Fatigue behaviour of alumina-fibre-reinforced epoxy resin composite pipes under tensile and compressive loading conditions

Fatigue tests have been conducted on composites consisting of epoxy resin reinforced with alumina fibres (AFRP) under cyclic tensile and compressive loading conditions with the variation of fibre orientation. The behaviour of the stress/strain curve for a ±45° sample is different from those for the ±15 and ±25° composite specimens, whereas, the monotonic strength decreases with increase in fibre angle for all specimens, which satisfies the maximum stress failure criterion. Fatigue results show that the applied stress decreases with an increase in the number of cycles to failure under both loading conditions for all composite pipes, but for the ±45° sample the decrease was slow. The results of fatigue tests on a macroscopic level indicate that the matrix crack density slowly increased with increase in the normalized number of cycles to failure in all the specimens. The normalized apparent stiffness therefore falls with an increase of the normalized number of cycles to failure. However, the maximum stress decreased with the increase in the number of cycles to failure in the case of the ±45° pipe. Finally, it is observed that matrix cracking and delaminations are occurring in the ±45° sample whereas delamination and fibre buckling are appearing in the ±15 and ±25° samples.     

Mechanical behavior of cast SiCp-reinforced Al-4.5%Cu-1.5%Mg alloy

SiC_p-reinforced Al-4.5%Cu-1.5%Mg composite specimens were processed by vigorous stirring of the carbide in a semi-solid alloy slurry, followed by remelting and casting (stir-casting). The tensile and fatigue properties were evaluated in the as-cast and in the heat-treated conditions. In monotonic tensile testing, reinforcement with SiC_p produced a substantial increase in the work hardening of the material. This increase became more significant with increasing volume fraction of carbide. The yield and ultimate tensile strength, and the elastic modulus of the material, increased with heat-treatment and volume fraction of carbide at the expense of ductility. These properties are inferior to those of other reinforced, more complex aluminum alloys processed by other methods. In stress-controlled fatigue tests under fully reversed (R = −1) bending conditions, the fatigue life of the composite was longer than that of the unreinforced specimen at intermediate and lower stress levels. At higher stress levels the improvement was negligible. In heat-treated reinforced alloy specimens the fatigue strength at 1 × 10⁷ cycles decreased with increasing carbide particle size. With solid solution and precipitation strengthening, as well as carbide dispersion strengthening of the alloy, the crack growth threshold stress intensity factor K_th, increased, as did the crack initiation time and the crack growth rate.     

Fatigue behaviour of a phenolic matrix composite

This paper presents results of a fatigue life investigations carried out in plate specimens of a fibre-glass-reinforced phenolic matrix composite. Tensile and Young's modulus data were obtained at four different testing temperatures (room temperature, 100, 150 and 200 °C). The fatigue S−N data were obtained at room temperature only and for two stress ratio values (R=0 and 0.4). Fatigue and tensile behaviour was assesesed in the composite with the fibres aligned in the longitudinal loading direction. The results were obtained for two values of volume fraction (0.28 and 0.42) and three different glass surface treatments. A detailed comparison of fatigue results is given taking into account several fatigue parameters and also the testing variables. Results of observations of SEM fracture surfaces are also presented.     

Fatigue damage in a unidirectional SiC/Al composite due to push-pull and zero-pull loading

Axial fatigue behaviour due to fully reversible and zero-tension cyclic loads on specimens cut from a 5 mm thick panel of a unidirectional SiC/A1 composite has been investigated at room temperature. The panel contained 40 vol.% SiC fibres (SCS-2), sandwiched between 32 layers of A1 6061 foils, which were bonded together by hot-pressing. The loading was always parallel to the fibres. Steady hysteresis loops were observed in the stress-strain plot after about 3 cycles of loading. A plot of S/N curves showed that at load ratio R = 0 the fatigue strength of the composite was about 3 times higher than that of the monolithic matrix metal. At R = −1, however, the fatigue strength of the composite was even lower than that of the matrix metal. At both R = 0 and R = −1, the composite suffered large modulus losses (about 15%) at cycles well before the final failure. At R = 0 the modulus loss involved fibre breakage and matrix cracks, which were transverse as well as parallel to the loading direction, while at R = −1 it involved delamination cracks and barrelling of outer layers. Fractography after the final failure at R = 0 showed secondary cracks and fibre pull-out.     

