Analysis of interfacial shear strength of SiC fiber reinforced 7075 aluminum composite by pushout microindentation

The interfacial shear strength of continuous silicon carbide fiber reinforced 7075 aluminum matrix composite (SiC_f/7075Al) has been investigated in this research by pushout microindentation. The SiC_f/7075Al composite specimens were processed by diffusion bonding alternate layers of SiC fibers and 7075Al alloy plates. From the measured stress-displacement curves of indentation tests, the interfacial shear strengths of the composite specimens were obtained, and the stress-displacement curves were basically divided into two regions: (1) elastic deformation and (2) interface decohesion and fiber sliding. With increasing aging time, the interfacial shear strength of the composite increased to 167 MPa for T6-treated specimens, and the variation of the interfacial shear strength well followed that of the ultimate tensile strength of 7075Al matrix alloy. With decreasing specimen thickness, the interfacial shear strength of the composite and the amplitude of stress fluctuation slightly decreased because of the stress relaxation effect near specimen surfaces. Under higher indentation velocities, both the interfacial shear strength and the amplitude of stress fluctuation became smaller.     

Energy-Based Modeling Approach for Debonding of FRP Plate from Concrete Substrate

For concrete beams and slabs strengthened with bonded fiber reinforced plastic (FRP) plates, plate debonding from the concrete substrate is a common failure mode. In this paper, the debonding process is modeled as the propagation of a crack along the concrete/adhesive interface, with frictional shear stress acting behind the crack tip. Crack propagation is taken to occur when the net energy release of the system equals the interfacial fracture energy. The analysis is first performed for the special case with constant shear stress along the debonded interface, and then for the general case with slip softening in the debonded zone. From the results, a direct correspondence between energy-based and strength-based analyses can be established for arbitrary softening behavior along the interface. Specifically, through the proper definition of an effective interfacial shear strength, the conventional strength-based approach can be employed to give the same results as the much more complicated energy-based analysis. Also, based on the relation between the effective shear strength and other material parameters, it is possible to explain the very high interfacial shear stresses observed in experimental measurements. As an application example, distribution of plate stress and interfacial shear stress for the linear softening case is derived. The model results are found to be in good agreement with experimental measurements, showing that the simple linear softening model can describe the debonding process in real material systems.     

Influence of fabrication technique on the fiber pushout behavior in a sapphire-reinforced NiAl matrix composite

Directional solidification (DS) of “powder-cloth” (PC) processed sapphire-NiAl composites was carried out to examine the influence of fabrication technique on the fiber-matrix interfacial shear strength, measured using a fiber-pushout technique. The DS process replaced the fine, equiaxed NiAl grain structure of the PC composites with an oriented grain structure comprised of large columnar NiAl grains aligned parallel to the fiber axis, with fibers either completely engulfed within the NiAl grains or anchored at one to three grain boundaries. The load-displacement behavior during the pushout test exhibited an initial “pseudoelastic” response, followed by an “inelastic” response, and finally a “frictional” sliding response. The fiber-matrix interfacial shear strength and the fracture behavior during fiber pushout were investigated using an interrupted pushout test and fractography, as functions of specimen thickness (240 to 730 μm) and fabrication technique. The composites fabricated using the PC and the DS techniques had different matrix and interface structures and appreciably different interfacial shear strengths. In the DS composites, where the fiber-matrix interfaces were identical for all the fibers, the interfacial debond shear stresses were larger for the fibers embedded completely within the NiAl grains and smaller for the fibers anchored at a few grain boundaries. The matrix grain boundaries coincident on sapphire fibers were observed to be the preferred sites for crack formation and propagation. While the frictional sliding stress appeared to be independent of the fabrication technique, the interfacial debond shear stresses were larger for the DS composites compared to the PC composites. The study highlights the potential of the DS technique to grow single-crystal NiAl matrix composites reinforced with sapphire fibers, with fiber-matrix interfacial shear strength appreciably greater than that attainable by the current solid-state fabrication techniques.     

