The effect of hyperbranched polyester and zirconium slag nanoparticles on the impact resistance of epoxy resin thermosets

A hyperbranched polyester (HBP) was synthesized through a polymerization of AB₂ approach with succinic anhydride and diethanolamine. The effect of HBP and Zirconium slag nanoparticle (ZSN, a kind of solid waste in Zirconium industry) content on the toughness enhancement and morphology of diglycidyl ether of bisphenol A epoxy resin (DGEBA) thermosets was studied. The results indicated that HBP can greatly improve the impact strength (IS) of epoxy thermosets, but the flexural strength (FS) was decreased with increasing the HBP content. The IS of epoxy thermosets modified with ZSN was also improved, and the FS decreases as increase of ZSN. The thermosets modified with both HBP and ZSN showed excellent IS and FS. The toughening enhancement mechanism was also discussed.     

A cut-ply specimen for the mixed-mode fracture toughness and fatigue characterisation of FRPs

The characterisation of mixed-mode fracture toughness and fatigue delamination growth in fibre-reinforced composites is crucial for assessing the integrity of structural elements in service. An asymmetric cut-ply coupon (ACP) loaded in four-point bending is here proposed to carry out the aforementioned characterisations. Analytical expressions of the energy release rate and mode-mixity for the ACP are derived and validated by means of finite element analysis. A fracture toughness and fatigue characterisation of the carbon/epoxy material IM7/8552 is carried out via ACP specimens. It is proved that the material data obtained from ACP specimens match those generated using ASTM standard mixed-mode bending (MMB) coupons. The main reason for the introduction of the ACP test resides in its applicability to characterisation scenarios where measuring the delamination length with optical means, as required for MMB coupons, is difficult. Such scenarios include the investigation of static and fatigue delamination growth at low and high temperatures, which requires the usage of environmental chambers. This poses significant constraints in terms of volume available for the test rigs, and, most importantly, limitations on visual access to observe delamination propagation. However, the manufacturing of ACP coupons is more complex than for MMB specimens and the testing requires several additional precautions that are here discussed in detail.     

Determining the mechanism controlling glass fibre strength loss during thermal recycling of waste composites

This paper presents an experimental investigation into the large reductions to the tensile fracture stress and the associated strength loss mechanism of E-glass fibres during thermal recycling. Fractographic analysis reveals the fracture process is controlled by surface flaws, irrespective of heat treatment temperature and duration. The fracture toughness is an important material property in order to understand possible changes in the strength–flaw relationship during heat treatment. Focussed ion beam (FIB) milling is used to artificially create a single nano-sized deep notch (between 30 and 1000 nm) in glass fibres. The strength loss, fracture toughness, fracture mirror constant and fracture mechanism observed for nano-notched and thermally recycled fibres are identical, indicating bulk property changes do not occur during thermal recycling. The study proves conclusively that surface flaw growth is the controlling mechanism reducing fibreglass strength during thermal recycling of waste polymer composites.     

Scaling of fracture response in Over-height Compact Tension tests

An experimental investigation into in-plane scaled Over-height Compact Tension (OCT) [45/90/−45/0]_4s carbon/epoxy laminates was carried out to study the scaling of fracture response. The dimensions of the baseline specimens were scaled up and down by a factor of 2. Interrupted tests were carried out for specimens of each size in which the tests were stopped after certain load drops in order to study the failure mechanisms. X-ray Computed Tomography (CT) scanning was applied after the interrupted tests to examine the damage development and its effect on the fracture response. The test results showed that the scaling of the initial propagation of fracture follows Linear Elastic Fracture Mechanics (LEFM), but the development of the damage process zone differs with specimen sizes. The OCT specimens were found to be not large enough to generate a self-similar damage zone during propagation, and so no conclusions could be drawn regarding the R-curve effect.     

Reinforcement and toughening mechanisms in polymer nanocomposites – Carbon nanotubes and aluminum oxide

The addition of nanoparticles has been reported as an option to increase the fracture toughness of thermosetting polymers without compromising the stiffness. In this paper, alumina or carbon nanotubes (CNTs), in three different concentrations, were dispersed in an epoxy resin. Mechanical properties were measured through tensile test and the results indicate increases for all nanocomposites, with a maximum for the addition of 0.5% of CNTs (17% in elastic modulus and 22% in ultimate stress). Using TEM images, it was possible to identify the nanostructures and mechanisms that lead to improved stiffness. Fracture toughness tests and SEM images showed that cavitation – shear yielding (for epoxy/alumina nanocomposites) and crack bridging – pull-out (for epoxy/CNTs nanocomposites) are the predominant mechanisms.     