Influence of stress ratio at baseline loading on delayed retardation phenomena of fatigue crack growth in A553 steel and A5083 aluminium alloy

The delayed retardation phenomena of fatigue crack growth following a single application of tensile overload were investigated under the baseline loading with the stress ratio, R = σ_min/σ_max, ranging from −1 to 0.5 for A553 steel and A5083 aluminium alloy. Two different overload cycles were applied; the one is the case that the ratio of peak stress range to baseline stress range, r = Δσ₂/Δσ₁, is equal to two and the other is the case that the ratio of maximum peak stress to maximum baseline stress, σ_2max/σ_1max, is equal to two. The retardation took place stronger in aluminium than in steel. Under the condition of r = 2 the normalized number of cycles, N_D/N_C, (N_D: the number of cycles during retardation, N_C: the number of cycles required for propagation through the overload-affected-zone size) decreased slightly as the R ratio increased from −1 to 0.5, while under the condition of σ_2max/σ_1max = 2 the N_D/N_C-values increased drastically as the R ratio increased from −1 to 0 (or the overload ratio, r, increased from 1.5 to 2) in both the materials. These retardation behaviors were expressed theoretically according to the model proposed by Matsuoka and Tanaka [1, 3] by using four parameters: the overload ratio, r, the exponent in Paris equation, m, the overload-affected-zone size, ω_D, and the distance at the inflection point, ω_B.     

The effect of the stress ratio on fatigue crack growth in a 3% NaCl solution

Corrosion fatigue crack growth tests have been carried out at various stress ratios for a low alloy steel SNCM 2 and type 304 stainless steel.

Measurements of the effective stress intensity factor range ratio U were performed to explain the effect of stress ratio R.

The corrosive environment decreased da/dN at R = 0.1, 0.4 and little affected da/dN at R = 0.9 for SNCM 2 and increased da/dN at all R ratios for SUS 304.

It was confirmed that there exists a threshold stress intensity factor ΔK_thCF in 3% NaCl solution for both materials tested.

The corrosive environment decreased ΔK_thCF for all conditions tested except at R = 0.1 and 0.4 for SNCM 2, where ΔK_thCF-values were nearly equal to ΔK_th-values in air. ΔK_thCF/ΔK_th was 0.6 at R = 0.9 for SNCM 2 and 0.8, 0.5 and 0.7 at R = 0.1, 0.7 and 0.9 for SUS 304, respectively.

It was shown that the complicated effect of stress ratios on crack growth for SNCM 2 can be explained using effective stress intensity factor ΔK_eff.     

Effect of an aluminide coating on precipitate rafting in superalloys

The microstructure of single crystal superalloy SRR99 is shown to be significantly affected by the combined effect of the application of an aluminide diffusion coating and the mechanical deformation caused by thermomechanical fatigue. In the case of an R = −∞ cycle (compressive strains), plates parallel to the coating surface develop in a layer underneath the subcoating zone, markedly differing from the precipitate coalescence observed, in the bulk. This effect is absent in the R = 0 cycles (tensile strains). This phenomenon is successfully explained in the light of a criterion for the prediction of γ′ rafting, by considering the superposition of the strains produced both by the TMF cycling and by a layer of γ′ which is observed to develop during the tests with R = −∞.     

The influence of high R ratio on notched fatigue behaviour of 1045 steel with three different heat treatments

Three 1045 steels with hardness levels of R_c=10, 37, and 50 were tested under cyclic axial load control conditions using mildly notched specimens, K_t=1.65, at high R ratios of 0.8 and 0.9. The notched ultimate tensile strengths, S_un, for the three steels were greater than the unnotched ultimate tensile strengths, S_u. This allowed values of nominal maximum stress, S_max, and mean stress, S_m, to exceed S_u in most tests. Thus, fatigue limits based on S_max were higher than S_u in 5 of the 6 test conditions. S–N_f curves were very flat in 5 of the 6 test conditions with appreciable scatter. With S_max and S_m>S_u in most tests, usual S–N_f fatigue life models involving S_u could not be used. Replacing S_u with S_un, allowed calculations, but these were completely inaccurate. Local strain-life, –N_f, models were also completely inaccurate for these high R ratios. R_c=10 specimens failed by cyclic creep/ratcheting from internal microvoid coelescence and not from fatigue. R_c=37 specimens failed by fatigue from surface thumbnail cracks, but were influenced by cyclic creep/ratcheting. R_c=50 specimens failed by brittle fracture from minute surface fatigue cracking without cyclic creep/ratcheting. In design situations at long life, usual S–N_f models with these materials and high R ratios would restrict S_max to levels well below the experimental fatigue limits resulting in very conservative results.     

