Tough–brittle transition in unidirectional composites with fibre breakage and fibre–matrix interfacial failure

International Journal of Fracture - Fracture of three-dimensional unidirectional composites is studied through Monte Carlo fracture simulations on model composites. Fracture develops in the model...     

Strength and failure modes in resistance welded thermoplastic composite joints: Effect of fibre–matrix adhesion and fibre orientation

The strength and failure modes of resistance welded thermoplastic composites were investigated. Special attention was paid to the effect of basic characteristics of the adherends such as fibre–matrix adhesion and fibre orientation. 8HS woven GF/PEI composites were resistance welded. Intralaminar failure was found to be the major failure mechanism for the well welded joints, consisting of either fibre–matrix debonding or laminate tearing. An improved fibre–matrix adhesion was found to result in significantly higher lap shear strength. Besides, the main apparent orientation of the fibres on the welding surfaces was found to have an effect on the strength of the joints.     

Thermal expansion of cross-ply and woven carbon fibre–copper matrix composites

This paper presents thermal expansion data for cross-ply and woven copper matrix–carbon fibre composites (Cu–C_f MMCs) that were prepared by diffusion bonding. Thermal expansion was measured in two perpendicular in-plane directions of plate samples. For cross-ply samples (57 vol.%fibres) the mean coefficient of thermal expansion (CTE) between −20 and 300°C changed from approximately 6.5×10⁻⁶/°C to 3.5×10⁻⁶/°C during heating/cooling. The in-plane CTE increases with decreasing fibre content. Composites with woven arrangement of carbon fibres show a slightly higher CTE at elevated temperature.     

Crack onset and propagation at fibre–matrix elastic interfaces under biaxial loading using finite fracture mechanics

A new fracture criterion able to predict crack onset and propagation at interfaces between solids is formulated, implemented in a computational code and applied to a particular problem in composites on a microscale. More specifically, this criterion is used to study the debond onset and propagation in mixed mode in the case of a single fibre subjected to a biaxial remote loading. The fracture criterion formulation is based on the Linear Elastic-(Perfectly) Brittle Interface Model (LEBIM) combined with a Finite Fracture Mechanics (FFM) approach, where the stress and energy criteria are suitably coupled. Each of these criteria is a necessary but not sufficient condition for crack onset and propagation. Two empirical mixed-mode fracture criteria are considered and tested: the interface fracture toughness law by Hutchinson and Suo and the quadratic stress criterion. The FFM + LEBIM approach developed offers an adequate characterization of the interface stiffness in contrast to the too restrictive, original LEBIM formulation.     

Influence of temperature on the delamination process under mode I fracture and dynamic loading of two carbon–epoxy composites

This paper experimentally analyzes the influence of temperature and type of matrix on the delamination process of two composites subjected to fatigue loading through the study of their fracture under mode I behavior. The materials were manufactured with the same AS4 unidirectional carbon reinforcement and two epoxy matrices with different fracture behavior. The chosen temperatures for the experiments were 20 (room temperature), 50 and 90 °C.The experimental study carried out under dynamic loading enabled the authors to determine the influence that temperature has on the onset of delamination for the entire range of fatigue life of the material, from the low number of cycles zone to the high number of cycles zone. That is, it enabled the plotting of fatigue curves, represented as G_Imax–N (number of cycles required for the onset of delamination given a certain energy release rate) for an asymmetry coefficient of 0.2 (the ratio between the maximum and minimum fracture energies applied during the dynamic tests).The experimental data obtained were treated with a probabilistic model based on a Weibull distribution which allowed the identification of relevant aspects of the fatigue behavior of the materials such as the estimation of fatigue strength for periods greater than the tested values and the analysis of the reliability of the results.     

Modelling of strain rate effects on matrix dominated elastic and failure properties of unidirectional fibre-reinforced polymer–matrix composites

A phenomenological-based, strain rate dependent failure theory, which is suitable for the numerical modelling of unidirectional (UD) carbon fibre reinforced polymer composites (CFRPs), is presented. A phenomenological-based approach is also proposed for the three-dimensional (3D) modelling of strain rate induced material hardening in UD polymer composites. The proposed theory and approach are implemented in the Finite element (FE) code ABAQUS/Explicit for one integration point solid elements. Validation is presented against experimental data from dynamic compressive tests using results available in the published literature.     

