Viscoelastically prestressed polymeric matrix composites – Effects of test span and fibre volume fraction on Charpy impact characteristics

A viscoelastically prestressed polymeric matrix composite (VPPMC) is produced by subjecting polymeric fibres to tensile creep, the applied load being removed before moulding the fibres into a resin matrix. After matrix curing, the viscoelastically strained fibres impart compressive stresses to the surrounding matrix, thereby improving mechanical properties. This study investigated the mechanisms considered responsible for VPPMCs improving impact toughness by performing Charpy impact tests on unidirectional nylon 6,6 fibre–polyester resin samples over a range of span settings (24–60 mm) and fibre volume fractions (3.3–16.6%). Comparing VPPMC samples with control (unstressed) counterparts, the main findings were: (i) improved impact energy absorption (up to 40%) depends principally on shear stress-induced fibre–matrix debonding (delamination) and (ii) energy absorption improves slightly with increasing fibre volume fraction, but the relationship is statistically weak. The findings are discussed in relation to improving the impact performance of practical structures.     

Viscoelastically prestressed polymeric matrix composites – Potential for useful life and impact protection

A viscoelastically prestressed polymeric matrix composite (VPPMC) is produced by applying tension to polymeric fibres, the tensile load being released prior to moulding the fibres into a matrix. Following matrix solidification, compressive stresses imparted by the viscoelastically strained fibres improve composite tensile, flexural and impact properties. This study focuses on the potential for useful life and impact protection capability by performing Charpy impact tests on nylon 6,6 fibre–polyester resin samples subjected to accelerated ageing. Prior to testing, time–temperature superposition principles were used, the samples being aged by heating to 60 °C for periods representing a 10-fold increase over previous work. The results demonstrated no deterioration in impact performance over a duration equivalent to 40 °C for ～20 years. Combining these data with previous work showed that VPPMC samples absorbed, on average, ～30% more impact energy than control (unstressed) counterparts. Four mechanisms are highlighted, which should enable VPPMCs to contribute towards high velocity (blast fragment) impact protection and crashworthiness applications, especially for situations requiring low mass components with complex geometries.     

Viscoelastically generated prestress from ultra-high molecular weight polyethylene fibres

The viscoelastic characteristics of ultra-high molecular weight polyethylene (UHMWPE) fibres are investigated, in terms of creep-induced recovery strain and force output, to evaluate their potential for producing a novel form of prestressed composite. Composite production involves subjecting fibres to tensile creep, the applied load being removed before moulding the fibres into a resin matrix. After matrix curing, the viscoelastically strained fibres impart compressive stresses to the surrounding matrix, to produce a viscoelastically prestressed polymeric matrix composite (VPPMC). Previous research has demonstrated that nylon fibre-based VPPMCs can improve mechanical properties without needing to increase mass or section dimensions. The viability of UHMWPE fibre-based VPPMCs is demonstrated through flexural stiffness tests. Compared with control (unstressed) counterparts, these VPPMCs typically show increases of 20–40 % in flexural modulus. Studies on the viscoelastic characteristics indicate that these fibres can release mechanical energy over a long-timescale and fibre core–skin interactions may have an important role.     

The low velocity impact response of non-woven hemp fibre reinforced unsaturated polyester composites

Hemp fibre reinforced unsaturated polyester composites (HFRUPE) were subjected to low velocity impact tests in order to study the effects of non-woven hemp fibre reinforcement on their impact properties. HFRUPE composites specimens containing 0, 0.06, 0.10, 0.15, 0.21 and 0.26 fibre volume fractions (V_f) were prepared and their impact response compared with samples containing an equivalent fibre volume fraction of chopped strand mat E-glass fibre reinforcement. Post-impact damage was assessed using scanning electron microscopy (SEM). A significant improvement in load bearing capability and impact energy absorption was found following the introduction hemp fibre as reinforcement. The results indicate a clear correlation between fibre volume fractions, stiffness of the composite laminate, impact load and total absorbed energy. Unreinforced unsaturated polyester control specimens exhibited brittle fracture behaviour with a lower peak load, lower impact energy and less time to fail than hemp reinforced unsaturated polyester composites. The impact test results show that the total energy absorbed by 0.21 fibre volume fraction (four layers) of hemp reinforced specimens is comparable to the energy absorbed by the equivalent fibre volume fraction of chopped strand mat E-glass fibre reinforced unsaturated polyester composite specimens.     