Constituent damage mechanisms in metal matrix composites under fatigue loading, and their effects on fatigue life

Load controlled fatigue experiments were performed on 8-ply unidirectional ([0]₈) SCS-6-Ti-15-3 metal matrix composites (MMCs) at different temperatures, and the results were interpreted in terms of the overall three-regime framework of fatigue. The emphasis was on understanding the mechanisms and mechanics of constituent damage evolution, and their effects on fatigue life. Most tests were performed at an R-ratio of 0.1, but limited fully-reversed (R = −1) tests were conducted. In regime 1, damage was fiber failure dominated, but the exact mechanisms were different at room and elevated temperatures. In regime 2, observation of matrix cracks and persistent slip bands provided convincing evidence of matrix dominated damage. Weak fiber-matrix interfaces contributed to crack bridging. However, fiber fracture also played an important role in regime 2; tension-tension and tension-compression tests showed similar lives on a maximum fiber stress basis, although the strain range, which primarily controls matrix crack growth, was almost double for R = −1 compared with R = 0 or 0.1. Good agreement was obtained from the different R-ratio tests, between the MMC and matrix data, and data at room and elevated temperatures, when compared based on the strain range in the tension part of a cycle. Analyses and observations of fiber pull-out lengths and fiber fractures in the matrix crack wake provided evidence of fiber damage; the analyses also helped to explain increased fiber bridging with fiber volume fraction. Issues of fatigue life prediction are briefly discussed.     

The effect of fibre content on the mechanical properties of hemp and basalt fibre reinforced phenol formaldehyde composites

In this study, mechanical properties such as tensile, flexural and impact strengths of hemp/phenol formaldehyde (PF), basalt/PF and hemp/basalt hybrid PF composites have been investigated as a function of fibre loading. Hemp fibre reinforced PF composites and basalt fibre reinforced composites were fabricated with varying fibre loading i.e. 20, 32, 40, 48, 56 and 63 vol%. The hybrid effect of hemp fibre and basalt fibre on the tensile, flexural and impact strengths was also investigated for various ratio of hemp/basalt fibre loading such as 1:0, 0.95:0.05, 0.82:0.18, 0.68:0.32, 0.52:0.48, 0.35:0.65, 0.18:0.82 and 0:1. Total fibre loading of the hybrid composites was 40 vol%. The results showed that the tensile strength and elongation at break increase with increasing fibre loading up to 40 vol% and decrease above this value for hemp fibre reinforced PF composite. Similar trend was observed for flexural strength and the maximum value was obtained for 48 vol% hemp fibre loading. Impact strength of hemp/PF composite showed a regular trend of increase with increasing fibre loading up to 63 vol%. Tensile strength, flexural strength and impact strength values of basalt/PF composites were found to be lower compared to hemp/PF composites. The tensile strength and elongation at break of basalt/PF composite increased by incorparation of basalt fibre up to 32 vol% and decreased beyond this value. Flexural strength of basalt/PF composite decreased linearly with fibre loading. However, the maximum impact strength was obtained for 48 vol% basalt fibre loading. For hemp/basalt hybrid PF composite, the tensile strength decreased with increasing basalt fibre loading. On the other hand, the flexural and impact strengths showed large scatter. The maximum flexural strength value was obtained for 0.52:0.48 hemp/basalt ratio. Corresponding value for impact strength was obtained for 0.68:0.32 hemp/basalt fibre ratio.     

Hydrogen embrittlement contributions to fatigue crack growth in a structural steel

The detrimental effects of a hydrogen atmosphere on the fatigue resistance of BS 4360 steel have been assessed by a comparison of crack growth rates in air and hydrogen at a low cycling frequency (0.1Hz), and at a number of temperature (25, 50 and 80 °C). The crack propagation rates in air are almost independent of temperature over this range, but those measured in hydrogen differ by more than an order of magnitude between 25 and 80 °C. The greatest enhancement is seen at 25 °C and at high values of ΔK, the maximum occurring between 40–45 MPa √m at each temperature. There is little hydrogen contribution to crack growth at values of ΔK below 20 MPa √m for R = 0.1.

The enhancement of crack growth rates is reflected by the presence of ‘quasi-cleavage’ facets on the fatigue fracture surfaces of specimens tested in hydrogen. These are most apparent where the greatest increases in growth rate are recorded. The facets show linear markings, which run both parallel and perpendicular to the direction of crack growth. The former are analogous to the ‘river’ lines noted on brittle cleavage facets, and reflect the propagation direction. The latter are more unusual, and indicate that facet formation by hydrogen embrittlement during fatigue is a step-wise process.     

