Comparison of Fatigue Life Between C/SiC and SiC/SiC Ceramic-Matrix Composites at Room and Elevated Temperatures

In this paper, the comparison of fatigue life between C/SiC and SiC/SiC ceramic-matrix composites (CMCs) at room and elevated temperatures has been investigated. An effective coefficient of the fiber volume fraction along the loading direction (ECFL) was introduced to describe the fiber architecture of preforms. Under cyclic fatigue loading, the fibers broken fraction was determined by combining the interface wear model and fibers statistical failure model at room temperature, and interface/fibers oxidation model, interface wear model and fibers statistical failure model at elevated temperatures in the oxidative environments. When the broken fibers fraction approaches to the critical value, the composites fatigue fracture. The fatigue life S–N curves and fatigue limits of cross-ply, 2D and 3D C/SiC and SiC/SiC composites at room temperature, 550 °C in air, 750 °C in dry and humid condition, 800 °C in air, 1000 °C in argon and air, 1100 °C, 1300 °C and 1500 °C in vacuum, have been predicted. At room temperature, the fatigue limit of 2D C/SiC composite with ECFL of 20 % lies between 0.78 and 0.8 tensile strength; and the fatigue limit of 2D SiC/SiC composite with ECFL of 20 % lies between 0.75 and 0.85 tensile strength. The fatigue limit of 2D C/SiC composite increases to 0.83 tensile strength with ECFL increasing from 20 to 22.5 %, and the fatigue limit of 3D C/SiC composite is 0.85 tensile strength with ECFL of 37 %. The fatigue performance of 2D SiC/SiC composite is better than that of 2D C/SiC composite at elevated temperatures in oxidative environment.     

Tension-Compression Fatigue of a Nextel™720/alumina Composite at 1200 °C in Air and in Steam

Tension-compression fatigue behavior of an oxide-oxide ceramic-matrix composite was investigated at 1200 °C in air and in steam. The composite is comprised of an alumina matrix reinforced with Nextel?720 alumina-mullite fibers woven in an eight harness satin weave (8HSW). The composite has no interface between the fiber and matrix, and relies on the porous matrix for flaw tolerance. Tension-compression fatigue behavior was studied for cyclical stresses ranging from 60 to 120 MPa at a frequency of 1.0 Hz. The R ratio (minimum stress to maximum stress) was ?1.0. Fatigue run-out was defined as 10⁵ cycles and was achieved at 80 MPa in air and at 70 MPa in steam. Steam reduced cyclic lives by an order of magnitude. Specimens that achieved fatigue run-out were subjected to tensile tests to failure to characterize the retained tensile properties. Specimens subjected to prior cyclic loading in air retained 100 % of their tensile strength. The steam environment severely degraded tensile properties. Tension-compression cyclic loading was considerably more damaging than tension-tension cyclic loading. Composite microstructure, as well as damage and failure mechanisms were investigated.     

Experimental determination of the mode I delamination fracture and fatigue properties of thin 3D woven composites

The mode I delamination fracture toughness and fatigue strength of thin-section three-dimensional (3D) woven composite materials is experimentally determined. The non-crimp 3D orthogonally woven carbon–epoxy composites were thin (2 mm) and consequently their through-thickness z-binder yarns were inclined at a very steep angle (about 70°) from the orthogonal direction. The steep z-binder angle has a marked effect on the delamination toughening and fatigue strengthening mechanisms. Experimental testing revealed that the fracture toughness and fatigue resistance increased progressively with the volume content of z-binders. However, the steep angle caused the z-binder yarns bridging the delamination crack to deform and fail in shear and through-thickness tension, rather than in-plane tension which usually occurs in thick 3D woven composites. Mode I pull-off tests on a single woven z-binder yarn embedded within the composite revealed that the crack bridging traction load, strain energy absorption and failure mechanism were strongly affected by the steep angle.     

