Fracture of mica-reinforced polypropylene: Mica concentration effect

Concepts of post-yield fracture mechanics were used to characterize the crack initiation and propagation resistances of mica-reinforced polypropylene containing different mica concentrations. Although mica addition leads to an apparently brittle composite, the crack initiation resistance is slightly increased with mica concentration up to 10 percent by weight; and significant improvement in crack propagation performance was found for polypropylene reinforced by up to 20 percent of mica in comparison to that of virgin polypropylene. The debonding of the interface between mica flakes and the matrix leads to a micro-ductility ahead of the crack tip in which the matrix is able to pull-out from mica particles and to stretch. This micro-ductility also prevents the brittle, unstable crack propagation, which is due to the coalescence of voids in pure polypropylene. Above 20 percent of mica, the reduction of the effective amount of the matrix material results in a substantial drop in the resistance to crack growth of mica-reinforced polypropylene.     

Fatigue crack growth in polyethylene

Fatigue crack propagation (FCP) rates are studied in 6 mm thick specimens of high density polyethylene (HDPE) containing razor notches, Centrally-notched plates and single-edg notched bars are subjected to sinusoidal tension-compressio or tension-zero cycling at 0.5 or 2.0 Hz under load control a room temperature; crack growth is monitored using a travelling microscope. After many thousands of cycles with no observable damage at the tip of the razor notch, a craze like zone begins to form. This zone grows slowly until it reaches the length characteristic of a mature crack at the same ΔK. Crack growth proper then begins. The number of cycles to initiate crack growth falls linearly with increasing ΔK at the razor notch Subsequent crack growth is determined both by the current value of ΔK and by loading history. When ΔK is increasing, FCP rates follow a standard Paris law curve. However, reduced, FCP rates are observed following an overload.     

The effect of molecular weight on fatigue crack propagation in nylon 66 and polyacetal

The influence of molecular weight on fatigue and fracture behavior in nylon 66 (N66) and polyacetal (PA) is examined. Fatigue crack propagation (FCP) resistance and apparent fracture toughness (K_cf) in these two semicrystalline polymers increase with increasing molecular weight in a manner consistent with that reported for another semicrystalline polymer (HDPE) as well as for several amorphous polymers. The improved FCP resistance with increasing molecular weight is attributed to the development of a molecular entanglement network that more effectively resists cyclic-load-induced breakdown. A type of discontinous crack growth is identified in PA at 100Hz and in N66 (2.6% H₂O) at 50 Hz and compared with that observed in amorphous polymers.     

Role of crack tip shielding mechanisms in fatigue of hybrid epoxy composites containing rubber and solid glass spheres

The fatigue crack propagation (FCP) resistance of epoxy-based composites containing various concentrations of solid glass spheres (SGS) and/or reactive liquid rubber (CTBN) was examined. The FCP results show that the simultaneous use of rubber and solid glass spheres (hybrid composites) results in synergistic improvement in FCP resistance of composites through the entire crack growth regime. The nature of synergistic interactions was elucidated by careful examination of the fatigue fracture surfaces and the subfatigue fracture surfaces of fatigue samples. It was shown that when rubber particles cavitate in the vicinity of the glass spheres, regardless of the nature of the interface, glass particle debonding from the matrix is suppressed due to a change in the crack tip localized stress state. This, in turn, results in improved pinning/bridging efficiency of the glass spheres. Furthermore, it was shown that crack tip plastic zone-rubber particle interactions induce a transition in FCP behavior of rubber-modified epoxies. Consequently, crack tip shielding mechanisms become active when the size of the plastic zone at the crack tip becomes large compared to the size of the rubber particles. © 1995 John Wiley & Sons, Inc.     

The effect of fiber-matrix adhesion on the fatigue fracture of glass-fiber-reinforced poly(vinyl chloride)

Fatigue crack propagation (FCP) of injection-molded glass-fiber-reinforced poly(vinyl chloride) was examined as a function of fiber-matrix adhesion (coupling) and fiber content at different load levels. Considering the entire FCP history, from crack initiation to critical propagation, it is shown that fatigue lifetime and fracture toughness of coupled composites increase with fiber weight fraction. Uncoupled material exhibits the highest fracture toughness at 10 wt% fiber, yet its fatigue life is considerably shorter. Damage analysis indicates that fiber debonding, pullout, and particularly fiber fracture seem to contribute to the higher fatigue lifetime noted in coupled composites. The Crack Layer Theory is employed to describe the observed FCP behavior. The effective enthalpy of damage parameterizes the resistance of the composite to FCP in terms of the observed mechanisms.     

