Abstract
In this study, different configurations of epoxy composite laminates that contained thin plies were prepared and characterised for sudden impact load bearing applications. The primary aim of this investigation was to develop a hybrid epoxy-based thin ply composite for aerospace and automotive applications that would be tolerant of high impacts. The impact properties of the selected configurations were investigated both experimentally and numerically under low-velocity Charpy impact loading conditions. Furthermore, any damage to the laminates was evaluated with an emphasis on the identification of dominant damage mechanisms and locations. This included a comparison between the laminates that were made from traditional plies and the thin ply laminates in terms of their absorbed energy and failure modes. The results revealed that the integration of thin plies into normal ply had a major effect on the amount of absorbed energy under flatwise conditions: up to 8.7 J at a cut-off angle of 90°. However, edgewise conditions produced a maximum observed energy of 10.0 J for the thin plies that were surrounded by normal plies (Plate 3). The damage assessments showed the increased damage resistance of the hybrid thin ply composites due to their uniform stress distribution. The traditional ply composites incurred large deformations from the impact loads. Moreover, it was noted that delamination formed in the middle regions of the traditional plies. The FEM model analysis revealed that it was capable of accurately predicting the absorbed energy for different configurations of composites, which were prepared and analysed experimentally. Both the experimental and numerical values were very similar to each other. These impact damage assessments improved the thin ply composites so that they could be used as working materials for applications that are prone to high loads, such as the aerospace, defence, automotive and structural industries.