The development of compression damage zones in fibrous composites

Recent experimental work (Narayanan S, Schadler LS. Mechanisms of kink band formation in graphite/epoxy compsites: a micromechanical experimental study. Comp Sci Technol 1999; 59:2201-13) suggests that kink bands in unidirectional continuous carbon fiber reinforced polymer composites initiate from damage zones formed under axial compressive loads. A damage zone consists of a cluster of locally crushed fibers and broken fibers, that are often fractured at an angle, θ > 0°, normal to the fiber axis. Typically, under compressive loads, fiber breaks in damage zones form roughly along a plane at an angle φ, normal to the fiber axis. These damage zones produce stress concentrations which can lead to instabilities in the nearby fiber and matrix and initiate microbuckling and kink bands. This paper extends a micromechanical influence function technique based on earlier shear lag fiber composite models. Our modified technique calculates the fiber axial and matrix shear stress concentrations due to multiple angled and crushed fibers in arbitrary configurations. Modeling reveals that angled or ‘shear’ breaks (θ > 0°) can lead to higher shear stress concentrations in the matrix than transverse breaks (θ=0°). Also we find that the damage zone is more likely to form at an angle φ, which is greater than that of its individual fiber breaks, θ. When φ is slightly greater than θ, the shear stress in the surrounding matrix regions within the damage zone achieves a maximum, potentially weakening the matrix and interface and consequently leading to kink band formation. Monte Carlo simulations incorporating this stress analysis predict that the initiation and propagation of crushed and angled breaks progress roughly along an angle, φ ≈ 17° in a linear elastic system. When possible, our model results are compared to strain measurements of fiber composites under compression obtained by Narayanan and Schadler using micro-Raman spectroscopy (MRS).     

Mid-infrared (2.5 ≤ λ ≤ 12.5 μm) optical absorption enhancement of textured silicon surfaces coated with an antireflective thin film

High-performance solar cells and optical detection devices frequently incorporate microscopic surface texturing and antireflective (AR) thin films to reduce the reflection of incident radiation and, thus, enhance optical absorption. Using conventional electrochemical and single-crystal silicon micromachining techniques, porous silicon (PS) and textured surfaces composed of randomly spaced and sized pyramids (RSSPs) were fabricated and optically characterized over the mid-infrared (2.5 ≤ λ ≤ 12.5 μm) portion of the optical spectrum. The utility of a 1.53 ± 0.03 μm thick yttrium oxide (Y₂O₃) AR thin film was also investigated in an attempt to enhance optical absorption. The optical measurements were accomplished using a 21 ° incident illumination angle (measured with respect to the sample's normal) and a Bomem® total integrating sphere to quantify the total (specular and diffuse) reflectance (R). A highly-polished, uncoated, single-crystal silicon wafer was used as a reference surface (R_ave = 0.436 with R_σ = 0.033). The performance of the uncoated PS samples revealed R_ave = 0.205 with R_σ = 0.078, and the RSSP samples manifested R_ave = 0.090 with R_σ = 0.003. The AR coating significantly improved the performance of the reference and the RSSP textured surfaces: reference sample, (R_ave = 0.251 with R_σ = 0.040; RSSP samples, (R_ave = 0.024 with R_σ = 0.017). The AR coating did not improve the mid-infrared optical performance of the PS samples; however, the R characteristics for the 0.5 ≤ λ ≤ 2.5 μm portion of the optical spectrum were reduced by more than 50%.     

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.     

Effect of stress ratio on the cyclic tension corrosion fatigue life of notched steel BS970:976M33 in sea water with cathodic protection

Steel conforming to BS970:976M33 has been fatigue tested in notched form in air and in synthetic sea water, both freely corroding and cathodically protected at −1050 mV with respect to the saturated Ag/AgCl reference electrode. The cyclic and mean stresses were varied to study the effects of changes in the stress ratio, R(σ_min/σ_max), from 0.05 to 0.75, on the fatigue life response. Compared with the fatigue performance obtained in air at R=0.05 free corrosion lowered the fatigue strength at 10⁶ cycles to failure from 430 MPa to 135 MPa and cathodic protection changed it to 270 MPa. In each condition changes in R from 0.05 to 0.5 lowered the fatigue strength in the short life range by approximately 50% but had a much smaller effect, of approximately 10%, at a fatigue life of 10⁶ cycles.     

