Effect of cooling rate and crack propagation direction on the mode 1 interlaminar fracture toughness of biaxial noncrimp warp‐knitted fabric composites made of glass/PP commingled yarn

The mode 1 interlaminar fracture toughness of biaxial (±45°) noncrimp warp‐knitted fabric composites made of glass/PP commingled yarn was investigated. The crack propagation along the warp and weft directions, respectively, was considered for the composites cooled at two different rates during laminate molding. The interlaminar fracture toughness was characterized by determining the critical strain energy release rate (G_IC) of initiation and propagation measured from the double cantilever beam tests. In the case of a slow cooling rate (1°C/min), most specimens possess pure interlaminar crack propagation and direction‐independence characteristics. Nevertheless, the high‐cooled (10°C/min) specimens fractured in both directions suffer extensive intraply damage (crack branching, debonding, and bridging of 45°‐oriented interfacial yarns) and knit thread breakage, leading to G_IC of propagation two times higher than that of the slow‐cooled specimens, and the clear difference in the G_IC values of initiation between the two directions may be due to the contribution of the knit thread breakage to the fracture energy. POLYM. COMPOS., 2008 © 2007 Society of Plastics Engineers     

Sliding mode interlaminar fracture toughness of interply hybrid composite materials

To measure the sliding mode interlaminar fracture toughness of interply hybrid composites, end notched flexure (ENF) specimens with three different types of stacking sequence have been utilized. Finite element analysis is applied to separate the contribution from different modes on the strain energy release rate. In addition, the methods of beam theory, compliance, and compliance calibration to calculate the G_C values are compared. The effects of interface friction, crack length, and specimen width are also discussed. The results show that the crack growth in the three types of specimens is dominated by the sliding mode and the Mode II interlaminar fracture toughness can be approximated. The compliance method is not recommended for hybrid ENF specimens and the effects of interface friction can be neglected. To get rid of the edge effect, the specimen width must be carefully chosen, while the fracture toughness does increase with the initial crack length.     

Fatigue delamination,initiation, and growth,under mode I and II of fracture in a carbon‐fiber epoxy composite

In this article, interlaminar crack initiation and propagation under mode I and II dynamic loading of an epoxy matrix reinforced with unidirectional carbon fibers were evaluated. Delamination in mode I was carried out employing the DCB test (Double Cantilever Beam). In mode II, the ENF test (End Notched Flexure) was used. The fracture toughness in mode I was obtained using the methods of the ASTM D5528 Standard, whereas in mode II, the methods were applied in accordance with the ESIS (European Structural Integrity Society) Protocol. Employing this experimental program, the fatigue curves (ΔG,N) and growth rate curves (ΔG, da/dN) in both fracture modes were determined for an asymmetry ratio R = 0.2. The influence of the manufacturing process of the material on its behavior with respect to crack growth onset may be deduced from the experimental results, mainly the presence of resin bags. Moreover, as the crack growth rate decreases for large crack lengths, crack growth may even cease if the critical fracture energy does not increase above the values obtained in the static characterization of the material. POLYM. COMPOS., 2010. © 2009 Society of Plastics Engineers     

Finite element analysis of composite T-joints used in wind turbine blades

Abstract

This paper presents a finite element (FE) analysis of the fracture behaviour of composite T-joints with various fibre reinforcement architectures subjected to pull-out loading. The FE model accounts for the effect of interface strength and interlaminar fracture energy on the ultimate load to failure; a linear softening fracture based law is adopted to describe crack growth in the form of delamination. The numerical simulation shows that the failure load increases with increasing interlaminar strength, which controls delamination initiation. The FE also demonstrates that the failure load increases with increasing interface fracture energy and the delamination propagation depends largely upon the fracture energy, which is enhanced by introducing interlaminar veils or through-thickness tuft yarns (stitching). Predictions were validated using experimental data for E-glass fibre/epoxy T-joints subjected to a tensile pull-out loading. The load–displacement response from the FE analysis is in a good agreement with measurements, illustrating the effectiveness of through thickness tufting that results to progressive, a more ‘ductile’, rather than abrupt catastrophic failure.     

