Damage tolerance assessment by bend and shear tests of two multilayer composites: Glass fibre reinforced metal laminate and aluminium roll-bonded laminate

The damage tolerance of an aluminium roll-bonded laminate (ALH19) and a glass fibre reinforced laminate (GLARE) (both based on Al 2024-T3) has been studied. The composite laminates have been tested under 3-point bend and shear tests on the interfaces to analyze their fracture behaviour. During the bend tests different fracture mechanisms were activated for both laminates, which depend on the constituent materials and their interfaces. The high intrinsic toughness of the pure Al 1050 layers present in the aluminium roll-bonded laminate (ALH19), together with extrinsic toughening mechanisms such as crack bridging and interface delamination were responsible for the enhanced toughness of this composite laminate. On the other hand, crack deflection by debonding between the glass fibres and the plastic resin in GLARE was the main extrinsic toughening mechanism present in this composite laminate.     

Novel test method for accurate characterization of intralaminar fracture toughness in CFRP laminates

A novel initial crack insertion method, “intralaminar film insertion method”, was proposed to investigate the fracture toughness of unidirectional carbon fiber reinforced plastic (CFRP) laminates when the crack propagates inside the ply and not in the interlayer resin-rich area. Here, a release film was inserted inside a single lamina during the resin impregnation process of prepreg manufacturing. Mode I intralaminar fracture toughness tests were carried out for conventional CFRP laminates and interlayer toughened CFRP laminates. For comparison, two conventional methods were used to introduce initial cracks. One is the “interlaminar film method”, where a release film is inserted between two prepreg plies during the lay-up process. The other is the “machined slit method”, where a slit notch is machined in parallel to the layer of CFRP laminates. It was demonstrated that the proposed “intralaminar film method” can correctly evaluate the intralaminar fracture toughness of both conventional CFRP laminate and interlayer toughened CFRP laminate from the initial value to the propagation value. For this range, it was also found that the intralaminar fracture toughness of interlayer toughened CFRP laminate was the same as that of conventional CFRP laminate. Thus, the intralaminar fracture toughness was not influenced by interlayer toughening.     

Enhanced fracture resistance in layered discontinuously reinforced aluminium

Bimaterial laminates may produce enhanced fracture resistance in brittle and semibrittle materials. The purpose of the present work was to investigate crack stabilisation in a discontinuously reinforced aluminium (DRA) material via lamination with a ductile aluminium alloy. In particular, the crack growth behaviour of the individual DRA layers in the laminate was compared with that of an equivalent thickness DRA material tested separately. In contrast to the DRA material, the DRA laminate exhibited R curve behaviour in which stable crack growth occurred concurrent with an increased load carrying capacity after fracture initiation, producing both an increase in the toughness and the work of rupture.

MST/3520     

基于断裂韧性预报复合材料层合板的开孔拉伸强度

开孔层合板的强度预报往往取决于孔边的临界长度,它不仅与材料性能,而且与铺层、孔径都有关。本文基于线弹性断裂力学,提出了一种预报对称铺层层合板开孔拉伸强度的新方法,只需提供正交层合板的断裂韧性和无缺口层合板的拉伸强度,显著降低对实验数据的依赖性。首先,将临界长度表作为层合板断裂韧性和无缺口拉伸强度的函数,再通过正交层合板[90/0]_8s的紧凑拉伸试验和虚拟裂纹闭合技术,确定出0°层断裂韧性,进而计算得到任意对称铺层层合板的断裂韧性。本文测试了T300/7901层合板[0/±45/90]_2s和[0/±30/±60/90]_s的开孔拉伸强度,孔径分别为3 mm、6 mm和9 mm。理论预报结果与试验值吻合较好,最大误差为15.2%,满足工程应用需求。      

Fracture toughness of transverse cracks in graphite/epoxy laminates at cryogenic conditions