A comparative study of tensile properties of non-crimp 3D orthogonal weave and multi-layer plain weave E-glass composites. Part 2: Comprehensive experimental results

This Part 2 paper presents results of comparative experimental study of progressive damage in 2D and 3D woven glass/epoxy composites under in-plane tensile loading. As Part 1, this Part 2 work is focused on the comparison of in-plane tensile properties of two non-crimp single-ply 3D orthogonal weave E-glass fibre composites on one side and a laminate reinforced with four plies of E-glass plain weave on the other. The damage investigation methodology combines mechanical testing with acoustic emission registration (that provides damage initiation thresholds), progressive cracks observation on transparent samples, full-field surface strain mapping and cracks observation on micrographs, altogether enabling for a thorough characterisation of the local micro- and meso-damage modes of the studied composites. The obtained results demonstrate that the non-crimp 3D orthogonal woven composites have significantly higher in-plane strengths, failure strains and damage initiation thresholds than their 2D woven laminated counterpart. The growth of transverse cracks in the yarns of 3D composites is delayed, and they are less prone to a yarn–matrix interfacial crack formation and propagation. Delaminations developing between the plies of plain weave fabric in the laminate at certain load level never appear in the 3D woven single-ply composites.     

Effect of frequency and environment on fatigue behavior of a CVI SiC/SiC ceramic matrix composite at 1200 °C

The fatigue behavior of a SiC/SiC CMC (ceramic matrix composite) was investigated at 1200 °C in laboratory air and in steam environment. The composite consists of a SiC matrix reinforced with laminated woven Hi-Nicalon™ fibers. Fiber preforms had boron nitride fiber coating applied and were then densified with CVI SiC. Tensile stress-strain behavior and tensile properties were evaluated at 1200 °C. Tension-tension fatigue tests were conducted at frequencies of 0.1, 1.0, and 10 Hz for fatigue stresses ranging from 80 to 120 MPa in air and from 60 to 110 MPa in steam. Fatigue run-out was defined as 10⁵ cycles at the frequency of 0.1 Hz and as 2 × 10⁵ cycles at the frequencies of 1.0 and 10 Hz. Presence of steam significantly degraded the fatigue performance. In both test environments the fatigue limit and fatigue lifetime decreased with increasing frequency. Specimens that achieved run-out were subjected to tensile tests to failure to characterize the retained tensile properties. The material retained 100% of its tensile strength, yet modulus loss up to 22% was observed. Composite microstructure, as well as damage and failure mechanisms were investigated.     

Characterising the loading direction sensitivity of 3D woven composites: Effect of z-binder architecture

Three different architectures of 3D carbon fibre woven composites (orthogonal, ORT; layer-to-layer, LTL; angle interlock, AI) were tested in quasi-static uniaxial tension. Mechanical tests (tensile in on-axis of warp and weft directions as well as 45° off-axis) were carried out with the aim to study the loading direction sensitivity of these 3D woven composites. The z-binder architecture (the through-thickness reinforcement) has an effect on void content, directional fibre volume fraction, mechanical properties (on-axis and off-axis), failure mechanisms, energy absorption and fibre rotation angle in off-axis tested specimens. Out of all the examined architectures, 3D orthogonal woven composites (ORT) demonstrated a superior behaviour, especially when they were tested in 45° off-axis direction, indicated by high strain to failure (∼23%) and high translaminar energy absorption (∼40 MJ/m³). The z-binder yarns in ORT architecture suppress the localised damage and allow larger fibre rotation during the fibre “scissoring motion” that enables further strain to be sustained by the in-plane fabric layers during off-axis loading.     

Creep of plain weave polymer matrix composites under on-axis and off-axis loading

Despite the increasing use of polymer woven composites in load-bearing structural applications, published research on their long-term durability is very limited. Hence, creep of plain weave polymer woven composites was investigated experimentally and analytically, using Hexcel Corporation’s F263/T300 2-harness (HS) composite material under on-axis (0°) and off-axis (45°) loading. Constant load creep experiments were conducted over a wide range of temperatures (80–240 °C) and stresses (1–70% of the ultimate tensile strength). Time–temperature-superposition-principle (TTSP) was used to obtain master creep curves at each stress level for a time period beyond the experimental time window. A modified equivalent laminate model (MELM) was developed to predict the creep compliance of plain weave composites for any load orientation with respect to fiber axis, using experimental creep compliance of unidirectional polymer composites. The model predictions were found to be in good agreement with the experimental results, within as well as beyond the experimental time window.     

