Effects of local fibre waviness on damage mechanisms and fatigue behaviour of biaxially loaded tube specimens

Damage development in and final failure process of glass fibre winding specimens during biaxial fatigue loading are investigated. The phenomena in nominally defect-free tubes and specimens exhibiting local fibre waviness in one layer are compared. A subset of wound tubes is analysed using non-destructive testing methods, i.e. air-coupled guided waves, thermography, optical fracture analysis by a high-speed camera, and discrete damage monitoring. Air-coupled guided waves are employed for detection of fibre waviness and for monitoring the failure progress initiated by this waviness. Stiffness degradation due to fatigue damage corresponds to a decline in guided wave velocity. Using infrared inspection, the fibre waviness can be detected in an early stage of fatigue life. Non-destructive evaluation reveals that initiation of final failure in the specimens is caused by local fibre waviness. Finally, the effect of local fibre waviness on the S–N curves of the specimens is illustrated.     

A test device for damage characterisation of composites based on in situ computed tomography

For engineering design of composites, suitable damage models are required which have to predict the onset of damage, the successive failure and the subsequent reduction of the mechanical properties. To verify existing modelling approaches, the clear experimental identification of the particular damage entities is an essential condition. However, due to the complexity of the failure mechanisms of novel materials like heterogeneous textile composites, a comprehensive damage analysis is still a challenging problem. Recent progress in the field of computed tomography enables in situ measurements to detect damage phenomena in composites under loading. The article describes such a novel test device that combines an integrated testing machine with a high precision computer tomograph. The in situ method was used to study the damage evolution in carbon fibre reinforced plastics (CFRPs) made of weft knitted and woven preforms. A special focus was set to damage processes under loading in thickness direction. For this purpose, cylindrical tensile specimens according to ASTM D 7291 were manufactured and tested. Compression specimens with different aspect ratios have been used to study the compressive failure of CFRP woven composites. The experimental results are discussed with respect to the possibilities and limitations of the in situ based test method.     

Microbuckling elastic modelling approach of a single carbon fibre embedded in an epoxy matrix

Carbon fibre alignment defect inside of an epoxy matrix is examined by the use of microscopy and video recording. The initiation and the growth of a fibre waviness defect was monitored during the cure of the matrix. The observations established that fibre defect appears during the hot stage of the epoxy matrix thermosetting reaction. The objective is to evaluate the possibility of a fibre microbuckling mechanism to explain the observations. A first elastic microbuckling model is proposed. Analytical expressions of the necessary elastic load for the appearance of a fibre buckling instability and its associated wavelength are established. The compressive load applied onto the fibre has been evaluated by using finite elements calculations based on mechanical characteristics of the materials. Comparison between the critical microbuckling load and the applied load onto the carbon fibre during the cure is in coherence with the observations. The associated wavelength is discussed.     

Air-coupled guided waves combined with thermography for monitoring fatigue in biaxially loaded composite tubes

Non-destructive methodologies for remote monitoring of fatigue induced by mechanical load in fibre reinforced plastics are presented. Hollow cylinders (glass fibre winding) were stepwise biaxially fatigued and measured in single-sided access configurations. Based on conversion of air-coupled ultrasound to guided waves, it is shown that accumulated fatigue damage is accompanied by decrease in phase velocity and increase in attenuation. The change in wave velocity caused by fatigue is shown to correlate closely with measurements of stiffness degradation of the composite. The attenuation of guided waves is affected by crack density which is visually traceable in the transparent composite. Monitoring of cyclic loading of the specimens by thermal imaging and a high-speed camera revealed that the initiation of final failure in the specimens coincides with spots of increased temperature. Air-coupled guided wave area scans allow for observing the development of these areas and other local damage in the composite.     