Determination of Nonlinear Softening Behavior at FRP Composite/Concrete Interface

For concrete beams and slabs, the bonding of fiber reinforced plastic (FRP) plates to the bottom surface is an effective and efficient technique for flexural strengthening. Failure of strengthened members often occurs due to stress concentrations at the FRP/concrete interface. For debonding failure initiated at the bottom of shear or shear/flexural cracks in the concrete, experimental results clearly indicate a progressive failure process accompanied by gradual reduction in shear transfer capability at the interface. Several existing models for FRP debonding have taken interfacial shear softening into account. However, the assumed shear stress versus slip relations employed in the models have never been properly measured. In this investigation, a combined experimental/theoretical approach for the extraction of interfacial stress versus slip relation is developed. With loading applied to a bonded FRP plate, strain is measured at various points along its length. Based on the strain measurements, the interfacial softening curve is derived from a finite element analysis. The present paper will present the proposed approach in detail, demonstrate its application to typical experimental data, and discuss the implications of the results.     

Moiré Interferometry Analysis of Fiber Debonding

Progressive fiber debonding in steel fiber∕cementitious matrix composites has been studied using a single fiber pullout test that permits simultaneous measurements of the load versus crack opening displacement relationship and Moiré interferometry fringe patterns. Analysis of Moiré interferometry patterns allows the fiber axial and interfacial shear stresses to be calculated along the entire fiber length. The interfacial shear stress distribution along the debonded length of the fiber indicates a steep decrease in shear stress with interfacial slip, from 6 to 1 MPa for 7 μm of fiber slip and a crack opening displacement of 22 μm. These results suggest that improvements in the toughness of cement-based composites could be achieved by developing materials in which the decrease in shear stress is less severe.     

Off axis loading of silicon carbide fibers in a titanium aluminide matrix

Silicon carbide SCS-6 fibers in a Ti24Al + 11Nb matrix were subjected to off axis loading in a “thin-slice” pushout test, resulting in various combinations of shear, radial compression, and tension along the fibers as a function of orientation angle. The load necessary for debonding decreased as the orientation angle increased, whereas the average frictional sliding stress after 60 s of sliding remained relatively constant for orientation angles less than 30 deg. Analyses of the specimen bending stresses and of the contact stresses by finite element modelling and thin plate theory are presented.     

Three-Parameter Model for Debonding of FRP Plate from Concrete Substrate

Concrete beams retrofitted with bonded fiber reinforced plastic (FRP) plates often fail by debonding of the plate from the concrete surface. To predict the failure load in design, a proper debonding model is required. As debonding is a nonlinear process involving material softening, it can be analyzed once the interfacial shear (τ) versus sliding (s) relationship is known. Recent experimental results indicate that the simplest τ-s relationship should involve three parameters: the maximum shear stress for debonding to initiate, the initial residual stress right after debonding occurs, and a parameter governing the reduction of shear stress with sliding. In this paper, a FRP debonding model based on these three parameters is developed. The applicability of the model is verified through comparison with experimental results. Through a systematic parametric study, the effect of various material and geometric properties on the debonding process is investigated. Implications to the design of FRP strengthened members are highlighted.     

The use of single fibre pushout testing to explore interfacial mechanics in SiC monofilament-reinforced Ti—I. A photoelastic study of the test

The frozen stress photoelastic technique has been used to investigate the elastic stress distribution during single fibre pushout testing. It is shown that the axial distributions of interfacial shear stress and axial stress in the fibre are broadly consistent with the Hseuh model, based on shear lag analysis. However, the experimental shear stress distribution is more uniform than that predicted, particularly for low aspect ratio fibres, so that interfacial shear debonding strength value obtained from debonding loads on the basis of the model may be overestimates. Estimates based on a uniform shear stress along the fibre length may be preferable, particularly for low aspect ratio fibres.     