Stress singularity of a transverse crack normal to ply-interface in a composite laminate is investigated using analytical and finite element methods. Four-point bending tests were performed on single-notch bend specimens of graphite/epoxy laminates containing a transverse crack perpendicular to the ply-interface. The experimentally determined fracture loads were applied to the finite element model to estimate the fracture toughness. The procedures were repeated for specimens under cryogenic conditions. Although the fracture loads varied with specimen thickness, the critical stress intensity factor was constant for all the specimens indicating that the measured fracture toughness can be used to predict delamination initiation from transverse cracks. For a given crack length and laminate configuration, the fracture load at cryogenic temperature was significantly lower. The results indicate that fracture toughness does not change significantly at cryogenic temperatures, but the thermal stresses play a major role in fracture and initiation of delaminations from transverse cracks.     

Investigation of fatigue crack growth rate in CARALL,ARALL and GLARE

Fibre metal laminates (FMLs) are being used to manufacture many structural components in aerospace industry because of their very high strength to weight ratios, yet the exact model for estimating fatigue crack propagation in FMLs cannot be developed because of many variable parameters affecting it. In this research, tensile strength, fatigue life and fracture toughness values of 2/1 configuration carbon reinforced aluminium laminate (CARALL), aramid reinforced aluminium laminate and glass laminate aluminium reinforced epoxy specimens have been investigated. Mechanical, chemical and electrochemical surface treatments were applied to AA 1050 face sheets to improve the adhesive properties of the laminates. The specimens were prepared using vacuum assisted resin transfer moulding technique and were cut to desired shapes. Fatigue tests were conducted on centre notched specimens according to ASTM Standard E399. Real time material data and properties of adhesive were used in definition of numerical simulation model to obtain the values of stress intensity factor at different crack lengths. It was observed that CARALL shows very superior tensile and fatigue strength because of stress distribution during failure. Numerical simulation model developed in this research accurately predicts fracture toughness of aramid reinforced aluminium laminate, CARALL and glass laminate aluminium reinforced epoxy with less than 2% error. An empirical analytical model using experimental data obtained during research was developed which accurately predicts the trend of FMLs fatigue life.     

Effect of mixed mode I/II on fracture behaviour of laminated metal matrix composites

Abstract

The effects of mixed mode loading (I/II) on the fracture toughness and fracture behaviour of both 6090/SiC/20_p-6013 diffusion bonded laminates and 2080/SiC/20_p-2080 adhesive bonded laminates tested in the crack arrester orientation were investigated. The effects of layer thickness and volume fraction ratio on the fracture behaviour under the mixed mode were also studied. The fracture behaviour under mode I/II of available similar discontinuously reinforced aluminium (DRA) materials was additionally compared to that of the laminates. The fracture behaviour of laminates under mode I/II was dependent on the volume fraction ratio and generally different from that of the monolithic and DRA. The increase in the fracture toughness of DRA by lamination with ductile layers under mode I changes somewhat under increasing load mixity, for 75/25 and 50/50 diffusion bonded laminate and 60/40 adhesive bonded laminate ABL. This results from extensive interfacial separation and delamination between the layers.     

Z-pin增强复合材料Ⅰ型断裂韧性数值分析

采用细观力学方法以及虚拟裂纹闭合法(VCCT)对含有Z-pin增强复合材料双悬臂梁(DCB)结构Ⅰ型断裂韧性进行了研究。利用有限元法建立了结构模型,采用实体单元模拟复合材料层压板结构和非线性弹簧元模拟Z-pin。通过计算应变能释放率对含有不同体积分数Z-pin的复合材料层压板Ⅰ型断裂韧性与不含Z-pin的复合材料层压板Ⅰ型断裂韧性进行了对比分析。研究表明,含有Z-pin增强复合材料双悬臂梁(DCB)结构Ⅰ型断裂韧性在裂纹扩展过程中受到Z-pin桥联作用的影响而显著增强,且其增强效果与Z-pin的体积分数、处在桥联区的Z-pin数目均相关,这表明Z-pin增强方法能够有效提高复合材料层压板的分层扩展阻力。     

Fracture mechanisms of aluminium alloy AA7075-T651 under various loading conditions

The fracture behaviour of the aluminium alloy AA7075-T651 is investigated for quasi-static and dynamic loading conditions and different stress states. The fracture surfaces obtained in tensile tests on smooth and notched axisymmetric specimens and compression tests on cylindrical specimens are compared to the fracture surfaces that occur when a projectile, having either a blunt or an ogival nose shape, strikes a 20 mm thick plate of the aluminium alloy. The stress state in the impact tests is much more complex and the strain rate significantly higher than in the tensile and compression tests. Optical and scanning electron microscopes are used in the investigation. The fracture surface obtained in tests with smooth axisymmetric specimens indicates that the crack growth is partly intergranular along the grain boundaries or precipitation free zones and partly transgranular by void formation around fine and coarse intermetallic particles. When the stress triaxiality is increased through the introduction of a notch in the tensile specimen, delamination along the grain boundaries in the rolling plane is observed perpendicular to the primary crack. In through-thickness compression tests, the crack propagates within an intense shear band that has orientation about 45° with respect to the load axis. The primary failure modes of the target plate during impact were adiabatic shear banding when struck by a blunt projectile and ductile hole-enlargement when struck by an ogival projectile. Delamination and fragmentation of the plates occurred for both loading cases, but was stronger for the ogival projectile. The delamination in the rolling plane was attributed to intergranular fracture caused by tensile stresses occurring during the penetration event.     

Improvement of the mode II interface fracture toughness of glass fiber reinforced plastics/aluminum laminates through vapor grown carbon fiber interleaves

The effects of acid treatment, vapor grown carbon fiber (VGCF) interlayer and the angle, i.e., 0° and 90°, between the rolling stripes of an aluminum (Al) plate and the fiber direction of glass fiber reinforced plastics (GFRP) on the mode II interlaminar mechanical properties of GFRP/Al laminates were investigated. The experimental results of an end notched flexure test demonstrate that the acid treatment and the proper addition of VGCF can effectively improve the critical load and mode II fracture toughness of GFRP/Al laminates. The specimens with acid treatment and 10 g m⁻² VGCF addition possess the highest mode II fracture toughness, i.e., 269% and 385% increases in the 0° and 90° specimens, respectively compared to those corresponding pristine ones. Due to the induced anisotropy by the rolling stripes on the aluminum plate, the 90° specimens possess 15.3%–73.6% higher mode II fracture toughness compared to the 0° specimens. The improvement mechanisms were explored by the observation of crack propagation path and fracture surface with optical, laser scanning and scanning electron microscopies. Moreover, finite element analyses were carried out based on the cohesive zone model to verify the experimental fracture toughness and to predict the interface shear strength between the aluminum plates and GFRP laminates.     

Interaction between matrix cracking and edge delamination in composite laminates

Matrix cracking and edge delamination are two main damage modes in continuous-fibre composite laminates. They are often investigated separately, and so the interaction between two damage modes has not yet been revealed. In this paper, a simple parallel-spring model is introduced to model the longitudinal stiffness reduction due to matrix cracking and edge delamination together. The energy release rate of edge delamination eliminating the matrix crack effect and the energy release rate of matrix cracking in the presence of edge delamination are then obtained. Experimental materials include carbon- and glass-fibre-reinforced bismaleimide composite laminates under static tension. The growth of matrix cracks and edge delaminations was recorded by means of NDT techniques. Results show that matrix cracks may initiate before or after edge lamination. This depends on the laminate layup, and especially on the thickness of the 90° plies. Edge delamination may also induce matrix cracking. Matrix cracking has a significant effect on the stiffness reduction in GRP laminates. The present model can predict the stiffness reduction in a laminate containing both matrix cracks and edge delaminations. The mixed-mode delamination fracture toughness obtained from the present model shows up to 50% differences compared with O'Brien's model for GRP laminates. However, matrix cracking has a small effect on the mixed-mode interlaminar fracture toughness of the CFRP laminates.     

各向异性复合材料开孔板拉伸强度预测及模型验证

基于有限断裂力学方法建立了一种预测多向复合材料开孔板拉伸强度的通用和半经验模型。该模型同时采用基于应力形式的失效准则和基于能量形式的失效准则预测失效。模型仅需铺层弹性常数、无缺口层合板的强度以及0°铺层的断裂韧性等参数。基于线弹性断裂力学建立了多向复合材料层合板的断裂韧性与0°铺层断裂韧性之间的关系, 进而预测了任意铺层复合材料开孔板发生纤维主导拉伸失效时的强度。将模型预测结果与开孔板拉伸强度的试验数据进行了对比验证, 预测误差最大为9.7%, 与点应力和平均应力等方法的对比表明, 该模型的预测精度高于传统的特征长度方法。      

On the notch effect in load bearing capacity,apparent fracture toughness and fracture mechanisms of polymer PMMA,aluminium alloy Al7075-T651 and structural steels S275JR and S355J2

This paper presents an analysis of the notch effect in the load bearing capacity, the apparent fracture toughness and the fracture mechanisms of four different materials: polymer PMMA, aluminium alloy Al7075-T651, and structural steels S275JR and S355J2 within their corresponding ductile-to-brittle transition zone.Concerning the load bearing capacity and the apparent fracture toughness, a clear notch effect has been observed. In the case of the apparent fracture toughness, this has been adequately predicted here through the Theory of Critical Distances.As for fracture mechanisms, it is shown how these progressively change with the notch radius, from basically brittle ones in cracked conditions, to non-linear mechanisms observed for higher notch radii. This evolution has been observed in the four analysed materials and, in all cases, has justified the corresponding consequences of the notch effect on both the load bearing capacity and the apparent fracture toughness.     

Effect of mendable polymer stitch density on the toughening and healing of delamination cracks in carbon–epoxy laminates

This paper presents an investigation into the effect of stitch density on the delamination toughening and self-healing properties of carbon–epoxy laminates. The stitches provide the laminate with the synergistic combination of high mode I interlaminar fracture toughness to resist delamination cracking and healing properties to repair delamination damage. The results show that the fracture toughness of the laminate increased with stitch density, due to higher traction (crack closure) loads exerted by the stitches bridging the delamination. During the healing process these bridging stitches first melt and then flow into the delamination, leading to self-healing with full restoration of the mode I fracture toughness. Furthermore, the stitches were capable of repairing delamination cracks many times larger than the original size of the stitches. The effect of stitch density on the healing process of delamination cracks and restoration of fracture toughness was found to remain approximately the same under multiple repair operations.     

Flight simulation fatigue crack propagation in 7010 and 7075 aluminium plate

The fatigue crack propagation resistances of 7010-T7651, 7010-T73651 and 7075-T7351 thick plate were compared for flight simulation (gust spectrum) loading conditions. The alloy 7075-T7351 was found to be slightly superior, and this superiority was not essentially due to its higher fracture toughness. The influence of specimen thickness on the crack propagation resistance was significant. Thinner specimens gave longer crack propagation lives and, generally, lower crack propagation rates and longer delays in crack growth following severe flights.     

Interfacial fracture toughness measurement using indentation

Recent models have been developed for relating fracture toughness to indentation strengths for brittle monolithic materials. Thus, indentation may provide a simple and non-destructive means to measure fracture toughness. The indentation technique is further explored to evaluate the interfacial toughness in this work. When microindentations at loads ranging from 50 g to 4 kg were placed close to the interface of an aluminium/aluminum composite laminate, the interface stayed intact. In contrast, the interface of a niobium silicide/niobium laminate indented under similar conditions was found to debond, indicating a weaker interface. However, a Rockwell indenter at loads ranging from 60 to 150 kg were sufficient to debond the interfaces of two of the aluminum composite/aluminum laminates. Finally, the interfacial toughness is correlated to the indenter load and the delamination length along the interface. A power-law relationship was found between the load and the delamination length.     

R-curve modeling for Ni/Al2O3 laminates

A metal/ceramic laminate has increased fracture toughness as compared to the ceramic monoliths. The toughness enhancement is controlled by the closure (‘bridging-stresses’) exerted by the metallic bridging layers (‘ligaments’) astride the crack in the ceramic layers. The crack-opening-displacement (COD) carries information on the level and location of these stresses. If the COD profile is known, the bridging-stresses and consequently, the R-curve behavior of the composite can be modeled. In this study, a weight-function-based approach is used to generate the R-curve and is compared with experimental results for Al₂O₃/Ni multilayer laminates.     

Interlaminar properties of polymer laminates containing internal sensor cavities

This research paper presents an experimental investigation into the sensitivity of the interlaminar properties of polymer laminates to long, narrow interlaminar galleries used in comparative vacuum monitoring (CVM). CVM is a structural health monitoring technique for the non-destructive detection of cracks in engineering materials. The paper examines the effect of CVM galleries on the mode I delamination toughness, interlaminar shear strength, and impact damage resistance of a carbon/epoxy laminate. It was found that the galleries improve the mode I delamination toughness by blunting and/or deflecting the crack tip; with the maximum improvement being double the toughness of the laminate free of galleries. The toughness increased with the diameter of the gallery up to a critical size, above which no further improvement was achieved. However, the composite is more prone to unstable delamination cracking in the presence of the galleries. The apparent interlaminar shear strength (ILSS) decreased at a linear rate with an increase in the diameter and volume fraction of galleries. The loss in ILSS is due to the reduction in the effective interlaminar load-bearing area caused by the galleries. Low-energy impact testing revealed that the galleries do not affect the impact damage resistance when below a critical diameter; however, above a threshold gallery size the impact resistance is degraded. This study shows that the incorporation of CVM galleries into laminates can have the added benefit of increased mode I delamination toughness, although the ILSS is degraded and the impact resistance is reduced by large galleries.     

冲击载荷下CFRP及GFRP层板断裂韧性的研究

利用Hopkinson杆加载装置, 对带有单边切口的炭纤维增强复合材料(CFRP)及玻璃纤维增强复合材料(GFRP)层板试件进行冲击拉伸加载实验。根据一维应力波理论求得作用于试件上的载荷P(t)和试件加载点的位移δ(t)。 根据试样中应力随时间的变化历史σ(t), 并基于断裂韧性测试原理, 建立了动态应力强度因子K_Ⅰ (t)响应曲线。利用柔度变化率方法确定起裂时间, 分别得到在两种加载速率下CFRP、 GFRP层板的动态断裂韧性。结果表明, 随着加载速率的提高, 这两种复合材料的断裂韧性降低。      

Interlayer toughened unidirectional carbon prepreg systems: effect of preformed particle morphology

A new production process was used to change the surface morphology and reduce the water sensitivity of a commercial preformed rubber particle used for interlayer composite toughening. These particles were incorporated in a model epoxy resin and impregnated into unidirectional carbon fibers. The mode II fracture toughness of a laminate made with experimental particles was 250% higher than the control system and 100% higher than a laminate made with the commercial preformed rubber particles. The new particles were also found to reduce the damage area resulting from impact; however, the ultimate laminate compression strength after impact was lower for the experimental particle modified composite than the commercial particle modified laminate. The composites were also subjected to hot–wet conditions and the initial water absorption rate was less for the experimental particle modified laminates than the laminate containing the commercial material. Yet, after 6400 h, the laminates made with experimental particles were found to absorb more water than the other materials.