The flexural stiffness characteristics of viscoelastically prestressed polymeric matrix composites

A novel composite material is described, where tension, applied to polymeric fibres, is released prior to moulding them into a matrix. On matrix solidification, compressive stresses imparted by the viscoelastically strained fibres improve mechanical properties. Previous studies showed that these viscoelastically prestressed composites had improved impact and tensile properties compared with control (unstressed) counterparts. In the current study, three-point bend tests on composites using nylon 6,6 fibre reinforcement in epoxy and polyester resins have demonstrated that the viscoelastic prestressing effect increases flexural stiffness. From deflections at 5 s and 900 s, using a freely suspended load on large span/thickness ratio (L/h) samples, the flexural modulus was increased by ～50% relative to control counterparts. Stiffness-increasing mechanisms relating to pre-tensioned fibre and matrix prestress effects are discussed. For small L/h samples (using controlled rate deflection up to ～5 s), the flexural modulus and resulting increase from viscoelastic prestressing were lower. This is attributed to shear effects and possibly fibre–matrix load transfer mechanisms. By exploiting time–temperature superposition, all samples were aged to the equivalent of 100 years at 20 °C and subsequent bend tests revealed no significant change in the modulus increase resulting from viscoelastic prestressing.     

An experimental study on the in situ strength of SiC fibre in unidirectional SiC/Al composites

In order to investigate the effect of strain rate and high temperature exposure on the mechanical properties of the fibre in the unidirectional fibre reinforced metal-matrix composite, in situ SiC fibre bundles are extracted from two kinds of SiC/Al composite wires, which are heat-treated at two different temperatures (exposed in the air at 400 and 600 °C for 40 min after composition). Tensile tests for these two fibre bundles are performed at different strain rates (quasi-static test: 0.001 s⁻¹, dynamic test: 200, 700, and 1200 s⁻¹) and the stress–strain curves are obtained. The experimental results show that their mechanical properties are rate-dependent, the modulus E, strength σ_b and unstable strain _b (the strain corresponding to σ_b) all increase with increasing strain rate. Compared with the mechanical properties of the original SiC fibre, those of the two in situ fibres degrade to some extent, the degradation of the in situ fibre extracted from the composite wire exposed at 600 °C (hereafter referred to as in situ fibre 2) is more serious than that of the in situ fibre extracted from the composite wire exposed at 400 °C (hereafter referred to as in situ fibre 1). The mechanism of the degradation is investigated. A bi-modal Weibull statistical constitutive equation is established to describe the stress–strain relationship of the two in situ fibre bundles. The simulated stress–strain curves agree well with the experimental results.     

Statistical fracture of E-glass fibres using a bundle tensile test and acoustic emission monitoring

Mechanical strength studies have been carried out on fibre bundles used in composite manufacturing. The variability in mechanical properties of glass fibres has been studied using bundles of about 2000 filaments. The fibre strength distributions were analysed using the survival probability-applied strain (S–ε) curve, in relation with various experimental conditions. We also examine the effect of lubricant’s viscosity on the fracture behaviour of E-glass fibre bundles. Acoustic emission (AE) was monitored during the bundle tensile tests in order to verify that individual filament failures are statistically independent. On tensile tests with lubricated bundles of E-glass fibres, it is shown that each individual fibre break can be detected using AE. Hence, AE monitoring of a lubricated bundle of E-glass fibres provides a convenient and relatively quick method to obtain the Weibull parameters of strength distribution.     

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.     

Tensile failure of pultruded glass-polyester composites under superimposed hydrostatic pressure

The tensile properties of five types of pultruded 0·52 V_f glass-fibre-polyester rods were investigated by extending waisted round specimens at atmospheric and superimposed hydrostatic pressures, −H, to 300 MPa. The maximum principal stress at fracture, −700 MPa, decreased, with the superimposition of −H, approximately by its magnitude. As −H increased the failure surfaces became flatter, the amount of fibre pull-out decreased and transverse cracks became shorter or were eliminated. Glass fibres in the failure surfaces were resin free, and failure of the glass fibre bundles appeared to control the fracture process in the entire pressure range for all materials. The decrease in maximum principal tensile stress with increasing −H indicates that the glass fibre failure process is not controlled by a critical tensile stress. Failure criteria are discussed, and in the tension-compression-compression octant of stress space the relevant criteria appear to be strain energy and deviatoric tensile stress, strain and strain energy for these GRPs and glass itself.     