Deformation and fracture in Al–Li-base alloys

Abstract

Aluminium–lithium-base alloys are of considerable interest because of their low density and high modulus. However, they have been shown to have low ductility and poor fracture toughness. This has been attributed to a variety of factors, including intense shear band formation, segregation to grain boundaries, and weakened grain boundaries due to precipitation and precipitate-free zones. The authors have investigated the deformation structures observed in binary and more complex commercial alloys. As would be expected, considering the microstructure of the alloys, extensive strain localization and shear band formation occurs in these alloys. However, it is shown that the commercial alloys are less sensitive to strain localization than the model binary alloy systems investigated. The stresss–train behaviour has been investigated. The alloys exhibit jerky flow, which is indicative of negative strain rate sensitivity, and strain rate change tests showed this to be the case. This is consistent with the deformation structures observed. The effect of weakened grain boundaries due to precipitation and precipitate-free zones has been studied by comparing the fracture characteristics of aged and unaged material. It is shown that the mode of failure is identical under appropriate conditions. It is concluded that segregation to grain boundaries is the major cause of the lower ductility and toughness of Al–Li alloys. This possibility has been investigated using in situ fracture surface analysis techniques. Results are presented on grain boundary segregation, and methods of reducing its influence on fracture behaviour are indicated.

MST/570     

Influence of refiner fibre quality and fibre modification treatments on properties of injection-moulded beech wood–plastic composites

Thermo-mechanical pulp (TMP) fibres made from beech wood were produced using increasing refiner gap widths and thus with increasing fibre length and coarseness. Fibres (60% by weight) were compounded in an internal kneading mixer using high-density polyethylene as the matrix and injection-moulded. Fibre lengths and length/width ratios were determined (a) before processing and (b) after injection-moulding and Soxhlet extraction using the optical FibreShape system. An increase in fibre length resulted in a decrease in water absorption and an improvement in flexural strength and modulus of elasticity of the wood–plastic composites (WPC). However, flexural strength of the WPC with TMP fibres was not improved compared to WPC with wood flour when maleic anhydride-grafted polyethylene (MAPE) was used as a coupling agent. After injection-moulding, differences in length of the various TMP fibre types were minor. Fibre geometry before processing strongly influences the water absorption and flexural properties of the composite. Fibre treatment with emulsified methylene diphenyl diisocyanate (EMDI) resin before compounding was shown to be equally efficient in reducing water absorption and improving flexural strength as the addition of MAPE during the compounding step.     

Influence of push–pull injection moulding on fibres and matrix of fibre reinforced polypropylene

Push–pull-processing (PPP) is a particular method of injection moulding with enlarged capabilities to control the melt flow during solidification. While the melt is solidifying from the mould wall to the mould centre an oscillating motion through the cavity maintains the melt flow. Aims were to investigate the capabilities of the process to control orientation of fibres and matrix and its effect on fibre length since this determines significantly the mechanical properties of plastic parts. Processing parameter variations were carried out on a Ferromatik K110/S60-2K injection-moulding machine. Sample plates were produced of short and long fibre reinforced polypropylene. The process and the control of it are described in the paper. Fibre orientation and fibre length were measured. Inter-laminar shear strength (ILSS) tests were performed to investigate the strength between shear layers. WAXD was applied to investigate orientation in the matrix. The results were correlated to process settings.     

Influence of reinforcement morphology and matrix strength of metal–matrix composites on the cyclic deformation and fatigue behaviour

The cyclic deformation behaviour of three metal–matrix composites, namely AA6061-T6 reinforced with 20 vol.% alumina particles and short-fibres, respectively, and pure aluminium reinforced with 20 vol.% short-fibres, has been investigated at temperatures between T=−100°C and T=300°C in total strain controlled symmetrical push–pull fatigue tests. The cyclic stress response exhibits initial cyclic hardening, subsequent saturation and cyclic softening, depending on the test parameters for temperatures lower than T=150°C. Initial cyclic hardening is less pronounced with increasing temperature and decreasing applied strain amplitude. Short-fibre reinforced composites — both with alloyed and unalloyed aluminium matrix — harden cyclically more than the particulate-reinforced composite. The comparison of the cyclic with monotonic stress–strain curves indicates that, depending on the testing conditions, both cyclic hardening and cyclic softening can occur.     

