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An experimental study on the axial compressive failure of cylindrical unidirectional (UD) carbon fibre-epoxy rods has been performed to better understand kink bands and the relevant damage mechanisms in three dimensions (3D). Post-mortem X-ray micro-computed tomography (micro-CT) imaging has shown that fibre kink bands predominantly all lie within the same plane in a cylindrical rod sample uniaxially compressed without lateral constraint. Kink bands at different stages of development are contained in the damage volume and the geometric parameters of fully developed kink bands are consistent through the damage zone, with a kink-band width ω ≈ 20-320 µm, kink-band angle β ≈ 11-40° and fibre rotation angle Φ (φ+φ o ) ≈ 18-52°. Fibre failure, longitudinal splitting and matrix micro-cracks within the fibre kink zone are identified by scanning electron microscopy (SEM) and X-ray micro-CT observations. The smallest radius of curvature that corresponds to maximum amount of bending of the unbroken buckled fibres was ～280 µm (40 fibre diameters). Kink-band 2 boundary planes and longitudinal splitting have been extracted and visualised in 3D for the first time.

Open-cell SiC foams clearly are promising materials for continuous-flow chemical applications such as heterogeneous catalysis and distillation. X-ray micro computed tomography characterization of cellular β-SiC foams at a spatial voxel size of 13.6 3 μm 3 and the interpretation of morphological properties of SiC open-cell foams with implications to their transport properties are presented. In-situ draining experiments were carried out in order to understand the nature of the residual static liquid hold-up in SiC foams enabling a better modeling and design of structured reactors based on SiC foams in the future. In order to see more practical uses, μ-CT data of cellular foams must be exploited to optimize the design of the morphology of foams for a specific application.

The effect of circular notch has been evaluated for three different architectures of three-dimensional (3D) carbon fibre woven composites (orthogonal, ORT; layer-to-layer, LTL; angle interlock, AI) through open-hole quasi-static tension and double-lap bearing strength tests in the off-axis (45°) direction. Damage characterisation is monitored using Digital Image correlation (DIC) for open-hole testing and X-ray Computed Tomography (CT) for double-lap bearing strength test. The off-axis notched 3D woven composites exhibits minor reduction (less than 10 %) of the notched strength compared to the un-notched strength. DIC strain contour clearly show stress/strain localisation regions around the hole periphery and stress/ strain redistribution away from the whole due to the z-binder existence, especially for ORT architecture. Up to 50 % bearing strain, no significant difference in the bearing stress/bearing strain response is observed. However when ORT architecture was loaded up to failure, it demonstrates higher strain to failure (~140 %) followed by AI (~105 %) and lastly LTL (~85 %). X-ray CT scans reveal the effect of the z-binder architecture on damage evolution and delamination resistance. The study suggests that off-axis loaded 3D woven composites, especially ORT architecture, has a great potential of overcoming the current challenges facing composite laminates when used in composite joints' applications.

The sudden compressive failure of unidirectional (UD) fibre reinforced composites at loads well below their tensile strengths is a cause of practical concern. In this respect and more generally, analytical and numerical models that describe composite behaviour have been hard to verify due to a lack of experimental observation, particularly in 3D. The aim of this paper is to combine fast in-situ X-ray computed tomography (CT) with advanced image analysis to capture the changes in fibre orientation in 3D during uninterrupted progressive loading in compression of a UD glass fibre reinforced polymer (GFRP). By analysing and establishing correspondence between a sequence of time-lapse X-ray CT images of the composite, we are able for the first time to follow each fibre and quantify the progressive deflection that takes place during axial compression in the steps leading up to fibre micro-buckling and kinking. Even at just 25% of the failure load, fibres have started to tilt in approximately the direction of the ultimate kink band. The rate of tilting increases as the composite approaches the collapse load. More generally, our approach can be applied to investigate the behaviour of a wide range of fibrous materials under changing loading conditions.

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Understanding the fatigue damage mechanisms in composite materials is of great importance in the wind turbine industry because of the very large number of loading cycles rotor blades undergo during their service life. In this paper, the fatigue damage mechanisms of a non-crimp unidirectional (UD) glass fibre reinforced polymer (GFRP) used in wind turbine blades are characterised by time-lapse ex-situ helical X-ray computed tomography (CT) at different stages through its fatigue life. Our observations validate the hypothesis that off-axis cracking in secondary oriented fibre bundles, the so-called backing bundles, are directly related to fibre fractures in the UD bundles. Using helical X-ray CT we are able to follow the fatigue damage evolution in the composite over a length of 20 mm in the UD fibre direction using a voxel size of (2.75 µm)3. A staining approach was used to enhance the detectability of the narrow off-axis matrix and interface cracks, partly closed fibre fractures and thin longitudinal splits. Instead of being evenly distributed, fibre fractures in the UD bundles nucleate and propagate locally where backing bundles cross-over, or where stitching threads cross-over. In addition, UD fibre fractures can also be initiated by the presence of extensive debonding and longitudinal splitting, which were found to develop from debonding of the stitching threads near surface. The splits lower the lateral constraint of the originally closely packed UD fibres, which could potentially make the composite susceptible to compressive loads as well as the environment in service. The results here indicate that further research into the better design of the positioning of stitching threads, and backing fibre cross-over regions is required, as well as new approaches to control the positions of UD fibres.

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