Compressive splitting response of glass-fiber reinforced unidirectional composites

An analytical and experimental study of the compressive behavior of unidirectional glass/epoxy composites loaded in the fiber direction has been carried out for a range of fiber volume fractions. It was observed experimentally that glass/epoxy composites failed predominantly by splitting at lower fiber volume fractions (V_f) and by a combination of splitting and kinking at higher V_f. In contrast, carbon/epoxy composites were found to fail by kinking only. A mechanical model developed by Lee and Waas is used to predict the compressive strength of the composites. The predicted compressive strengths were then compared with existing experimental data in the literature. The effectiveness of the model in including the effect of initial misalignment of fibers on the predicted compressive strengths has also been studied.     

The durability of controlled matrix shrinkage composites

During fatigue of aligned fibre pultrusions, the flexural modulus decreases continuously when the applied stresses are tensile and directed along the fibres (R=0.1). In addition, the Poisson's ratio increases continuously, and so does the energy absorbed during the fatigue cycle. Holes in the specimens continuously increase in size in a direction at right angles to the applied stress, but change little in the stressing direction. These effects are enhanced by including compressive stresses in the cycle (R=–0.3) and are reduced by reducing the polymer cure shrinkage pressure. There are notable similarities between fatigue failure and compressive failure in aligned fibre composites, and evidence that matrix stresses are produced at right angles to the fibres, which are probably large enough to cause matrix fatigue failure. These observations lead to the conclusion that the fatigue failure may well originate from misaligned fibres, which generate off-axis stresses. These cause interface failure and polymer fragmentation, which can then lead to fibre failure (and thus composite failure) even when the applied stresses are always tensile.     

On the impact performance of carbon fibre laminates with epoxy and PEEK matrices

A study was made of the mechanical properties and impact performance of carbon fibre/PEEK (0,90), ($\text{±45}$) and ($\text{±45,0}$) laminates and comparisons were made with similar carbon fibre/epoxy laminatesFibre dominated properties such as plain tensile strength were similar to those of epoxy laminates with similar fibres and volume fractions. Because of the increased toughness of PEEK there was less extensive matrix cracking, even though there was fibre debonding, and this gave increased transverse and shear cracking strains, increased shear strengths but decreased notched tensile strengths. The lower modulus and yield stress of PEEK caused lower compressive strengths, but PEEK absorbed little moisture and at 120°C moisture had little effect on mechanical properties.Dropweight impact produced less extensive damage in carbon fibre/PEEK laminates. Residual tensile strengths were similar but, because of the less extensive damage and greater delamination fracture energy, the residual compressive strengths were significantly greater with a PEEK matrix.Microscopic examination showed less matrix cracking and more fibre buckling in the carbon fibre/PEEK and this is discussed in relation to mechanical properties.     

Compression fracture of unidirectional carbon fibre-reinforced plastics

The effect of volume fraction and tensile strength of fibres, temperature and stress concentrators on the compression strength and fracture mode of unidirectional CFRP was studied. The cause of kinking is different for composites reinforced by low-(<3 GPa) and high-strength fibres. If fibre strength is high, the kink is initiated by composite splitting followed by fibre bend fracture in the tip of the split. In the case of low-strength fibres, kinking is initiated by compressive fracture of the fibres. The effect of stress concentrators on the CFRP compressive strength is described by linear fracture mechanics. In the presence of defects, fracture is a result of the emergence of splits near a hole. As the critical stress of splitting growth initiation reduces in proportion to the square root of the defect size, the Griffith criterion describes the composite compressive fracture. At elevated temperature, failure is caused by fibre buckling. The fracture band in this case is oriented perpendicular to the fibre direction. Carbon fibre compressive strength may be measured by the loop method. Bending a strand of carbon fibres glued to the elastic beam gives a fibre-controlled upper limit of the composite compressive strength.     

