Microscopic failure mechanisms of fiber-reinforced polymer composites under transverse tension and compression

The mechanical behavior of unidirectional fiber-reinforced polymer composites subjected to tension and compression perpendicular to the fibers is studied using computational micromechanics. The representative volume element of the composite microstructure with random fiber distribution is generated, and the two dominant damage mechanisms experimentally observed – matrix plastic deformation and interfacial debonding – are included in the simulation by the extended Drucker–Prager model and cohesive zone model respectively. Progressive failure procedure for both the matrix and interface is incorporated in the simulation, and ductile criterion is used to predict the damage initiation of the matrix taking into account its sensitivity to triaxial stress state. The simulation results clearly reveal the damage process of the composites and the interactions of different damage mechanisms. It can be concluded that the tension fracture initiates as interfacial debonding and evolves as a result of interactions between interfacial debonding and matrix plastic deformation, while the compression failure is dominated by matrix plastic damage. And then the effects of interfacial properties on the damage behavior of the composites are assessed. It is found that the interfacial stiffness and fracture energy have relatively smaller influence on the mechanical behavior of composites, while the influence of interfacial strength is significant.     

Effect of coupling agents on reinforcing potential of recycled carbon fibre for polypropylene composite

Polypropylene (PP) composites reinforced with recycled carbon fibre have been prepared through extrusion compounding and injection moulding. The reinforcing potential of the recycled fibre was increased by improving the interfacial adhesion between the fibre and PP matrix and this was done by the addition of maleic anhydride grafted polypropylene (MAPP) coupling agents. Three MAPP couplers with different molecular weights and maleic anhydride contents were considered. The effects on the mechanical properties of the composite were studied, and scanning electron microscopy (SEM) was used to study the fracture morphology of the tensile specimens. It was observed that with the addition of MAPP the interfacial adhesion was improved as fewer fibres were pulled-out and less debonding was seen. A microbond test was performed and a significant improvement in interfacial shear strength was measured. This resulted in composites with higher tensile and flexural strengths. The maximum strength was achieved from MAPP with the highest molecular weight. Increased modulus was also achieved with certain grades of MAPP. It was also found that the composite impact strength was improved significantly by MAPP, due to a higher compatibility between the fibre and matrix, which reduced crack initiation and propagation.     

Deformation micromechanics of a model cellulose/glass fibre hybrid composite

Interfacial stress transfer in a model hybrid composite has been investigated. An Sm³⁺ doped glass fibre and a high-modulus regenerated cellulose fibre were embedded in close proximity to each other in an epoxy resin matrix dumbbell-shaped model composite. This model composite was then deformed until the glass fibre fragmented. Shifts of the absolute positions of a Raman band from the cellulose fibre, located at 1095 cm⁻¹, and a luminescence band from a doped glass fibre, located at 648 nm, were recorded simultaneously. A calibration of these shifts, for both fibres deformed in air, was used to determine the point-to-point distribution of strain in the fibres around the breaks in the glass fibre. Each break that occurred in the glass fibre during fragmentation was shown to generate a local stress concentration in the cellulose fibre, which was quantified using Raman spectroscopy. Using theoretical model fits to the data it is shown that the interfacial shear stress between both fibres and the resin can be determined. A stress concentration factor (SCF) was also determined for the regenerated cellulose fibre, showing how the presence of debonding reduces this factor. This study offers a new approach for following the micromechanics of the interfaces within hybrid composite materials, in particular where plant fibres are used to replace glass fibres.     

The role of interfaces and matrix void nucleation mechanism on the ductile fracture process of discontinuous fibre-reinforced composites

The role of fibre morphology, interface failure and void nucleation mechanisms within the matrix on the deformation and fracture behaviour of discontinuous fibre-reinforced composites was numerically investigated. The matrix was modelled using a constitutive relationship that accounts for strength degradation resulting from the nucleation and growth of voids. For the matrix, two materials exhibiting identical strength and ductility but having different void-nucleation mechanisms (stress-controlled and strain-controlled) were considered and fibres were assumed to be elastic. The debonding behaviour at the fibre interfaces was simulated in terms of a cohesive zone model which describes the decohesion by both normal and tangential separation. The results indicate that in the absence of interface failure, for a given fibre morphology the void nucleation in the matrix is the key controlling parameter of the composite strength and ductility, hence, of the fracture toughness. The weak interfacial behaviour between the fibres and the matrix can significantly increase the ductility without sacrificing strength for certain fibre morphology and for certain matrix void-nucleation mechanisms.     