Controlled energy dissipation in fibrous composites I. Controlled delamination

Delamination mechanisms in continuous fiber reinforced composites were investigated. The concept of controlled interlaminar bonding (CIB) is proposed as a guideline for preparing fiber-epoxy composite laminates with enhanced fracture toughness without significant degradation in strength properties. The interlaminar bonding was manipulated by several specialized techniques including insertion of delamination promotors and surface modification of laminae. Results indicated that the plane-strain fracture toughness of E-glass-epoxy laminates could be improved by inserting perforated interlaminar films of aluminum, paper, polyester and polyimide, and fabrics. Such interlayers were used to promote delamination which dissipate strain energy by blunting and diverting a propagating crack. The fracture resistance of a laminate was found to be dependent on the degree of delamination. The competition between the growth of delamination cracks and the propagation of a main crack is controlled by the relative magnitude of the interlaminar bonding strength and the lamina cohesive strength. The interlaminar bonding is controlled by the degree of interlayer perforation and the adhesion between interlayer and lamina. The loading direction was found to be very important in dictating the failure processes. Experimental results from several composite systems are presented and discussed along with post-failure analysis data.     

Delamination toughness of fiber-reinforced composites containing a carbon nanotube/polyamide-12 epoxy thin film interlayer

We present a simple, out-of-autoclave approach to improve the delamination toughness of fiber-reinforced composites using epoxy interlayers containing 20 wt.% polyamide-12 (PA) particles and 1 wt.% multi-walled carbon nanotubes (MWCNTs). Composites were prepared by integrating partially cured thin films at the laminate mid-plane using vacuum-assisted resin transfer molding. The introduction of epoxy/PA interlayers increased fracture toughness due to the ductile deformation and crack bridging of PA particles within an interlaminar damage zone with uniform thickness of about 20 μm. Composites interlayered with epoxy/PA/MWCNT exhibited nearly 2.5 and 1.5 times higher fracture toughness than composites containing neat epoxy and epoxy/PA interlayers, respectively, without an observable increase in interlaminar thickness. The fracture surface was analyzed to identify failure modes responsible for the fracture toughness improvement. The MWCNTs are proposed to inhibit critical loading of defects by minimizing stress concentration within the interlaminar region, thereby enabling greater deformation of the PA particles during fracture.     

Mode I interlaminar fracture toughness of Nylon 66 nanofibrilmat interleaved carbon/epoxy laminates

Carbon/epoxy laminates interleaved with laboratory scale electrospun Nylon 66 nanofibrilmat and spunbonded nonwoven mats were investigated. The effect of the nanoscale fibers on the fracture toughness of the composite under pure Mode I loading was evaluated. It was shown that the nanofibrilmat is responsible for a major interlaminar fracture toughness improvement, as high as 255–322%, compared to a noninterleaved carbon/epoxy reference laminate. We further studied the improvement mechanism of the electrospun nanofibrilmat compared to a commercial spunbonded nonwoven Nylon 66 mat. A combination of two interlayer fracture mechanisms responsible for the toughness improvement is suggested: the first is related to the high energy dissipated by bridged thermoplastic nanofibers and the second is attributed to the generation of a plastic zone near the crack tip. The interlaminar fracture mechanisms of both electrospun nanofibrilmat and the nonwoven mat interleaving was analyzed and discussed. POLYM. COMPOS., 2011. © 2011 Society of Plastics Engineers     

The effect of silicon carbide whiskers on the Mode I interlaminar fracture of carbon fiber composites

This paper reports on the Mode I interlaminar fracture toughness improvement of carbon fiber-epoxy composites as a result of incorporating SiC whiskers in the epoxy matrix. Five laminates of unidirectional carbon fiber-epoxy composites at different weight fractions of SiC whiskers were manufactured using hand layup vacuum bagging process. Optical and scanning electron microscopic analysis were conducted to give an insight into the fracture morphogoloy, failure mechanisms, and the energy dissipation mechanisms created by the presence of the whiskers in the composite. Experimental results showed that composites containing 5 wt% whiskers exhibited 67% increase in the crack initiation interlaminar fracture toughness G_IC, whereas it exhibited 55% increase in the maximum G_IC compared to pristine composite. The optical and SEM fractographs revealed a strong relation between the microstructure of the fractured surfaces and the energy release rate trend of the composites.     

