Mechanical analysis of fracture in an automotive radiator head produced from a nylon–glass fibre composite

The fracture during assembly of a radiator head produced from a nylon–short glass fibre composite is studied in the framework of complexities such as determining elastic constants and fracture stresses on the one hand and manufacturing problems such as distortion after moulding and deformations induced during assembly on the other. The combination of in situ measurements, SEM observation of fracture surfaces and reverse modelling of non-linear material properties permitted to make a sufficiently accurate estimate of the real mechanical behaviour of the material, as opposed to the properties mentioned in its data sheet. While the method was applied to solve a particular production problem, its applicability in process evaluation and redesign of injection-moulded short fibre composites is general.     

Post-cracking strength and ductility of glass–GFRP composite beams

This paper presents results of experimental and numerical investigations on the structural behaviour of composite beams made of annealed glass panes and glass fibre reinforced polymer (GFRP) pultruded profiles. The main goal of the transparent structural solutions presented here is to increase the post-cracking residual strength and ductility of glass by using GFRP strengthening laminates. The experimental programme included (i) tensile tests on double lap joints between glass and GFRP pultruded laminates, bonded with different types of structural adhesives, and (ii) full-scale flexural tests on glass beams and glass–GFRP composite beams, with different strengthening geometries and structural adhesives. Results obtained in this study show that, unlike glass beams, in glass–GFRP composite beams it is possible to obtain relatively ductile failure modes, with a significant increase of both strength and deformation capacity after the initial cracking of glass. The stiffness of the structural adhesive used, together with the geometry of the GFRP strengthening element, have a major influence on the structural response of the composite beams. Finite element models were developed for all tested beams, allowing to simulate their serviceability behaviour (prior to glass cracking) with fairly good accuracy, namely in what concerns the degree of shear interaction at the bonded interfaces.     

Determination of mechanical properties of intra-layer abaca–jute–glass fiber reinforced composite

Composites made with natural fibers are finding applications in a wide variety of engineering fields due to their low cost and eco-friendly nature. This paper deals with the fabrication and evaluation of hybrid natural fiber composite using jute and abaca fibers along with glass fibers. Each composite is made up of five layers with three layers of jute and abaca enclosed by two layers of glass fibers. The composites are manufactured with three different fiber orientations and the compositions are varied in three different proportions. The fabricated composite samples are tested to investigate their various mechanical properties. From the test results, it is observed that fiber orientation plays a vital role in determining the mechanical properties of the composite. Morphological analysis is done using Scanning Electron Microscope (SEM).     

Seawater effect on impact behavior of glass–epoxy composite pipes

The effect of seawater immersion on impact behavior of glass–epoxy composite pipes is experimentally investigated. Glass–epoxy pipes with [±55°]₃ orientation were fabricated using filament winding method. Composite pipes were selected for four different diameters as 50 mm, 75 mm, 100 mm, and 150 mm. The pipes were immersed in artificial seawater having a salinity of about 3.5% for 3, 6, 9, and 12 months in laboratory conditions. At the end of the conditioning period, the specimens were impacted at three distinct energy levels as 15 J, 20 J, and 25 J at ambient temperature of 20 °C. The comparisons between the dry and immersed cases were carried out by using contact force, deflection and absorbed energy data of the impact tests. Results show that moisture absorption, salt in seawater, diameter of specimen and residual stresses produced by manufacturing process of the composite pipe have significant effect on maximum contact force, maximum deflection, absorbed energy and failure of composite pipes according to exposure time to seawater.     

Evaluation of mechanical and thermal properties of banana–flax based natural fibre composite

Hybrid materials of any kind are the keynote for today’s demands. This paper deals with one of such hybrid composite made of natural fibres namely, banana and flax fibres. The structural build-up is such that one layer of banana fibre is sandwiched between two layers of flax fibres by hand layup method with a volume fraction of 40% using Epoxy resin and HY951 hardener. Glass fibre reinforcement polymer (GFRP) is used for lamination on both sides. This lamination also increases the overall mechanical properties along with better surface properties. The properties of this hybrid composite are determined by testing its tensile, impact, and flexural loads using a Universal testing machine. Thermal properties are analysed and hybrid composites of flax and banana with GFRP have better thermal stability and flame resistance over flax, banana with GFRP single fibre hybrid composites. Morphological analysis is done using Scanning Electron Microscope (SEM). The result of test shows that hybrid composite has far better properties than single fibre glass reinforced composite under impact and flexural loads. However it is found that the hybrid composite have better strength as compared to single fibre composites.     

