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The AE method allows the detection and location of damage using specific localisation algorithms. Knowledge of the propagation velocity and attenuation of the AE wave is required. However, contrary to metallic material, the anisotropic nature of composite material gives a large range of propagation velocity due to fibre orientation. Moreover, the attenuation of the AE waves is more complex than in a homogeneous material [2]. In addition, in a same composite material, wave attenuation is more significant in cracked than in healthy state, which will complicate the signal processing after few damage modes have developed, especially for the amplitude distribution. Qualifying damage started first in 2D composites and Mehan and Mullin in 1968 [3] managed to identify three basic failure mechanisms: (i) fiber fracture; (ii) matrix cracking; (iii) and fibre/matrix interfacial debonding. The authors reported the application of AE in composites in 1971 [4], discriminating audible types for these three basic damage modes using an AE system. After forty years, Godin et al. [5] conducted mapping of cross-ply glass/epoxy composites during tensile tests. They have classified four different acoustic signatures of failure and determined four conventional analyses of AE signals.

All of these studies show the difficulty of identifying damage modes for 2D composites and becomes more complicated for 3D woven composites. Only a small amount of investigation has been reported for monitoring evolution of damage and ultimate failure in 3D woven composites. Li et al. [15] studied AE signals for 3D non-crimp orthogonal woven glass/epoxy composites from cluster analysis point of view. These clusters are based on different parameters of peak amplitude, peak frequency, and RA value (rise time divided by peak amplitude). From their investigation, cluster 1 (low frequency, low amplitude events) and 2 (moderate frequency, low amplitude) is correlated to matrix cracking, cluster 3 (low to moderate frequency with high amplitude) with fibre and matrix de-bonding, and cluster 4 (high frequency) with delamination and fibre breakage. Lomov et al. [25] investigated AE response in 3D non-crimp orthogonal woven carbon/epoxy composites undergone damage.

where ΔE is the strain energy released due to the cracking formation. This is determined by subtracting the strain energy density of a cracked cell from the strain energy density of non-cracked cell while ΔA represents the area of the cracked surface. Strain energy release rate actually defines the potential locations for crack formation along the yarn or its cross section. Cracks are more likely to form in locations where the strain energy release rate is high.

Figure 3 is a graph to illustrate the theory behind the finite fracture mechanics. The toughness of the material for a specific cracking mechanism (Gc) is a material property which is constant while the energy release rate increases with increasing applied stress/strain. Once the energy release rate associated with a specific cracking mechanism exceeds the critical value, crack formation and damage evolution starts.

On more issue regarding the fracture of composite materials is that the fracture occurs due to multiplication of cracking events rather than growth of a single crack. Therefore, the fracture response of composite materials is more like discrete instantaneous crack propagation. For further details about the application of finite fracture mechanics of composite materials, the reader is referred to [38].

To determine which constituent part of the 3D woven will experience cracking in the case of uniaxial tension, strain energy density components are calculated for the 3D AI woven composites unit cell when applying 1% strain along the weft direction. The finite element model is run using the COMSOL Multi-physics software package. Figure 4 shows that the transverse component eTT of the strain energy density is the highest when compared to the longitudinal eLL and shear eLT components. This implies that the strain energy release rate for the transverse component is the one that leads to matrix cracking in the weft yarn under this loading condition. In addition, having a constant energy release rate along the whole yarn length, it suggests that there is no preferable location within the yarn for the crack to start from. This also means that once a crack is initiated in the yarn, it grows instantaneously through the thickness and along the whole yarn length. The complete study of damage mechanisms is well explained and characterised in references [43,44].

(a) Strain energy release rate along weft yarn (TT: Transverse component; LT: shear component; LL: axial component); (b) crack on a warp yarn cross section (Transverse crack).

Matrix cracking is a phenomenon that generates a motion which is essentially in plane. The motion of the crack faces is parallel to the plane of the specimen. It can thus be expected that matrix cracks will generate AE waves which contain a predominant extensional mode. Fibre fracture follows the same general behaviour and should therefore also be characterised by a large extensional mode [45].

where [C] is the stiffness matrix; [ε] is the dielectric matrix and [e] is the piezoelectric matrix. PWAS has a density of ρ = 7600 Kg/m3, diameter of 7 mm, and thickness of 500 µm. The 3D composite properties are shown in Table 3 and the Rayleigh damping coefficients from reference [2] are used. It should be noted that these Rayleigh damping coefficients may have an effect on the wave amplitude of the signal but not the shape of the waveform, which is used in characterizing the damage mode.

(a) Source function used: at time zero the force step up from 0 to a nominal value 1, and then return to 0 at 2 μs; (b) two-point source force to simulate the energy release by the transverse crack.

Snapshot of the MP-FEM simulation of guided waves generate by a pair of point forces simulating an acoustic emission by the transverse crack in a 3D angle interlock composite tensile specimen at (a) 10 μs; (b) 20 μs; (c) 30 μs; (d) 40 μs. 2ff7e9595c