Multiple matrix cracking in a fiber-reinforced titanium matrix composite under high-cycle fatigue

An experimental study of multiple matrix cracking in a fiber-reinforced titanium alloy has been conducted. The focus has been on the effects of stress amplitude on the saturation crack density and the effects of crack density on hysteresis behavior. Comparisons have been made with predictions based on unit cell models, assuming the sliding resistance of the interface to be characterized by a constant interfacial shear stress. In addition, independent measurements of the sliding stress have been made using fiber pushout tests on both pristine and fatigued specimens. D.P. WALLS, Graduate Student, formerly with the Materials Department, University of California, Santa Barbara     

Design,analysis and application of an improved push-through test for the measurement of interface properties in composites

An improved fiber push-through test has been designed and used to obtain new information about interfaces in composites consisting of matrices of a Ti alloy and borosilicate glass, both reinforced with SiC fibers. Interpretation of these results is accomplished through an analysis of coupled debonding and push-through, followed by push-back. The sliding stress is found to vary with push-out distance and to be substantially reduced in the vicinity of a fatigue crack in the Ti matrix composite. These effects are attributed to asperity wear, matrix plasticity and fragmentation of the fiber coating around the debonded interface. Reseating effects on push-back have been demonstrated, but have been found to diminish as the relative fiber-matrix displacement increases. Fiber roughness has been identified as an important aspect of interface sliding.     

Interfacial sliding near a free surface in a fibrous or layered composite during thermal cycling

This paper presents a simple shear lag model of interfacial sliding at a free surface in a layered or continuous fiber composite. The interface is characterized by a critical interfacial shear stress, τ₀, which might represent the critical stress for frictional sliding at a weakly bonded interface, or the shear flow stress of a thin, ductile interface layer at a well bonded interface. We calculate the history during heating and cooling of the relative normal displacement of the reinforcing inclusions and the matrix on a free surface cut normal to the inclusions. The calculated history is shown to depend on both the absolute value and the temperature dependence of τ₀, as well as on the magnitudes of the bulk residual stresses. Analytical results are obtained for the first few heating and cooling cycles and the equilibrium hysteresis loop under thermal cycling of uniform amplitude. The variety of possible displacement histories suggests that they are a rich source of information about τ₀ and the residual stresses. A discussion of feasible experiments and some results for continuous fiber titanium and titanium aluminide composites are presented in a companion paper.     

The use of single fibre pushout testing to explore interfacial mechanics in SiC monofilament-reinforced Ti—II. Application of the test to composite material

Single fibre pushout testing has been used to measure the load needed to displace a fibre, as a function of its aspect ratio. This has been done for SiC monofilaments, having duplex carbon/TiB₂ coatings, embedded in a matrix of Ti6Al4V. Wedge-shaped specimens have been used, allowing pushout of fibres with a range of aspect ratios from a single specimen. Partially pushed-out fibres have also been pushed back into the matrix. Specimens have been examined in the as-fabricated form and also after subsequent heat treatments. Analysis of the results indicates that in all cases it was the resistance to the onset of frictional sliding which was determining the pushout load. Values of the interfacial shear stress necessary for frictional sliding, τ_fr, have been established, although it was not possible to measure separately the coefficient of static friction or the residual radial compressive stress. The value of τ_fr was found to increase progressively on heat treating the composite. Preliminary chemical analysis work suggests that this results from an interfacial reaction, possibly one which causes the carbon layer to become reduced in thickness.     

Evaluation of interfacial shear strength,residual clamping stress and coefficient of friction for fiber-reinforced ceramic composites

The shear strength, the residual clamping stress, the coefficient of friction and the frictional stress at the fiber/matrix interface are evaluated for fiber-reinforced ceramic composites by using the theoretical analysis for fiber push-out and the corresponding experimental results. The shear strength is evaluated from the load at which debonding initiates. Sliding occurs at the interface after complete debonding. For a fiber with a Poisson's ratio greater than zero, the characteristics of the nonlinear relationship between the load required to push out the fiber and the sample thickness enable the residual clamping stress, the coefficient of friction and the interfacial frictional stress to be evaluated in the present analysis.     

