The role of matrix cracks and fibre/matrix debonding on the stress transfer between fibre and matrix in a single fibre fragmentation test

The single fibre fragmentation test is commonly used to characterise the fibre/matrix interface. During fragmentation, the stored energy is released resulting in matrix cracking and/or fibre/matrix debonding.Axisymmetric finite element models were formulated to study the impact of matrix cracks and fibre/matrix debonding on the effective stress transfer efficiency (EST) and stress transfer length (STL). At high strains, plastic deformation in the matrix dominated the stress transfer mechanism. The combination of matrix cracking and plasticity reduced the EST and increased STL.For experimental validation, three resins were formulated and the fragmentation of an unsized and uncoupled E-glass fibre examined as a function of matrix properties. Fibre failure was always accompanied by matrix cracking and debonding. With the stiff resin, debonding, transverse matrix cracking and conical crack initiation were observed. With a lower modulus and lower yield strength resin the transverse matrix crack length decreased while that of the conical crack increased.     

The environmental stress corrosion cracking of glass fibre-reinforced laminates and single E-glass filaments

The environmental stress corrosion cracking of epoxy/glass fibre crossply, unidirectional coupons and single E-glass filaments have been compared. At initial applied strains > 0.15% the resin does not protect the fibres as shown by their equivalent failure times. The failure occurs in the environment and planar fractures occur because of the localized stress in the load bearing plies adjacent to a transverse crack in the 90° ply of the 0°/ 90°/0° coupons. These transverse cracks result from stress corrosion of the glass/resin interface, which leads to a reduction of the transverse cracking strain. At applied strains < 0.15% fracture occurs within the unexposed half of the coupons and is thought to be caused by rapid transport of glass corrosion products where they crystallize within the coupon. This phenomenon is also responsible for the progressive transverse cracking that occurs in both the 0° and 90° plies of the unimmersed half of the crossply coupon under zero load.     

界面脱粘对正交铺设SiC/CAS复合材料基体开裂的影响

采用细观力学方法研究了正交铺设SiC/CAS复合材料在单轴拉伸载荷作用下界面脱粘对基体开裂的影响。采用断裂力学界面脱粘准则确定了0°铺层纤维/基体界面脱粘长度, 结合能量平衡法得到了主裂纹且纤维/基体界面发生脱粘(即模式3)和次裂纹且纤维/基体界面发生脱粘(即模式5)的临界开裂应力, 讨论了纤维/基体界面剪应力、 界面脱粘能对基体开裂应力的影响。结果表明, 模式3和模式5的基体开裂应力随纤维/基体界面剪应力、 界面脱粘能的增加而增加。将这一结果与Chiang考虑界面脱粘对单向纤维增强陶瓷基复合材料初始基体开裂影响的试验研究结果进行对比表明, 该变化趋势与单向SiC增强玻璃陶瓷基复合材料的试验研究结果一致。     

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.     

The behaviour of cross-ply hybrid matrix composite laminates: Part 1: Experimental results

Two types of cross-ply laminate have been made from prepreg: (a) hybrid matrix laminates consisting of longitudinal plies of glass fibres in epoxy resin and transverse plies of glass fibres in epoxy resin/urethane elastomer blend; and (b) uniform matrix laminates with the same resin in both the longitudinal and transverse plies. The presence of the urethane in the transverse plies increases the applied strains necessary for the initiation and development of transverse cracking during the extension of both hybrid matrix and uniform matrix laminates. The effect is greater with increasing amounts of urethane. The cracking data, stress/strain behaviour, acoustic emission response and ply thickness effects on crack development are discussed in the light of existing theories concerning transverse cracking.     

Experiments on shear deformation,debonding and local load transfer in a model graphite/glass/epoxy microcomposite

Recent statistical theories for the failure of polymer matrix composites depend heavily on details of the stress redistribution around fibre breaks. The magnitudes and length scales of fibre overloads as well as the extent of fibre/matrix debonding are key components in the development of longitudinal versus transverse crack propagation. While several theoretical studies have been conducted to investigate the roles of these mechanisms, little has been substantiated experimentally about the matrix constitutive behaviour and mechanisms of debonding at the length scale of a fibre break. In order to predict the growth of transverse and longitudinal cracks using the same micromechanical model, we microscopically observed the epoxy shear behaviour around a single fibre break in a three-fibre microcomposite tape. The planar specimens consisted of a single graphite fibre placed between two larger glass fibres in an epoxy matrix. The interfibre spacing was less than one fibre diameter (<6 m) in order to reflect the spacing between fibres found in typical composites. The epoxy constitutive behaviour was modelled using shear-lag theory where the epoxy had elastic, plastic, and debond zones. The criteria for debonding were modified from conventional shear-lag approaches to reflect the orientational hardening in the epoxy network structure. The epoxy, which is brittle in bulk, locally underwent a shear strain of about 60% prior to debonding from the fibre.     

