Cryogenic delamination growth in woven glass/epoxy composite laminates under mixed-mode I/II fatigue loading

This paper investigates the fatigue delamination growth behavior in woven glass fiber reinforced polymer (GFRP) composite laminates under mixed-mode I/II conditions at cryogenic temperatures. Fatigue delamination tests were performed with the mixed-mode bending (MMB) test apparatus at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K), in order to obtain the delamination growth rate as a function of the range of the energy release rate, and the dependence of the delamination growth behavior on the temperature and the mixed-mode ratio of mode I and mode II was examined. The energy release rate was evaluated using three-dimensional finite element analysis. The fractographic examinations by scanning electron microscopy (SEM) were also carried out to assess the mixed-mode fatigue delamination growth mechanisms in the woven GFRP laminates at cryogenic temperatures.     

Comparative study of dynamic and static delamination behaviour of carbon fibre/epoxy composite laminates

Dynamic and static delamination characteristics of two unidirectional carbon fibre-reinforced epoxy composite laminates (Hercules MI 1610 and Torayca T300) have been studied under impact and low-speed (2 mm min¹) test conditions. The influence of interlaminar reinforcement with chopped Kevlar fibres on toughness has also been examined. The quasi-static or low-speed delamination tests were conducted with the usual double cantilever beam, end-notched flexure and mixed-mode flexure specimens. To determine the corresponding mode I, mode II and mixed-mode toughnesses under the impact condition, a special specimen design has been adopted and tests were performed with a Charpy impact machine. The novel aspect of the test scheme in the present study is that a single-plane delamination surface with a well-defined fracture mode has been obtained. The dynamic and static delamination characteristics of the same fracture mode were then studied by scanning electron microscopy, and special features were compared. While interlaminar reinforcement with a small amount of chopped Kevlar fibres resulted in an appreciable increase in the quasi-static delamination toughness, it was less effective under the impact condition.     

Bridging effect on mode I fatigue delamination behavior in composite laminates

This paper discusses the bridging effect of fibres on mode I fatigue delamination growth in unidirectional and multidirectional polymer composite laminates based on a series of double cantilever beam (DCB) tests. From the results, there is sufficient evidence that fibre bridging can decrease the crack growth rate da/dN significantly, and using only one fatigue resistance curve to determine the delamination behavior in composite materials with large-scale fibre bridging may be inadequate. The bridging created in fatigue delamination is different from that of quasi-static delamination at the same crack length. So it is incorrect to use the resistance curve (R-curve) from quasi-static delamination tests to normalize fatigue delamination results.     

Effects of Stitching on Delamination of Satin Weave Carbon-Epoxy Laminates Under Mode I,Mode II and Mixed-Mode I/II Loadings

The objective of the present study is to characterize the effect of modified chain stitching on the delamination growth under mixed-mode I/II loading conditions. Delamination toughness under mode I is experimentally determined, for unstitched and stitched laminates, by using untabbed and tabbed double cantilever beam (TDCB) tests. The effect of the reinforcing tabs on mode I toughness is investigated. Stitching improves the energy release rate (ERR) up to 4 times in mode I. Mode II delamination toughness is evaluated in end-notched flexure (ENF) tests. Different geometries of stitched specimens are tested. Crack propagation occurs without any failure of stitching yarns. The final crack length attains the mid-span or it stops before and the specimen breaks in bending. The ERR is initially low and gradually increases with crack length to very high values. The mixed-mode delamination behaviour is investigated using a mixed-mode bending (MMB) test. For unstitched specimens, a simple mixed-mode criterion is identified. For stitched specimens, stitching yarns do not break during 25% of mode I ratio tests and the ERR increase is relatively small compared to unstitched values. For 70% and 50% of mode I ratios, failures of yarns are observed during crack propagation and tests are able to capture correctly the effect of the stitching: it clearly improves the ERR for these two mixed modes, as much as threefold.     

Effect of variation in fibre volume fraction on modes I and II delamination behaviour of 5HS woven composites manufactured by RTM

Composites produced by resin infusion techniques will inevitably suffer from variation in resin distribution due to imprecise fibre placement and distortion of the preform during mould closure and infusion. This paper describes an investigation into the effect of variations in fibre volume fraction (FVF) on mode I and mode II delamination behaviour for 5 harness satin (5HS) woven carbon–fibre/epoxy resin composites manufactured by resin transfer moulding (RTM). Additionally, the effect of satin face tow orientation on interlaminar toughness was investigated. In mode I, it was found that toughness increased with increasing FVF and that a strong correlation between fracture surface damage and measured interlaminar fracture toughness was observed. In mode II, measured toughness values were higher than expected and tests were repeated using a mixed-mode rig with 5% mode I. It was found that fracture toughness measurements in pure mode II are significantly affected by friction or mechanical interlocking between the delamination surfaces.     

