Fracture toughness of unidirectional fibre reinforced composites in MODE II

Experimental investigations have been performed on unidirectional glass fibre reinforced/epoxy composites in Mode II (Forward shear) with the presence of crack parallel to the fibres direction through the use of end-cracked beam. A concentrated load at the Centre of the beam produced bending-induced shear deformation at the crack tip. Calibration factors for Mode II have been obtained. The stress-intensity factor at instability $\text{K}$_IIR(INR) is obtained by experiments on a small end cracked beam through a compliance matching procedure. The crack growth resistance at instability and the corresponding critical strain energy release rate are independent of initial crack in the range of crack length investigated. In composite materials, fibre-matrix interfacial shear stress play an important role in load transfer mechanism: hence Mode II study may be very useful to analyse the interfacial mechanisms and to understand the fracture behaviour of unidirectional fibre reinforced composites in Mode I when load is applied in the direction of the fibres.     

Evaluation of fibre bridging stress of short fatigue cracks in SCS-6/Ti-15-3 composite

Single‐edge notched specimens of a unidirectional SiC long fibre reinforced titanium alloy, were fatigued under four point bending. The propagation behaviour of short fatigue cracks from a notch was observed on the basis of the effects of fibre bridging. The branched fatigue cracks were initiated from the notch root. The fatigue cracks propagated only in the matrix and without fibre breakage. The crack propagation rate decreased with crack extension due to the crack bridging by reinforced fibres. After fatigue testing the loading and residual stresses in the reinforced fibres were measured for the arrested cracks by the X‐ray diffraction method. The longitudinal stresses in the reinforced fibres were measured using high spatial resolution synchrotron radiation. A stress map around the fatigue cracks was then successfully constructed. The longitudinal stress decreased linearly with increasing distance from a location adjacent to the wake of the matrix crack. This region of decreasing stress corresponded to the debonding area between the fibre and the matrix. The interfacial frictional stress between the matrix and the fibre could be determined from the fibre stresses. The bridging stress on the crack wake was also measured as a function of a distance from a notch root. The threshold stress intensity factor range, corrected on the basis of the shielding stress, was similar to the propagation behaviour of the monolithic matrix. Hence the main factor influencing the shielding effect in composites is fibre bridging.     

The structure of the interface in carbon fibre composites by scanning Auger microscopy

Scanning Auger microscopy (SAM) has been used to study the fibre/matrix interface of composite materials. This novel application of Auger spectroscopy enables further understanding of the mechanism of failure in composites when applied to carbon fibre-reinforced epoxy material. Initial work was carried out on carbon fibres prior to their incorporation into the resin matrix. Auger spectroscopy can be used to detect the presence of thin polymeric layers on the carbon fibres if a suitable, matrix-specific element is chosen to form the scanning Auger image. Two composite materials have been investigated. They differ from each other by the fracture mechanisms. In the case of unidirectional continuous fibre composites, a high volume fraction of conducting carbon fibres makes Auger analysis possible although the failure surface is predominantly polymer residues. For short-fibre composites the technique is more difficult considering the low volume fraction of fibres, but Auger spectroscopy enables the identification of microfailure mechanism and of the effect of fibre surface treatment on the failure mode.     

Influence of residual stresses and interfacial shear strength on matrix properties in fibre-reinforced ceramic matrix composites

Zircon matrix composites, uniaxially reinforced with a variety of SiC fibres were fabricated in order to create composites with different interfacial properties. Interfacial properties were varied by changing the nature of fibre coatings. The effect of changes in interfacial shear strength on important matrix properties, such as hardness and fracture toughness, was studied on a micro-scale using the microindentation technique. In addition, the relative orientation of the indented cracks with respect to the fibres was varied to investigate the existence of anisotropic behaviour of the matrix. The results indicated that the crack growth in the matrix was influenced by the presence of residual radial and axial stresses, such that relatively higher crack lengths were seen in certain directions in the matrix with respect to other directions. This asymmetric nature of the crack formation upon indentation was the reason for the observed anisotropic fracture toughness of the matrix. The residual stresses also led to anisotropic hardness and a critical load for crack initiation in the matrix.     