Numerical and experimental evaluation of the Mode III interlaminar fracture toughness of composite materials

The Crack Rail Shear (CRS) specimen is a proposed test method to characterize the interlaminar Mode III critical strain energy release rate (G_IIIc) of continuous fiber-reinforced composite materials. The specimen utilizes the two rail shear test fixture and contains embedded Kapton film between designated plies to provide a starter crack for subsequent fracture testing. Analytical expressions for specimen compliance and G_III are based upon Strength of Materials (SM) principles. The model identifies important material and geometric parameters and provides a simple data reduction scheme. A quasi-three-dimensional, linear elastic finite element stress analysis verifies the purity of the Mode III fracture state and identifies admissible crack lengths to be used in the experimental study. A fully three-dimensional linear elastic finite element analysis of the CRS is employed to investigate the influence of edge effects on the fracture state for the finite length sample. Results based upon a uniform crack extension indicate a small region of mixed mode behavior at traction free edges which decay to a pure Model III fracture state in the interior of the sample. Furthermore, the G_III distribution along the crack front decreases at the free edges from a maximum plateau region in the interior. The three-dimensional analysis allows edge effects to be minimized by selecting appropriate specimen lengths. Compliance and strain energy release rates are in good agreement with the SM model. An experimental program was performed to measure G_IIIc of two graphite epoxy systems. G_IIIc results for AS4/3501-6 were found to be 1.6 times the Mode II fracture toughness, while IM7/8551-7 exhibited equivalent Mode II and Mode III fracture toughnesses. Mode III fracture surfaces revealed microstructural deformations characteristic of Mode II fracture.     

Mode I interlaminar fracture behavior of 2D woven ceramic matrix composites

Interlaminar fracture properties of melt-infiltrated woven SiC/SiC ceramic matrix composites were investigated using traditional and wedge-loaded double cantilever beam methods. The two methods produced comparable G_IC results for some specimens. The difference in boundary conditions between the two methods appeared to influence the crack propagation path. The DCB method, having free-end boundary condition, allowed more interaction between the crack and the composite microstructure than the wedge method did. The effect of fiber tow layout sequence had an effect on the interlaminar properties. Higher toughness was observed for the orientation where crack propagation occurs between planes with more transverse tows. Jump-arrest phenomenon was found to have higher significance on the rising R-curve behavior than fiber bridging.     

Temperature and loading rate effects in the mode II interlaminar fracture behavior of carbon fiber reinforced PEEK

The combined effect of varying loading rate and test temperature on the mode II interlaminar fracture properties of AS4/carbon fiber reinforced PEEK has been investigated. End notch flexure tests have shown that this thermoplastic‐based composite system offers a very high value of interlaminar fracture toughness at room temperature. Increasing the test temperature leads to a reduction in the mode II interlaminar fracture toughness of the composite, with the value at 150°C being approximately one half of the room temperature value. In contrast, increasing the crosshead displacement rate has been shown to increase the value of G_IIc by up to 25%. A more detailed understanding of the effect of varying temperature and loading rate on the failure mechanisms occurring at the crack tip of these interlaminar fracture specimens has been achieved using the double end notch flexure (DENF) geometry. Here, extensive plastic flow within the crack tip region was observed in all specimens. It is believed that the rate sensitivity of G_IIc reflects the rate‐dependent characteristics of the thermoplastic resin.     

Determination of initiation value of mode I interlaminar fracture toughness of unidirectional polymer composites

The use of interlaminar fracture tests to measure the delamination resistance of unidirectional composite laminates is now widespread. However, because of the frequent occurrence of fiber bridging and multiple cracking during the tests, it leads to artificially high values of delamination resistance, which will not represent the behavior of the laminates. Initiation fracture from the crack starter, on the other hand, does not involve bridging, and should be more representative of the delamination resistance of the composite laminates. Since there is some uncertainty involved in determining the initiation value of delamination resistance in mode I tests in the literature, a power law of the form G_IC= A · Δ a^b (where G_IC is mode I interlaminar fracture toughness and Δ a is delamination growth) is presented in this paper to determine initiation value of mode I interlaminar fracture toughness. It is found that initiation values of the mode I interlaminar fracture toughness. G_ICini, can be defined as the G_IC value at which 1 mm of delamination from the crack starter has occurred. Examples of initiation values determined by this method are given for both carbon fiber reinforced thermoplastic and thermosetting polymers.     