Tensile fatigue behaviour of glass plain-weave fabric composites in on- and off-axis directions

The tension–tension fatigue behaviour of woven fabric composites was investigated in the on-axis and off-axis directions. Similar to the static tensile properties of woven fabric composites, the tension–tension fatigue behaviour of woven fabric composites was also observed to be anisotropic. The fatigue damage development in both the directions was studied using scanning electron microscopy and acoustic emission techniques. The influence of the applied fatigue frequency and the fatigue stress ratio in both the directions was investigated. At a fatigue frequency of 5 Hz, the hysteresis heating will occur more severely in the off-axis direction than in the on-axis direction. Increasing fatigue stress ratio will lead to a lower hysteresis heating.     

A Finite Element and Experimental Analysis of Composite T-Joints Used in Wind Turbine Blades

In this study, a finite element failure model was created using ABAQUS to determine the location where delamination is initiated and its subsequent propagation. The effect of fibre-reinforced structures on delamination behaviour was studied. The composite T-joints were made of glass fabric infused with epoxy resin using a vacuum assisted resin transfer moulding technique. The veil layer and 3D weave techniques were employed to improve the properties in the through-thickness direction that can delay or prevent delamination when in service. All the pull-out tensile tests were conducted in an Instron testing machine using a specially designed test fixture. The 3D weave T-joints were found to have improved performance under both static and fatigue loading. Increasing the static properties increases fatigue life performance. The location for the through-thickness reinforcement plays an important role in extending fatigue life of the T-joints.     

Progressive damage analysis and strength prediction of 2D plain weave composites

A two-step, multi-scale progressive damage analysis is implemented to study the damage and failure behaviors of 2D plain weave composites under various uniaxial and biaxial loadings. In the progressive damage mode (PDM), a formal-unified 3D Hashin-type criterion is formed to facilitate analysis work and engineering application, with shear nonlinearity considered in the stiffness matrix of yarn. The periodic boundary conditions are developed for the off-axis loading simulations. The simulated stress–strain curves under on-axis uniaxial tension and compression show good agreements with experimental results. The influences of different 3D Hashin-type criteria are subsequently discussed. Moreover, the strength decrease at different off-axis angles and the failure envelopes under on-axis and 45° off-axis biaxial loadings are obtained, with the discussion of different failure characteristics under each loading condition.     

Investigating the Potential of Using Off-Axis 3D Woven Composites in Composite Joints’ Applications

The effect of circular notch has been evaluated for three different architectures of three-dimensional (3D) carbon fibre woven composites (orthogonal, ORT; layer-to-layer, LTL; angle interlock, AI) through open-hole quasi-static tension and double-lap bearing strength tests in the off-axis (45°) direction. Damage characterisation is monitored using Digital Image correlation (DIC) for open-hole testing and X-ray Computed Tomography (CT) for double-lap bearing strength test. The off-axis notched 3D woven composites exhibits minor reduction (less than 10 %) of the notched strength compared to the un-notched strength. DIC strain contour clearly show stress/strain localisation regions around the hole periphery and stress/strain redistribution away from the whole due to the z-binder existence, especially for ORT architecture. Up to 50 % bearing strain, no significant difference in the bearing stress/bearing strain response is observed. However when ORT architecture was loaded up to failure, it demonstrates higher strain to failure (~140 %) followed by AI (~105 %) and lastly LTL (~85 %). X-ray CT scans reveal the effect of the z-binder architecture on damage evolution and delamination resistance. The study suggests that off-axis loaded 3D woven composites, especially ORT architecture, has a great potential of overcoming the current challenges facing composite laminates when used in composite joints’ applications.     