Fatigue behavior of neat and long glass fiber (LGF) reinforced blends of nylon 66 and isotactic PP

This paper focuses on the study of the fatigue behavior of neat and long glass fiber (LGF) reinforced nylon 66/PP-blends. The fatigue was characterized using Parislaw plots in the stable crack growth acceleration range. The fatigue crack propagation (FCP) is presented as a function of the crack growth per cycle (da/dN), the amplitude of the stress intensity factor ΔK, and of the strain energy release rate ΔG. It was also of interest to compare the order of performance found in fatigue to that in the static fracture test. The fracture surfaces were characterized with SEM to determine the failure mechanisms. Further, thermographic camera recordings were used to study the size of a “heated” area (ΔT = 2°C) that developed around the crack tip during the cyclic loading of LGF-PP with different amounts of maleic anhydride grafted PP (PP-g-MAH). For the neat materials, a different order of performance was detected under static and cyclic loading. This was explained by the different failure mechanisms observed after static and cyclic fracture that were related to different stress states of the specimens during the fracture process. On the other hand, the LGF-blends showed a similar order of performance during the static and the fatigue test. This was explained by the observation that similar fiber related failure mechanisms occurred in the composite, both after failure caused by the static and cyclic loading, respectively. For the LGF-PPs with varying PP-g-MAH content, the order of performance in fatigue did not correspond to the size of the “heated area” around the crack tip. This was caused by a change in the composite failure mechanisms, which contributed differently to the size of the “heated area” and to the fatigue performance.     

CRACK GROWTH IN ADHESIVELY BONDED JOINTS SUBJECTED TO VARIABLE FREQUENCY FATIGUE LOADING

The main aim of this article is to investigate the effect of frequency on fatigue crack propagation in adhesively bonded joints. Adhesively bonded double-cantilever beam (DCB) samples were tested in fatigue at various frequencies between 0.1 and 10 Hz. The adhesive used was a toughened epoxy, and the substrates used were a carbon fibre-reinforced polymer (CFRP) and mild steel. Results showed that the crack growth per cycle increases and the fatigue threshold decreases as the test frequency decreases. The locus of failure with the CFRP adherends was predominantly in the adhesive layer, whereas the locus of failure with the steel adherends was in the interfacial region between the steel and the adhesive. The crack growth was faster, for a given strain energy release rate, and the fatigue thresholds lower for the samples with steel adherends. Tests with variable frequency loading were also carried out, and a generalised method of predicting crack growth in samples subjected to a variable frequency loading was introduced. The predicted crack growth using this method agreed well with experimental results.     

A crack layer approach to fatigue crack propagation in high density polyethylene

Fatigue crack propagation (FCP) in high density polyethylene (HDPE) is observed to occur with an accompanying layer of damage ahead of the crack tip. The crack layer theory, which accounts for the presence of both the damage and the main crack, is applied to the problem. It is observed that the kinetic behavior of HDPE under fatigue consists of three regions: initial acceleration, constant crack speed (“deceleration”), and reacceleration to failure. Within the first two regions, crack propagation appears “brittle,” while in the third region “ductile” behavior is manifested. Ultimate failure occurs via massive yielding of the unbroken ligament. Two damage mechanisms are found to be responsible for HDPE failure: formation of fibrillated voids and yielding. Both mechanisms are present throughout the entire lifetime of the crack, but the former dominates the “brittle” crack propagation region, while the latter is more prominent in the “ductile.” Throughout the analysis the resistance moment R_t is approximated as the total volume of transformed material associated with crack advance. Crack layer analysis produces a satisfactory fit of the experimental data and yields a specific enthalpy of damage, γ^*, value in the 1–2 cal/g range.     

Fatigue crack propagation behavior of cellulose esters

The effect of plasticizer concentration on fatigue crack propagation (FCP) rate in cellulose acetate-propionate (CAP) was determined. Compact tension specimens were machined from 6.2 mm-thick injection molded plaques and tested on an MTS servohydraulic testing machine using a sinusoidal waveform with a frequency of 1 Hz. Two FCP mechanisms were identified: a crazing mechanism, which dominated at low values of stress intensity factor range, ΔK, and a shear yielding mechanism, which dominated at high values of ΔK. The value of ΔK at the onset of the transition from the crazing mechanism to the shear yielding mechanism was a function of plasticizer concentration, and therefore yield strength of the CAP. The transition in crack propagation mechanism created a V-shaped feature on the fracture surface, which could be used to weight the contributions from the two crack propagation mechanisms to the overall FCP rate.     

