Plasma surface modification of advanced organic fibres

The interlaminar shear strength, interlaminar fracture energy, flexural strength and modulus of extended-chain polyethylene/epoxy composites are improved substantially when the fibres are pretreated in an ammonia plasma to introduce amine groups on to the fibre surface. These property changes are examined in terms of the microscopic properties of the fibre/matrix interface. Fracture surface micrographs show clean interfacial tensile and shear fracture in composites made from untreated fibres, indicative of a weak interfacial bond. In contrast, fracture surfaces of composites made from ammonia plasma-treated fibres exhibit fibre fibrillation and internal shear failure as well as matrix cracking, suggesting stronger fibre/matrix bonding, in accord with the observed increase in interlaminar fracture energy and shear strength. Failure of flexural test specimens occurs exclusively in compression, and the enhanced flexural strength and modulus of composites containing plasma-treated fibres result mainly from reduced compressive fibre buckling and debonding due to stronger interfacial bonding. Fibre treatment by ammonia plasma also causes an appreciable loss in the transverse ballistic impact properties of the composite, in accord with a higher fibre/matrix interfacial bond strength.     

The effect of transverse shear on the longitudinal compressive strength of fibre composites

Experimental work on glass/epoxy composites shows that the compressive strength is sensitive to the method of gripping, that the failure mode in compression varies with fibre volume fraction, and that bending of the specimen may occur as a result of misalignment. Some aspects of these observations are examined. The critical Euler buckling load is significantly reduced if transverse shear occurs. The buckling load depends on specimen dimensions and a good deal of scatter results from this. The predicted compressive strength taking into account the effect of transverse shear and specimen geometry includes the experimental results within a wide scatter band. The present analysis based upon the macro-buckling of the specimen, reproduces some predictions of compressive strength based upon the micro-buckling of fibres.     

Low velocity response of simple geometry pultruded glass/polyester composite

This paper describes an investigation into the low velocity impact response of relatively simple geometry coupons taken from a pultruded glass/polyester product. The pultruded lay-up is a typical three ply design – a unidirectional fibre ply sandwiched between two continuous filament mat plies. By employing a simple geometry the impact response under transverse and longitudinal bending, and shear loading are considered. Impact tests from low energy through to final failure were conducted using the instrumented falling weight impact test technique. Through a detailed analysis involving ultrasonic C-scan, optical microscopy, and thermal deply all the major damage modes (delamination, fibre breakage and matrix cracking) were related to the force-deflection responses.     

Computational micromechanics evaluation of the effect of fibre shape on the transverse strength of unidirectional composites: An approach to virtual materials design

Computational micromechanics of composites is an emerging tool required for virtual materials design (VMD) to address the effect of different variables involved before materials are manufactured. This strategy will avoid unnecessary costs, reducing trial-and-error campaigns leading to fast material developments for tailored properties. In this work, the effect of the fibre cross section on the transverse behaviour of unidirectional fibre composites has been evaluated by means of computational micromechanics. To this end, periodic representative volume elements containing uniform and random dispersions of 50% of parallel non-circular fibres with lobular, polygonal and elliptical shapes were generated. Fibre/matrix interface failure as well as matrix plasticity/damage were considered as the fundamental failure mechanisms operating at the microscale under transverse loading. Circular fibres showed the best averaged behaviour although lobular fibres exhibited superior performance in transverse compression mainly due to the higher tensile thermal residual stresses generated during cooling at the fibre/matrix interface.     

Strength evaluations of sinusoidal core for FRP sandwich bridge deck panels

Fiber-reinforced polymer (FRP) sandwich deck panels with sinusoidal core geometry have shown to be successful both in new construction and the rehabilitation of existing bridge decks. This paper is focused on an experimental study of the strength evaluations of a honeycomb sandwich core under out-of-plane compression and transverse shear. The sinusoidal core is made of E-glass Chopped Strand Mat (ChSM) and Polyester resin. The compressive, tensile and shear strengths were first obtained from coupon tests. The out-of-plane compression tests were performed on representative single-cell volume elements of sandwich panels, and the tests included “stabilized” samples to induce compression failure, and “bare” samples to induce local buckling of the core. Finally, four-point bending tests were conducted to study the structural strength behavior under transverse shear. Two types of beam samples were manufactured by orienting the sinusoidal wave either along the length (longitudinal) or along the width (transverse). Both typical shear failure mode of the core material and delamination at the core–facesheet bonding interface were observed for longitudinal samples. The failure for transverse samples was caused by core panel separation. For both single-cell and beam-type specimen tests, the number of bonding layers, i.e., the amount of ChSM contact layer and resin used to embed the core into the facesheet, and the core thickness are varied to study their influence. The experimental results described herein can be subsequently used to develop design guidelines.     