Rate dependent deformation of carbon fibre reinforced Al–Li metal matrix composite

Abstract

The dynamic deformation characteristics and failure behaviour of laminated carbon fibre reinforced Al–Li metal matrix composite has been studied experimentally with the objective of investigating the dependence of mechanical properties on the applied strain rate and fibre volume fraction. A vacuum melting/casting process was used for manufacturing the tested composite. Impact testing was performed using a Saginomiya 100 metal forming machine and a compressive split Hopkinson bar over a strain rate range of 10^-1 s^-1 to 3×10³ s^-1. It is shown that the flow stress of the composite increases with strain rate and fibre volume fraction. The highest elongation to fracture values were found at low rate loading conditions, although a significant increase in ductility is obtained in the dynamic range. The composite appears to exhibit a lower rate of work hardening during dynamic deformation. Strain rate sensitivity and activation volume are strongly dependent on strain rate and fibre volume fraction. Fractographic analysis using scanning electron microscopy reveals that there is a distinct difference in the morphologies of the fractures, with corresponding different damage mechanisms, between specimens tested at low and high strain rates. Both strain rate and fibre volume fraction are important in controlling fibre fragment length and the density of the Al–Li debris. The relationships between mechanical response and fracture characteristics are also discussed.     

Interface strength in glass fibre–polypropylene measured using the fibre pull-out and microbond methods

Interface strength in glass fibre–polypropylene was measured using both fibre pull-out and microbond methods. Excellent correlation between two methods was obtained. Data from microbond test could be divided into two groups according to whether or not there was constant interfacial friction after debonding. Microscopy observation on tested microbond samples which had exhibited decreasing interfacial friction after debonding revealed considerable residual resin around the debonded area of samples. Further investigation indicated that this unexpected difference was caused by the variation in mechanical properties of the matrix due to thermal degradation during sample fabrication.     

Metallic glass–steel composite with improved compressive plasticity

A Zr_52.5Cu₁₈Ni_14.5Al₁₀Ti₅ bulk metallic glass toughened with a commercially available spring-shaped steel wire has been produced by centrifugal casting. The addition of the steel spring significantly affects shear band nucleation and propagation through the blockage, deflection and multiplication of shear bands at the glass–spring interface. As a result of the more homogeneous distribution of the plastic strain, the room temperature plasticity increases from 0.9% for the monolitic glass to about 4% for the glass–spring composite. Given the low volume fraction of the spring used in the composite (4.2 vol.%), these results demonstrate the extreme effectiveness of the steel spring for improving the plasticity of the metallic glass.     

Sintering characteristics of nano-sized Ag–Pd–glass composite powders with high Pd content

Nano-sized Ag–Pd (50–50) alloy powders coated with Pb-based glass material with low and high glass transition temperature are directly prepared by high-temperature flame spray pyrolysis. Nano-sized Ag–Pd–glass composite powder is formed from the evaporated vapors by nucleation and growth process, and then glass material moves out to the outside of the powder by crystallization process of alloy. The thickness of the glass coating layer measured from the TEM image is 2.8 nm. The mass changes of the Ag–Pd alloy and Ag–Pd–glass composite powders in the TG analysis under 900 °C are 10.9 and 6.8%, respectively. Glass materials improve the uniformity and density of the Ag–Pd electrode layers by act as sintering agent and adhesion improvement. The Ag–Pd electrode formed from the composite powders with high glass transition temperature glass material has thin and uniform thickness. The specific resistances of the electrodes formed from the nano-sized Ag–Pd–glass composite powders are 0.27, 0.09, and 0.03 mΩ cm at firing temperatures of 700, 800, and 900 °C, respectively.     

