A study on residual fatigue bending strength and damage behavior of CFRP composites subjected to impact loadings

This paper evaluates the static and fatigue bending strengths of CFRP (carbon-fiber reinforced plastic) laminates having impact damages, e.g., foreign object damages (FOD). Composite laminates used in this experiment are CF/EPOXY and CF/PEEK orthotropy laminated plates with two-interfaces [0°₄/90°₄]_s A steel ball launched by an air gun collides against the CFRP laminates to generate impact damages. The damage growth during a bending fatigue test is observed by a scanning acoustic microscope (SAM). When the impacted side is compressed, the residual fatigue bending strength of CF/PEEK specimen P is greater than that of CF/EPOXY specimen B. On the other hand, when the impacted side is in tension, the residual fatigue bending strength of CF/PEEK specimen P is smaller than that of CF/EPOXY specimen B. In the case of impacted-side compression, the fracture is propagated from the transverse crack generated near the impact point. In the case of impacted-side tension, however, the fracture develops toward the impact point from the edge of interface-B delamination.     

Impact damages and residual bending strength of CFRP composite laminates subjected to impact loading

The purpose of this study is to confirm the decreasing in residual bending strength, and the failure mechanisms experimentally when CFRP composite laminates are subjected to foreign object damage (FOD). Composite laminates used in this test are CFRP orthotropic laminated plates, which are stacked with two-interfaces [0^o ₆/90^o ₆] _sym and four-interfaces [0^o ₃/90^o ₆/0^o ₃] _sym . When the specimen was subjected to transverse impact by a steel ball, the delamination area generated by the impact damage was observed by using the SAM (scanning acoustic microscope). Also, the fracture surfaces obtained by three-point bending test were observed by using the SEM (scanning electron microscope). Further, failure mechanisms were investigated based on the observed delamination areas and fracture surfaces.     

层压复合材料剪切疲劳寿命预估

将Iosipescu剪切强度测试方法推广到剪切疲劳试验.以碳纤维/树脂基T300/QY8911复合材料层压板为研究对象,对三种多向铺层试件进行剪切疲劳试验.用一种疲劳损伤累积模型和自行开发的有限元/疲劳寿命分析程序预测被试多向层压板的剪切强度,模拟局部疲劳失效演变的过程,给出疲劳寿命和剩余强度预估结果,比较两种静强度准则(Tsai-Hill准则和Puck修正准则)对预估结果的影响.寿命预测结果与试验结果基本相符.     

Tribological behaviour of Si3N4 and Si3N4-%TiN based composites and multi-layer laminates

Si₃N₄-TiN based multi-layer laminates exhibit differences in residual stress between individual layers due to a variation of the thermal expansion coefficient between the layers. The residual stress distribution in these multi-layer laminates is known to improve the apparent macroscopic fracture toughness. In this work, the tribological behaviour of bulk, composites and multi-layers laminates are investigated. Si₃N₄ bulk, Si₃N₄ based composites with 10, 20 and 30 wt% TiN and different multi-layer laminates have been tested under dry conditions with reciprocal movement using a ball-on-block configuration. In particular, the influence of sliding directions with respect to the layer orientations has been investigated.The experimental results show that wear resistance increased with increasing TiN content in Si₃N₄-TiN composites. However, multi-layer laminates exhibit an up to three times higher apparent fracture toughness, but do not show an improvement of wear resistance compared to composites.     

Interlaminar fracture toughness of CFRP laminates with silk fibers interleave

Interlaminar fracture toughness of CFRP laminates with silk fibers interleave was evaluated in this paper. Silk fibers were obtained from silkworm cocoon. Long silk fibers were wound around a bobbin and cut into specimen size. Resin films were bonded on both sides of a sheet of silk fibers. Silk fibers with resin films were put between [0₁₂] and [0₁₂] and cured by following the curing process. Evaluation of mode I and mode II interlaminar fracture toughness was accomplished by DCB and ENF test, respectively. Mode I interlaminar fracture toughness of CFRP laminates with silk fibers interleave was 59% higher than that of CFRP. Mode II interlaminar fracture toughness of CFRP laminates with silk fibers interleave was 44% higher than that of CFRP. It seems that CFRP laminates with silk fibers interleave will be useful to structures which need high interlaminar fracture toughness.     

