Fractography of interlaminar fracture surfaces of CF/PI and CF/BMI composites

Interlaminar fracture is recognized as an important mode of failure of composite materials and structures. In order to characterize twobismaleinimide-matrix (BMI) composites and two polyimide-matrix (PI) composites regarding their delamination behaviour, interlaminar fracture tests in mode I, mode II and mixed-mode loading conditions were carried out. The aim of this study was to examine the fracture surfaces and to find relationships between features of the fracture surface and the corresponding mechanical data. The characteristic features of failure have been pointed out and the changes of the features with variations in matrix material, testing rate and loading mode have been shown. The results of the mechanical testing can be explained by means of SEM images.     

基于剪切非线性三维损伤本构模型的复合材料层合板失效强度预测

基于连续损伤力学,建立了同时考虑复合材料剪切非线性效应和损伤累积导致材料属性退化的三维损伤本构模型。模型能够区分纤维损伤、基体损伤和分层损伤不同的失效模式,并定义了相应损伤模式的损伤变量。复合材料层合板层内纤维初始损伤采用最大应力准则判定,基体初始损伤采用三维Puck准则中的基体失效准则判定,分层初始损伤采用三维Hou准则中的分层破坏准则判定,为了计算Puck失效理论中的基体失效断裂面角度,本文提出了分区抛物线法,通过Matlab软件编写计算程序并进行分析。结果表明,与Puck遍历法和分区黄金分割法对比,本文提出的分区抛物线法有效地降低了求解断裂面角度的计算次数,提高了计算效率和计算精度。推导了本构模型的应变驱动显式积分算法以更新应力和解答相关的状态变量,开发了包含数值积分算法的用户自定义子程序VUMAT,并嵌于有限元程序Abaqus v6.14中。通过对力学行为展现显著非线性效应的AS4碳纤维/3501-6环氧树脂复合材料层合板进行渐进失效分析,验证了本文提出的材料本构模型的有效性。结果显示,已提出的模型能够较准确地预测此类复合材料层合板的力学行为及其失效强度,为复合材料构件及其结构设计提供一种有效的分析方法。      

Interlaminar Fracture Toughness of Carbon Fibre‐Reinforced Polymer Laminates With Nano‐ and Micro‐Fillers

Abstract: Vapour growth carbon nanofibres (CNF) and lead zirconate titanate (PZT) piezoelectric particles were added in the matrix of carbon fibre‐reinforced polymer laminates. The fracture toughness of the modified composites was measured under mode I and mode II loading and compared with plain epoxy carbon fibre‐reinforced composites. The mode I fracture toughness of the composites improved with the incorporation of the carbon nanofibres and deteriorated with the incorporation of PZT piezoelectric particles. When both fillers were added in the composite matrix, the mode I fracture toughness improved but to a lesser extend. The mode II fracture toughness of the modified composites was improved in all three cases. The aforementioned behaviour was attributed to competing fracture mechanisms instigated by the different fillers, and backed by fractographic evidence from the failed composite coupons; during the tests, the acoustic emission activity of the coupons was monitored and classified in three major energy absorbing mechanisms which were attributed to the failure of distinct composite phases.     

A simplified tensile damage analysis method for composite laminates using a quasi-three-dimensional model

Measurement of the strength of laminated composites is very difficult because their failure processes imply various failure modes, which are, for example, an interlaminar delamination, a destruction of matrix and an interfacial fracture between fiber and matrix. However, that strength is one of the most important characteristics in structural design using laminated composites. Hence we try a fractural progress analysis of laminated composites using a quasi-three-dimensional analysis method under a tensile load. The quasi-three-dimensional model is constructed of shell elements and beam elements which represent fiber and matrix respectively. The fractural progress analyses of the laminated composites are carried out to evaluate this proposed model. The precision is very good. Therefore we confirm that this proposed model can simulate a transverse crack and an interlaminar delamination.     