An evaluation of acoustic emission from fibre-reinforced composites

An analysis of acoustic emission(AE) from epoxy matrices of different amounts of hardener and model composites containing a glass bead, carbon and glass fibres has been carried out to identify the sources of emission. A few AE events generated by microcracking were observed for epoxy matrix near the final fracture strain. From microscopic and emission observations it was found that the emission was generated by interfacial debonding at the pole for the model composite containing a single particle of the glass bead, and that the source of AE bursts for a continuous single carbon fibre/epoxy composite was succeeding fibre fractures along fibre length. The high AE activity due to fibre fracture was observed for a composite consisting of a bundle of glass fibres. The total of AE events was in agreement with the number of fibre fracture counted with the aid of a microscope in a carbon/epoxy composite. The shear strength at the carbon/epoxy interface was evaluated by a critical length of the fractured fibres using the AE results.     

Development of kenaf-glass reinforced unsaturated polyester hybrid composite for structural applications

The main aim of this paper is to develop kenaf-glass (KG) fibres reinforced unsaturated polyester hybrid composite on a source of green composite using sheet moulding compound process. Unsaturated polyester resin (UPE) and KG fibres in mat form were used at a ratio of 70:30 (by volume) with treated and untreated kenaf fibre. The kenaf fibre was treated with 6% sodium hydroxide (NaOH) diluted solution for 3 h using mercerization method. The hybrid composites were tested for flexural, tensile and Izod impact strength using ASTM D790-03, ASTM D618 and ASTM D256-04 standards respectively. The highest flexural, tensile and impact strength were obtained from treated kenaf with 15/15 v/v KG fibres reinforced UPE hybrid composite in this investigation.Scanning electron microscopy fractography showed fibre cracking, debonding and fibre pulled-out as the main fracture mode of composites and kenaf treated 15/15 v/v KG reinforced hybrid composite exhibited better interfacial bonding between the matrix and reinforcement compared to other combinations.     

Effects of fibre/matrix adhesion on carbon-fibre-reinforced metal laminates—I.: Residual strength

The role of interfacial adhesion between fibre and matrix on the residual strength behaviour of carbon-fibre-reinforced metal laminates (FRMLs) has been investigated. Differences in fibre/matrix adhesion were achieved by using treated and untreated carbon fibres in an epoxy resin system. Mechanical characterisation tests were conducted on bulk composite specimens to determine various properties such as interlaminar shear strength (ILSS) and transverse tension strength which clearly illustrate the difference in fibre/matrix interfacial adhesion. Scanning electron microscopy confirmed the difference in fracture surfaces, the untreated fibre composites showing interfacial failure while the treated fibre composites showed matrix failure. No clear differences were found for the mechanical properties such as tensile strength and Young's modulus of the FRMLs despite the differences in the bulk composite properties. A reduction of 7·5% in the apparent value of the ILSS was identified for the untreated fibre laminates by both three-point and five-point bend tests. Residual strength and blunt notch tests showed remarkable increases in strength for the untreated fibre specimens over the treated ones. Increases of up to 20% and 14% were found for specimens with a circular hole and saw cut, respectively. The increase in strength is attributed to the promotion of fibre/matrix splitting and large delamination zones in the untreated fibre specimens owing to the weak fibre/matrix interface.     

Fracture mechanics approach for a partially debonded cylindrical fibre

The mechanical behaviour of the fibre-reinforced composites depends on the properties of the matrix, the fibres and their reciprocal bonding. Degrading effects occurring in such materials under service – such as matrix–fibre detaching (debonding), fibre breaking, matrix cracking – must be taken into account in the safety assessments. In the present paper, the fibre–matrix debonding phenomenon at the fibre–matrix interface is examined through fracture mechanics concepts, since a geometric discontinuity arises at the edge of the debonded zone (between two dissimilar materials) producing a stress singularity. The mixed mode stress-intensity factors are determined, and the effects of the geometrical and mechanical parameters related to matrix and fibres are discussed.     

Characterization of interfacial stress transfer ability of particulate cellulose composite materials

Composites with cellulose reinforcements are steadily gaining increased use. The stress transfer ability between reinforcement and polymer matrix has a strong influence on mechanical properties like strength and fracture toughness. This work presents a method to assess the stress transfer ability between cellulose and polymer matrix from a model material with cellulose spheres embedded in a polymer matrix. Such a material show smaller variability compared with composites based on natural cellulose fibres, and is less cumbersome than single fibre tests with regard to interfacial characterization. Measured elastic moduli of particulate composites is compared with predicted values from a micromechanical model based on a composite sphere assembly in a self-consistent scheme with only a spring constant of an imperfect interface as fitting parameter expressed in Pa/m. This interface parameter is identified through inverse modelling and used to quantify stress-transfer ability of cellulose/polylactide and cellulose/polystyrene composite interfaces. A higher degree of interfacial interaction was found for the former. This ranking was corroborated by adhesive force measurements using a micrometre sized cellulose sphere attached to the end of a cantilever in an atomic force microscope. With the model microstructure of a cellulose-sphere composite, an interfacial efficiency parameter can be backed out from stiffness measurements to be used in e.g. ranking of different fibre surface treatments and choice of matrix in the development of stronger natural-fibre composites.     