Evaluation of material properties and internal damage within CFRP and CFRP/Al sandwich panels due to impact loading

In the present paper, damage development within Carbon fiber reinforced plastic (CFRP) laminates and CFRP/Aluminum (Al) honeycomb core sandwich panels by impact loading was evaluated, and change in material properties due to the damage development was investigated. Falling weight impact tests, 3-point bending tests and cross-sectional observation were carried out. As results, it is found that falling rate of bending elastic modulus due to internal damage in the laminate only is lower than that in the upper face-sheet of the sandwich panel, and that difference in the falling rate between them becomes maximum at the impact energy of 5.1 J. As a result of investigating the relationship between reduction in bending elastic modulus and internal damage development, the reduction is caused by delamination within CFRP laminates mainly. Since total length of cracks in CFRP/Al honeycomb core sandwich panels is smaller than that in the laminates only, the sandwich panels have high impact tolerance because of absorption of impact energy by damaging Al honeycomb core.     

A study on fatigue damage modeling using neural networks

Fatigue crack growth and life have been estimated based on established empirical equations. In this paper, an alternative method using artificial neural network (ANN) -based model developed to predict fatigue damages simultaneously. To learn and generalize the ANN, fatigue crack growth rate and life data were built up using in-plane bending fatigue test results. Single fracture mechanical parameter or nondestructive parameter can’t predict fatigue damage accurately but multiple fracture mechanical parameters or nondestructive parameters can. Existing fatigue damage modeling used this merit but limited real-time damage monitoring. Therefore, this study shows fatigue damage model using backpropagation neural networks on the basis of X-ray half breadth ratioB/B ₀ , fractal dimensionD _f and fracture mechanical parameters can estimate fatigue crack growth rateda/dN and cycle ratioN/N _f at the same time withinengineering limit error (5%).     

Fatigue damage of quasi-isotropic composite laminates under tensile loading in different directions

The purpose of this work is to investigate fatigue damage of quasi-isotropic laminates under tensile loading in different directions. Low cycle fatigue tests of [0/−60/60]_s laminates and [30/−30/90]_s laminates were carried out. Material systems used are AS4/Epoxy and AS4/PEEK. The fatigue damage of [30/−30/90]_s is very different from that of [0/−60/60]_s. The experimental results are compared with the result obtained from the method for determining strain energy release rate components proposed by the authors. The analytical results were in good agreement with the experimental results. It is proved that the failure criterion based on the strain energy release rate is an appropriate approach to predict the initiation and growth of delaminations under cyclic loading.     

基于累积损伤的三维复合材料层合板疲劳寿命研究

基于渐进疲劳损伤模型,建立复合材料层合板的三维疲劳寿命预测模型,模型以单向板单轴疲劳试验数据为基础,结合正则化剩余刚度模型、正则化剩余强度模型和等寿命曲线,通过层合板三维应力分析、失效分析和材料性能退化的循环迭代进行疲劳寿命计算,在Ansys软件平台上利用APDL语言编写相应的计算程序,估算不同铺层参数层合板在单轴和多...     