Influence of Cr and W alloying on the fiber-matrix interfacial shear strength in cast and directionally solidified sapphire nial composites

Sapphire-reinforced NiAl matrix composites with chromium or tungsten as alloying additions were synthesized using casting and zone directional solidification (DS) techniques and characterized by a fiber pushout test as well as by microhardness measurements. The sapphire-NiAl(Cr) specimens exhibited an interlayer of Cr rich eutectic at the fiber-matrix interface and a higher interfacial shear strength compared to unalloyed sapphire-NiAl specimens processed under identical conditions. In contrast, the sapphire-NiAl(W) specimens did not show interfacial excess of tungsten rich phases, although the interfacial shear strength was high and comparable to that of sapphire-NiAl(Cr). The postdebond sliding stress was higher in sapphire-NiAl(Cr) than in sapphire-NiAl(W) due to interface enrichment with chromium particles. The matrix microhardness progressively decreased with increasing distance from the interface in both DS NiAl and NiAl(Cr) specimens. The study highlights the potential of casting and DS techniques to improve the toughness and strength of NiAl by designing dual-phase microstructures in NiAl alloys reinforced with sapphire fibers. R. TIWARI, formerly Research Associate, Department of Chemical Engineering, Cleveland State University     

On the toughening of intermetallics with ductile fibers: Role of interfaces

The role of fiber debonding and sliding on the toughness of intermetallic composites reinforced with ductile fibers is examined. The toughness is shown to be a function of the matrix/fiber interface properties, residual stresses and the volume fraction, size and flow behavior of the fibers. Mechanical testing and in situ microstructural observations were carried out on a Ti-25at.%Ta-50at.%Al intermetallic matrix reinforced with W-3Re fibers. The fibers were coated with a thin oxide layer in order to induce debonding and prevent interdiffusion between the fiber and the matrix. The ductility, high strength and debond characteristics of coated tungsten-rhenium fibers promote a large increase in toughness. However, the mismatch in thermal expansion coefficients is the source of large residual tensile stresses in the matrix that induces spontaneous matrix cracking. Matrix cracking and composite toughness are examined as a function of the interfacial properties, residual stresses and properties of the fiber.     

Transverse elastic moduli of unidirectional fiber composites with interfacial debonding

A mathematical model is developed to predict the transverse elastic moduli of unidirectional fiber composites. Two cases of fiber/matrix interfacial bondings are investigated: perfect bonding and complete debonding,i.e., no transferring of tensile stress on surfaces where the fiber and matrix materials are separated. Fibers are assumed to exhibit transverse isotropy, and the elastic interactions among fibers are also considered. In the analysis of the completely debonded case, the cavity formation model is adopted and the original fiber and surrounding cavities are replaced by an imaginary anisotropic inclusion. Closed form solutions of effective elastic moduli are obtained for transverse tensile and compressive moduli, and transverse shear moduli. The limiting case of fiber-like voids is also studied. Numerical results are presented for two metal matrix composites, where the optimal wetting between the fiber and matrix is difficult to be obtained and hence the interfacial bonding and transverse property have been major concerns. Formerly Visiting Associate Professor at The University of Delaware     

Stress Transfer and Fracture Propagation in Different Kinds of Adhesive Joints

To effectively and efficiently utilize fiber-reinforced plastic (FRP) laminates (plates or sheets) in strengthening civil infrastructures, a design strategy integrating the properties of FRP reinforcement and composite structural behavior needs to be adopted. The interfacial stress transfer behavior including debonding should be considered to be one of the most important effects on the composite structural behavior. In this paper, two kinds of nonlinear interfacial constitutive laws describing the pre- and postinterfacial microdebonding behavior are introduced to solve the nonlinear interfacial stress transfer and fracture propagation problems for different kinds of adhesive joints in FRP/steel-strengthened concrete or steel structures. Expressions for the maximum transferable load, interfacial shear stress distribution, and initiation and propagation of interfacial cracks (debonding) are derived analytically. In addition, numerical simulations are performed to discuss the factors influencing the interfacial behavior and the theoretical derivations are validated by finite-element analysis.     