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.     

2D and 3D imaging of fatigue failure mechanisms of 3D woven composites

A detailed investigation of the failure mechanisms for angle-interlocked (AI) and modified layer-to-layer (MLL) three dimensional (3D) woven composites under tension–tension (T–T) fatigue loading has been conducted using surface optical microscopy, cross-sectional SEM imaging, and non-destructive X-ray computed tomography (CT). X-ray microCT has revealed how cracks including surface matrix cracks, transverse matrix cracks, fibre/matrix interfacial debonding or delamination develop, and has delineated the complex 3D morphology of these cracks in relation to fibre architecture. For both weaves examined, transverse cracks soon become uniformly distributed in the weft yarns. A higher crack density was found in the AI composite than the MLL composite. Transverse cracking initiates in the fibre rich regions of weft yarns rather than the resin rich regions. Delaminations in the failed MLL specimen were more extensive than the AI specimen. It is suggested that for the MLL composite that debonding between the binder yarns and surrounding material is the predominant damage mechanism.     

An evaluation of acoustic emission from fibre-reinforced composites

An analysis of acoustic emission (AE) from model composites consisting of a single aramid fibre and different epoxy matrix systems has been carried out to identify the source of acoustic emission. The AE activity was observed in a narrow range of strain when fibre fracture occurred, whereas in a relatively wide range of strain, debonding occurred at the fibre-matrix interface. Ion-etched fibres showed a good adhesion of the fibres to the matrix so as to produce fibre fracture in place of interfacial debonding. The total number of AE events has one to one correspondence with the number of broken fibres. The effect of surface treatment and matrix systems on the shear fracture strength between the fibre and matrix were described based on the critical length of the broken fibres using AE results.     

Mechanical properties of 3D KD-I SiCf/SiC composites with engineered fibre-matrix interfaces

Three-dimensional (3D) silicon carbide (SiC) matrix composites reinforced with KD-I SiC fibres were fabricated by precursor impregnation and pyrolysis (PIP) process. The fibre-matrix interfaces were tailored by pre-coating the as-received KD-I SiC fibres with PyC layers of different thicknesses or a layer of SiC. Interfacial characteristics and their effects on the composite mechanical properties were evaluated. The results indicate that the composite reinforced with as-received fibre possessed an interfacial shear strength of 72.1 MPa while the composite reinforced with SiC layer coated fibres had a much higher interfacial shear strength of 135.2 MPa. However, both composites showed inferior flexural strength and fracture toughness. With optimised PyC coating thickness, the interface coating led to much improved mechanical properties, i.e. a flexural strength of 420.6 MPa was achieved when the interlayer thickness is 0.1 μm, and a fracture toughness of 23.1 MPa m^1/2 was obtained for the interlayer thickness of 0.53 μm. In addition, the composites prepared by the PIP process exhibited superior mechanical properties over the composites prepared by the chemical vapour infiltration and vapour silicon infiltration (CVI-VSI) process.     

Evaluation of interface fracture energy for single-fibre composites

Raman and luminescence spectroscopy have been used for the first time to determine the interface fracture energy for single-fibre composites. By using the measured fibre stress distributions in single-fibre fragmentation composite specimens and a simple energy-balance scheme, the energy for the initiation of interfacial debonding has been estimated for carbon (T50) and α-alumina (PRD-166 and Nextel 610) fibres embedded in epoxy resins. It has been found that the interface fracture energy shows good sensitivity to changes in the level of fibre/matrix adhesion due to surface treatment and sizing of the fibres. It is also found that the values of interface fracture energy correlate well with measured values of interfacial shear strength determined for the same fibre/matrix systems.     

Investigation of the influence of surface-activated carbon fibres on debonding energy and frictional stress in polymer-matrix composites by the micro-indentation technique

The influence on fibre/matrix adhesion of the acidic and basic nature of surface-activated carbon fibres in epoxy and PPS matrices has been investigated by means of the micro-indentation method. The fibre ‘push-out’ and ‘push-in’ techniques were used for this study. The debonding energy and frictional stress are calculated, and the adhesion behaviour is compared with the calculated thermodynamical work of adhesion (as derived from the fibre surface tension) and surface oxygen content. Influence of surface activation on the interfacial frictional stress is discussed.     