Crack tip heating in short-fibre composites under fatigue loading conditions

Crack tip heating in cyclically loaded short-fibre polymer matrix composites occurs by a combination of hysteretic heating and frictional heating. While the former mechanism is caused by plastic and viscoelastic deformations within the polymeric matrix, the latter is due to interfacial friction between matrix and fibres, and crack surface interference associated with crack closure. The relative contribution of these two principal mechanisms depends upon a number of variables including the viscoelastic and plastic characteristics and frictional properties of the matrix polymer, the degree of interfacial adhesion, the fibre content and fibre orientation distribution and the loading conditions. The results confirm that even in a tension/tension loading mode, frictional heating may play a dominant role, at least in some systems.     

The influence of fibre surface properties on the mode of failure in carbon-fibre/epoxy composites

A series of mechanical tests have been performed on composites consisting of high-strength carbon fibres in an amine-cured epoxy resin. A comparison has been made between composites containing untreated, commercially treated (electrochemically), and plasma treated fibres. While both treatments improve interfacial adhesion, the manner in which the composite fails is totally different. In composites that contain electrochemically treated fibres failure is, in most cases, matrix dominated, whereas interfacial failure always occurs in samples made from plasma-treated fibres. This behaviour can be explained in terms of the nature of the fibre surface after each type of treatment.     

Surface modification of superdrawn polyoxymethylene fibres

A new surface modification of superdrawn polyoxymethylene (POM) fibres, curing with resorcinol at mild temperatures, was developed to apply to rubber composites and the adhesion to the rubber matrix behaviour of modified fibres is discussed in terms of the interfacial miscibility between the fibre and adhesive surface layers. The modified fibre reached the maximum pull-out adhesion level in which a cohesive failure of the fibre occurs, resulting from the fact that the modified POM layer is spectroscopically close to the standard resorcinol-formaldehyde (RF) resin, thoroughly miscible and thermodynamically compatible with the resorcinol-formaldehyde-latex (RFL) adhesive.     

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.     

Conditions for matrix crack deflection at an interface in ceramic matrix composites

This paper describes a numerical approach developed to simulate the mechanism of matrix crack deflection at the fibre/matrix interface in brittle matrix composites. For this purpose, the fracture behaviour of a unit cell (microcomposite) consisting of a single fibre surrounded by a cylindrical tube of matrix was studied with the help of a finite element model. A fracture mechanics approach was used to design a criterion for deflection at the fibre/matrix interface of an annular crack present in the matrix. The analysis of the fracture behaviour of SiC/SiC and SiC/glass ceramics microcomposites shows that the introduction of a low modulus and low toughness interfacial layer at the fibre/matrix interface (e.g. a carbon coating) greatly favours matrix crack deflection at the interphase/fibre interface.     

In State of Art: Mechanical and tribological behaviour of polymeric composites based on natural fibres

In this article, a comprehensive literature review on the mechanical and tribological behaviour of polymeric composites based on natural fibres is introduced. The effects of volume fraction, orientations, treatments and physical characteristics of different types of natural fibres on the mechanical and tribological properties of several thermoset and thermoplastic polymers are addressed. The effects of the tribological operating parameters (applied load, sliding velocity and sliding distance) on the frictional and wear performance of natural fibre polymer composites are demonstrated. The collected date and analyses revealed that volume fraction, orientations, type of treatment and physical characteristics of the natural fibres significantly influence the mechanical and tribological behaviour of composites. The most influence key in designing natural fibre/polymer composite is the interfacial adhesion of the fibre with the matrix. NaOH chemical treatment found to be the most useful treatment method to enhance the interfacial adhesion of the natural fibres with the matrix, while other techniques exhibited either no effect or deterioration on the fibre strength. Frictional characteristics of the natural fibre composites are poor and solid lubricants are recommended to reduce the friction coefficient of the materials.     

Effect of coupling agents on reinforcing potential of recycled carbon fibre for polypropylene composite

Polypropylene (PP) composites reinforced with recycled carbon fibre have been prepared through extrusion compounding and injection moulding. The reinforcing potential of the recycled fibre was increased by improving the interfacial adhesion between the fibre and PP matrix and this was done by the addition of maleic anhydride grafted polypropylene (MAPP) coupling agents. Three MAPP couplers with different molecular weights and maleic anhydride contents were considered. The effects on the mechanical properties of the composite were studied, and scanning electron microscopy (SEM) was used to study the fracture morphology of the tensile specimens. It was observed that with the addition of MAPP the interfacial adhesion was improved as fewer fibres were pulled-out and less debonding was seen. A microbond test was performed and a significant improvement in interfacial shear strength was measured. This resulted in composites with higher tensile and flexural strengths. The maximum strength was achieved from MAPP with the highest molecular weight. Increased modulus was also achieved with certain grades of MAPP. It was also found that the composite impact strength was improved significantly by MAPP, due to a higher compatibility between the fibre and matrix, which reduced crack initiation and propagation.     

