Fibre debonding and breakage in a whisker-reinforced metal

A numerical cell-model analysis of the development of damage in aluminium reinforced by aligned, short SiC fibres, is given for materials with arrays of transversely aligned fibres, to be compared with the results obtained previously for transversely staggered fibres. The stress distributions in the matrix and fibres are quite different for the different fibre arrangements, and this has a significant effect on failure by fibre breakage or decohesion. Fibre fracture is represented by a critical value of the average tensile stress on a cross-section, while interfacial failure is modelled in terms of a cohesive zone formulation that accounts for decohesion by normal separation as well as by tangential separation. It is shown that highly constrained plastic flow associated with transversely aligned fibres gives rise to early transverse void growth towards coalescence, but the onset of failure requires higher stress levels.     

The impact strength of fibre composites

Two models have been developed which predict the crack initiation energy, notched impact strength and unnotched impact strength of fibre composites. One is applicable to composites containing short fibres and the other to composites containing long fibres. Data obtained with randomly oriented short fibre composites were consistent with the one model. The other model has been verified using composites containing uniaxially oriented long fibres and long fibres oriented randomly in a plane. The success of the model demonstrates that the high notched impact strength with long fibres is due to the redistribution of stress away from the stress concentrating notch, the extra stress that can be held by the fibre relative to the matrix and the work required to pull fibres out of the matrix during crack propagation. The parameters which have been shown to control the fracture energy are composite modulus, fibre length, fibre volume fraction, effective fibre diameter, fibre tensile strength and the coefficient of friction during fibre pull-out from the matrix. The matrix toughness on the other hand usually has no effect at all for composites containing fibres randomly oriented in two dimensions and only a minor effect in exceptional cases. The shear strength of the fibre-matrix bond has only an indirect effect in that it controls the number of fibres which pull out rather than fracture.     

A non-local fracture model for composite laminates and numerical simulations by using the FFT method

In this paper, we present a fracture model for composite laminates and its numerical solution by using the Fast Fourier Transforms (FFTs). The FFT-based formulation initially proposed for seeking the average behaviour of linear and non-linear composites by means of the homogenisation procedures [1], [2] was adapted to evaluate the damage growth in brittle materials. A non-local damage model based on the maximal principal stress criterion was proposed to assess the failure in the matrix and the fibres. This non-local model was then connected to the Griffith–Irwin criterion in the aim of predicting crack growth. In order to assess the matrix/fibre interface delamination, we have adapted the cohesive model developed by Li [3] for accounting the mixed-mode dependent interface failure. To this end, the interfaces between the matrix and the fibres are replaced by a thin layer of interphase with the purpose of facilitating the FFT simulations. By using the proposed model, we carried out several numerical simulations on fracture process in different specimens. From these studies, we can conclude that the present FFT-based analysis is capable to deal with crack initiation and crack growth in composite laminates with high accuracy and efficiency, especially in the cases of matrix/fibre interface debonding and of multi-crack growth.     

Fatigue crack growth in hybrid boron/glass/aluminium fibre metal laminates

The crack growth behaviour of hybrid boron/glass/aluminium fibre metal laminates (FMLs) under constant‐amplitude fatigue loading was investigated. The hybrid FMLs consist of Al 2024‐T3 alloy as the metal layers and a mixture of boron fibres and glass fibres as the fibre layers. Two types of boron/glass/aluminium laminates were fabricated and tested. In the first type, the glass fibre/prepreg and the boron fibre/prepreg were used separately in the fibre layers, and in the second type, the boron fibres and the glass fibres were uniformly mingled together to form a hybrid boron fibre/glass fibre prepreg. An analytical model was also proposed to predict the fatigue crack growth behaviour of hybrid boron/glass/aluminium FMLs. The effective stress intensity factor at a crack tip was formulated as a function of the remote stress intensity factor, crack opening stress intensity factor, and the bridging stress intensity factor. The bridging stress acting on the delamination boundary along the crack length was also calculated based on the crack opening relations. Then, the empirical Paris‐type fatigue crack growth law was used for predicting the crack growth rates. A good correlation between the predicted and experimental crack growth rates has been obtained.     

Fracture response of fibre-reinforced materials with macro/microcrack damage using the Boundary Element Technique

The Boundary Element Method (BEM) incorporating the Embedded Cell Approach (ECA) has been used to analyse the effects of constituent material properties, fibre spatial distribution and microcrack damage on the localised behaviour of transversely fractured, unidirectional fibre-reinforced composites. Three specific composites, i.e., glass fibre reinforced polyester, carbon fibre reinforced epoxy and a glass-carbon hybrid, are considered. The geometrical structures examined were perfectly periodic, uniformly spaced fibre arrangements in square and hexagonal embedded cells. In addition, numerical simulations were also conducted using embedded cells containing randomly distributed fibres. The models involve both elastic fibres and matrix, with the interfaces between the different phases being fully bonded. The results indicate that the constituent material properties (two phase composite) and spatial distribution have a significant effect on the localised stress distributions around the primary crack tip. However, the strain energy release rate associated with crack propagation is predominantly influenced by the material composition. The three-phase hybrid composite exhibited an apparent intermediate fracture toughness value, compared to the all-glass and all-carbon models. Furthermore, the strain energy release rate for the macrocrack lowers as it enters a zone of localised damage (microcracking). The presence of microcracks relaxes the stress field, which can result in a significant reduction in the energetics of the primary crack.     