Reduction of hygrothermal transverse stresses in unidirectional hybrid composites under cyclic environmental conditions

When fiber-reinforced polymer plates are exposed to cyclic environmental conditions, polymer matrix absorbs or desorbs continuously the moisture due to the variation in service temperature and relative humidity. Both temperature and moisture concentration produce an important hygrothermal transverse stresses, which are maximum on both edges of the composite plates. These transverse stresses which are more important at first times of moisture diffusion, can produce a probable damage of composite plates. To extend the durability of our composite plate, interplay hybrid composites are adopted to reduce the transverse stresses on edges. Therefore, a variation of the relationship between thicknesses of unidirectional hybrid composites constituents AS/3501-5 and T300/5208 is carried out in order to find minimal transverse stresses. This thicknesses variation enables us to find the best configuration which gives favourable service conditions of our hybrid composite, i.e., to predict firstly a considerable reduction of hygrothermal transverse stresses at both edges of our hybrid plate, secondly to reduce or to attenuate the edge effect developed in 6 days and 6 weeks periods.     

Discrimination of matrix–fibre interactions in all-cellulose nanocomposites

All-cellulose nanocomposites are produced using dissolved microcrystalline cellulose (MCC) as the matrix and cellulose nanowhiskers (CNWs), produced by acid hydrolysis, as the reinforcement. These nanocomposites are then characterised using X-ray diffraction to determine their crystallinity, and Raman spectroscopy to discriminate the reinforcing phase (cellulose I) from the CNWs and the matrix phase (cellulose II) from the dissolved MCC. Mechanical testing of the composites shows that there is a significant systematic reinforcement of the matrix material with the addition of CNWs. Furthermore, Raman spectroscopy is used to show that distinct spectroscopic bands for each phase within the composite spectrum can be used to discriminate the effects of both reinforcement and matrix. It is shown that a Raman band located approximately at 1095 cm⁻¹ can be used to follow the micromechanical deformation of the CNWs and matrix, whereas another band located at 895 cm⁻¹ arises purely from the matrix. This spectroscopic fingerprint is used to gain insights into the complex interactions occurring in these potentially recyclable composite materials, and offers a way forward to optimising their properties.     

Nylon 66/poly(vinyl pyrrolidone) reinforced composites:: 1. Interphase microstructure and evaluation of fiber–matrix adhesion

Nylon 66, an aliphatic semicrystalline polyamide, was reinforced with E-glass fibers or high-modulus (AS4) carbon fibers. As in many reinforced semicrystalline thermoplastics, an interphase composed of transcrystallinity developed owing to the high nucleation density of the polymer on the fiber surface. The influence of this region on the fiber–matrix adhesion was studied with a modified microdebond test. E-glass fibers were freshly prepared in our laboratory by traditional glass-forming techniques and embedded in a film of Nylon 66 or a Nylon 66/poly(vinyl pyrrolidone) (PVP) blend. Previous work has shown that PVP, an amorphous polar polyamide, has a dramatic influence on the morphology of Nylon 66. This phenomenon was utilized to manipulate the interphase formation in the Nylon 66 composite from one having a complete transcrystalline interphase to a composite with the absence of an interphase. PVP was introduced to the matrix by solution blending with Nylon 66 and/or to the fibers as a sizing prior to embedment. The resulting morphologies were studied by polarized hot-stage optical microscopy. From the microdebond and morphology results, it was shown that the fiber–matrix adhesion in this composite system is dependent upon interphase microstructure. Composites containing transcrystallinity have higher interfacial shear strength values than those that do not contain this interphase. This has profound implications for the bulk mechanical properties of the composite, which are addressed in Part 2 of this paper.