Some aspects of crack growth and failure in fibre reinforced composites

A theoretical analysis, previously developed to deal with the machanics of matrix cracking in unidirectional composites and with transverse ply cracking in cross ply laminates, has been developed further to deal with the tensile failure of unidirectional fibrous composites in with the fibres have a known distribution of strengths. It is proposed that, under the application of a tensile load, stable transverse cracks are formed which originate from regions of initial damage and which become unstable at some critical strain value. The model takes account of various parameters including the interfacial fibre/matrix debonding energy, the residual frictional shear strength of the debonded interface and the elastic properties of fibres and matrix. Comparisons are made between the predictions of the model and the observed failing strains of the 0° plies in carbon fibre polymer matrix laminates. The relevance of the model to the study of delayed fracture in fibrous composites is discussed. The modification of this model, previously developed to describe crack growth in the transverse plies of 0°/90° laminates, is used to predict the initial cracking strains for a wide range of CFRP laminate geometries and initial crack sizes. Some aspects of the mechanics of crack extension across interply interfaces are discussed.     

Post-impact compressive behaviour of low temperature curing woven CFRP laminates

The polymeric matrix in a fibre-reinforced composite serves to bind the fibres together, transfer load to the fibres and protect them against environmental attack and damage due to handling. The matrix has a strong influence on several mechanical properties of the composite such as transverse modulus and strength, impact resistance, shear properties and properties in compression. This paper describes the results of an experimental study to determine the effect of resin (matrix) on the post-impact compressive behaviour of carbon fibre woven laminates. Three new low temperature cure (50–125°C) epoxy resins are examined: an unmodified (LTM12), a rubber-modified (LTM25) and a thermoplastic toughened epoxy resin (MT8E). Note, however, that the first two are post-cured at 190°C. Velocities and impact energies were used to simulate momenta typical of low velocity impact hazards associated with aircraft in-service. Measurements of impact damage and damage growth during compression are made using ultrasonic C-scanning and penetrant-enhanced X-ray radiography techniques. For low impact energies the superior performance of the thermoplastic toughened epoxy is confirmed. Its residual compressive strength compares favourably with that obtained for high strength carbon fibre/epoxy laminates manufactured from unidirectional sheets cured at 190°C.     

Non-linear compression stress-strain curve of pitch-based high modulus carbon fibre composites and structural responses

The longitudinal compression behaviour of unidirectional composites is studied to understand the role of the fibre compressive property in deformation and failure by systematically varying the tensile modulus of reinforcing high modulus carbon fibre. As the composites deform, their softness increases with increasing compressive strain, and the loading path is traced back when the load is removed. The intensity of softening is correlated to the fibre's tensile modulus and possible softening mechanisms are discussed in conjunction with fibre and matrix properties. Further, it is investigated how the non-linear stress-strain relation affects the stress and strain distributions and deformation when plates fabricated from these fibres are tested by the three-point bending test.     

Effect of hot water immersion on the performance of carbon reinforced unidirectional poly(ether ether ketone) (PEEK) composites: Stress rupture under end-loaded bending

This paper describes the behaviour of AS4 and T700SC reinforced PEEK composites (SUPreM™ and ACP-2) under applied compressive bending strain. The effect of an increased molecular weight of the polymer matrix on the residual time under endloaded compression bending conditions is studied. Generally for a given composite material, the higher the testing temperature and the applied strain the faster the failure occurs. At test temperatures exceeding the glass transition temperature or at high strain ratios the time-to-failure for CF/PEEK composites follows a master curve. The residual times under endloaded compression bending conditions increase with increasing toughness of the PEEK matrix but decrease with increasing tensile strength of the reinforcing fibres. It seems that the better the fibre/matrix adhesion the lower is the time to failure of an endloaded composite, because more load is transferred from the matrix into the fibres.In order to simulate composite applications under ‘harsh’ conditions the CF/PEEK composites have been exposed to boiling water. PEEK is known to be highly resistant to environmental effects, but water uptake significantly influences the overall performance of CF/PEEK composites under endloaded compression bending conditions. The tensile properties of the composites have been measured as function of exposure time in boiling water. The fibre dominated uniaxial tensile strength is not/or only slightly affected by the boiling water conditioning even after extended exposure times but the transverse tensile strength decreases significantly after exposure to boiling water. The performance of SUPreM™ CF/PEEK-150 and 450 composites under endloaded compression bending conditions are positively affected by water conditioning whereas APC-2 fails at shorter residual times. The fracture behaviour under endloaded conditions is also affected by the ingress of water into the composite.The obtained results show clearly that applications of thermoplastic composites leading to large out of plane deformations can only be ‘safe’ if the maximum service temperatures of the finished part will be well below the glass transition temperature of the polymer matrix otherwise even at low bending radii a dramatic failure of the material cannot be excluded.     