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.     

Extended Voronoi cell finite element model for multiple cohesive crack propagation in brittle materials

This paper introduces an extended Voronoi cell finite‐element model (X‐VCFEM) for modelling cohesive crack propagation in brittle materials with multiple cracks. The cracks are modelled by a cohesive zone model and their incremental directions and growth lengths are determined in terms of the cohesive energy near the crack tip. Extension to VCFEM is achieved through enhancements in stress functions in the assumed stress hybrid formulation. In addition to polynomial terms, the stress functions include branch functions in conjunction with level set methods, and multi‐resolution wavelet functions in the vicinity of crack tips. The wavelet basis functions are adaptively enriched to accurately capture crack‐tip stress concentrations. Conditions and methods of stability are enforced in X‐VCFEM for improved convergence with propagating cracks. Two classes of problems are solved and compared with existing solutions in the literature for validation of the X‐VCFEM algorithms. The first set corresponds to results for static cracks, while in the latter set, the propagation of cohesive cracks are considered. Comparison of X‐VCFEM simulation results with results in literature for several fracture mechanics problems validates the effectiveness of X‐VCFEM. Copyright © 2005 John Wiley & Sons, Ltd.     

A fracture evolution procedure for cohesive materials

The present paper deals with the problem of the evaluation of the softening mechanical response of cohesive materials under tensile loading. A nonlinear fracture mechanics approach is adopted. A new numerical procedure is developed to study the evolution of the crack processes for 2D solids. The proposed algorithm is based on the derivation and use of the fracture resistance curve, i.e., the R-curve, and it takes into account the presence of the process zone at the crack tip. In fact, assuming a nonlinear constitutive law for the cohesive interface, the procedure is able to determine the R-curve, the process zone length and hence the mechanical response of any material and structure. Numerical applications are developed for studying the damage behavior of a infinite solid with a periodic crack distribution. Size effects are investigated and the ductile-brittle transition behavior for materials characterized by the same crack density is studied. The results obtained adopting the proposed procedure are in good accordance with the results recovered through nonlinear step by step finite element analyses. Moreover, the developed computations demonstrate that the procedure is simple and efficient.     

Non‐linear analysis of shells with arbitrary evolving cracks using XFEM

A new formulation and numerical procedures are developed for the analysis of arbitrary crack propagation in shells using the extended finite element method. The method is valid for completely non‐linear problems. Through‐the‐thickness cracks in sandwich shells are considered. An exact shell kinematics is presented, and a new enrichment of the rotation field is proposed which satisfies the director inextensibility condition. To avoid locking, an enhanced strain formulation is proposed for the 4‐node cracked shell element. A finite strain plane stress constitutive model based on the logarithmic corotational rate is employed. A cohesive zone model is introduced which embodies the special characteristics of the shell kinematics. Stress intensity factors are calculated for selected problems and crack propagation problems are solved. Copyright © 2004 John Wiley & Sons, Ltd.     

A combined experimental-numerical investigation of crack growth in a carbon–carbon composite

A combined experimental–numerical investigation of crack growth in a carbon–carbon composite is reported. In this material, both matrix fracture and fibre bridging contribute significantly to toughness. Crack growth experiments were performed using side‐notched DCB specimens with doublers. A digital image correlation method was used to measure displacements fields on the specimen surfaces, crack extension and crack opening profiles. An effective cohesive zone law was determined from the experimental data. The effective cohesive zone law is subsequently separated into the individual contributions from matrix cracking and fibre bridging. Numerical simulation of crack growth based on this cohesive zone law and experimental data are in good agreement. Special focus of the numerical study is on the investigation of the discontinuous nature of crack growth.     

Statistical analysis of failure of unidirectionally fibre-reinforced composites with local load-sharing

A shear-lag model is presented in this paper for analysis of stress concentration of fibres adjacent to a crack in unidirectionally fibre-reinforced composites. The analytic expressions of stress concentration factors of fibres adjacent to the tip of a crack with r broken fibres are obtained by using this model. The maximum stress concentration factors of the fibre at the tip of the crack are calculated, and the numerical results show little difference with Hedgepeth's [1]. In addition, the concept of the effective stress concentration factor is used since shear-lag analysis overestimates stress concentration of fibres [2], and the affected length of a crack-tip fibre is defined by value of the stress concentration factor. The affected length has clear physical meaning and increases gradually with extension of the crack, which is in accord with the actual case. Finally, based on the previous investigation, statistical analysis of strength of unidirectionally fibre-reinforced composites is done by applying the method of the critical crack core model [3, 4]. The numerical results are close to the experimental results, and those obtained by using the effective stress concentration factors approach the experimental results most closely.     