The effect of isothermal exposure on the transverse properties of a continuous fibre metal-matrix composite

The effect of isothermal exposure at 500° C on the transverse mechanical properties of 30 and 50 vol % continuous boron-fibre reinforced 1100 aluminium composites has been investigated. Experimental results indicate that the fibre-matrix interfacial reaction gives rise to an increase in the fibre-matrix bond strength. Consequently, the fracture mode undergoes a transition from interfacial debonding to fibre splitting with increasing exposure time. The fracture surfaces and fibre-matrix interfaces have been studied by scanning electron microscopy and the observations coincide with the above interpretation of the mechanical test results. Finally, a new theoretical model using Eshelby's theory is developed to analyse the stress-strain behaviour of a continuous fibre reinforced metal matrix composite subjected to transverse tensile loading.On leave from Pioneering R & D Laboratories, Toray Industries, Inc., 2-1, 3-chome, Sonoyama, Otsu, Shiga 520, Japan.     

Interfacial failure in poly(p-phenylene benzobisoxazole) (PBO)/epoxy single fibre pull-out specimens

The pull-out behaviour of poly(p-phenylene benzobisoxazole) fibres from an epoxy resin has been shown to follow that predicted by the elastic stress transfer shear-lag model at low applied strains, but at higher matrix strains a partial debonding model was more suitable. Debonding of the fibre/matrix interface led to interfacial failure where only friction resisted fibre extraction. Raman spectroscopy was able to quantify this level of friction and together with in situ optical microscopy proved an excellent method for the close monitoring of the frictional pull-out process. The effect of fibre surface treatment was also studied. The interfacial shear stress values from the heat-treated and corona-treated fibres showed only small differences. The failure processes were examined further using scanning electron microscopy and clean fibre pull-out was observed with the heat-treated fibre whereas fracture of the free fibre occurred with the corona-treated fibre.     

Effect of water on the mechanical adhesion of the glass/epoxy interface

In recent years, the quality of the fibre/matrix bonding in polymer composites has been quantified by means of a single mechanical parameter, the interfacial shear strength, based on measurements made using micromechanical techniques. It has gradually appeared, however, that this parameter is both ambiguous in terms of its physical meaning and, at the same time, difficult to measure reliably in many cases. Moreover, different micromechanical techniques yield differing values of the interfacial shear strength. Finally, it has been suggested in a few studies that it may not be the critical factor governing fibre/matrix debonding. In this paper an energy balance approach is proposed, by which the degree of fibre/matrix bonding is now quantified by means of the interfacial energy, as a function of the fibre geometrical and mechanical characteristics, the stress transfer length and the debonding length. The validity of the approach is discussed in the case of the single-fibre composite test, in which progressive fragmentation of a single brittle fibre in a more ductile polymeric matrix takes place, using data for E-glass fibres embedded in epoxy, both in the dry state and in the presence of hot distilled water.     

Tailoring of dual-interface in high tenacity PP composites – Toughening with positive hybrid effect

The study proves the feasibility of manufacturing injection moulded polypropylene composites reinforced with short rayon cellulose fibres of two selectively tailored fibre–matrix interfaces. The originally developed method relies on selective chemical grafting of two different polymer waxes onto the surface of cellulose fibres in order to obtain two different strengths of fibre–matrix interfaces in one composite. This selective tailoring of a dual-interface is meant to improve the notched impact strength without deteriorating of its flexural strength. Compatibilised fibres have a strong interphase, which conditions the transfer of strain from the matrix to fibres during deformation. Fibres tailored for a weak interface more efficiently hinder the crack propagation at crash. A 32% improvement of composite notched impact strength was achieved with merely a 5% deterioration of its flexural strength. Its specific properties are on the level or better than those of polypropylene counterpart reinforced with the same content of glass fibres.     

Effects of the presence of compression in transverse cyclic loading on fibre–matrix debonding in unidirectional composite plies

Fatigue of composite materials is of great concern in load-carrying structures. The first type of damage to appear is generally transverse cracks in off-axis plies. These cracks form when fibre–matrix debonds coalesce. The underlying mechanism is hence fatigue growth of debonds at the fibre–matrix interfaces. In the present study, debond growth has been characterized under tensile and compressive cyclic loading of single glass fibres embedded in polymer matrix. The debond length was determined by in situ microscopy with transmitted polarized light showing the more damaging effect of tension–compression cyclic loading than tension–tension cyclic loading. A boundary element model has been developed and interfacial fracture mechanics concepts applied over the numerical results aiming to give an explanation of this experimental fact. These results may be used to formulate a fatigue growth law at a local microscopic level, at a stage prior to the formation of any visible damage, i.e. transverse cracks. Ideas of how to develop this methodology further are also discussed.