Creep Behavior in Interlaminar Shear of a SiC/SiC Ceramic Composite with a Self-healing Matrix

Creep behavior in interlaminar shear of a non-oxide ceramic composite with a multilayered matrix was investigated at 1,200 °C in laboratory air and in steam environment. The composite was produced via chemical vapor infiltration (CVI). The composite had an oxidation inhibited matrix, which consisted of alternating layers of silicon carbide and boron carbide and was reinforced with laminated Hi-Nicalon? fibers woven in a five-harness-satin weave. Fiber preforms had pyrolytic carbon fiber coating with boron carbide overlay applied. The interlaminar shear properties were measured. The creep behavior was examined for interlaminar shear stresses in the 16–22 MPa range. Primary and secondary creep regimes were observed in all tests conducted in air and in steam. In air and in steam, creep run-out defined as 100 h at creep stress was achieved at 16 MPa. Larger creep strains were accumulated in steam. However, creep strain rates and creep lifetimes were only moderately affected by the presence of steam. The retained properties of all specimens that achieved run-out were characterized. Composite microstructure, as well as damage and failure mechanisms were investigated.     

Notch Sensitivity of Fatigue Behavior of a Hi-Nicalon™/SiC-B4C Composite at 1,200 °C in Air and in Steam

The effect of holes on the fatigue life of a non-oxide ceramic composite processed via chemical vapor infiltration (CVI) was examined at 1,200 °C in laboratory air and in steam. The effect of holes on tensile strength at 1,200 °C was also evaluated. The composite comprised laminated woven Hi-Nicalon? fibers in an oxidation inhibited matrix, which consisted of alternating layers of silicon carbide and boron carbide. Fiber preforms had pyrolytic carbon fiber coating with boron carbon overlay applied. Unnotched specimens and specimens with a center hole having a radius to width ratio of 0.24 were tested in tension-tension fatigue at 0.1 Hz and at 1.0 Hz. The fatigue stresses ranged from 100 to 140 MPa in air and in steam. Fatigue run-out was defined as 10⁵ cycles at 0.1 Hz and as 2?×?10⁵ cycles at 1.0 Hz. The net-section strength was less than the unnotched ultimate tensile strength. Comparison of notched and unnotched data also revealed that the fatigue performance was notch insensitive in both air and steam environments. Composite microstructure, as well as damage and failure mechanisms were investigated.     

Effects of Steam Environment on Fatigue Behavior of Two SiC/[SiC+Si<Subscript>3</Subscript>N<Subscript>4</Subscript>] Ceramic Composites at 1300°C

The fatigue behaviors of two SiC/[SiC+Si₃N₄] ceramic matrix composites (CMC) were investigated at 1,300°C in laboratory air and in steam. Composites consisted of a crystalline [SiC+Si₃N₄] matrix reinforced with either Sylramic™ or Sylramic-iBN fibers (treated Sylramic™ fibers that possess an in situ BN coating) woven in a five-harness satin weave fabric and coated with a proprietary boron-containing dual-layer interphase. The tensile stress–strain behaviors were investigated and the tensile properties measured at 1,300°C. Tension–tension fatigue behaviors of both CMCs were studied for fatigue stresses ranging from 100 to 180 MPa. The fatigue limit (based on a run-out condition of 2 × 10⁵ cycles) in both air and steam was 100 MPa for the CMC containing Sylramic™ fibers and 140 MPa for the CMC reinforced with Sylramic-iBN fibers. At higher fatigue stresses, the presence of steam caused noticeable degradation in fatigue performance of both composites. The retained strength and modulus of all run-out specimens were characterized. The materials tested in air retained 100% of their tensile strength, while the materials tested in steam retained only about 90% of their tensile strength.     