Flexural failure mechanisms and global stress plane for unidirectional composites subjected to four-point bending tests

Glass fibre-reinforced epoxy and polyester composites of different fibre/matrix interface strengths exhibited tensile, compressive and shear failure modes in four-point bending tests. The flexural tensile mechanism comprised fibre ridging, transverse matrix cracking and longitudinal matrix cracking; the flexural compressive mode was caused by microbuckling of fibres. The interface strength appeared to affect each of these failure mechanisms, with the flexural tensile mode associated with the strongest and the shear failure mode corresponding to the poorest interface condition. The apparent flexural strength also decreased rapidly as the interface degraded. These phenomena are rationalized by a newly developed ‘global stress plane’, the theoretical basis of which is that the dependency of the interlaminar shear strength on the interfacial shear strength is larger than that of the longitudinal compressive strength, which in turn is larger than that of the longitudinal tensile strength.     

Effect of off-axis ply orientation on 0°-fibre microbuckling

The aim of the present work is to study both experimentally and theoretically the compression failure mechanisms in multi-directional composite laminates, and especially the effect of the off-axis ply orientation on fibre microbuckling in the 0°-plies. The critical mechanism in the compressive fracture of unidirectional polymer matrix composites is plastic microbuckling/kinking. In multi-directional composites with internal 0°-plies, catastrophic failure also initiates by kinking of 0°-plies at the free-edges or manufacturing defects, followed by delamination. When 0°-plies are located at the outside, or in the case of cross-ply laminates, failure rather tends to occur by out-of-plane buckling of the 0°-plies. T800/924C carbon-fibre–epoxy laminates with a [(±θ/0₂)₂]_s lay-up are used here to study the effect of the supporting ply angle θ on the stress initiation of 0°-fibre microbuckling. Experimental data on the compressive strength of laminates with θ equal to 30, 45, 60 or 75° are compared to theoretical predictions obtained from a fibre kinking model that incorporates interlaminar shear stresses developed at the free edges at (0/θ) interfaces. Initial misalignment of the fibres and non-linear shear behaviour of the matrix are also included in the analysis.     

复合材料横向压缩性能的研究

本文考察了由两种力学性能不同的基体制备的玻璃纤维、碳纤维和碳/玻混杂纤维复合材料的横向压缩性能及破坏特征,导出了估算复合材料横向压缩强度半经验公式,其估算值与实测值比较吻合。      

Analytical prediction of damage due to large mass impact on thin ply composites

This article presents analytical models for predicting large mass impact response and damage in thin-ply composite laminates. Existing models for large mass impact (quasi-static) response are presented and extended to account for damage phenomena observed in thin-ply composites. The most important addition is a set of criteria for initiation and growth of bending induced compressive fibre failure, which has been observed to be extensive in thin ply laminates, while it is rarely observed in conventional laminates. The model predictions are compared to results from previous tests on CFRP laminates with a plain weave made from thin spread tow bands. The experiments seem to confirm the model predictions, but also highlight the need to include the effects of widespread bending induced fibre failure into the structural model.     

Damage and fracture of a cross woven C/SiC composite subject to compression loading

In order to understand the mechanical behaviours of ceramic matrix composites under various loading conditions, the compression stress-strain behaviour of a cross woven C/SiC ceramic matrix composite was characterized in terms of damage and fracture mechanisms, which were observed by scanning electron microscope (SEM) on a side-polished sample. The compression stress-strain curve was found to consist of two stages. The first stage, which extends to about 300 MPa, covers linear elastic deformation with a compression modulus of 140 GPa. The second stage starts with the occurrence of compression damage modes, which include ply delamination, bundle separation and transverse bundle cracking. Depending on the local structure of the sample, the second stage of the stress-strain curve can be either mostly linear or non-linear. The fracture of the composite under compression is by kinking, shearing and bending fracture of fibre bundles individually or in groups, forming a macroscopic shear band in the sample.     