Micromechanics of multiple cracking Part II Statistical tensile behaviour

A computational model for fibre-reinforced brittle materials in tension is developed. The model includes multiple cracking and strain-hardening processes, as well as single fracture and strain softening. The composite behaviour is derived from a single-fibre analysis by integrating over all possible fibre locations and orientations. The single-fibre analysis is based on symmetry fibres satisfying the equilibrium condition. The result is a complete constitutive relation: stress–strain or stress–crack width curve, and a prediction of crack spacing. The model is an extension of the ACK theory by Aveston, Cooper and Kelly, as it can be used with discontinuous fibres with different distributions, as well as for analysing hybrid composites. Fibre orientation introduces additional phenomena, which are taken into account with simple models. It was seen that matrix spalling at the fibre exit point may have a considerable effect on the composite strain and the crack width. The effect of fibre aspect ratio on the failure mode was studied, and it was found that with an intermediate fibre diameter the composite fails by fibre pull-out in a multiple-cracking stage, resulting in a strain-hardening material with a high ductility. The proposed model was verified against experimental results of a strain-hardening material, called an engineered cementitious composite. The model can be used in tailoring new materials to meet certain requirements, or in studying the effects of micromechanical properties on the composite behaviour, including the crack width, crack spacing, post-cracking strength, ultimate strain, and ductility. The derived constitutive relationship can further be used in finite element analyses defining the behaviour perpendicular to the crack. © 1998 Kluwer Academic Publishers     

The fibre pull-out energy of misaligned short fibre composites

A theoretical study on the fibre pull-out energy has been carried out for short fibre-reinforced composites. Two probability density functions were introduced for modelling the fibre-length distribution and the fibre-orientation distribution. By taking into account the effect of snubbing friction between fibres and matrix at the fibre exit point during fibre pull-out, and that of the fracture stress of fibres obliquely crossing the fracture plane (i.e. the inclined strength of fibres), the fibre pull-out energy of composites has been derived as a function of fibre-length distribution and fibre-orientation distribution, as well as interfacial properties. The previously existing fibre pull-out energy theories can be deduced from the present model. The effects of fibre-length distribution, fibre-orientation distribution, interfacial properties, snubbing-friction coefficient and parameter A for determining the inclined strength of fibres on the fibre pull-out energy, have been studied in detail. The present study provides the necessary information as to which fibre-length distribution, fibre-orientation distribution and interfacial property are required to achieve a desired fibre pull-out energy and hence a desired composite toughness. High-strength fibres, a large fibre-volume fraction and a large fibre diameter for a comparatively large mean fibre length, are shown to be favourable for achieving a high fibre pull-out energy. This revised version was published online in November 2006 with corrections to the Cover Date.     

Cohesive modeling of dynamic fracture in functionally graded materials

The dynamic fracture of functionally graded materials (FGMs) is modeled using an explicit cohesive volumetric finite element scheme that incorporates spatially varying constitutive and failure properties. The cohesive element response is described by a rate-independent bilinear cohesive failure model between the cohesive traction acting along the cohesive zone and the associated crack opening displacement. A detailed convergence analysis is conducted to quantify the effect of the material gradient on the ability of the numerical scheme to capture elastodynamic wave propagation. To validate the numerical scheme, we simulate dynamic fracture experiments performed on model FGM compact tension specimens made of a polyester resin with varying amounts of plasticizer. The cohesive finite element scheme is then used in a parametric study of mode I dynamic failure of a Ti/TiB FGM, with special emphasis on the effect of the material gradient on the initiation, propagation and arrest of the crack.     