Mechanical behavior of injection-molded polystyrene/polyethylene blends: Fracture toughness vs. fatigue crack propagation

Blends of polystyrene and polyethylene (PS/PE), including belnds in which a styrene/ethylene-butylene/styrene (SEBS) terpolymer was employed as a compatibilizer, were studied. Their rheology showed that the effect of the addition of SEBS to PS/PE blends was strongly affected by the blend composition and the shear rates involved in the blending and post-forming processes. The addition of PE to PS led to a reduction of fracture toughness compared with that of PS. This effect was attributed to the fine minor phase morphology of the blends obtained after extrusion blending and injection molding. The fatigue crack propagation (FCP) results showed that the fatigue crack growth rates were significantly reduced at low and moderate range of stress intensity factor (ΔK) by the presence of PE. Performance was enhanced when SEBS was present. The results also showed that both the fracture toughness and the FCP behavior of the blends were strongly dependent on the loading direction, the minor phase morphology, the composition of the blend, and, to a lesser degree, the presence of a compatibilizer. This study demonstrates that the fracture toughness and the FCP performance of such polymer blends can vary inversely.     

Crack growth in adhesively bonded joints subjected to variable frequency fatigue loading

The main aim of this article is to investigate the effect of frequency on fatigue crack propagation in adhesively bonded joints. Adhesively bonded double-cantilever beam (DCB) samples were tested in fatigue at various frequencies between 0.1 and 10 Hz. The adhesive used was a toughened epoxy, and the substrates used were a carbon fibre-reinforced polymer (CFRP) and mild steel. Results showed that the crack growth per cycle increases and the fatigue threshold decreases as the test frequency decreases. The locus of failure with the CFRP adherends was predominantly in the adhesive layer, whereas the locus of failure with the steel adherends was in the interfacial region between the steel and the adhesive. The crack growth was faster, for a given strain energy release rate, and the fatigue thresholds lower for the samples with steel adherends. Tests with variable frequency loading were also carried out, and a generalised method of predicting crack growth in samples subjected to a variable frequency loading was introduced. The predicted crack growth using this method agreed well with experimental results.     

Overload effect on the fatigue crack propagation of PC/ABS alloy

The effect of single overload within an otherwise constant amplitude loading sequence on the fatigue crack propagation (FCP) behavior of the alloy of polycarbonate and acrylonitrile-butadiene-styrene (PC/ABS) is experimentally investigated in this paper. An improved compliance method is employed to measure the fatigue crack length of the specimen. Optical and scanning electron microscopes are used to observe the features of crack surface and the process of crack tip deformation. The overload waveform has slight effect, while the overload ratio has great effect on the crack growth retardation. A small crack increment is produced during overloading. The crack growth rate reduces quickly, and then increases gradually until it reaches the steady crack growth rate level when the loading recovers to normal constant amplitude fatigue loads. Porous or dimple features govern the fatigue crack surfaces.     

The influence of temperature and absorbed water on the fatigue crack propagation in nylon-6,6

The effect of absorbed water on the fatigue crack propagation (FCP) of nylon-6,6 was investigated over a range of test temperatures and is correlated with dynamic mechanical properties. Both the storage modulus, a measure of specimen stiffness, and the loss compliance, a measure of energy dissipation and hysteretic heating, influence FCP response. At a given temperature, fatigue resistance is greatest for a given water content corresponding to an optimum combination of storage modulus, E′, and loss compliance, D″. The use of an empirical shift parameter to normalize the temperature dependence of the FCP behaviour of nylon with various water contents is discussed.     

A stochastic approach for continuous and discontinuous crack growth in polycarbonate under cyclic loading

This article presents a stochastic approach to predict fatigue crack propagation (FCP) diagrams of continuous crack growth (CCG) and discontinuous crack growth (DCG) in polycarbonate (PC) under cyclic loading. First, it is assumed that the macroscopic fatigue crack propagates stochastically. The transition probability is then expressed in conjunction with the craze fibril breakdown model for CCG. Second, the stochastic process is applied to DCG assuming that DCG occurs because of an unstable crack growth in the craze zone. A fracture criterion using a stress intensity factor is introduced for the unstable crack growth. As a result, we obtain an FCP diagram where the rate in CCG is lower than that in DCG. The stress intensity factor range for the DCG–CCG transition can be theoretically determined. Finally, to verify the present approach, the experimental data of DCG and CCG of PC are fitted to the Paris equation. In addition, the relationship between the DCG band size and the number of cycles required for DCG is predicted in order to compare it with the experiment data. POLYM. ENG. SCI., 2013. © 2013 Society of Plastics Engineers     

Fatigue fracture of short-glass-fiber-reinforced poly(vinyl chloride): A crack layer approach

The fatigue behavior and fracture toughness of injection molded short-glass-fiber-reinforced poly(vinyl chloride) (sgfr-PVC) were investigated using the Crack Layer approach and fractography, Fatigue crack propagation (FCP) experiments in single-edge-notched (SEN) specimens were conducted concurrently with microscopic observations. Fracture was observed to propagate as a main crack surrounded by a layer of damage. The magnitude of damage was controlled by the content of glass fiber, which in turn controlled crack reduced acceleration and fracture toughness. FCP behavior was successfully described by the Crack Layer theory, which accounts for the damage associated with crack propagation. In absence of significant interfacial bonding, mechanical fiber/matrix interlocking provided the main resistance to crack propagation. Fiber-induced matrix deformation and fiber pull-out appeared to be the dominant energy absorbing mechanisms.     

