Development of an image processing algorithm (IPA‐Delfin) for the digital reconstruction of composite overwrapped pressure vessels

Abstract

Wet filament winding has been established as the primary manufacturing process for overwrapped pressure vessels. However, the prediction of the mechanical performance of pressure vessels is still not sufficiently accurate, mostly due to process‐induced deviations within the laminate structure. In this work, we present an image processing algorithm (IPA‐Delfin) that enables the real‐time generation of a digital reconstruction based on the actual geometry and position of the placed roving. A Type‐IV pressure vessel is analyzed under real manufacturing conditions. Our approach allows the measurement of the overlapping degree of roving within the laminate and the prediction of gaps. The results show that the fiber‐band width and the overlapping area vary significantly when the roving is placed directly on the vessel's polymer liner. A more constant and uniform fiber‐band width and overlapping area were observed when the filament winding took place on the previously placed roving. Hence, the IPA‐Delfin can be potentially used for the generation of digital twins of composite overwrapped pressure vessels.

Progressive damage analysis of Z‐pin reinforced composite laminates based on CDM

“…where the symbols jÀ and j+ denote the jth set of relative parallel surfaces of the singletons, respectively, and u à i is the same at the corresponding points of the relative parallel surfaces of the periodic singletons, which is obtained from Equation (5).…”

“…To enhance the properties in the thickness direction and to compensate for the weakness of poor interlaminate ply toughness, a variety of techniques for thickness direction reinforcement have emerged, such as three-dimensional weaving, three-dimensional braiding, stitching, flocking, and Z-pin. [1][2][3][4][5] Z-pin technology for composites is done by embedding Z-pins of a certain bulk density in the thickness direction of the composite laminate. The most commonly used Z-pin process involves the insertion of Z-pins into the preforms of the laminate using ultrasonic tools and then curing the preforms to form the composite laminate.…”

“…Fiber‐reinforced resin matrix composite is a material with new properties composed of the organic polymer as a matrix and high‐performance fibers such as quartz fiber, carbon fiber, or basalt fiber as reinforcement, both of which are composed by physical or chemical methods at the macroscopic scale. To enhance the properties in the thickness direction and to compensate for the weakness of poor interlaminate ply toughness, a variety of techniques for thickness direction reinforcement have emerged, such as three‐dimensional weaving, three‐dimensional braiding, stitching, flocking, and Z‐pin 1–5 . Z‐pin technology for composites is done by embedding Z‐pins of a certain bulk density in the thickness direction of the composite laminate.…”

Design, manufacture, and experiments of lightweight CFRP hydraulic cylinder tube without metal liner

“…6 With its high strength and low density, CFRP has been widely applied for aviation, 7-9 automobile 10,11 and pressure vessels fields. 12,13 The specific strength of CFRP can reach 1147.4 kNÁm/kg, 3 while that of conventional 45# steel is about 45.5 kNÁm/kg. If hydraulic cylinders are manufactured with CFRP, the hydraulic cylinder weight would be significantly reduced, which would enhance the aircraft's performance.…”

“…With its high strength and low density, CFRP has been widely applied for aviation, 7–9 automobile 10,11 and pressure vessels fields 12,13 . The specific strength of CFRP can reach 1147.4 kN·m/kg, 3 while that of conventional 45# steel is about 45.5 kN·m/kg.…”