Effect of fabric compaction and yarn waviness on 3D woven composite compressive properties

3D-woven fabrics incorporate through-thickness reinforcement and can exhibit remarkable inter-laminar properties that aid damage suppression and delay crack propagation. However, distortions in the internal architecture such as yarn waviness can reduce in-plane properties, especially in compression. The degree of yarn waviness present in a 3D woven fabric can be affected by a range of factors including weave parameters and manufacturing-induced distortions such as fabric compaction. This paper presents a thorough analysis of the effect of fabric compaction and yarn waviness on the mechanical properties and failure mechanisms of an angel-interlock fabric in compression. Tests were conducted on coupons moulded to different volume fractions and data compared to previous measurements of local yarn angle. Major findings show the importance of yarn straightness on compressive strength and how this can be affected by optimising moulding thickness. Failure initiation was also found to be heavily influenced by weave style and yarn interlacing.     

Acoustic emission analysis for characterisation of damage mechanisms in fibre reinforced thermosetting polyurethane and epoxy

Acoustic emission analysis is used to investigate microscopic damage mechanisms and damage progress in unidirectional glass and carbon fibre reinforced composites. Under static loading the influence of fibre orientation on damage initiation and propagation is determined. A novel polyurethane matrix system significantly enhances material performance in terms of crack initiation load levels, crack growth, damage tolerance and off-axis tensile strength. Hysteresis measurements during stepwise increasing dynamic load tests highlight the effect of fibre–matrix-adhesion and resin fracture toughness in unidirectional 0° fibre reinforced composites. Acoustic detection of beginning fibre breakage correlates with a significant increase of loss work per cycle.     

Determining the effect of voids in GFRP on the damage behaviour under compression loading using acoustic emission

Defects in composite structures, such as voids, have a major influence on the damage behaviour and mechanical properties. Based on the conducted experiments the influence of voids on the mechanical properties of multi-axial glass fibre non crimp fabric composites under quasi-static compression load was examined. Optical in-situ inspection and acoustic emission measurement were applied to detect the failure behaviour during compression tests, while paying special attention to the early stages of damage appearance where the Young’s modulus is determined. The specimens were produced by resin transfer moulding with different processing parameters to obtain various void contents and morphologies.     

Influence of load ratio on the biaxial fatigue behaviour and damage evolution in glass/epoxy tubes under tension–torsion loading

An extensive experimental campaign was carried out to understand the influence of the multiaxial stress state and load ratio on the matrix-dominated damage initiation and evolution in composite laminates under fatigue. Tubular glass/epoxy specimens were tested under combined tension–torsion loadings with different values of the load ratio and biaxiality ratio (shear to transverse stress ratio). Results are reported in terms of S–N curves for the first crack initiation and Paris-like diagrams for crack propagation, showing a strong influence of both parameters. Fracture surfaces were also analysed to identify the damage mechanisms at the microscopic scale responsible for the initiation and propagation of transverse cracks. Eventually, a crack initiation criterion presented by the authors in a previous work is applied to the experimental data showing a good agreement.     

ESEM investigations for assessment of damage kinetics of short glass fibre reinforced thermoplastics - Results of in situ tensile tests coupled with acoustic emission analysis

The damage mechanisms of short glass fibre reinforced polypropylene (PP) and polybutene-1 (PB-1) materials were investigated. For this purpose, in situ tensile tests were conducted in the environmental scanning electron microscope (ESEM) while simultaneously recording the acoustic emission (AE). To be able to observe damage mechanisms directly during loading, notched specimens were used. This method allows the direct correlation of the recorded load - elongation data with observed damage mechanisms, as well as correlations with acoustic emission data. Hence, it is possible to describe the damage kinetics of short glass fibre composite.It was found that different bonding conditions of the two investigated materials result in different damage mechanisms as well as in different AE behaviour. For fibre reinforced PP with excellent bonding conditions of the fibres in the polymeric matrix, fibre fracture, slipping of fibres in the delamination area, debonding and pull-out with matrix yielding was observed. The determined AE parameter amplitude A_p and energy E_AE for the PB-1 material are lower because of the weak bonding of the fibres to the PB-1-matrix. Hence, energy dissipative damage mechanisms like pull-out with matrix yielding can occur only in a limited part of such materials.     