Sol–gel derived composite from bioactive glass–polyvinyl alcohol

Investigation of novel biomaterials for bone engineering is based on the development of porous scaffolds, which should match the properties of the tissue that is to be replaced. These materials need to be biocompatible, ideally osteoinductive, osteoconductive, and mechanically well-matched. In the present paper, we report the preparation and characterization of hybrid macroporous scaffold of polyvinyl alcohol (PVA)/bioactive glass through the sol–gel route. Hybrids containing PVA (80, 70 and 60 wt%) and bioactive glass with composition 58SiO₂–33CaO–9P₂O₅ were synthesized by foaming a mixture of polymer solution and bioactive glass via sol–gel precursor solution. PVA with two different degree of hydrolysis (DH), 98.5% (high degree) and 80% (low degree) were also investigated, in order to evaluate the influence of residual acetate group present in polymer chain on the final structure and properties of 3D porous composite produced. The microstructure, morphology and crystallinity of the hybrid porous scaffolds were characterized by X-ray diffraction (XRD), Infrared Fourier Transform spectrometry (FTIR) and Scanning electron microscopy (SEM/EDX) analysis. In addition, specific surface area was assessed by B.E.T. nitrogen adsorption method and mechanical behavior was evaluated by compression tests. Preliminary cytotoxicity and cell viability were also performed by the MTT assay. VERO cell monolayers were grown in 96-well microtiter plates. The results have clearly showed that hybrid foams of polyvinyl alcohol/bioactive glass (PVA/BG) with interconnected macroporous 3D structure were successfully produced. All the tested hybrids of PVA/BG have showed adequate cell viability properties for potential biological applications.     

Mechanical property analysis of kenaf–glass fibre reinforced polymer composites using finite element analysis

Nowadays, natural fibres are used as a reinforcing material in polymer composites, owing to severe environmental concerns. Among many different types of natural resources, kenaf plants have been extensively exploited over the past few years. In this experimental study, partially eco-friendly hybrid composites were fabricated by using kenaf and glass fibres with two different fibre orientations of 0° and 90°. The mechanical properties such as tensile, flexural and impact strengths of these composites have been evaluated. From the experiment, it was observed that the composites with the 0° fibre orientation can withstand the maximum tensile strength of 49.27 MPa, flexural strength of 164.35 MPa, and impact strength of 6 J. Whereas, the composites with the 90° fibre orientation hold the maximum tensile strength of 69.86 MPa, flexural strength of 162.566 MPa and impact strength of 6.66 J. The finite element analysis was carried out to analyse the elastic behaviour of the composites and to predict the mechanical properties by using NX Nastran 9.0 software. The experimental results were compared with the predicted values and a high correlation between the results was observed. The morphology of the fractured surfaces of the composites was analysed using a scanning electron microscopy analysis. The results indicated that the properties were in the increasing trend and comparable with pure synthetic fibre reinforced composites, which shows the potential for hybridization of kenaf fibre with glass fibre.     

Strength and failure modes in resistance welded thermoplastic composite joints: Effect of fibre–matrix adhesion and fibre orientation

The strength and failure modes of resistance welded thermoplastic composites were investigated. Special attention was paid to the effect of basic characteristics of the adherends such as fibre–matrix adhesion and fibre orientation. 8HS woven GF/PEI composites were resistance welded. Intralaminar failure was found to be the major failure mechanism for the well welded joints, consisting of either fibre–matrix debonding or laminate tearing. An improved fibre–matrix adhesion was found to result in significantly higher lap shear strength. Besides, the main apparent orientation of the fibres on the welding surfaces was found to have an effect on the strength of the joints.     

Carbon nanotube-doped composite sol–gel coatings for float glass

We have demonstrated the feasibility of synthesizing sol–gel composite coatings consisting of SiO₂ and multiwalled carbon nanotubes (MWCNTs) on float glass, and investigated the effect of the nature of surfactants, which ensure stability of MWCNT suspensions in water and SiO₂ sol and wetting of the glass by the suspensions. We have found conditions that enable uniform MWCNT dispersion and stabilization during the growth of composite coatings. Different, technologically viable approaches to producing composite coatings have been examined. Using laser Raman spectroscopy, we have assessed the MWCNT distribution over the composite coatings. The electrical conductivity, microhardness, and optical transmission of the coatings have been measured. It has been shown that the MWCNT-containing composite coatings possess enhanced microhardness and high electrical conductivity compared to the uncoated glass.     

Nanoindentation measurement of core–skin interphase viscoelastic properties in a sandwich glass composite

Mechanics of Time-Dependent Materials - Debonding at the core–skin interphase region is one of the primary failure modes in core sandwich composites under shear loads. As a result, the...     