Effect of interlaminar toughness on the low‐velocity impact damage in composite laminates

Based on the continuum damage mechanics (CDM) and the cohesive zone model (CZM), a numerical analysis method for the evaluation of damage in composite laminates under low‐velocity impact is proposed. The intraply damage including matrix crack and fiber fracture is represented by the CDM which takes into account the progressive failure behavior in the ply, using the damage variable to describe the intraply damage state. The delamination is characterized by a special contact law including the CZM which takes into account the normal crack and the tangential slip. The effect of the interlaminar toughness on the impact damage is investigated, which is as yet seldom discussed in detail. The results reveal that as the interlaminar fracture toughness enhances, the delamination area and the dissipated energy caused by delamination decrease. The contribution of normal crack and tangential slip to delamination is evaluated numerically, and the later one is the dominant delamination type during the impact process. Meanwhile, the numerical prediction has a good agreement with the experimental results. The study is helpful for the optimal design and application of composite laminates, especially for the design of interlaminar toughness according to certain requirements. POLYM. COMPOS. 37:1085–1092, 2016. © 2014 Society of Plastics Engineers     

The effect of postcure time on the fracture properties and nodular morphology of an epoxy resin

The effect of different postcure times on the fracture properties and morphology of an epoxy resin was studied. The fracture energy for crack initiation and arrest was calculated for each sample and plotted as a function of the postcure time. Nodules (25–35 nm in diameter) were observed on all fracture surfaces. Of considerable interest was the alignment of nodules in the direction of crack propagation. Longer postcure times are thought to alter the fracture energy by causing additional crosslinking in the internodular matrix.     

PET interleaving veils for improved fracture toughness of glass fibre/low‐styrene‐emission unsaturated polyester resin composites

The use of interleaved polyethylene terephthalate (PET) veils to increase the interlaminar fracture toughness of glass fiber‐reinforced, low‐styrene emission, unsaturated polyester resin composites, was investigated. PET, being chemically similar to the unsaturated polyester resin, was expected to exhibit good wetting and strong interaction with the matrix. Composite laminates were manufactured by hand lay‐up, with the veil content varying up to 7%. The effects of PET veils on the interlaminar shear strength, flexural strength, flexural modulus, glass transition temperature, damping parameters, and Mode‐I interlaminar fracture toughness of the composite were studied. The veils were found to enhance most of these properties, with only minor negative effects on flexural stiffness and T_g. The PET/resin bonding did indeed prove to be strong, but the enhancement of fracture toughness was not as much as expected, because of the weaker glass/resin interface providing an alternative crack propagation path. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 42877.     

Fracture toughness of filled polypropylene copolymer systems

The impact strength to stiffness balance of a toughened polypropylene copolymer was modified through the addition of mineral fillers. The stiffness was improved over the base resin value for all formulations. However, the impact strength exhibited complex behavior. The fracture toughness G_c calculated using the linear elastic fracture mechanics theory was indicative of the materials resistance to crack propagation. The G_c values were modified significantly with the addition of fillers and for some formulations was greater than the base resin value. The LEFM analysis indicates that this is due to an increase in the damage zone size r_p where the energy absorbing mechanisms are concentrated. However, the specific energy absorbed per unit volume decreased with the addition of fillers. The total energy to fracture measured using unnotched samples was indicative of crack initiation and crack propagation energies. This upper bound value decreased for all formulations indicating a reduction in the crack initiation resistance, in the presence of stress concentrating heterogeneities in the filled systems.     