Effect of test frequency and water content on localized crack-tip heating in nylon-6,6

Fatigue crack propagation (FCP) tests were conducted at various frequencies on nylon-6,6 specimens equilibrated over a range of moisture levels to determine the crack growth rates and the crack-tip temperatures as a function of water content. Frequency-sensitivity was correlated with the amount of crack-tip heating taking place, with crack-tip temperature being found to depend strongly on the estimated loss compliance, D″, of the material. The frequency-sensitivity of FCP in nylon was seen also to be affected by mean stress, suggesting that creep processes are often significant in FCP of nylon.     

Fatigue fracture of reaction injection molded (RIM) nylon composites

This study was undertaken to determine how milled glass fibers affect the fatigue resistance of reaction injection molded (RIM) nylon 6. Specifically the effects of glass content, fiber length, orientation, and surface treatment were investigated. The fatigue crack growth rates for unfilled and glass-filled samples were observed to follow the well-known Paris equation in terms of dependence on cyclic stress intensity factor. For the unfilled nylon a line shaped zone was observed in advance of the crack tip. Fractography results suggest that the zone was the projection of the actual crack tip profile through the thickness of the sample rather than a distinct plastic or deformation zone. The fatigue fracture surface exhibited a patchy type structure with features 50–150 μm in size, suggesting a void coalescence type of mechanism as has been reported for injection molded nylons. A diffuse damage zone, several millimeters in size, was observed at the crack tip for the glass-filled RIM nylon 6. The zone was observed to pulsate with the applied oscillating load. The growth of the damage zone volume with increasing crack length (and thus increasing stress intensity factor range) followed the Paris law, as did the crack growth rate data. The damage mechanism is attributed to void formation and microcracking at the fiber–matrix interface. The results of this study show that, for milled glass-reinforced RIM nylon 6, the crack growth rates were much more rapid than observed for injection-molded nylon 6 containing chopped glass fibers. This difference is attributed to the greatly reduced glass fiber lengths for the milled glasses.     

The fracture behaviour of a PXE/HIPS polyblend

As part of an overall examination of the fatigue crack propagation (FCP) behaviour of impact-modified polymers, a study of the fracture morphology of a PXE/HIPS polyblend polymer subjected to monotonic and cyclic loading conditions is reported. The HIPS rubbery-phase particles are found to fail by particle rupture in both fatigue and fast fracture. Another impact modifying addition, PE, is found to fail by a combination of interfacial rupture and tearing, the balance depending on the prevailing stress intensity value and the strain rate. Matrix failure is via multiple crazing at low fatigue crack growth rates, but shear yielding is believed to become a major fracture mechanism with increasing K. The degree of plastic deformation of the matrix increases with increasing strain rate. This fact is manifested by the increasing void size associated with the interfacial separation of the PE particles.     

Effect of processing on fracture toughness and fatigue crack propagation in unplasticized polyvinyl chloride (uPVC)

The effect of processing on the fracture toughness and fatigue crack propagation rates in unplasticized PVC pipes, both along and perpendicular to the extrusion direction, is evaluated in this paper. The methylene chloride test is used to distinguish between well processed and poorly processed pipes. Well processed pipes have higher fracture toughness under monotonic loading test conditions. However, under impact conditions processing has no significant effects on notched Charpy fracture toughness. For the well processed pipes, there is no directional effect on the fatigue crack propagation rates. For the poorly processed pipes, fatigue crack growth is faster in the extrusion direction, but slight improvement in the processing level removes this difference. Generally, fatigue in the longitudinal direction is independent of the level of processing, but in the transverse (extrusion) direction it is quite sensitive to variations in processing.     

The use of crack layer theory to predict the lifetime of the fatigue crack growth of high density polyethylene

In the case of high density polyethylene (HDPE), the fatigue crack propagates in a discontinuous manner, which can be observed by distinct striations. In this article, fatigue crack growth (FCG) experiments were conducted on two grades of HDPE pipe with compact‐tension (CT) and cracked round bar (CRB) specimens. The effects of the stress ratio (R‐ratio) which is defined as the ratio of minimum stress and maximum stress of fatigue loadings and the frequency on FCG behavior were experimentally studied. Although FCG rates showed a great dependence on the R‐ratio in terms of the range of the stress‐intensity factor, the effect of the frequency may be considered to be significant in the low crack growth region. In addition, these experimental data were employed for predicting the lifetime on the basis of the crack layer (CL) theory. Only a few steps of FCG are needed to determine all necessary parameters for CL theory, and the FCG behavior can be reconstructed based on a computer program that has been developed for the application of CL theory. The predictions from this program accord with experimental data. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers