimum drilling-induced damage, followed by the twist drill. In terms of material performance, the Al₂O₃-reinforced hybrid nanocomposite exhibited superior drilling behavior compared to the SiC-reinforced and neat CFRP laminates. Overall, the results demonstrate that drilling-induced damage under hot drilling conditions can be effectively minimized through appropriate selection of tool geometry and process parameters, confirming the suitability of hot drilling for machining aerospace-grade CFRP hybrid nanocomposites. Full article

This study investigates the shear performance of high-strength concrete (HSC) beams reinforced with steel, fiber composite grids (CFRP and GFRP), and their hybrid configurations in the absence of transverse reinforcement. A total of six full-scale beams with varying reinforcement configuration and shear span-to-depth (a/d) ratios were experimentally tested under monotonic loading to evaluate their load capacity, cracking characteristics, failure modes, and serviceability behavior. The results revealed that beams reinforced solely with fiber grids exhibited significantly reduced strength and brittle shear failure. Hybrid systems incorporating both steel and fiber grids demonstrated improved strength and ductility, closely matching or surpassing control specimens with conventional steel reinforcement. Key structural parameters such as effective moment of inertia, cracking moment, shear strength, and midspan deflection were compared against analytical predictions based on ACI 318-16 and the Canadian Education Module code. While predictions generally aligned for hybrid beams, notable discrepancies were found for FRP-only systems, particularly in serviceability performance. The findings highlight the potential of hybrid reinforcement as a viable design strategy for HSC beams, offering a balance between strength, ductility, and service performance. Full article

The M21 epoxy matrix is a toughened material designed to enhance the fracture resistance of carbon fiber-reinforced polymers (CFRPs). This study presents an experimental characterization of the shear and interlaminar properties required for validating computational damage models of hybrid laminated composite panels manufactured with the M21 material system. In-plane shear behavior was evaluated using ±45 (PM45) tests, while interlaminar fracture properties were characterized through double cantilever beam (DCB) and end-notched flexure (ENF) tests. The results demonstrate that hybrid laminates exhibit high interfacial fracture toughness, with notably increased resistance observed in woven–woven and unidirectional–woven interface pairs. Parametric studies identified cohesive strength and fracture energy as the dominant parameters governing delamination behavior in numerical simulations. Corresponding values were extracted for each interface type, enabling accurate representation of damage initiation and propagation in finite element models. To the authors’ knowledge, this work provides the first experimental dataset for the listed M21-based hybrid unidirectional–woven and woven–woven interfaces, establishing a benchmark for future modeling and simulation of toughened composite structures. Full article

This paper presents the design, manufacturing, instrumentation and validation by tests (ground and icing wind tunnel) of a full-scale Hybrid Laminar Flow Control (HLFC) leading-edge demonstrator based on Airbus A330 outer wing plan-form. The Ground-Based Demonstrator (GBD) was developed to reproduce a full-scale, realistic wing section integrating into the leading-edge three key systems: micro-perforated skin for the hybrid laminar flow control suction system (HLFC), the hot-air Wing Ice Protection System (WIPS) and a folding “bull nose” Krueger high-lift device. The demonstrator combines a superplastic-formed and diffusion-bonded (SPF/DB) perforated titanium skin mounted on aluminum ribs jointed with a carbon-fiber-reinforced polymer (CFRP) wing box. Titanium internal ducts were designed to ensure uniform hot-air distribution and structural compatibility with composite components. Manufacturing employed advanced aeronautical processes and precision assembly under INCAS coordination. Ground tests were performed using a dedicated hot-air and vacuum rig delivering up to 200 °C and 1.6 bar, thermocouples and pressure sensors. The results confirmed uniform heating (±2 °C deviation) and stable operation of the WIPS without structural distortion. Relevant tests were performed in the CIRA Icing Wind Tunnel facility, verifying the anti-ice protection system and Krueger device. The successful design, fabrication, testing and validation of this multifunctional leading edge—featuring integrated HLFC, WIPS and Krueger systems—demonstrates the readiness of the concept for subsequent aerodynamic testing. Full article

Carbon fiber reinforced polymers (CFRPs) are widely used in aerospace and wind power applications, but the complex failure mechanisms of their connection structures pose challenges for connection design. This study aims to investigate the influence of bonding interface inclination angle and connection method on the failure mechanisms of CFRP joints under bending loads. The study investigated two design parameters: the joint geometry of the bonding interface (single-slope, transition-slope, and single-step) and the connection methods (bonding, bolting, and hybrid bonding–bolting). Finite element simulations analyzed the mechanical performance and failure modes under different design parameters. Bending tests validated the mechanical properties of the joint interface, validating the effectiveness of the numerical simulation. The study found that under bonded connections, the bending load increased with the slope of the connection interface, with improvements of 21.87% and 39.75%, respectively. The main reason is stress concentration caused by sharp geometric discontinuities. The hybrid connection had the highest peak load, with improvements of 38.38% and 43.91% compared to the other connection methods. Hybrid bonding–bolting connections further optimized structural performance and damage tolerance. This study reveals the damage mechanisms of the bonding interface and provides a reliable prediction method for aerospace and wind turbine blade applications. Full article