Fracture behaviour of hybrid glass matrix composites: thermal ageing effects

The thermal aging of a glass matrix composite reinforced by short carbon fibres as well as by ZrO₂ particles (hybrid composite) was investigated at temperatures in the range 500–700 °C for exposure durations of 24 h in air. The mechanical properties of as-received and aged samples were evaluated at room temperature by using the three-point flexure chevron notch technique. The fracture toughness values of as-received specimens were in the range 2.6–6.4 MPa m^1/2. Fracture toughness was affected by the thermal aging conditions. For thermal aging at temperatures <700 °C, degradation of fibre–matrix interfaces occurred and therefore the apparent fracture toughness and flaw tolerant resistance decreased. For the most severe ageing conditions tested (700 °C/24 h), fracture toughness values dropped to 0.4 MPa m^1/2. Significant degradation of the material was detected for this aging condition, mainly characterised by porosity formation in the matrix as a result of softening of the glass and oxidation of the carbon fibres.     

Dynamic response of multidirectional composites in hygrothermal environments

Drilling is an essential operation in the assembly of the structural frames of automobiles and aircrafts. The life of the joint can be critically affected by the quality of the drilled holes. The main objective of the present paper is to investigate the influence of some parameters on the thrust force, torque and surface roughness in drilling processes of fiber-reinforced composite materials. These parameters include cutting speed, feed, drill size and fiber volume fraction. The quasi-isotropic composite materials were manufactured from randomly oriented glass fiber-reinforced epoxy, with various values of fiber volume fractions (V_f), using hand-lay-up technique. Two components drill dynamometer has been designed and manufactured to measure the thrust and torque during the drilling process. The dynamometer was connected with a data acquisition, which installed in a PC computer. This set-up enable to monitor and record the thrust force and torque with the aid of a computer program that designed using Lab View utilities.

The results indicate that the start point of torque cycle is delayed by few seconds (depending on the value of feed) than the thrust force. This time is consumed to penetrate the specimen by chiseling edge. After the thrust force reached its maximum value it is gradually decreased during the full engagement of the drill and goes to zero when both the chisel edge and the cutting lips have exit of the laminate. In contrast the torque was gradually increased up to the end of the cycle and sudden jump to a value about 10 times the peak value. Cutting speed has insignificant effect on the thrust force and surface roughness of epoxy resin. For glass fiber-reinforced epoxy composites (GFREC) with V_f=9.8–23.7% the thrust force and torque were decreased with increasing cutting speed. On contrast increasing feed, drill size and fiber volume fractions lead to increase the thrust force and torque. The drilled holes of GFREC with lower V_f ratio at lower feed have greater roughness than that drilled at higher feed. Specimens with high V_f ratio have a contrary behavior. Drill diameter combined with feed has a significant effect on surface roughness.     

A one-dimensional model for non-linear behaviour of piezoelectric composite materials

In this paper, a one-dimensional analytical model is proposed to investigate the non-linear behaviour for piezoelectric and piezoelectric fibre reinforced composite (PFRC) materials in the fibre direction. The required linear and non-linear constants for purely piezoelectric materials are obtained using the curve-fitting method and the measured S₃–E₃ non-linear loops of the corresponding piezoelectric materials, whereas those for PFRC materials are determined by employing the quadratic non-linear constitutive equations for a purely piezoelectric material, the iso-field assumptions and linear and non-linear constants of the composite constituents. A numerical study is conducted. The numerical results reveal a significant effect of stress T₃ on S₃–E₃ non-linear behaviour for both soft PZT–5H ceramics and PZN–4.5%PT crystals. It is also found that the piezoelectric fibre volume fraction V_f and strain S₃ can significantly affect the T₃–E₃ non-linear behaviour for both PZT–5H/piezo-polymer polyvinylidene fluoride (PVDF) and PZN–4.5%PT/PVDF PFRC materials. A good correlation is noted between the piezoelectric constants d₃₃ and e₃₃ predicted using the present method and those recommended by manufacturer for PZT–5H ceramics and PZN–4.5%PT crystals.     

Development of kenaf-glass reinforced unsaturated polyester hybrid composite for structural applications

The main aim of this paper is to develop kenaf-glass (KG) fibres reinforced unsaturated polyester hybrid composite on a source of green composite using sheet moulding compound process. Unsaturated polyester resin (UPE) and KG fibres in mat form were used at a ratio of 70:30 (by volume) with treated and untreated kenaf fibre. The kenaf fibre was treated with 6% sodium hydroxide (NaOH) diluted solution for 3 h using mercerization method. The hybrid composites were tested for flexural, tensile and Izod impact strength using ASTM D790-03, ASTM D618 and ASTM D256-04 standards respectively. The highest flexural, tensile and impact strength were obtained from treated kenaf with 15/15 v/v KG fibres reinforced UPE hybrid composite in this investigation.Scanning electron microscopy fractography showed fibre cracking, debonding and fibre pulled-out as the main fracture mode of composites and kenaf treated 15/15 v/v KG reinforced hybrid composite exhibited better interfacial bonding between the matrix and reinforcement compared to other combinations.     