应力波载荷作用下CFRP、GFRP层板动态拉伸性能的实验研究

介绍了Hopkinson杆冲击拉伸实验设备以及实验技术,推导了应力、应变的计算公式。利用Hopkinson杆加载装置对CFRP、GFRP层合板进行了冲击拉伸实验研究,得到不同应变率下CFRP、GFRP层板的应力、应变(бε)曲线,以及断裂强度、拉伸模量、断裂应变等力学参数,以期对复合材料层板在冲击拉伸情况下动态力学行为和变形、破坏机理有一个初步的认识。     

一种可用于复合材料寿命预测的非线性疲劳损伤累积模型

结合试验数据,提出了一种含有3个待定参数的非线性疲劳损伤累积模型,该模型能够描述复合材料结构疲劳损伤扩展3个阶段,即可以模拟初始循环载荷的损伤快速增长阶段、达到特征损伤状态时的缓慢增长阶段及断裂前损伤快速扩展的阶段。通过算例验证:本文模型与试验数据吻合性较好,可用于对复合材料结构疲劳寿命进行预测及损伤评估。     

高速列车S38C车轴外物致损模拟与疲劳性能研究

外物致损是造成高速列车车轴疲劳失效的典型因素之一。采用立体显微镜分析CRH2系列高速列车S38C车轴表面的损伤，借助轻型空气炮向取于S38C车轴表面的四点弯曲疲劳试样发射多种角度、速度的球形和正方形钨钢弹体，模拟外物致损。采用逐步加载法来确定损伤试样的疲劳强度，在场发射扫描电镜下观测损伤特征和疲劳断口形貌。结果表明，车轴表面的损伤大部分是刮擦，少部分是缺口。球形弹体垂直冲击损伤随着速度的增大变得逐渐恶劣，材料缺失和微裂纹分布在损伤边缘，底部出现绝热剪切带引发的裂纹；球形弹体斜冲击损伤出射区主要以形变和剪切作用下的掉块为主；方形弹体冲击损伤形态各异。不考虑损伤形成的工况，试样疲劳强度随着损伤深度的增加而降低，深度作为损伤评价参数具有可操作性，本研究为车轴外物致损检修标准的制定提供参考。     

纤维金属层板铆接剩余强度影响因素研究

为研究单搭铆接接头中纤维金属层板耦合损伤行为,运用金属硬化Johnson-Cook失效准则、纤维增强复合材料三维Hashin损伤准则、脱层B-K失效理论以及刚度退化失效准则建立了纤维金属层板铆接渐进失效模型,并结合实验验证了模型的合理性。考察了单搭铆接二次弯曲效应、层板铝合金体积分数、预紧力、层板孔边距对纤维金属层板铆接强度和失效模式的影响,为提高纤维金属层板铆接剩余强度提供可靠建议。分析结果表明：二次弯曲效应加速损伤发生,从而降低层板铆接强度,其中偏心加载可以削弱二次弯曲效应,更好地提高铆接强度;层板铝合金体积分数的增大能够提高层板铆接强度,但当体积分数大于50%时层板铆接比刚度和比强度反而下降;预紧力的增加能够提高层板铆接强度和增强层板损伤抗力;随着孔边距的递增,铆接剩余强度有所提高,破坏模式由灾难性拉断失效模式逐渐转化为理想的挤压失效模式,但当孔边距达到一定数值时,铆接强度不再明显提高,而失效模式也维持为挤压破坏。     

Bending strength analysis of micro WC-shaft manufactured by micro electro-discharge machining

Micro electro-discharge machining (micro-EDM) is a critical technology to fabricate high aspect ratio 3D micro-components. However, the surfaces of micro-components manufactured by micro-EDM will exhibit micro-cracks to produce notch effects, and lead to stress concentrate and reduction of fatigue strength. This paper performs micro-bending tests to investigate the influence of various roughness and size on the bending fracture strength of micro WC-shafts manufactured by micro-EDM. The experimental results indicate that the surface roughness, axial surface area, volume, and length of the specimen will affect its bending fracture strength. For specimens with the same size, the mean bending fracture strength decreases as the surface roughness increases, and the bending fracture probability of the specimens also increases (roughness effect). For specimens with the same roughness, reducing the length or axial surface area will increase the mean bending fracture strength, and reduces the bending fracture probability (size effect).     

