NATIONAL

ENGINEERING
SCHOOL OF SFAX

Graduation Project
FOR THE NATIONAL ENGINEERING DIPLOMA

presented and publicly supported on 12/12/2020

by

Chaker TEYEB

fets de s m édica me n ts et des facte u rs systé m iq u es

s u r Computed
l ro le
Tomography
e t
Investigation
t r i t e m e Of
n t Hybrid
o r t h o Profile
dontiq ue

JURY:
President : Mr. Nader HADDAR
Reviewer : Mrs. Rim TAKTAK
Supervisors : Mr. Khaled ELLEUCH
Mrs. Manel ELLOUZ
Mr. Thomas KORDISCH 1
 PLAN
Introduction

Conclusion
01
Manufacturing
Process of hybrid
05 02 Profile

04 03
Analysis & Results Fatigue Testing

2
 PLAN
Introduction

Conclusion
01
Manufacturing
Process of hybrid
05 02 Profile

INTRODUCTION
04 03
Analysis & Results Fatigue Testing

3
01
INTRODUCTION
MOTIVATION

STIFFNESS

WEIGHT
MOTIVATION
Metal
Contents Title
Composite STRENGHT

COST
FRP Price

Hybrid Laminates 7
01
INTRODUCTION

Naval

Aerospace Wind Turbin

Aeronautics Construction

Sport Nuclear

Automotive

5
01
INTRODUCTION

55%

!
6
01
INTRODUCTION

Aluminum CFRP

Steel Metal Hybrid Material Composite GFRP

Titanium
Hybrid Piece
AFRP
!
10
 GOALS
01
INTRODUCTION

! Examination of the quality of our manufactured hybrid laminate

!
GOALS
Analyzation of failure mechanisms caused by Fatigue test

8
 PLAN
Introduction

Conclusion
01
Manufacturing
Process of hybrid
05 02 Profile

MANUFACTURING PROCESS
Analysis & ResultsOF HYBRID
04 PROFILE
03
Fatigue Testing

9
02 MANUFACTURING PROCESS OF HYBRID PROFILES

Features Trailing Arm

Axle damper

• Absorption of tensile Wheel carrier

Brake caliper
and compressive forces
Control arm
and moments.

• Critical load situations:

driving in circles,
Trailing arm
accelerating / braking,
Track bar
collision with curbs,
environmental impacts.

11
02 MANUFACTURING PROCESS OF HYBRID PROFILES

1 2 3

MANUFACTRUING
• Bending aluminum sheets in
the form of the hybrid profile
• Cleaning the surface
Pressing layers of prepregs after Pressing the 2 materials together
arranging them in a specific way CFRP
(according to fiber orientation) F = 40 KN
t = 60 min

STEPS 0°
-15°
15°
0° 0° AL
-15° -15°
15°
15°
0°
0°
-15°
15° Final Product
0° Aluminum alloy 12
 PLAN
Introduction

Conclusion
01
Manufacturing
Process of hybrid
05 02 Profile

FATIGUE TESTING
04 03
Analysis & Results Fatigue Testing

13
03
FATIGUE TESTING

Test Parameters

• Average force: F = 9 kN

• Amplitude of ± 5 kN
F
Fmax = 14 KN

Fmin = 4 KN

• Frequency of 2 Hz

• Trial duration : 60 min

14
 PLAN
Introduction

Conclusion
01
Manufacturing
Process of hybrid
05 02 Profile

ANALYSIS & RESULTS

04 03
Analysis & Results Fatigue Testing

15
04

CT Machine
ANALYSIS & RESULTS

CT Machine

16
04
ANALYSIS & RESULTS
Analysis Process

01 02 03

Piece Scan CT Software Piece Analysis

Non damaged profile:
• 213 kV ; 3.1 mA
• small focal point Ø = 0.4 mm
Radiation-shielded
• 4 mm copper filter cabin
• exposure time 100 ms • Characteristics : porosity, wall
• X-ray source
16 integrations, 1440 steps Detector
thickness, displaced fibers and
Object
Damaged profile:
• Cone-beam
213 kV ; 3.9 mA internal dimensions ...
• large focal point Ø = 1mm
• 5 mm copper filter
• Defaults : cracks, delamination,
• exposure time 100 ms
•
Manipulator
16 integrations, 1440 steps
inclusion, cavities ...

17
04
ANALYSIS & RESULTS
Piece Repartition
Part 1 Part 2 Part 3

Part 3 Part 2 Part 1

Main Part
18
04
ANALYSIS & RESULTS
Analysed Parts
(2D X Ray images)

NON LOADED PIECES LOADED PIECES

Defects Detected = 0

The ones which have not undergone fatigue • Parameters

The ones which have undergone fatigueoftests
production
:

tests: process are working optimally.

The investigation of these pieces is used to
The investigation for these pieces is used to
optimize the production method according to • Quality and dimensional
the requirements of automotive applications. reveal possible defects (cracks, porosities,
standards are respected.
delamination, failure …)

Part 1 Part 2 Part 3

19
04
ANALYSIS & RESULTS
LOADED PIECES
Debonding Matrix cracks IFF

XY
Matrix cracks

n
Pla
Pla
n XZ
Z

X
Y

Part 1
Part 1 Part 2 Part 3
20
04
ANALYSIS & RESULTS
LOADED PIECES

Plan XY

Delamination

Z
Pla
X
n XZ
Y

Part 1

21
04
ANALYSIS & RESULTS
Tensile Test

Crack

21
04
ANALYSIS & RESULTS
LOADED PIECES

Section Plan

IFF

XY
an
Pl
Z

X
Y

Part 2 IFF
Part 1 Part 2 Part 3
22
04
ANALYSIS & RESULTS
LOADED PIECES

Debonding
Section Plans

XY
an
Pl
Pla
n XZ
Z

X Matrix cracks
Y

Part 3 Part 1 Part 2 Part 3

23
04
ANALYSIS & RESULTS Assumptions

Part Design
Hybrid part presents a sudden change in form
Part Design (curvature), this may causes an imbalance in
the stress distribution and a stress variation.

Residual
Production
Thermal
Pressure
Stresses

Production Pressure Residual Thermal Stresses

Low pressure during the curing process Large mismatch in the coefficient of
leads to pores formation and delamination thermal expansion (CTE) between the CFRP
between layers. and aluminum alloy: residual thermal
stresses
 PLAN
Introduction

Conclusion
01
Manufacturing
Process of hybrid
05 02 Profile

CONCLUSION
04 03
Analysis & Results Fatigue Testing

24
05 CONCLUSION

• The analysis of the CT images and the identification of defects were

based on two essential factors: Location and Shape.

• Matrix cracking, IFF and delamination are the prevailing failure

modes in Carbon fiber reinforced aluminum laminate with tolerance
of the severity of each defect on the structure.

• Major production probem is the level of thermal internal stresses

related to the manufacturing temperature.

• It would be judicious to think of furthermore exploiting the CT

software to better identify the defects.
• Thinking about methods to decrease the residual stresses in OU
the part. TLO
O K

25