Heat pump cycles based on the AF–F transition in Fe–Rh alloys induced by tensile stress

The heat-pumping scheme based on the 1st order antiferromagnetism–ferromagnetism transition induced in FeRh alloy by one-dimensional tensile stress is proposed. Using the model S–T diagram for this alloy, the heat-pump cycles are drawn up based both on the transition latent heat absorption and emission when the transition is induced isothermally and on the change in alloy's temperature when the transition is induced adiabatically by applying tensile stress. The calculated values of heat coefficient φ for the cycles are 30 at ΔT=5 К and 20 at ΔT=10 К, where ΔT is the difference between the temperature surrounding and that of the heat receiver. These values are achieved using the tensile stress of 1·10⁹ Pa. The high values of φ make it possible to consider Fe–Rh alloys near the equiatomic composition as an effective refrigerant for elastocaloric heat-pumping near the room temperature.     

Single crystal structure of a layered intercalating phosphate with features of two dimensions and H-bonds

A new organic phosphate of (8-HQDH)(H₂PO₄)·H₂O has been obtained by hydrothermal reaction. The crystal structure was determined with data: triclinic, space group P , a=6.541(1) Å, b=8.5909(8) Å, c=10.769(1) Å, =98.734(7)°, β=91.20(1)°, γ=97.91(1)°, V=591.9(1) ų, and Z=2. The (H₂PO₄)⁻ groups and H₂O molecules stack into sheets and 8-HQ cations fixed parallelly with each other to form an intercalating compound by H-bonds.     

Interpretation of ductile fracture toughness temperature dependence of a low strength steel in terms of a local approach

Fracture toughness and notch ductility tests were performed on two heats of A508 steel tested over the temperature range between 100°C and 450°C. Both types of experiments showed that the materials exhibited a ductility trough at temperatures close to 300°C. At this temperature tensile tests showed the existence of strain aging phenomenon. Tests on axisymmetric notched tensile specimens were used to derive the critical value for void growth, R_c/R₀, used in a model for ductile fracture. A good correlation between J_Ic and R_c/R₀ was observed. This was used to predict the variations of J_Ic with temperature. A reasonable agreement between the predicted values and the experimental results is observed.     

Investigation on the cross sensitivity of NO2 sensors based on In2O3 thin films prepared by sol-gel and vacuum thermal evaporation

In₂O₃ thin films have been prepared from commercially available pure In₂O₃ powders by high vacuum thermal evaporation (HVTE) and from indium iso-propoxide solutions by sol-gel techniques (SG). The films have been deposited on sapphire substrates provided with platinum interdigital sputtered electrodes. The as-deposited HVTE and SG films have been annealed at 500°C for 24 and 1 h, respectively. The film morphology, crystalline phase and chemical composition have been characterised by SEM, glancing angle XRD and XPS techniques. After annealing at 500°C the films’ microstructure turns from amorphous to crystalline with the development of highly crystalline cubic In₂O_3−x (JCPDS card 6-0416). XPS characterisation has revealed the formation of stoichiometric In₂O₃ (HVTE) and nearly stoichiometric In₂O_3−x (SG) after annealing. SEM characterisation has highlighted substantial morphological differences between the SG (highly porous microstructure) and HVTE (denser) films. All the films show the highest sensitivity to NO₂ gas (0.7–7 ppm concentration range), at 250°C working temperature. At this temperature and 0.7 ppm NO₂ the calculated sensitivities (S=R_g/R_a) yield S=10 and S=7 for SG and HVTE, respectively. No cross sensitivity have been found by exposing the In₂O₃ films to CO and CH₄. Negligible H₂O cross has resulted in the 40–80% relative humidity range, as well as to 1 ppm Cl₂ and 10 ppm NO. Only 1000 ppm C₂H₅OH has resulted to have a significant cross to the NO₂ response.     

Effects of control mode and R-ratio on the fatigue behaviour of a metal matrix composite

Thick specimens of [0]₃₂ SiC/Ti-15-3 were cycled under a variety of loading conditions. Specimens were fatigued in strain- and load-controlled modes at both R = 0 (zero-tension) and R = −1 (fully reversed) loading ratios. In addition, a hybrid strain-controlled mode at R = 0 was used to simulate the true strain-controlled behaviour. The strain-controlled specimens had longer lives compared with the load-controlled specimens when cycled at an R-ratio of zero. Under fully reversed loading, there was no difference between the strain- and load-controlled modes. The hybrid strain-controlled data were found to approximate the load-controlled data better, rather than the true strain-controlled situation. Damage occurred through transverse fibre cracks for R = 0 loading for both the load- and strain-controlled modes. However, fully reversed loading caused matrix cracking to be the operative damage mechanism.