Mode II delamination failure mechanisms of polymer matrix composites

The failure process of mode II delamination fracture is studied on the basis of the microscopic matrix failure modes (microcracks and hackles) as well as fracture mechanics principles. The crack tip matrix stresses leading to delamination is analysed by examining an adhesive bond with a crack analogous to a delamination crack in the resin layer of a composite. Such crack tip stresses induce matrix microcracks involving two major events: (a) single microcrack initiation and (b) development of multiple microcracks with regular spacing. The microcrack initiation shear stress τ* is found by the use of fracture mechanics to be related to certain resin properties (shear modulus G and mode I fracture toughness GIC) and microcrack length of the order of the resin layer thickness t (related to resin content). The more or less regular microcrack spacing S deduced from shear lag considerations can be related to resin properties GIC, G, τy (resin yield strength) and t. The multiple microcracks reduce the effective resin modulus and strongly affect the subsequent microcrack coalescence process. As a result of the detailed analysis of the failure process, mode II laminate fracture toughness GIIC can be quantitatively expressed as a function of resin GIC and (τ2y/G). The failure process modelled is used to interpret the mode II delamination behaviour of several carbon/epoxy systems studied here and that reported in the literature. This study reveals the critical importance of resin fracture (GIC related) and deformation (yielding) mechanisms in controlling mode II delamination resistance of laminated composites. This revised version was published online in November 2006 with corrections to the Cover Date.     

Micromechanical modeling to determine the compressive strength and failure mode interaction of multidirectional laminates

Computational models to predict the compressive strength of carbon fiber reinforced polymer matrix composites are proposed here, motivated by the failure mechanisms observed in compression tests. Delamination, fiber kink-banding and their interaction are seen to dominate the failure response. An upscaled semi-homogenized laminate model is developed to predict the observed compressive response of multidirectional laminates. A generalized 2-D formulation is presented to determine the interfaces most susceptible to delamination. Subsequently, cohesive elements are added along these interfaces to introduce delamination capability in the model. Predictions of the model are compared against experimental data, and are found to be in agreement with respect to compressive strength and failure modes. Further, the effect of stacking sequence on the compressive strength and failure mode is investigated.     

Fractographical analysis on the mode II delamination in woven carbon fiber reinforced epoxy composites

Mode II delamination phenomena of woven fabric carbon/epoxy composites were investigated by scanning electron microscopy. End notch flexural (ENF) test was used to examine the mode II delamination. Woven fabric composites showed two peculiar crack propagation patterns due to the complexity of woven geometry. In warp yarn region, crack propagated with forming a shear band and breaking the fiber/matrix interface. In fill yarn region, however, no shear band was observed. Considering these crack patterns, matrix shear property and fiber/matrix interfacial strength played an important role in enhancing the delamination properties of woven fabric carbon/epoxy composites. Due to the woven geometry, matrix rich positions, which are interstitial and undulated region, were formed in woven carbon/epoxy composite. In these regions, matrix fracture and complex crack path were mainly observed.     

Compressive fracture behavior of 3D needle-punched carbon/carbon composites

Compressive fracture behavior under transverse and longitudinal compressive loading are determined for 3D needle-punched carbon/carbon (C/C) composites with single rough laminar (RL) pyrocarbon matrix or dual matrix of RL pyrocarbon and resin carbon. The results of Weibull statistics analysis indicate that scale parameter σ₀ of transverse and longitudinal compression of the composites with single matrix are 153.41 and 94.26 MPa, and σ₀ of the composites with dual matrix are 205.16 and 105.33 MPa, respectively. The mean compressive strength of both composites is nearly equal to σ₀ under each experimental condition. Failure modes of both composites under transverse and longitudinal compressive loading are shear and extension, respectively. Both composites exhibit quasi-ductile fracture behavior under transverse compression. Many small fragments of fibers and matrix carbon on the fracture surface of the composites are observed for single matrix composites. And the fiber bundle breakage with extensive debonding occurs for dual matrix composites. Under longitudinal loading, the composites with single matrix show quasi-ductile fracture behavior and delamination and splitting of non-woven long carbon fiber cloth layers are observed. The composites with dual matrix exhibit catastrophic failure behavior and crack runs through the composites along compressive loading direction.     