Nesting effect on the mode II fracture toughness of woven laminates

The mode II fracture toughness is evaluated for carbon fibre T700-epoxy reinforced woven laminates using the end notch flexure set-up. The analysed woven composites have a different tow size (3K/12K). Three different nesting/shifting configurations are applied to the plies at the fracture surface. Corrected Beam Theory with effective crack length method (CBTE) and Beam Theory including Bending rotations effects method (BTBE) are evaluated for obtaining mode II fracture toughness. During data post-processing, the importance of the bending angle of rotation and the test configuration is observed to be important. The results show that crack propagation under mode II is more stable if the matrix is evenly distributed on the surface. The nesting does not significantly affect mode II fracture toughness values, although a greater presence of matrix on the delaminated area increases its value.     

Characterization of strain-softening behavior and failure mechanisms of composites under tension and compression

A methodology is presented to directly measure the damage properties and strain softening response of laminated composites by conducting over-height compact tension (OCT) and compact compression (CC) tests. Through the use of digital image correlation (DIC) technique, and analysis of the measured surface displacement/strain data, the strain-softening response of composites is constructed. This method leads to a direct determination of the Mode I translaminar fracture properties with the assumption that the shear stress is negligible around the damage zone and the crack growth occurs in the symmetric opening mode. Using this methodology, and by correlating the observed failure mechanisms with the strain-softening curves, the interaction of failure mechanisms leading to the final failure and also the distinction between the tensile and compressive failure mechanisms can be studied. The effectiveness of the method in accurate identification of the damage parameters is demonstrated through sectioning and deplying techniques. As a consistency check and further verification of the method, the obtained strain-softening curves are fed into a numerical damage mechanics model and successfully used to simulate the detailed response of the very same OCT and CC specimens from which the strain-softening curves were extracted.     

Improved fracture toughness and integrated damage sensing capability by spray coated CNTs on carbon fibre prepreg

The development of a hierarchically engineered micro-nano hybrid composite system is described. A spray coating technique has been utilized as an effective way to deposit carbon nanotubes (CNTs) onto carbon fibre prepregs with good control of network formation and the potential for localization. Compared to more traditional approaches of introducing CNTs into epoxy matrices for enhancing composite properties, this technique has benefits in terms of its simplicity and versatility, as well as the potential for industrial scale-up. The effectiveness of the technique is demonstrated by the extremely low CNT loading (0.047 wt.%) needed to significantly increase the Mode-I fracture toughness of the carbon fibre laminates by about 50%, which is so far the largest reported improvement for such extremely low concentrations of non-functionalized CNTs. In-situ damage sensing has also been presented for the monitoring of structural health of these nano-engineered composite laminates upon loading, and a systematic analysis of sensing signals is performed.     

Mechanical and thermal properties of carbon fiber/polypropylene composite filled with nano-clay

The effect of organoclay on the mechanical and thermal properties of woven carbon fiber (CF)/compatibilized polypropylene (PPc) composites is investigated. Polypropylene–organoclay hybrids nanocomposites were prepared using a maleic anhydride-modified PP oligomer (PP-g-MA) as a compatibilizer. Different weight percentages of Nanomer® I-30E nanoclay were dispersed in PP/PP-g-MA (PPc) using a melt mixing method. The PPc/organoclay nanocomposite was then used to manufacture plain woven CF/PPc nanocomposites using molding compression process. CF/PPc/organoclay composites were characterized by different techniques, namely; dynamic mechanical analysis (DMA), fracture toughness and scanning electron microscope. The results revealed that at filler content 3% of organoclay, initiation and propagation interlaminar fracture toughness in mode I were improved significantly by 64% and 67% respectively, which could be explained by SEM at given weight as well; SEM images showed that in front of the tip, fibers pull out during initiation delamination accounting for fracture toughness improvement. Dynamic mechanical analysis showed enhancement in thermomechanical properties. With addition 3 wt.% of organoclay, the glass transition temperature increased by about 6 °C compared to neat CF/PPc composite indicating better heat resistance with addition of organoclay.     

Notch radius effect on fracture toughness of ceramics pertinent to grain size

Unlike fracture toughness, the notch fracture toughness of a ceramic is not a constant; rather, it increases with the notch-root radius ρ in a notched specimen. In this study, by analyzing the fracture measurements of eight different notched ceramics with an average grain size G of 3–40 μm, a simple model describing the relation between the notch fracture toughness and fracture toughness is proposed as a function of the relative notch-root radius ρ/G. The normal distribution is incorporated to consider the inevitable scatter in measurements where fracture mechanisms and errors are present. The results demonstrate that the model can effectively predict the quasi-brittle fracture variation trend for ceramics, including the upper and lower bounds, with 96% reliability, from a normal distribution; thus, it can address virtually all of the experimental data. We also determined that the notch fracture toughness approximates the fracture toughness if ρ ≤ G.