Correlation between nodular morphology and fracture properties of cured epoxy resins

Various bulk epoxy resin formulations, based on diglycidyl ether of bisphenol A (DGEBA) and cured with diethylene triamine (DETA) were studied. Methods of linear elastic fracture mechanics were employed and all systems were characterized by the corresponding values of the critical strain energy release rate for crack initiation and crack arrest. Fracture morphology was studied by scanning electron microscopy and transmission electron microscopy of carbon—platinum surface replicas. An apparent correlation between morphology and ultimate mechanical properties has been found. All fracture surfaces are shown to be characterized by distinct nodular morphology. Nodules, ranging in size from 15–45 nm, represent the sites of higher crosslink density in an inhomogeneous network structure. Fracture surfaces were further characterized by three crack propagation zones. A smooth, brittle fracture zone was preceded and followed by crack initiation and crack arrest zones, respectively. An apparent plastic flow was confined to the initiation and arrest regions. No crazing phenomenon was seen in the initiation zone; instead a step-like fracture was observed, typified by the ‘flow’ of internodular matrix during step formation. Local plastic deformation in the initiation zone and the corresponding value of critical strain energy release rate, G_Ic, were correlated with the nodular morphology. The size of nodules was found to vary with the curing agent concentration, thus allowing us to establish a fundamental correlation between the nodular morphology and the ultimate mechanical properties of epoxy resins.     

Effect of thermoplastic veils on interlaminar fracture toughness of a glass fiber/vinyl ester composite

The effects of two thermoplastic micro‐veils, polyamide (PA) and polyethylene terephthalate (PET) veil, on the interlaminar fracture toughness of a glass fiber/vinyl ester (GF/VE) composite were investigated. The veils incorporated into the composite as interleaving materials were first characterized via scanning electron microscopy (SEM), differential scanning calorimetry (DSC), contact angle and tensile testing in order determine the best candidate as toughening agent for the GF/VE composite. Composite laminates were manufactured by vacuum‐assisted resin infusion process. Double cantilever beam (DCB) testing was performed to investigate the Mode I type interlaminar fracture toughness of the composites, which was characterized by critical strain energy release rate (G _IC). An increased G _IC was obtained by incorporating the PA veil, but it changed negligibly by the addition of the PET veil. The analysis of the composites fracture surface via SEM revealed increased fiber bridging between adjacent plies in the case of PA veil interleaved composites which played a key role in enhancing the Mode I interlaminar fracture toughness. However, the PET veil present in the interlaminar region did not take part in any energy absorbing mechanism during the delamination, thus keeping the G _IC of the composite unaltered. POLYM. COMPOS., 38:2501–2508, 2017. © 2015 Society of Plastics Engineers     

Particulate interlayer toughening of dicyanate matrix composites

Toughening of dicyanate matrix composites with particulate-modified resin-rich interlayers was investigated in this study. Specifically, the cure behavior, viscosity, and fracture toughness of the modified dicyanate systems were analyzed. Creation of a layered composite structure showed no improvement in Mode 1 interlaminar fracture toughness (GIc), but greatly increased the Mode II interlaminar fracture toughness (GIIc). Furthermore, the concentration of modifier particles in the interlayer resin was found to directly affect the toughness improvement and fracture path.     

Mechanical Behavior and Fracture Toughness of Poly(L‐lactic acid)‐Natural Fiber Composites Modified with Hyperbranched Polymers

Summary: The use of hyperbranched polymers (HBP) with hydroxy functionality as modifiers for poly(L ‐lactic acid) (PLLA)‐flax fiber composites is presented. HBP concentrations were varied from 0 to 50% v/v and the static and dynamic tensile properties were investigated along with interlaminar fracture toughness. Upon addition of HBP, the tensile modulus and dynamic storage modulus (E′) both diminished, although a greater decline was noticed in the static modulus. The elongation of the composites with HBP showed a pronounced increase as large as 314% at 50% v/v HBP. The loss factor (tan δ) indicated a lowering of the glass transition temperature (T_g) due to a change in crystal morphology from large, mixed perfection spherulites to finer, smaller spherulites. The change in T_g could have also resulted from some of the HBP being miscible in the amorphous phase, which caused a plasticizing effect of the PLLA. The interlaminar fracture toughness measured as the critical strain energy release rate (G_IC) was significantly influenced by HBP. At 10% v/v HBP, G_IC was at least double that of the unmodified composite and a rise as great as 250% was achieved with 50% v/v. The main factor contributing to high fracture toughness in this study was better wetting of the fibers by the matrix when the HBP was present. With improved ductility of the matrix, it caused ductile tearing along the fiber‐matrix interface during crack propagation.

ESEM photograph of propagation region of the interlaminar fracture toughness specimens with 30% v/v of HBP.