Temperature effects on mixed mode I/II delamination under quasi-static and fatigue loading of a carbon/epoxy composite

This paper addresses the effect of temperature on the mixed-mode interlaminar fracture toughness and fatigue delamination growth rate of a carbon-fibre/epoxy material, namely IM7/8552. Quasi-static and fatigue characterisation tests were carried out at −50 °C, 20 °C, 50 °C and 80 °C, using asymmetric cut-ply coupons. The experimental results show that temperature may have an accelerating or delaying effect on delamination growth, depending on the loading regime, i.e. either quasi-static or fatigue. Fractographic examinations were also carried out in order to assist the interpretation of the experimental data. A semi-empirical equation is introduced to describe the experimentally observed fatigue delamination growth rates at elevated temperatures.     

Environmental effects on mode II fatigue delamination growth in an aerospace grade carbon/epoxy composite

An investigation of the effects of water, hydraulic fluid and deicing fluid exposure on mode II delamination propagation in an aerospace grade composite is presented. All exposed specimens suffered a loss in delamination toughness and an increase in fatigue delamination growth rate, which was particularly significant for deicing fluid exposure. The number of cycles for delamination onset was also reduced by these exposures, although scanning electron micrographs showed no significant differences between the fracture pattern of dry and exposed specimens. It was also shown that environmental effects can be simply accounted for in a cohesive zone based finite element model.     

Monitoring of delamination onset and growth during Mode I and Mode II interlaminar fracture tests using guided waves

A delamination monitoring method was proposed to characterize Mode I and Mode II delamination onset in carbon fiber/epoxy (CF/EP) composite laminates through interrogation of guided waves activated and captured using piezoelectric actuators and sensors in a pitch–catch configuration. Mode I and Mode II interlaminar fracture tests were conducted using double cantilever beam (DCB) and end notch flexure (ENF) specimens to evaluate the proposed method. The changes in wave propagation velocity and wave magnitude (or attenuation), and the degree of waveform similarity between excitation and response signals, were calculated as delamination-sensitive wave parameters and plotted versus displacement recorded using a materials testing system. The kink points determined from wave parameter–displacement curves agreed well with the deviation from linearity (NL), visual observation (VIS) and maximum load (Max) points, which are often used in conventional methods for determining interlaminar fracture toughness. The propagation characteristics of the A₀ wave mode in a low frequency range were demonstrated to have high sensitivity to Mode I and in particular Mode II delamination onset in CF/EP composite laminates. It was concluded that the guided waves propagating in the DCB and ENF specimens were capable of determining Mode I and Mode II interlaminar fracture toughness, complementing current practices based on visual inspection or trivial interrogation using load–displacement curve alone.     

Characterization of the interlaminar fracture toughness of a laminated carbon/epoxy composite

Delamination between layers is an important problem in applications of fiber reinforced composite laminates. Tests were carried out to determine the interlaminar fracture toughness of AS4/3501-6 (carbon/epoxy) composite laminates using mixed-mode bending tests. Analysis of the test specimens in terms of mode I and mode II energy release rates showed good agreement between methods based on beam equations, compliance measurements, and detailed finite element analyses. The results showed that the critical mode I energy release rate for delamination decreased monotonically with increasing mode II loading. This is in contrast to some results in the literature. Various analytic representations of the mode interaction from the literature were compared, and shown to fit the data with reasonable accuracy.     

A cut-ply specimen for the mixed-mode fracture toughness and fatigue characterisation of FRPs

The characterisation of mixed-mode fracture toughness and fatigue delamination growth in fibre-reinforced composites is crucial for assessing the integrity of structural elements in service. An asymmetric cut-ply coupon (ACP) loaded in four-point bending is here proposed to carry out the aforementioned characterisations. Analytical expressions of the energy release rate and mode-mixity for the ACP are derived and validated by means of finite element analysis. A fracture toughness and fatigue characterisation of the carbon/epoxy material IM7/8552 is carried out via ACP specimens. It is proved that the material data obtained from ACP specimens match those generated using ASTM standard mixed-mode bending (MMB) coupons. The main reason for the introduction of the ACP test resides in its applicability to characterisation scenarios where measuring the delamination length with optical means, as required for MMB coupons, is difficult. Such scenarios include the investigation of static and fatigue delamination growth at low and high temperatures, which requires the usage of environmental chambers. This poses significant constraints in terms of volume available for the test rigs, and, most importantly, limitations on visual access to observe delamination propagation. However, the manufacturing of ACP coupons is more complex than for MMB specimens and the testing requires several additional precautions that are here discussed in detail.     

Influence of z-pin length on the delamination fracture toughness and fatigue resistance of pinned composites

The effect of z-pin length on the mode I and mode II delamination toughness and fatigue resistance of z-pinned carbon-epoxy composites is investigated. Experimental testing and mechanical modelling reveals that both the mode I fracture toughness and fatigue resistance increase with the z-pin length due to increased bridging traction loads generated by elastic stretching and pull-out of the pins. The opposite trend occurs for mode II toughness, which decreases with increasing z-pin length due to lower traction loads arising from restrictions on the shear-induced rotation and pull-out of the pins. The mode II fatigue resistance is increased by z-pinning, although it is not dependent on the z-pin length. Increasing the z-pin length beyond a critical size also changes the mode I and mode II delamination fracture and fatigue processes from single to multiple cracking. The effect of z-pin length on the delamination toughening and fatigue strengthening mechanisms is determined.     

Acoustic Emission-Based Methodology to Evaluate Delamination Crack Growth Under Quasi-static and Fatigue Loading Conditions

The aim of this study was to investigate the applicability of acoustic emission (AE) technique to evaluate delamination crack in glass/epoxy composite laminates under quasi-static and fatigue loading. To this aim, double cantilever beam specimens were subjected to mode I quasi-static and fatigue loading conditions and the generated AE signals were recorded during the tests. By analyzing the mechanical and AE results, an analytical correlation between the AE energy with the released strain energy and the crack growth was established. It was found that there is a 3rd degree polynomial correlation between the crack growth and the cumulative AE energy. Using this correlation the delamination crack growth was predicted under both the static and fatigue loading conditions. The predicted crack growth values was were in a good agreement with the visually recorded data during the tests. The results indicated that the proposed AE-based method has good applicability to evaluate the delamination crack growth under quasi-static and fatigue loading conditions, especially when the crack is embedded within the structure and could not be seen visually.     

Experimental determination of the mode I delamination fracture and fatigue properties of thin 3D woven composites

The mode I delamination fracture toughness and fatigue strength of thin-section three-dimensional (3D) woven composite materials is experimentally determined. The non-crimp 3D orthogonally woven carbon–epoxy composites were thin (2 mm) and consequently their through-thickness z-binder yarns were inclined at a very steep angle (about 70°) from the orthogonal direction. The steep z-binder angle has a marked effect on the delamination toughening and fatigue strengthening mechanisms. Experimental testing revealed that the fracture toughness and fatigue resistance increased progressively with the volume content of z-binders. However, the steep angle caused the z-binder yarns bridging the delamination crack to deform and fail in shear and through-thickness tension, rather than in-plane tension which usually occurs in thick 3D woven composites. Mode I pull-off tests on a single woven z-binder yarn embedded within the composite revealed that the crack bridging traction load, strain energy absorption and failure mechanism were strongly affected by the steep angle.     

Fatigue delamination growth in woven glass/epoxy composite laminates under mixed-mode II/III loading conditions at cryogenic temperatures

We investigate the cryogenic delamination growth behavior in woven glass fiber reinforced polymer (GFRP) composite laminates under mixed-mode II/III fatigue loading. Fatigue delamination tests were conducted with six-point bending plate (6PBP) specimens at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K), and the delamination growth rate data for various mixed-mode ratios of Modes II and III were obtained. The energy release rate was evaluated using the three-dimensional finite element method. In addition, the fatigue delamination growth mechanisms were characterized by scanning electron microscopic observations of the specimen fracture surfaces.     

Influence of mode ratio and hygrothermal condition on the delamination toughness of a thermoplastic particulate interlayered carbon/epoxy composite

Double cantilever beam, end-notched flexure and single leg bending tests were used to determine the effects of temperature and moisture on the toughness of a thermoplastic particulate-toughened carbon/epoxy composite. Tests were performed on both dry and moisture-saturated specimens at temperatures of ?43 °C, 21 °C and 98 °C, and on dry specimens only at 125 °C. In-situ observations and post-test scanning electron microscopy showed increasing matrix ductility with increasing temperature and moisture content. This correlated to an increase in the mode I and a decrease in the mode II toughness. The mixed-mode toughness data and fracture surface morphologies displayed a blend of the mode I and mode II behaviors.     