Carbon nanotube grafted carbon fibres: A study of wetting and fibre fragmentation

Carbon nanotubes (CNTs) were grafted on IM7 carbon fibres using a chemical vapour deposition method. The overall grafting process resulted in a threefold increase of the BET surface area compared to the original primary carbon fibres (0.57 m²/g). At the same time, there was a degradation of fibre tensile strength by around 15% (depending on gauge length), due to the dissolution of iron catalyst into the carbon; the modulus was not significantly affected. The wetting behaviour between fibres and poly(methyl methacrylate) (PMMA) was directly quantified using contact angle measurements for drop-on-fibre systems and indicated good wettability. Single fibre fragmentation tests were conducted on hierarchical fibre/PMMA model composites, demonstrating a significant (26%) improvement of the apparent interfacial shear strength (IFSS) over the baseline composites. The result is associated with improved stress transfer between the carbon fibres and surrounding matrix, through the grafted CNT layer. The improved IFSS was found to correlate directly with a reduced contact angle between fibre and matrix.     

Effect of surface treatment upon the pull-out behaviour of aramid fibres from epoxy resins

A detailed study has been undertaken of the pull-out behaviour of aramid fibres with different surface characteristics from blocks of an epoxy resin matrix. The fibres employed had either no surface treatment (HM), a standard surface finish (HMF) or had been treated with a special epoxy-based adhesion-activating finish (HMA). The point-to-point variation of axial fibre strain along the fibres both inside and outside of the resin matrix has been determined from stress-induced Raman band shifts. This has enabled the distribution of interfacial shear stress along the fibre/matrix interface to be determined and, in combination with scanning electron microscope analysis of the specimens following pull-out testing, the failure mechanisms to be elucidated. It is found that pull out of the HM fibre takes place by a debond propagating along the fibre/matrix interface at a low level of interfacial shear stress. The HMF fibre showed better adhesion to the epoxy matrix with pull out occurring in a complex manner through both separation of the fibre skin and failure at the fibre/finish interface. No evidence of debonding was found for the HMA fibre and failure occurred by fracture of the fibre at the point where it entered the resin block.     

Influences of interfacial bonding strength and scatter of fibre strength on tensile behaviour of unidirectional metal matrix composites

The influences of interfacial bonding strength and scatter of strength of fibres on tensile behaviour of unidirectional metal matrix composites, whose matrix has low yield stress in comparison to the strength of fibres, were studied using the Monte-Carlo simulation technique using two-dimensional model composites. The following results were found. The strength of composites increases with increasing bonding strength, especially when the bonding strength exceeds the shear yield stress of the matrix and then remains nearly constant. The strength of composites is very sensitive to bonding strength when the scatter of fibre strength is large, but not when it is small. The fracture mode varies from non-cumulative to cumulative with increasing scatter of fibre strength for both cases of weak and strong interfacial bondings. The fracture surface becomes irregular when bonding strength becomes low and scatter of fibre strength becomes large. The applicability of the Rosen and Zweben models and the rule of mixtures to predict the strength of composites was examined.     

The role of interfaces and matrix void nucleation mechanism on the ductile fracture process of discontinuous fibre-reinforced composites

The role of fibre morphology, interface failure and void nucleation mechanisms within the matrix on the deformation and fracture behaviour of discontinuous fibre-reinforced composites was numerically investigated. The matrix was modelled using a constitutive relationship that accounts for strength degradation resulting from the nucleation and growth of voids. For the matrix, two materials exhibiting identical strength and ductility but having different void-nucleation mechanisms (stress-controlled and strain-controlled) were considered and fibres were assumed to be elastic. The debonding behaviour at the fibre interfaces was simulated in terms of a cohesive zone model which describes the decohesion by both normal and tangential separation. The results indicate that in the absence of interface failure, for a given fibre morphology the void nucleation in the matrix is the key controlling parameter of the composite strength and ductility, hence, of the fracture toughness. The weak interfacial behaviour between the fibres and the matrix can significantly increase the ductility without sacrificing strength for certain fibre morphology and for certain matrix void-nucleation mechanisms.     