A MODEL TO PREDICT THE FATIGUE LIFE OF FIBRE-REINFORCED TITANIUM MATRIX COMPOSITES UNDER CONSTANT AMPLITUDE LOADING

A model based on micro-mechanical concepts has been developed for predicting fatigue crack growth in titanium alloy matrix composites. In terms of the model, the crack system is composed of three zones: the crack, the plastic zone and the fibre. Crack tip plasticity is constrained by the fibres and remains so until certain conditions are met. The condition for crack propagation is that fibre constraint is overcome when the stress at the location of the fibre ahead of the crack tip attains a critical level required for debonding. Crack tip plasticity then increases and the crack is able to propagate round the fibre. The debonding stress is calculated using the shear lag model from values of interfacial shear strength and embedded fibre length published in the literature. If the fibres in the crack wake remain unbroken, friction stresses on the crack flanks are generated, as a result of the matrix sliding along the fibres. The friction stresses (known as the bridging effect) shield the crack tip from the remote stress, reducing the crack growth relative to that of the matrix alone. The bridging stress is calculated by adding together the friction stresses, at each fibre row bridging the crack, which are assumed to be a function of crack opening displacement and sliding distance at each row. The friction stresses at each fibre row will increase as the crack propagates further until a critical level for fibre failure is reached. Fibre failure is modelled through Weibull statistics and published experimental results. Fibre failure will reduce the bridging effect and increase the crack propagation rate. Calculated fatigue lives and crack propagation rates are compared with experimental results for three different materials (32% SCS6/Ti-15-3, 32% and 38% SCS6/Ti-6-4) subjected to mode I fatigue loading. The good agreement shown by these comparisons demonstrates the applicability of the model to predict the fatigue damage in Ti-based MMCs.     

Analysis of viscoelastic behaviour of transversely isotropic materials

In this paper a constitutive equation to describe the mechanical behaviour of materials, reinforced with unidirectional fibres, is presented. The material behaviour of both matrix and fibres may be viscoelastic. The constitutive equation is a linear relation between the second Piola–Kirchhoff stress tensor and the Green–Lagrange strain tensor. The effective relaxation functions in the constitutive equation are composed of component relaxation functions employing the structural model of Hashin and Rosen. A two-dimensional membrane element incorporating this constitutive equation is implemented in a finite element program. The results of several calculations are presented in order to demonstrate the possibilities of the numerical tool. One calculation concerns a square membrane with a circular hole in its centre. The effect of fibre orientation on deformation and stresses will be displayed for this structure as well as for another membrane structure.     

A partition of unity finite element method for obtaining elastic properties of continua with embedded thin fibres

The numerical analysis of large numbers of arbitrarily distributed discrete thin fibres embedded in a continuum is a computationally demanding process. In this contribution, we propose an approach based on the partition of unity property of finite element shape functions that can handle discrete thin fibres in a continuum matrix without meshing them. This is made possible by a special enrichment function that represents the action of each individual fibre on the matrix. Our approach allows to model fibre‐reinforced materials considering matrix, fibres and interfaces between matrix and fibres individually, each with its own elastic constitutive law. Copyright © 2010 John Wiley & Sons, Ltd.     

The fracture process in quasi‐brittle materials simulated using a lattice dynamical model

The damage process in quasi‐brittle materials is characterized by the evolution of a micro‐crack field, followed by the joining of micro‐cracks, stress localization and crack instability. In network models, masses are lumped at nodal points which are interconnected by one‐dimensional elements with a bilinear constitutive relation, considering the energy consistency during the simulated process. In order to replicate the material imperfections, to render a realistic behaviour in damage localization, the model has not only random elastic and rupture properties, but also a geometric perturbation. In the present paper 2D plates with different levels of brittleness are simulated. The numerical results are presented in terms of global stress vs strain diagram, final network configuration, energy balance during the process and as geometric damage evolution. Therefore, the predictive potential of the lattice discrete element model to capture fracture processes in quasi‐brittle materials is demonstrated.     

Crack growth resistance behavior of a functionally graded material: computational studies

This paper describes crack growth resistance simulation in a ceramic/metal functionally graded material (FGM) using a cohesive zone ahead of the crack front. The plasticity in the background (bulk) material follows J₂ flow theory with the flow properties determined by a volume fraction based, elastic-plastic model (extension of the original Tamura-Tomota-Ozawa model). A phenomenological, cohesive zone model with six material-dependent parameters (the cohesive energy densities and the peak cohesive tractions of the ceramic and metal phases, respectively, and two cohesive gradation parameters) describes the constitutive response of the cohesive zone. Crack growth occurs when the complete separation of the cohesive surfaces takes place. The crack growth resistance of the FGM is characterized by a rising J-integral with crack extension (averaged over the specimen thickness) computed using a domain integral (DI) formulation. The 3-D analyses are performed using WARP3D, a fracture mechanics research finite element code, which incorporates solid elements with graded elastic and plastic properties and interface-cohesive elements coupled with the functionally graded cohesive zone model. The paper describes applications of the cohesive zone model and the DI method to compute the J resistance curves for both single-edge notch bend, SE(B), and single-edge notch tension, SE(T), specimens having properties of a TiB/Ti FGM. The numerical results show that the TiB/Ti FGM exhibits significant crack growth resistance behavior when the crack grows from the ceramic-rich region into the metal-rich region. Under these conditions, the J-integral is generally higher than the cohesive energy density at the crack tip even when the background material response remains linearly elastic, which contrasts with the case for homogeneous materials wherein the J-integral equals the cohesive energy density for a quasi-statically growing crack.