Double-double laminates

Double–double (DD) laminates, or DD laminates, are a class of composite laminates composed of repeated four-ply sub-laminates arranged in the form [±Φ/±Ψ], where the ply orientations are defined by two continuous angle parameters, Φ and Ψ. Unlike conventional composite laminates that employ a limited set of discrete ply angles, DD laminates use continuous variation of ply orientation.[1][2][3] The concept is employed in structural engineering applications involving composite materials.

Mechanical behavior

Studies have reported that, when DD laminates are manufactured using thin plies and a sufficiently large number of repeated sub-laminates, the laminate response can be approximated as homogenized.[4][5][6] Under these conditions, the overall mechanical behavior has been described as similar to that of a symmetric laminate, even though the stacking sequence is not explicitly symmetric.[4][5][6] A characteristic feature of this homogenization is the reduction of bending–stretching coupling effects, such that the corresponding terms in the ([B]) stiffness matrix become negligible.[7][8][9]

Applications and manufacturing considerations

DD laminates have been discussed in the literature in the context of lightweight structural applications, particularly where changes in laminate thickness are required.[10] Under homogenized conditions, tapering has been reported to be implemented on a ply-by-ply basis using single-ply drops, without the requirement to maintain mid-plane symmetry.[4] In addition, the use of continuous ply-angle parameters has been presented as allowing a broader range of stiffness tailoring compared with conventional quadriaxial laminates, which typically rely on standard ply orientations of 0°, ±45°, and 90°.[1] DD laminates are typically described as being manufactured by stacking of repeated four-ply sub-laminates, following the prescribed angle parameters.[1]

References

  1. ^ a b c Tsai SW. Double–Double: New Family of Composite Laminates. AIAA Journal 2021; 59 (11): 4293-4305. DOI: 10.2514/1.J060659.
  2. ^ Zhao K, Kennedy D, Miravete A, Tsai SW, Featherston CA, Liu X. Defining the Design Space for Double-Double Laminates by Considering Homogenization Criterion. AIAA Journal 2023; 61(7): 3190-3203. DOI: 10.2514/1.J062639.
  3. ^ Ju R, Zhao K, Featherston CA, Liu X. Buckling Performance Evaluation of Double-Double Laminates with Cutouts Using Artificial Neural Network and Genetic Algorithm. Materials 2024; 17(19): 4677. DOI: 10.3390/ma17194677.
  4. ^ a b c Kappel E. Unique manufacturing opportunity. In: Double-Double: simplifying the design and manufacture of composite laminates. Stanford University Press, 2023.
  5. ^ a b Kappel E. Double–double laminates for aerospace applications — finding best laminates for given load sets. Composer Part C Open Access 2022; 8: 100244. DOI: 10.1016/j.jcomc.2022.100244.
  6. ^ a b Vermes B, Tsai SW, Massard T, Springer GS, Czigany T. Design of laminates by a novel "double–double" layup. Thin-Walled Struct 2021; 165: 107954. DOI: 10.1016/j.tws.2021.107954.
  7. ^ Garofano A, Sellitto A, Di Caprio F, Riccio A. On the use of double-double design philosophy in the redesign of composite fuselage barrel frame components. Polymer Composites 2024; 45(5): 4250-4265. DOI: 10.1002/pc.28056.
  8. ^ Hawkins A, Millen SLJ, Aravand A. Homogenisation of Double-Double (DD) laminates: warpage mitigation and new stacking sequence approaches. Journal of Composite Materials 2025. DOI: 10.1177/00219983251362358.
  9. ^ Kappel E. On stacking-sequence independent bending properties of Double-Double laminates—A short communication. Composites and Advanced Materials 2024;33. DOI: 10.1177/26349833241237244.
  10. ^ Shrivastava S, Sharma N, Tsai SW, Mohite P.M. D and DD-drop layup optimization of aircraft wing panels under multi-load case design environment. Composite Structures 2020, 248: 112518. DOI: 10.1016/j.compstruct.2020.112518.
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