Mechanical characterization of hierarchical carbon fiber/nanofiber composite laminates

Susceptibility to matrix driven failure is one of the major weaknesses of continuous-fiber composites. In this study, helical-ribbon carbon nanofibers (CNF) were dispersed in the matrix phase of a continuous carbon fiber-reinforced composite. Along with an unreinforced control, the resulting hierarchical composites were tested to failure in several modes of quasi-static testing designed to assess matrix-dominated mechanical properties and fracture characteristics. Results indicated CNF addition offered simultaneous increases in tensile stiffness, strength and toughness while also enhancing both compressive and flexural strengths. Short-beam strength testing resulted in no apparent improvement while the fracture energy required for the onset of mode I interlaminar delamination was enhanced by 35%. Extrinsic toughening mechanisms, e.g., intralaminar fiber bridging and trans-ply cracking, significantly affected steady-state crack propagation values. Scanning electron microscopy of delaminated fracture surfaces revealed improved primary fiber–matrix adhesion and indications of CNF-induced matrix toughening.     

弹道防护用超高分子量聚乙烯纤维增强热塑性树脂基复合材料的拉伸力学行为

以弹道防护用超高分子量聚乙烯(Ultra-high molecular weight polyethylene,UHMWPE)纤维增强热塑性树脂基复合材料作为研究对象,通过热压工艺制备单向正交结构的复合材料层压板。基于自主设计的拉伸试验装置,开展UHMWPE纤维增强热塑性树脂基复合材料在宏观尺度和准细观尺度上的面内拉伸试验,研究其面内拉伸力学性能及失效模式。研究结果显示：弹道防护用UHMWPE纤维增强热塑性树脂基复合材料在准细观尺度上的面内拉伸力学性能是其本征性能;随着偏轴角度的增加,拉伸断裂强度呈现指数型下降,这是由于失效模式由纤维的拉伸断裂破坏转变为纤维-树脂基体的界面破坏;此外,其在宏观尺度上的拉伸破坏强度比在准细观尺度上的拉伸断裂强度降低了50.52%,这是由于宏观尺度上的面内拉伸力学响应是其面内拉伸变形和层间分层破坏的耦合结果,即层压板的叠层效应。     

预氧化Cf/SiC陶瓷基复合材料及其构件的抗疲劳特性研究

采用在线销钉集成技术实现了二维C_f/SiC复杂构件的近尺寸成型,并考察预氧化C_f/SiC销钉集成构件的高周疲劳寿命及破坏模式。实验结果表明:C_f/SiC构件在不同激振加速度条件下均表现为由销钉断裂所引起的整体分层破坏,层板连接处为C_f/SiC构件的振动疲劳薄弱部位。通过ANSYS振动应力分析和微观组织分析可以推论出,疲劳试验时,裂纹容易沿着层板间的基体扩展,在基体开裂失效后,全部应力施加于销钉处,最终在疲劳应力作用下销钉发生断裂,导致构件整体分层破坏。     

Manufacturing Influence on the Delamination Fracture Behavior of the T800H/3900-2 Carbon Fiber Reinforced Polymer Composites