Discrete element modelling of unidirectional fibre-reinforced polymers under transverse tension

The mechanical behaviour of unidirectional fibre-reinforced polymer composites subjected to transverse tension was studied using a two dimensional discrete element method. The Representative Volume Element (RVE) of the composite was idealised as a polymer matrix reinforced with randomly distributed parallel fibres. The matrix and fibres were constructed using disc particles bonded together using parallel bonds, while the fibre/matrix interfaces were represented by a displacement-softening model. The prevailing damage mechanisms observed from the model were interfacial debonding and matrix plastic deformation. Numerical simulations have shown that the magnitude of stress is significantly higher at the interfaces, especially in the areas with high fibre densities. Interface fracture energy, stiffness and strength all played important roles in the overall mechanical performance of the composite. It was also observed that tension cracks normally began with interfacial debonding. The merge of the interfacial and matrix micro-cracks resulted in the final catastrophic fracture.     

Mechanical behaviour of a cross-weave ceramic matrix composite

The deformation and fracture processes of a cross-weave carbon fibre/SiC composite prepared by a chemical vapour deposition process has been explored by interrupted-loading tests and SEM examination of cracking and fracture processes. The tensile stress-strain curves show non-linear behaviour associated with progressive matrix cracking and spalling, and the occasional fracture of a fibre. Re-loading curves and compressive stress-strain curves show linear behaviour. The fracture process does not involve cracking by a single dominant crack but occurs by the development of multiple damage sites operating around the transverse fractures of groups of four to eight fibres followed by longitudinal cracking at their fibre-matrix interfaces and temporary arrest of the cracks, until specimen failure occurs and there is massive fibre debonding and pull-out.     

Plasticity of brittle epoxy resins during debonding failures

A remarkably high degree of plasticity in brittle epoxies during debonding failures is reported. The plasticity is exhibited by the presence of ridges on the debonded surfaces having a width and height above the general level of these surfaces of the order of 100 nm. The surfaces of the more rigid substrates from which the debonding has occurred, by contrast, are smooth after debonding. The ridges have been found in several forms: in more or less straight rows parallel to the debonding fracture direction; as irregularly-shapes rings or craters, probably formed from secondary crack growth; as paraboloids, which also seem to be related to secondary crack growth; and as serpentine rows more or less perpendicular to the debonding fracture direction. This behaviour has been exhibited by various epoxy formulations. The 100 nm widths and heights for the ridges suggest that during debonding, plastic deformation has occurred rather uniformly in the epoxy to a depth below the interface of this order. This behaviour is in contrast to the simple notion of brittle fracture, in which atoms or molecules separate across planes in an elastically strained body. It differs also from the bulk fracturing process with these resins, in which a smaller amplitude, more random ridge and groove texture, referred to as the basic longitudinal or fingering texture, is seen.     

Stress transfer in the fibre fragmentation test: Part III Effect of matrix cracking and interface debonding

A theoretical stress analysis has been developed for the fibre fragmentation test in the presence of matrix cracks at sites of fibre breaks. The strain energy release rates for both matrix cracking and interface debonding are calculated for a carbon fibre/epoxy matrix composite. By comparing these strain energy release rates with the corresponding specific fracture resistances, the competition between matrix crack growth and interface debonding has been studied. The distributions of fibre axial stress and interfacial shear stress obtained from the present analysis show that the matrix crack substantially reduces the efficiency of stress transfer from the matrix to the fibre. This revised version was published online in November 2006 with corrections to the Cover Date.     

Effect of interfacial adhesion and statistical fiber strength on tensile strength of unidirectional glass fiber/epoxy composites. Part I: experiment results

The effects of fiber surface treatment on ultimate tensile strength (UTS) of unidirectional (UD) epoxy resin matrix composites are examined experimentally. The interfacial shear strength (IFSS) and statistical fiber strength are significantly altered by five different kinds of surface treatments, which are: (a) unsized and untreated; (b) γ-glycidoxypropyltrimethoxysilane (γ-GPS); (c) γ-methacryloxypropyltrimethoxysilane (γ-MPS); (d) mixture of γ-aminoxypropyltrimethoxysilane (γ-APS), film former (urethane) and lubricant (paraffin); and (e) urethane-sized. The maximum UTS is obtained for the relatively strong interfacial adhesion (glass/γ-MPS/epoxy) but not for the strongest interfacial adhesion (glass/γ-GPS/epoxy). The governing micro-damage mode around a broken fiber and the interface region is matrix cracking for γ-GPS treated fibers, and a combination of interfacial debonding and matrix cracking for γ-MPS treated fibers. The micro-damage mode related to the interfacial adhesion strongly affects the fracture process, and thus the UTS of UD composites. The results also indicate that the interfacial adhesion can be optimized for effective utilization of fiber strength for fiber composites. A parameter called “efficiency ratio” of fiber strength in UD composites is proposed to examine and distinguish different effects of IFSS and fiber strength on the UTS of UD composites. The experimental results show that improved UTS of UD composites due to surface treatments mainly result from the increase in fiber strength but not from the modified interface.     

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.     