Effect of prestress level on the strength of CFRP composite laminate

The effect of fiber prestressing has been investigated on the tensile strength, modulus strength, flexural properties and residual stresses of Carbon fiber reinforced polymer (CFRP) composites. Unidirectional carbon fiber in an epoxy resin has been examined under different prestressing levels (0, 5, 10, 15, 20, 30, 45, 60, 80 MPa) at ambient temperature and 50 % fiber volume fraction. A new method was implemented to produce the prestressed laminates for several standard tests. The results showed that prestressing on 3-ply unidirectional carbon fibers improved the fiber tensile strength to 99 % and the tensile modulus to 31 %. Similarly on 8-ply unidirectional carbon fibers has improved the fiber flexural strength to 63 % and flexural modulus to 81 %. A new technique was used to measure the residual stresses and tensile modulus of the composite laminate by recording the final extension and the remaining load directly after the curing process and releasing the applied load.

     

Measurement of Temperature and Residual Strain during Fatigue of a CFRP Composite Using Fiber Bragg Grating Sensors

Fatigue behaviour has important implications for engineering composite structures in sectors ranging from automotive to aerospace. Optical sensing technology displays excellent performance in these fields for monitoring. In this paper, temperature and residual strain during fatigue of a carbon fiber reinforced polymer(CFRP) are investigated. Four autoclaved CFRP beam specimens, with fiber Bragg grating(FBG) sensors and thermocouples embedded at selected locations, are subjected to three-point bending cyclic loading on the BOSE testing machine for fatigue testing. Thermocouples are used to measure the temperature while FBGs can sense the temperature and strain as well. Seven tests in total are conducted at different frequencies, and each test lasts for several days. From the experimental results, transient steep peaks of temperature increases (up to 2.3 ℃) are discovered at the beginning of the load. The following constant temperature increments are around 1.0 ℃, which is not relevant to frequencies from 0.1 Hz to 20 Hz and suspected due to fatigue. Residual strains of 1×10-5-2×10-5 during fatigue, fading away rapidly when unloading, are also reported. Embedded FBGs here are validated to sense temperature and strains in composite structures, which demonstrates promising potentials in structure monitoring fields. CFRP are verified to have an excellent performance during fatigue with low temperature increase and residual strain.     

Study on vital static properties of fine blanking of GFRP composites with that of conventional drilling

Among the high performance engineering materials, fiber-reinforced plastics play an important role. The present work is concerned with the comparison of vital static strength properties of fine blanking with conventional drilling on hand lay-up made glass fiber-reinforced plastic (GFRP) laminates of four different reinforcement lay-up sequences such as unidirectional [0/0]_n, angle ply [0?±?45]_ns, quasi-isotropic [0/45/90]_ns, and cross-ply [0/90]_n. Observation includes tensile and flexural bending strengths of the specimens without hole and with hole by conventional drilling and fine blanking. In this work, an endeavor has been made to simulate the service conditions to determine their effect on the response of composite laminates. Detailed studies on GFRP composites when subjected to different loading environments such as static loading, particularly tensile loading, and low frequency high amplitude (fatigue) loading were carried out. The response of the composite laminates to these service environments has been evaluated in terms of flexural strength and modulus. From the tensile study, it was observed that by inserting a hole at center by drilling, the strength was reduced to one third, and by inserting a hole at center by fine blanking, the strength was increased nearly 20% than that of drilling. Apart from this, the flexural test conducted on polymeric composite specimens showed that an exposure to low frequency and high amplitude loading enhances the flexural strength up to certain duration of exposure, beyond which, due to accumulation of damage within the composites, the flexural strength reduces with number of cycles. This can be attributed to possible strain-induced stiffening of fibers and interface.     