Fracture behaviour of SiC fibre-reinforced nitrogen glass matrix composites

Both Nicalon and Hi-Nicalon SiC fibre-reinforced nitrogen glass composites were prepared by slurry infiltration and hot-pressing, and the interfacial features, fracture behaviour and mechanical properties of these composites were investigated. It was found that the interfacial characteristics were mainly dictated by the thermal expansion properties of the matrix and the type of SiC fibre. Yttrium sialon glass has a higher thermal expansion coefficient than SiC fibres, so a radial compressive stress on the fibre due to thermal mismatch caused a larger interfacial frictional stress between fibre and matrix. As a result, the composite failed in a brittle manner with no effective strengthening and toughening. Strong reaction between the Hi-Nicalon SiC fibre and matrix also resulted in relatively poor performance of these composites. In contrast, lithium sialon glass provided a matrix for these composites with significantly improved mechanical properties.     

Discrete element modelling of unidirectional fibre-reinforced polymers under transverse tension

The mechanical behaviour of unidirectional fibre-reinforced polymer composites subjected to transverse tension was studied using a two dimensional discrete element method. The Representative Volume Element (RVE) of the composite was idealised as a polymer matrix reinforced with randomly distributed parallel fibres. The matrix and fibres were constructed using disc particles bonded together using parallel bonds, while the fibre/matrix interfaces were represented by a displacement-softening model. The prevailing damage mechanisms observed from the model were interfacial debonding and matrix plastic deformation. Numerical simulations have shown that the magnitude of stress is significantly higher at the interfaces, especially in the areas with high fibre densities. Interface fracture energy, stiffness and strength all played important roles in the overall mechanical performance of the composite. It was also observed that tension cracks normally began with interfacial debonding. The merge of the interfacial and matrix micro-cracks resulted in the final catastrophic fracture.     

Plasma surface modification of advanced organic fibres

A marked improvement in the interlaminar shear strength and flexural strength of aramid/ epoxy composites is observed when the fibres are pretreated in an ammonia or ammonia/ nitrogen gaseous discharge (plasma) to introduce amine groups on to the fibre surface. Scanning electron and optical microscopic observations are used to examine the microscopic basis for these results. Scanning electron micrographs of shear fracture surfaces show clean fibre/matrix separation in composites made from untreated fibres, indicative of weak interfacial bonding. In contrast, shear fracture surfaces of composites containing plasma-treated fibres exhibit clear evidence of fibre fibrillation and matrix cracking, suggesting stronger interfacial bonding. Optical microscopic examination of flexure specimens shows that enhanced strength results mainly from reduced compressive fibre buckling and debonding, due to an increase in fibre/matrix interfacial bond strength. This increase is not accompanied by any significant change in the interlaminar fracture energy or flexural modulus of the composites, but there is an appreciable loss in transverse ballistic impact properties. These results are also examined in terms of the observed increase in fibre/matrix interfacial strength.     

The influence of thermal treatments on interfacial properties and fatigue crack growth resistance in SCS-6/Ti β21s composites

The mechanical properties of fibre-reinforced composites are dependent on the properties of the fibres, the matrix and the fibre/matrix interface. The latter two were investigated in a metastable β Ti matrix (Ti β21s) reinforced with silicon carbide (SCS-6) fibres by heat treatment for 2 and 6 h at 910°C (solution treatment) and 8 h at 540°C (ageing). Characterization of the microstructure using scanning and transmission electron microscopies revealed that the interfacial reaction layer had become thicker in the solution-treated specimens. This variation did not result in any significant change in interfacial shear strength, determined by a fibre push-out technique, nor in the fatigue crack growth resistance in three-point bending. Conversely, ageing at 540°C resulted in the precipitation of 34% volume fraction of α plates with negligible change to the fibre/matrix reaction layer thickness. This resulted in a large increase in both the interfacial debonding and frictional shear strength, which was consistent with local volume changes in the matrix on precipitation of α. The fatigue crack growth resistance of the peak-aged composite was also reduced under some testing conditions employed. In particular, the number of cycles to failure was decreased markedly after ageing.