Toughening performance of glass fibre composites with core–shell rubber and silica nanoparticle modified matrices

The fracture energies of glass fibre composites with an anhydride-cured epoxy matrix modified using core–shell rubber (CSR) particles and silica nanoparticles were investigated. The quasi-isotropic laminates with a central 0°/0° ply interface were produced using resin infusion. Mode I fracture tests were performed, and scanning electron microscopy of the fracture surfaces was used to identify the toughening mechanisms.The composite toughness at initiation increased approximately linearly with increasing particle concentration, from 328 J/m² for the control to 842 J/m² with 15 wt% of CSR particles. All of the CSR particles cavitated, giving increased toughness by plastic void growth and shear yielding. However, the toughness of the silica-modified epoxies is lower as the literature shows that only 14% of the silica nanoparticles undergo debonding and void growth. The size of CSR particles had no influence on the composite toughness. The propagation toughness was dominated by the fibre toughening mechanisms, but the composites achieved full toughness transfer from the bulk.     

An experimental study of the influence of fibre–matrix interface on fatigue tensile strength of notched composite laminates

The objective of this study was to investigate the effect of fibre–matrix interfacial adhesion on fatigue residual strength of polymer matrix composite laminates containing a circular hole. Composite laminates were manufactured using surface-treated and -untreated carbon fibres, and the interfacial adhesion was quantified by measuring the transverse flexural strength of the two material systems. Tensile–tensile cyclic fatigue experiments were conducted at three load levels. Residual strength of notched laminates, subjected to cyclic loading was then measured for the two composite systems. Damage mechanisms were analysed using C-scan and SEM fractography and correlated with notched residual strength.     

As received Ti–6AI–4V/σ-SiC fibre composite

Abstract

A Ti–6Al–4V/σ (SM 1240) composite prepared by diffusion bonding has been studied in the as received condition, using Auger electron spectroscopy, transmission electron energy loss spectroscopy, and scanning electron microscopy. The SiC based σ fibre has a tungsten core, and a duplex coating of carbon (adjacent to the SiC deposit) and TiB_x. It is shown that boron from the TiB_x layer diffused into the matrix and formed TiB needles. Carbon was detected in the TiB_x layer and was present in elemental free form. A continuous SiO₂+ carbon layer was detected at the SiC/carbon layer interface. Analysis of in situ fracture composite surfaces in an Auger spectrometer has shown that the tensile failure was initiated within the carbon layer or at the TiB_x/matrix interface. An oxide layer detected at the TiB_x/matrix interface influenced the fracture behaviour of the composite.

MST/2027     

Environmental effect on fatigue life of glass–epoxy composite pipes subjected to impact loading

The main objective of this experimental study was to investigate the effects of seawater and impact loading on the fatigue life of glass–epoxy composite pipes under cyclic internal pressure. The pipes were produced by filament winding technique. Composite specimens were immersed in seawater for periods of 3, 6, and 9 months. After the impact tests are carried out at three different energy levels (5, 7.5, and 10 J), fatigue tests were conducted on the specimens. It is seen from results that fatigue life changes according to both impact energy and seawater immersion time. Fatigue life of non-impacted specimen is greater than the impacted one. Fatigue life increases in the impacted specimens up to 3 months and reaches generally maximum value. After that it decreases with increase in seawater immersion time. During the fatigue tests, fatigue damage types named perspiration, leakage, and eruption were observed.     

Improved mechanical properties of an epoxy glass–fiber composite reinforced with surface organomodified nanoclays

An organomodified surface nanoclay reinforced epoxy glass-fiber composite is evaluated for properties of mechanical strength, stiffness, ductility and fatigue life, and compared with the pristine or epoxy glass-fiber composite material not reinforced with nanoclays. The results from monotonic tensile tests of the nanoclay reinforced composite material at 60 °C in air showed an average 11.7% improvement in the ultimate tensile strength, 10.6% improvement in tensile modulus, and 10.5% improvement in tensile ductility vs. these mechanical properties obtained for the pristine material. From tension–tension fatigue tests at a stress-ratio = +0.9 and at 60 °C in air, the nanoclay reinforced composite had a 7.9% greater fatigue strength and a fatigue life over a decade longer or 1000% greater than the pristine composite when extrapolated to 10⁹ cycles or a simulated 10-year cyclic life. Electron microscopy and Raman spectroscopy of the fracture and failure modes of the test specimens were used to support the results and conclusions. This nanocomposite could be used as a new and improved material for repair or rehabilitation of external surface wall corrosion or physical damage on piping and vessels found in petrochemical process plants and facilities to extend their operational life.