Bending fatigue strength of case-carburized helical gears with large helix angles up to 40 degrees

Case-carburizing of helical gears with large helix angles may form too large hardened layers near the tooth width end on the acute angle side (ACUTE-END), and adversely affect the bending fatigue strength. We investigated the bending fatigue strength of casecarburized helical gears with large helix angles up to approximately 40° through a bending fatigue test, hardness test, and residual stress measurement. We found that the case-carburizing formed large hardened layers near ACUTE-END, reduced the compressive residual stress near ACUTE-END, and restricted the improvement of the bending fatigue strength in a meshing state where tooth root stress became large near ACUTE-END. Based on the obtained bending fatigue limits, we revealed that ISO 6336-3:2006 overestimated the rate of increase of the permissible circumferential loads for helix angles exceeding approximately 30°, and ISO/DIS 6336-3:2018 underestimated this rate for helix angles near 30°.

     

Boundary element analysis of stress singularity in dissimilar metals by friction welding

Friction-welded dissimilar metals are widely applied in automobiles, rolling stocks, machine tools, and various engineering fields. Dissimilar metals have several advantages over homogeneous metals, including high strength, material property, fatigue endurance, impact absorption, high reliability, and vibration reduction. Due to the increased use of these metals, understanding their behavior under stress conditions is necessary, especially the analysis of stress singularity on the interface of friction-welded dissimilar metals. To establish a strength evaluation method and a fracture criterion, it is necessary to analyze stress singularity on the interface of dissimilar metals with welded flashes by friction welding under various loads and temperature conditions. In this paper, a method analyzing stress singularity for the specimens with and without flashes set in friction-welded dissimilar metals is introduced using the boundary element method. The stress singularity index (??) and the stress singularity factor (??) at the interface edge are computed from the stress analysis results. The shape and flash thickness, interface length, residual stress, and load are considered in the computation. Based on these results, the variations of interface length (c) and the ratio of flash thickness (t ₂/t ₁) greatly influence the stress singularity factors at the interface edge of friction-welded dissimilar metals. The stress singularity factors will be a useful fracture parameter that considers stress singularity on the interface of dissimilar metals.     

Assessment of the sulfide corrosion fatigue strength for a multi-pass welded A106 Gr B steel pipe below the low SSCC limit

In the area of heavy construction, welding processes are vital in the production and maintenance of pipelines and power plants. Welding processes happen to produce residual stresses and change the metal structure as a result of the large nonlinear thermal loading that is created by a moving heat source. The fusion welding process generates formidable welding residual stresses and metallurgical change, which increase the crack driving force and reduce the resistance to the brittle fracture as well as the environmental fracture. This is a serious problem with many alloys as well as the A106 Gr B steel pipe. This pipe that is used in petrochemical and heavy chemical plants either degrades due to corrosive environments, e.g., chlorides and sulfides, and/or become damaged during service due to the various corrosion damage mechanisms. Thus, in this study, after numerically and experimentally analyzing the welding residual stress of a multi-pass welded A106 Gr B steel pipe, the sulfide stress corrosion cracking (SSCC) characteristics were assessed in a 3.5 wt.% NaCl solution that was saturated with H₂S gas at room temperature on the basis of NACE TM 0177-90. The specimens used are of two kinds: un-notched and notched. Then, the sulfide corrosion fatigue (SCF) strength for the un-notched specimen was assessed below the low SSCC limit that was previously obtained from the SSCC tests for the notched specimen. From the results, in terms of the SSCC and SCF, all the specimens failed at the heat-affected zone, where a high welding residual stress is distributed. It was found that the low SSCC limit of un-notched specimens (σ_{SSCCun-notched}) was 46% (230 MPa) of the ultimate tensile strength (σ_U=502 MPa) of a multi-pass welded A106 Gr B steel pipe, and the notched specimens (σ_SSCCnotched) had 40% (200 MPa) of the ultimate tensile strength. Thus, it was determined that σ_{SSCCun-notched} was 13% lower than σ_SSCCnotched. Further, the sulfide corrosion fatigue limit (σ_{SCFun-notched}) was 32% (160 MPa) of the ultimate tensile strength of welded specimens. This σ_{SCF un-notched} was 20% lower than σ_SSCCnotched.