Crack tip damage development and crack growth resistance in particulate reinforced metal matrix composites

A study of crack tip damage development and crack growth resistance of aluminium 359/20% V_f silicon carbide and aluminium 6061/20% V_f Micral^Tm particulate reinforced metal matrix composites has been conducted. Observations of crack tip process zone development at the specimen surface have been compared with the results of fractographic examination of the centre of the specimen. Both materials were found to fracture by a process of void nucleation, growth and coalescence. Void nucleation was found to be by fracture or debonding of reinforcement particles, and/or fracture or debonding of secondary matrix particles. The preferred mode of void nucleation was found to vary depending on the constituents of the PR MMC and even the heat treatment state of the material. It was found that in these materials fractured particles identified on the fracture surface fractured during loading rather than being pre-cracked during fabrication. It was further found that observations of damage development from the specimen surface did not necessarily reflect the mechanisms prevailing in the specimen bulk. Under plane strain conditions, both materials were found to exhibit decreasing crack growth resistance as crack extension proceeded, due to the “anti-shielding” effect of damage accumulated in the process zone ahead of the crack tip. In thin specimens of the Comral-85 composite, however, dramatically improved toughness was obtained, and K_R curves have been obtained for such specimens. The method of measuring crack length was found to have a profound effect on the K_R curve; it was concluded that the K_R curve determined using the crack length measured at the specimen surface best reflected the true crack growth resistance of these materials.     

A study of the mechanical behaviour on fibre reinforced hollow microspheres hybrid composites

This paper presents the results of an investigation into the effects of hollow glass microsphere fillers and of the addition of short fibre reinforcements on the mechanical behaviour of epoxy binding matrix composites. Properties like flexural stiffness, compressive strength, fracture toughness and absorbed impact energy, were studied. The specimens were cut from plates produced by vacuum resin transfer moulding having a microsphere contents of up to 50% and with fibre reinforcement up to 1.2% by volume. The tests performed with unreinforced composites show that flexural and compressive stiffness, maximum compressive stresses, fracture toughness and impact absorbed energy decrease significantly with increasing filler content. However, in terms of specific values, both flexural and compressive stiffness and impact absorbed energy increase with microsphere content. The addition of glass fibre produces only a slight improvement in the flexure stiffness and fracture toughness, while increasing significantly the absorbed impact energy. In contrast, the addition of a small percentage of carbon fibres produces an important improvement in both fracture toughness and flexure stiffness, when hybrid composites with 0.9% carbon fibre are compared to unreinforced foam, but did not improved absorbed impact energy.     

Atmospheric plasma fluorination as a means to improve the mechanical properties of short-carbon fibre reinforced poly (vinylidene fluoride)

The impact of fluorination of carbon fibres on the properties of short fibre reinforced polyvinylidene fluoride (PVDF) composites was studied. As received and continuously atmospheric plasma fluorinated (APF) carbon fibres were cut to an average fibre length of 2 mm. Short fibre composites (SFC) containing 5, 10 and 15 wt.% carbon fibres were manufactured using a twin-screw mixer. Test specimens were produced by injection moulding. The mechanical properties of the SFC were studied using tensile and compression testing. As expected, the incorporation of short-carbon fibres into PVDF led to an increase in strength and stiffness. The tensile strength and Young’s modulus of the SFC containing APF-treated carbon fibres increased by up to 17% and 190%, respectively. Furthermore, the compressive strength and modulus of the SFC containing APF-treated carbon fibres also increased by 19% and 35%, respectively. APF of carbon fibres results only in a marginal increase in the bulk matrix crystallinity of PVDF as determined by DSC. Scanning electron micrographs of fracture surfaces from tensile tested specimens exhibited a typical brittle failure mode with low fibre loading fraction. Despite the presence of up to 5% of voids and visible resin rich regions at fracture surface, SFC containing APF-treated fibres suggest better bonding at the fibre/matrix interface which led to the much enhanced mechanical properties.