'Torayca' T800H/3900-2 is the first material qualified on Boeing Material Specification (BMS 8-276) which utilizes the thermoplastic-particulate interlayer toughening technology. Two manufacturing processes, the autoclave process and the fast heating rated Quickstep™ process, were employed to cure this material. The Quickstep process is a unique composite production technology which utilizes the fast heat transfer rate of fluid to heat and cure polymer composite components. The manufacturing influence on the mode I delamination fracture toughness of laminates was investigated by performing double cantilever beam tests. The composite specimens fabricated by two processes exhibited dissimilar delamination resistance curves (R-curves) under mode I loading. The initial value of fracture toughness G_IC-INIT was 564 J/m² for the autoclave specimens and 527 J/m² for the Quickstep specimens. However, the average propagation fracture toughness G_IC-PROP was 783 J/m² for the Quickstep specimens, which was 2.6 times of that for the autoclave specimens. The mechanism of fracture occurred during delamination was studied under scanning electron microscope (SEM). Three types of fracture were observed: the interlayer fracture, the interface fracture, and the intralaminar fracture. These three types of fracture played different roles in affecting the delamination resistance curves during the crack growth. More fiber bridging was found in the process of delamination for the Quickstep specimens. Better fiber/matrix adhesion was found in the Quickstep specimens by conducting indentation-debond tests.     

Charakterisierung des Delaminationsverhaltens von Schichtverbunden unter Mode I- und Mode II-Belastungen

Characterization of the delamination behaviour of composites under mode I- and mode II-loading In order to determine fracture toughness properties of fibre-reinforced polymers the „Double Cantilever Beam”︁-test (DCB) has been used for mode I loading and the „End Notched Flexure”︁-test (ENF) for mode II loading. By these methods the energy release rate G and the corresponding R-curve (crack resistance curve) have been measured which characterise the crack resistance of the material against delamination. Especially the influence of fibre coatings, different structures of the laminate, and matrix modifiers on fracture toughness have been examined for epoxy as well as for thermoplastic composites (polyamide and polypropylene/glass fibres).     

Interlaminar and intralaminar fracture surface morphology in graphite/epoxy laminates

Fracture surface morphological studies of graphite/epoxy (T300/934) laminates have been performed to distinguish between mode I and mode II interlaminar and intralaminar fractures. Additionally, the effect of a few hygrothermal conditions on mode I fracture surface is also assessed. Centre notched tension, compact tension, double cantilever beam and cracked lap shear specimens have been used to study these fracture modes. While mode I fracture is characterized by branched cracks between fibers, river pattern and chevron markings on resin rich zones, the epoxy hackles dominate mode II fracture surface. The interlaminar and intralaminar fractures can be distinguished by fiber spacings and some matrix features. The effect of increase in temperature and/or moisture is seen to cause reduction in matrix microcracking and increase in fiber pullout in mode I.     

MIXED-MODE DELAMINATION OF MULTIDIRECTIONAL CARBON FIBER/EPOXY LAMINATES

Scanning electron microscopy was used to identify fractographic features that are characteristic of different modes of interlaminar fracture. The cusp angle and the amount of fiber pull-out on the fracture surface can be used to characterize the different loading modes. A large amount of fiber pull-out is the dominant feature of a mode I fracture, while in mode II large cusp angles and many cusps are the main characteristics. The amount of fiber pull-out, and subsequently brokenfibers, per unit area was investigated and found to vary in proportion to the degree of mode I loading. Such methods can be used to analyze failure and the propagation ofdelamination in structural components. The energy associated with cusp formation constitutes a large proportion of the mode IIfracture toughness component, while the amount of fiber pull-out and fracture has a considerable influence on the mode I fracture component. The cusp angle was seen to provide a quantitative measure of the fracture surface roughness. A failure criterion that takes the fracture surface appearance into account was evaluated. The cusp angle was subsequently used to modify this failure criterion. As a consequence, this provided improved agreement with the experimental data.     