Fracture surface evolution and apparent delamination toughness in split composite beam specimens subjected to mixed mode I–III loading

The influence of specimen twisting during global anti-plane shear loading in composite split beam specimens is studied. Tests were conducted on specimens with different thicknesses and delamination lengths to produce different amounts of specimen twisting prior to fracture. It is shown that specimen twisting causes mode I stresses to develop, thereby producing mixed mode I–III conditions along the delamination front. This causes near-tip transverse cracks to initiate, prior to delamination advance, at an orientation related to the mode mix. Unlike in homogeneous materials, transverse crack extension is accompanied by planar delamination advance, and transverse crack rotation during extension is restricted by the laminate’s fibers. The overall fracture surface evolution is therefore strongly controlled by specimen geometry. The influence of these findings on the apparent delamination toughness as obtained from composite split beam and other types of mode III tests is discussed.     

Comparison of Interlaminar Fracture Toughness in Unidirectional and Woven Roving Marine Composites

This paper investigates the effect of fibre lay-up and matrix toughness on mode I and mode II interlaminar fracture toughness (G_Ic and G_IIc) of marine composites. Unidirectional and woven roving fibres were used as reinforcements. Two vinyl ester resins with different toughness were used as matrices. Results from both modes showed toughness variation that is consistent with matrix toughness. Values of G_Ic were not significantly influenced by fibre lay-up except at peak load points in the woven roving/brittle-matrix composite. Each peak load point, caused by interlocked bridging fibres, signified the onset of unstable crack growth. For unidirectional specimens, crack growth was stable and G_Ic statistically more reliable than woven roving specimens, which gave fewer G_Ic values due to frequent unstable crack growth. Mode II tests revealed that, except for crack initiation, G_IIc was higher in woven roving composites. This was due to fibre bridging, perpendicular to the crack growth direction, which encouraged stable crack growth and increased energy absorption. Mode II R-curves were obtained for the woven roving specimens. These R-curves provide additional information useful for characterising delamination resistance. The paper concludes that composites with woven roving fibres show similar mode I delamination characteristics to the unidirectional composites; but their mode II delamination characteristics, after crack initiation, are quite different.     

Interpreting the stress ratio effect on delamination growth in composite laminates using the concept of fatigue fracture toughness

This paper provides a study on fatigue delamination growth in composite laminates using energy principles. Experimental data has been obtained from fatigue tests conducted on Double Cantilever Beam (DCB) specimens at various stress ratios. A concept of fatigue fracture toughness is proposed to interpret the stress ratio effect in crack growth. The fatigue fracture toughness is demonstrated to be interface configuration independent but significantly stress ratio dependent. An explanation for this phenomenon is given using SEM fractography. Fracture surface roughness is observed to be similar in different interfaces at the same stress ratio. But it is obviously more rough for high stress ratio in comparison with that for low stress ratio, causing the fatigue resistance increase. Therefore, the stress ratio effect in fatigue crack growth can be physically explained by a difference in resistance to crack growth.     

Measuring the rate-dependent mode I fracture toughness of composites – A review

Composite materials are often subjected to mechanical impact causing delamination. For quasi-static loading, measuring the mode I fracture toughness has been standardized. However, for high-rate loading, additional challenges arise. Consequently, no standard test has yet been defined for measuring the mode I fracture toughness under high rates of loading. This article therefore reviews candidate tests for measuring the high-rate mode I fracture toughness. Strength and weaknesses of different specimen designs and test setups are shown. Different approaches to measuring crack growth and loads are presented. The different approaches are compared and recommendations are provided for measuring the mode I fracture toughness of composites under high rates of loading.     

A new approach for evaluating crack growth resistance curve of mode II delamination by doubly end-notched tension tests

Quantitative determination of interlaminar fracture toughness that governs onset and growth of delamination is essential for engineering of composite materials and structures. This study proposes a new approach to evaluate both the initial fracture toughness and the crack growth resistance property of pure mode II delamination by tensile tests of specimens having two initial cracks, which were conceived from double-lap joints. The proposed test method achieves stable growth of mode II delamination using a fundamental testing system. This study presents the specimen configuration, the theory to evaluate the energy release rate, and experiment results. The mode II initial fracture toughness measured by the present approach agreed well with the results of conventional end-notched flexure tests. Furthermore, the crack growth resistance curves were evaluated by unloading-reloading tests of the proposed doubly end-notched tension specimens.