A Discrete Model for Simulation of Composites Plate Impact Including Coupled Intra- and Inter-ply Failure

Laminated composites can undergo complex damage mechanisms when subjected to transverse impact. For unidirectional laminates it is well recognized that delamination failure usually initiates via intra-ply shear cracks that run parallel to the fibres. These cracks extend to the interface of adjacent orthogonal plies, where they are either stopped, or propagate further as inter-ply delamination cracks. These mechanisms largely determine impact energy absorption and post-delamination bending stiffness of the laminate. Important load transfer mechanisms will occur that may lead to fibre failure and ultimate rupture of the laminate. In recent years most Finite Element (FE) models to predict delamination usually stack layers of ply elements with interface elements to represent inter-ply stiffness and treat possible delamination. The approach is computationally efficient and does give some estimate of delamination zones and damaged laminate bending stiffness. However, these models do not properly account for coupled intra-ply shear failure and delamination crack growth, and therefore cannot provide accurate results on crack initiation and propagation. An alternative discrete meso-scale FE model is presented that accounts for this coupling, which is validated against common delamination tests and impact delamination from the Compression After Impact (CAI) test. Ongoing research is using damage prediction from the CAI simulation as a basis for residual strength analysis, which will be the published in future work.     

Micromechanics characterization of sublaminate damage

A micromechanics analytical model is developed for characterizing the fracture behaviour of a fibre reinforced composite laminate containing a transverse matrix crack and longitudinal debonding along 0/90 interface. Both the matrix and the fibres are considered as linear elastic. A consistent shear lag theory is used to represent the stress-displacement relations. The governing equations, a set of differential-difference equations, are solved satisfying the boundary conditions appropriate to the damage configuration by making use of an eigenvalue technique. The properties of the constituents appear in the model explicitly. Displacements and stresses in the fibres and the matrix are obtained, and the growth of damage is investigated by using the point stress criterion. The investigation includes fibre stress distribution in zero degree plies, transverse crack and debonding intitiation as functions of laminate geometry, and the effect of fibre breaks in the zero degree ply on damage growth. The predicted damage growth patterns and the corresponding critical strains agree with the finite element and experimental results.     

含材料非线性的热塑性聚乙烯自增强复合材料逐渐损伤分析

以分段线弹性方法考虑了单向复合材料纵向、横向与剪切的非线性特性,建立了静拉伸热塑性PE/PE层合板逐渐损伤模型,利用有限元技术模拟研究了UHMWPE/LDPE层合板逐渐损伤的过程及机理.研究表明,纵向非线性对层合板的拉伸力学行为非线性有显著影响;各向非线性的分段线弹性处理可简便有效地分析复合材料及其结构的非线性问题,结合逐渐损伤分析可清楚揭示基体开裂、纤一基剪切和纤维断裂等损伤模式及其进程.算例分析的理想结果验证了模型的有效性.     

The influence of fibre microstructure on fibre breakage and mechanical properties of natural fibre reinforced polypropylene

The aim of the study was to investigate the influence of fibre morphology of different natural fibres on the composites mechanical properties and on the fibre breakage due to extrusion process. The composite materials were manufactured using LTF (long fibre thermoplastic) extrusion and compression moulding and the used fibres were sisal, banana, jute and flax, and the matrix was a polypropylene. The results showed that sisal composites had the best impact properties and the longest fibres after the extrusion. Generally, the composites flexural stiffness was increased with increased fibre content for all fibres, being highest for flax composites. The flexural strength was not affected by the addition of fibres because of the low compatibility. The addition of 2 wt.% maleated polypropylene significantly improved the composites properties. Unlike the other three fibres, flax fibres were separated into individual elementary fibres during the process due to enzymatic retting and low lignin content.     

Effect of Polymer Form and its Consolidation on Mechanical Properties and Quality of Glass/PBT Composites

The aim of this study was to understand the role of the processing in determining the mechanical properties of glass fibre reinforced polybutylene terephthalate composites (Glass/PBT). Unidirectional (UD) composite laminates were manufactured by the vacuum consolidation technique using three different material systems included in this study; Glass/CBT (CBT160 powder based resin), Glass/PBT (prepreg tapes), and Glass/PBT (commingled yarns). The different types of thermoplastic polymer resin systems used for the manufacturing of the composite UD laminate dictate the differences in final mechanical properties which were evaluated by through compression, flexural and short beam transverse bending tests. Microscopy was used to evaluate the quality of the processed laminates, and fractography was used to characterize the observed failure modes. The study provides an improved understanding of the relationships between processing methods, resin characteristics, and mechanical performance of thermoplastic resin composite materials.