Numerical Investigation of Delamination in Drilling of Carbon Fiber Reinforced Polymer Composites

Drilling of carbon fiber reinforced polymer (CFRP) is a challenging task in modern manufacturing sector and machining induced delamination is one of the major problems affecting assembly precision. In this work, a new three-dimensional (3D) finite element model is developed to study the chip formation and entrance delamination in drilling of CFRP composites on the microscopic level. Fiber phase, matrix phase and equivalent homogeneous phase in the multi-phase model have different constitutive behaviors, respectively. A comparative drilling test, in which the cement carbide drill and unidirectional CFRP laminate are employed, is conducted to validate the proposedmodel in terms of the delamination and the similar changing trend is obtained. Microscopic mechanism of entrance delamination together with the chip formation process at four special fiber cutting angles (0°, 45°, 90° and 135°) is investigated. Moreover, the peeling force is also predicted. The results show that the delamination occurrence and the chip formation are both strongly dependent on the fiber cutting angle. The length of entrance delamination rises with increasing fiber cutting angles. Negligible delamination at 0° is attributed to the compression by the minor flank face. For 45° and 90°, the delamination resulted from the mode III fracture. At 135°, serious delamination which is driven by the mode I and III fractures is more inclined to occur and the peeling force reaches its maximum. Such numerical models can help understand the mechanism of hole entrance delamination further and provide guidance for the damage-free drilling of CFRP.     

斜纹编织碳纤维/环氧树脂复合材料II型分层性能及损伤演化表征

为研究编织复合材料在静载及疲劳载荷下的分层特性及损伤演化模式,对斜纹编织CF3052/3238A碳纤维/环氧树脂复合材料II型静开裂及疲劳开裂性能进行了测试。结果表明:斜纹编织CF3052/3238A碳纤维/环氧树脂复合材料裂纹扩展行为受纬向纤维影响存在周期性局部受阻现象,分层破坏模式除层间开裂外还存在纬向纤维脱粘;斜纹编织CF3052/3238A碳纤维/环氧树脂复合材料裂纹扩展速率符合Paris公式,不同加载控制模式下编织复合材料疲劳驱动力增长规律存在本质区别:恒幅疲劳载荷下斜纹编织复合材料疲劳驱动力呈抛物线型单调增长;而恒幅疲劳位移下复合材料疲劳驱动力随分层长度呈波峰型分布;采用基于载荷控制模式和位移控制模式下的疲劳驱动力模型,可对斜纹编织CF3052/3238A碳纤维/环氧树脂复合材料进行损伤演化表征,其表征效果良好,具有工程参考价值。      

A study on the failure mechanisms of carbon fiber/epoxy composite laminates using acoustic emission

The complex failure mechanisms that are commonly considered as the distinctive characteristic of composites are being amenable to nondestructive test advance. This research adopts the acoustic emission technique to study the failure mechanisms and damage evolution of carbon fiber/epoxy composite laminates. Effects of different lay-up patterns and hole sizes on the acoustic emission response are studied to set up the mapping between the failure properties and the acoustic signal features such as the energy, counting and amplitude. Moreover, the microscopic properties of different composite specimens after fracture are watched and analyzed by scanning electron microscope (SEM). Based on the mapping conception, the controlling microscopic failure mechanisms of composites including the splitting matrix cracking, fiber/matrix interface debonding, fiber pull-out and breakage as well as delamination are identified. It is expected the influence of complex lay-up patterns and sizes on the damage and failure properties of composites is represented by creating true mapping based on the acoustic emission technique.     

Failure modes and fracture mechanisms in flexure of Kevlar-epoxy composites

The results of testing in three-point bending of aramid fibre-reinforced epoxy composites are described. This loading mode has been chosen in order to increase the variety of failure modes and of fracture mechanisms. The main failure modes observed are tensile and delamination, with a transition at a fibre volume fraction of about 46%. This mode transition is detectable by monitoring various mechanical properties and acoustic emission data against the fibre volume fraction. The tensile mode comprises a fracture mechanism of fibre splitting and pull-out and the delamination comprises fibre bending, tearing off of fibre skin and shearing of individual filaments. Other effects such as the shifting of the neutral axis and the compressive failure at the compression side are also reported.