The micromechanics of fatigue crack growth at 25 °C in Ti-6Al-4V reinforced with SCS-6 fibers

Micromechanics parameters for fatigue cracks growing perpendicular to fibers were measured for the center-notched specimen geometry. Fiber displacements, measured through small port holes in the matrix made by electropolishing, were used to determine fiber stresses, which ranged from 1.1 to 4 GPa. Crack opening displacements at maximum load and residual crack opening displacements at minimum load were measured. Matrix was removed along the crack flanks after completion of the tests to reveal the extent and nature of the fiber damage. Analyses were made of these parameters, and it was found possible to link the extent of fiber debonding to residual COD and the shear stress for fiber sliding to COD. Measured experimental parameters were used to compute crack growth rates using a well-known fracture mechanics model for fiber bridging tailored to these experiments.     

Interface characterization of duplex metal-coated SiC fiber-reinforced Ti-15-3 matrix composites

The interfacial reaction behavior of duplex metal (Cu/Mo and Cu/W)-coated SiC (SCS-6) fiber-reinforced Ti-15-3 composites, before and after thermal exposure, has been studied. The effect of thermal exposure on the shear sliding resistance of these composites was also obtained using a thin-specimen push-out test. The results are compared to those of an original SiC (SCS-6) fiber-reinforced Ti-15-3 composite. The interfacial reaction behavior is strongly affected by the existence of a coating layer. Both the Cu/Mo and Cu/W coating layers prevent the growth of a reaction layer. However, the coatings could not effectively prevent diffusion of alloying elements; only the W layer exists after the thermal exposure. On the other hand, the interface shear sliding stress minimally depends on the duplex metal coating layers prior to the thermal exposure, and this sliding stress in both the SiC/Cu/Mo/Ti-15-3 and SiC/Cu/W/Ti-15-3 composites decreases slightly relative to that in the SiC/Ti-15-3 composite. After thermal exposure, the interface shear sliding stress increases for the SiC/Ti-15-3 composite. In distinction, the interface shear sliding stress significantly decreases after thermal exposure in both the SiC/Cu/Mo/Ti-15-3 and SiC/Cu/W/Ti-15-3 composites. Theses behaviors are attributed to the decrease of radial clamping stress, which originates from a volume expansion associated with the β → α phase transformation.     

Effect of interfacial debonding and sliding on matrix crack initiation during isothermal fatigue of SCS-6/Ti-15-3 composites

Direct observation of initial damage-evolution processes occurring during cyclic testing of an unnotched SCS-6 fiber-reinforced Ti-15-3 composite has been carried out. The aligned fibers break at an early stage, followed by debonding and subsequent sliding along the interface between the reaction layer (RL) and Ti-15-3 alloy matrix. Matrix cracking initiation from the initial broken fiber and RL was avoided. This fracture behavior during cyclic loading is modeled and analyzed by the finite-element method, with plastic deformation of the matrix being considered. The plastic strain in the matrix at the initial crack and at the deflected crack tips, when the interface crack is deflected into the RL after extensive interface debonding propagation, is characterized. The effects of interfacial debond lengths and test temperatures on the matrix cracking mechanism are discussed, based on a fatigue-damage summation rule under low-cycle fatigue conditions. The numerical results provide a rationale for experimental observations regarding the avoidance and occurrence of the matrix cracking found in fiber-reinforced titanium composites.