Acoustic emission from stress corrosion cracks in aligned GRP

Acoustic emission (AE) produced by the propagation of stress corrosion cracks in an aligned glass fibre/polyester resin composite material has been recorded. Tests have been carried out over a range of crack growth rates and the variation of AE with crack velocity/applied stress intensity has been examined. The main source of AE is fibre fracture and there is a one-to-one relationship between the number of fibre fractures and the number of high-amplitude AE signals. This enables crack growth to be monitored directly from acoustic emission. The amplitude of AE signals produced by fibre failure appears to be proportional to the fracture stress of the fibres, although further analysis requires a greater understanding of the generation, transmission and detection of AE signals. This work demonstrates that stress corrosion cracking is an ideal source for the study of AE produced by fibre fracture without complications caused by interface effects, such as fibre debonding or pullout.On leave from the Technical University of Wroclaw, Wroclaw, Poland.     

Impact surface fractures of glass-fiber/epoxy lamina-coated glass plates by small steel-ball

Fiber orientation effects on the impact surface fracture of glass plates coated with a glass-fiber/epoxy lamina layer were investigated using a small-diameter steel-ball impact experiment. Four kinds of materials were used: soda-lime glass plates, unidirectional glass-fiber/epoxy layer (one ply, two plies) coated glass plates, crossed glass-fiber/epoxy layer (only two plies) coated glass plates. The maximum stress and absorbed fracture energy of these plates were measured by a single-grid strain gage bonded to the back surface of the glass plates during the impact of the steel ball. With increasing impact velocity, various surface cracks, such as ring, cone, radial and lateral cracks, occurred near the impact sites of the uncoated glass plates. Plates with glass-fiber coating had a plastic deformation zone between the fiber layer and the glass plate that formed around the impact site while the surface cracks in the plates drastically diminished. The principal direction of this plastic deformation and delamination followed the fiber orientation. The impact surface-fracture index expressed in terms of the maximum stress and the absorbed energy could be used as an effective evaluation parameter for surface resistance.     

A study of damage development in a weft knitted fabric reinforced composite. Part 1: Experiments using model sandwich laminates

Coupons consisting of single layers of Milano weft knitted glass fabric reinforced epoxy resin have been tested with the knitted fabric oriented at various angles to the loading direction, alone and sandwiched between outer layers of unidirectional glass/epoxy reinforcement. The sandwich coupons enable the initiation of damage to be observed directly. Tensile tests have shown that the first damage occurs as microdebonding between the loop cross-over points in the knitted fabric structure. Matrix cracking damage develops from these initiation sites and the pattern of cracking is intimately related to the fabric architecture and the fabric orientation with respect to the loading direction. Cyclic tests of sandwich specimens, and a representation of the results in terms of cumulative strain, indicate that some of the acoustic emission activity during loading and unloading of the specimens is likely to be associated with the debonding and pulling-out of knitted fabric tows across the fracture surfaces of the matrix cracks.     

Mechanical properties of epoxy composites filled with silane-functionalized graphene oxide

In this work, the effects of as-produced GO and silane functionalized GO (silane-f-GO) loading and silane functionalization on the mechanical properties of epoxy composites are investigated and compared. Such silane functionalization containing epoxy ended-groups is found to effectively improve the compatibility between the silane-f-GO and the epoxy matrix. Increased storage modulus, glass transition temperature, thermal stability, tensile and flexural properties and fracture toughness of epoxy composites filled with the silane-f-GO sheets are observed compared with those of the neat epoxy and GO/epoxy composites. These findings confirm the improved dispersion and interfacial interaction in the composites arising from covalent bonds between the silane-f-GO and the epoxy matrix. Moreover, several possible fracture mechanisms, i.e. crack pinning/deflection, crack bridging, and matrix plastic deformation initiated by the debonding/delamination of GO sheets, were identified and evaluated.     

Fracture mechanisms in glass-reinforced plastics

Model glass fibre/polyester resin composites have been made in the form of double cantilever beams and the effect of a small number of fibres on quasi-static crack propagation has been studied by simultaneous plotting of load/deflection curves, measurements of crack length, and observation of the progress of fibre/resin debonding and fibre pull-out. By varying the condition of the fibre surface and the arrangement of the fibres to a limited extent and carrying out subsidiary experiments on single-fibre samples of identical character it has been possible to make direct measurements of all of the important parameters required for an analysis of the macroscopic behaviour in terms of established models of fibre/matrix interaction. Agreement between experimental and calculated fracture energies for these model composites is not highly satisfactory, but it seems clear that the fracture energy of grp is likely to be determined very largely by work done against friction between fibres and matrix after the debonding process has occurred. This conclusion opposes the currently-held view which attributes the largeγ _F values of grp to the fibre/resin debonding mechanism.     

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.     

Stress corrosion cracking of GRP pultruded rods in acid environments

Stress corrosion cracking of GRP pultruded rods has been investigated in 0.0001 to 5.0 N hydrochloric acid environments under bending and tensile loading modes. Crack initiation takes place at exposed glass fibres in the surface of the rod, and crack propagation is planar and at right angles to the rod axis. Leaching of calcium and aluminium from the fibres takes place during the cracking process, and time-to-failure is dependent on the acid concentration, the stress level and the ease of access of the acid to the glass fibre surface. Possible mechanisms of crack propagation through the glass fibres and resin are discussed.