This study presents the development, calibration, and validation of cohesive zone models (CZMs) for epoxy-based adhesive joints connecting stainless steel and CFRP composites. The objective of this study is to develop and rigorously validate cohesive zone models for epoxy-based adhesive joints between stainless steel and CFRP composites, ensuring their reliability for numerical simulations of structural failure under quasi-static and large-deformation conditions. The work focuses on accurately describing the quasi-static behaviour and failure mechanisms of hybrid adhesive interfaces, which are crucial for multimaterial structures in modern transportation systems. Experimental tests in Mode I (DCB) and Mode II (ENF) configurations were performed to determine the cohesive parameters of the structural adhesive SikaPower 1277. The obtained data were further analysed through analytical formulations and validated numerically using PAM-CRASH. Excellent agreement was achieved between experiments, analytical predictions, and simulations, confirming the reliability of the proposed material definitions under large deformations. The validated models were subsequently implemented in a large-scale numerical simulation of a bus rollover according to UN/ECE Regulation No. 66, demonstrating their applicability to real structural components. The results show that the developed cohesive zone models enable accurate prediction of failure initiation and propagation in adhesive joints between dissimilar materials. These findings provide a robust foundation for the design of lightweight, crashworthy structures in transportation and open new perspectives for integrating epoxy-based adhesives into additively manufactured hybrid metal–composite systems. Full article

This study introduces a hybrid framework combining an Artificial Neural Network (ANN) with the Jaya optimization algorithm to predict the minimum Carbon Fiber Reinforced Polymer (CFRP) area required for flexural strengthening of reinforced concrete (RC) cantilever walls. A multilayer perceptron (MLP) network was trained on 500 Jaya-optimized design scenarios incorporating twelve design variables, including geometry, loads, and material properties. The ANN achieved high predictive accuracy, with R-values near 1.0 across training, validation, and testing phases. Five independent test cases yielded an average error of 3.69%, and 10-fold cross-validation confirmed model robustness (R = 0.9996). A global perturbation-based sensitivity analysis was also conducted to quantify the influence of each input parameter, highlighting wall length, moment demand, and concrete strength as the most significant features. This integrated ANN–Jaya model enables rapid, code-compliant CFRP design in accordance with ACI 318 and ACI 440.2R-17, minimizing material usage and ensuring economic and sustainable retrofitting. The proposed approach offers a practical, data-driven alternative to traditional iterative methods, suitable for application in modern performance-based structural engineering. Full article

This study investigates the quasi-static axial crushing behaviour of carbon fibre-reinforced polymer (CFRP) tubes with variations incorporating polyurethane foam (PU) and aluminium tubes. Six different composite configurations were fabricated, including a baseline hollow CFRP tube and hybrid structures with foam and aluminium reinforcements. The mechanical response was evaluated through load–displacement behaviour and energy absorption. Visual inspection of the failure modes revealed distinct fracture mechanisms influenced by the type of reinforcement. The results indicate that incorporating aluminium significantly enhances load-bearing capacity, energy absorption, and crushing efficiency, with the sample containing four aluminium secondary tubes exhibiting the highest specific energy absorption. Meanwhile, foam-filled samples improved load-bearing capacity while mitigating brittle failure. These findings suggest that CFRP hybrid structures with aluminium and foam reinforcements offer promising solutions for lightweight Crashworthiness applications in the automotive and aerospace industries. Full article

Laser micro-drilling was applied to Fe substrates to enhance the interfacial properties of carbon fiber-reinforced polymer/iron laminates. This architecture is referred to as a resin-interlocked Fe-CFRP hybrid composite. Inspired by human hair follicles’ exceptional adhesion and filling efficiency, novel biomimetic frustum-integrated cylindrical cavities were engineered for Fe surface modification. Experimental results demonstrate that laser-processed surfaces with varied hole geometries (conical, conical frustum, cylindrical, and frustum-integrated cylindrical cavities) exhibit significantly improved interfacial performance compared to untreated Fe controls. Specifically, RI-Fe/CFRP specimens containing frustum-integrated cylindrical cavities achieved the highest shear strength, with a 44.8% increase over non-drilled counterparts. Subsequent molecular dynamics simulations confirmed the critical role of the cavity geometry, demonstrating that the frustum-integrated cylindrical cavity elevates the Fe–Diglycidyl ether of bisphenol-A interfacial energy and van der Waals interactions by 45.44% and 50.66%, respectively, versus the flat surface. The interfacial energy enhancement mechanism via distinct hole configurations was systematically studied. Furthermore, comprehensive micro-hole topology analysis elucidated the reinforcement mechanism in resin-interlocked Fe-CFRP hybrid composites. Results demonstrate that frustum-integrated cylindrical cavities significantly enhance DGEBA-3,3′-diaminodiphenyl sulfone fluidity during interface simulation, promoting mechanical interlocking and optimized resin-filling efficiency. Laser micro-drilling effectively improves Fe-DGEBA interfacial performance. These findings provide critical insights for designing high-performance composites in aerospace and automotive applications. Full article

Carbon-Fiber-Reinforced Plastic (CFRP) is a typical lightweight material used in the aerospace industry. However, the automotive industry has focused on the application of composite materials in vehicle components for weight reduction. In particular, hybrid parts consisting of CFRP reinforcement and a steel outer have been investigated in many studies as a solution to satisfy weight reduction and high strength. In this paper, a steel/CFRP hybrid part was evaluated by impact analysis using several material models, such as the Johnson–Cook model, progressive damage analysis (PDA), and cohesive zone model (CZM). First, the mechanical properties of the steel were determined under different strain rates to assess collision effects. Subsequently, the material properties of the CFRP were evaluated to predict the failure of composite material in the tensile and compressive directions. In addition, the cohesive properties of adhesive film were evaluated under normal and shear modes. Finally, impact analysis using the obtained material properties was conducted to predict the behavior and strength of the steel/CFRP hybrid part under collisions, and the results were compared with the experimental results for verification. Full article