Tension–compression fatigue of a SiC/SiC ceramic matrix composite at 1200 °C in air and in steam

Tension–compression fatigue behavior of a non-oxide ceramic composite with a multilayered matrix was investigated at 1200 °C in laboratory air and in steam. The composite was produced via chemical vapor infiltration (CVI). The composite had an oxidation inhibited matrix, which consisted of alternating layers of silicon carbide and boron carbide and was reinforced with laminated woven Hi-Nicalon™ fibers. Fiber preforms had pyrolytic carbon fiber coating with boron carbide overlay applied. Tension–compression fatigue behavior was studied for fatigue stresses ranging from 80 to 200 MPa at a frequency of 1.0 Hz. Presence of steam significantly degraded the fatigue performance. Specimens that achieved fatigue run-out were subjected to tensile tests to failure to characterize the retained tensile properties. The material retained 100% of its tensile strength. Composite microstructure, as well as damage and failure mechanisms were investigated.     

温度对三维五向编织/环氧树脂复合材料拉伸性能的影响

研究了三维五向编织/环氧树脂复合材料和树脂基层合复合材料在室温、80℃、150℃和180℃的拉伸性能,讨论了不同温度对三维五向编织复合材料和层合复合材料拉伸的影响规律。研究结果表明,三维五向编织复合材料在80℃、150℃时的拉伸强度与室温相近,而在180℃时,比室温时的拉伸强度下降了15.37%;层合复合材料在80℃、150℃和180℃时的拉伸强度则比室温分别下降了3.45%、13.3%和34.42%。造成层合复合材料高温拉伸强度下降较大的原因是:在高温时,由于树脂被破坏,使层合复合材料发生了分层。说明相同树脂基体的复合材料,增强体结构对复合材料在高温时的拉伸性能有着重要的影响。     

复杂面内应力状态下平面编织高铝纤维增强氧化铝基复合材料强度及疲劳寿命预测方法

针对平面编织氧化铝基复合材料提出了一种复杂面内应力状态下的强度准则和疲劳寿命预测方法。通过拉伸、压缩及纯剪切试验,分别获得了材料的静强度指标。考虑材料拉、压性能的差异和面内拉-剪联合作用对材料强度的影响机制,提出了修正的Hoffman强度理论。采用该强度理论预测得到的偏轴拉伸强度与试验结果基本一致,偏差不超过10%。开展了偏轴角θ=0°、15°、30°、45°,应力比R=0.1,频率f=10 Hz的拉伸疲劳试验,试验结果表明随着偏轴角的增加,相同轴向拉伸载荷下的疲劳寿命逐渐降低。由于面内剪切应力分量的作用,疲劳失效由纤维主导逐渐过渡到纤维和基体共同主导的模式。基于单轴疲劳寿命曲线,采用Broutman-Sahu剩余强度模型表征剩余强度随疲劳循环次数的变化规律,结合剩余强度演化模型和修正的Hoffman强度理论,提出了一种面内复杂载荷条件下的疲劳寿命预测模型,并引入疲劳剪切损伤影响因子表征拉-剪应力联合作用对材料疲劳行为的影响。采用本文提出的疲劳寿命预测模型,预测不同偏轴角拉伸疲劳寿命,预测结果与试验结果基本一致,偏差在1倍寿命范围内。比较结果表明在给定应力比、温度和疲劳载荷频率条件下,该疲劳寿命预测模型可以用来预测平面编织氧化铝基复合材料拉-剪复杂面内载荷条件下疲劳寿命。      

Bending, compression, and shear behavior of woven glass fiber–epoxy composites

The mechanical properties and failure mechanisms of through-the-thickness stitched plain weave glass fabric–epoxy composites were studied. Unstitched plain weave and biaxial non-crimp fabrics were used for comparison. Composite panels were fabricated using Resin Transfer Molding. Z-directional stitching increased the delamination resistance and lowered the bending strength of the composites. Composites made from through-the-thickness stitched fabrics demonstrated improved compression after impact behavior as compared to the unstitched fabrics. The results presented in this investigation should be useful in tailoring textile composites to achieve specific property goals.