Compressive failure of finite size unidirectional composite laminates with a region of fibre waviness

The compressive behaviour of finite unidirectional composites with a region of misaligned reinforcement is investigated via finite element analyses. Models with and without fibre bending stiffness are compared, confirming that compressive strength is accurately predicted without modelling fibre bending stiffness for real composite components which typically have waviness defects of several millimetres wavelength. Various defect parameters are investigated. Results confirm the well-known sensitivity of compressive strength to misalignment angle, and also show that compressive strength falls rapidly with the proportion of laminate width covered by the wavy region. A simple empirical equation is proposed to model the effect of a single patch of waviness in finite specimens. Other parameters such as length and position of the wavy region are found to have a smaller effect on compressive strength. The modelling approach is finally adapted to model distributed waviness and thus determine the compressive strength of composites with realistic waviness defects.     

Investigation of damage mechanism of flax fibre LPET commingled composites by acoustic emission

Tensile failure and fracture behaviour of parallel laid twisted flax fibre reinforced low melting polyethylene terephthalate (LPET) composites were investigated. The tensile failure results of the model specimens were compared with AE results in terms of amplitude, energy and counts. The failure results of the flax fibre LPET composites exhibited mainly matrix crack initiation as a brittle failure for low, medium and high fibre contents. Since the composites at high fibre contents have higher porosity content, they show higher strain to failure, higher variation in the tensile results and have different appearances on their fracture surfaces than those of the composites at low and medium fibre contents.     

Single-fibre Broutman test: fibre–matrix interface transverse debonding

The single-fibre Broutman test was used to study the fibre–matrix interface debonding behaviour when subjected to a transverse tensile stress. During testing, damage was detected using both visual observation under polarized light and acoustic emission (AE) monitoring. Separation of failure mechanisms, based on AE events, was performed using time domain parameters (amplitude and event width) and fast Fourier transform (FFT) frequency spectra of the AE waveforms. The latter can be considered as a fingerprint allowing to discriminate fibre failure, matrix cracking, fibre–matrix interface debonding, friction and ‘parasite noise’. Stresses in the specimens were evaluated using a two-dimensional finite element model (FEM) and monochromatic photoelasticity was used to verify the simulated stress distribution.Two failure mechanisms appeared to be in competition in the Broutman test: fibre failure under compressive stresses and fibre–matrix interface debonding under transverse tensile stresses. For systems in which the interfacial adhesion is not so ‘good’, like glass fibre–polyester systems for instance, fibre–matrix debonding was observed, and the progression of the debonding front with the interfacial transverse stress was recorded. Thermal stresses are also discussed, and a FEM simulation shows that they encourage fibre failure under compressive stresses.     

Numerical investigation of progressive damage and the effect of layup in overheight compact tension tests

This work describes a numerical investigation into progressive damage development in notched fibre-reinforced composite laminates. A finite element approach is used which explicitly models the sub-critical damage in the form of delamination and splits using interface elements, and fibre failure using a progressive statistical failure theory. Failure predictions were made for Overheight Compact Tension (OCT) test specimens using five different layups made up from IM7/8552 carbon/epoxy pre-preg. Owing to the detailed modelling of the individual damage modes, their interaction is well characterised. The numerical results obtained compare well with detailed test observations, capturing delamination, intraply splitting and fibre breakage. By including the subcritical damage that occurs at the notch tip in the model, it is able to represent the effect on the stress concentration and hence to predict ultimate specimen failure.     

Fatigue performance characterisation of resistance-welded thermoplastic composites

This study investigates the fatigue performance of resistance-welded thermoplastic composites. Lap shear specimens consisting of unidirectional carbon fibre/poly-ether-imide (CF/PEI), unidirectional carbon fibre/poly-ether-ketone-ketone (CF/PEKK) and 8-harness satin weave fabric glass fibre/poly-ether-imide (GF/PEI) composites were resistance-welded using a metal mesh heating element. The specimens were fatigue-tested at various percentages of their static lap shear strengths at a load ratio R = 0.1 and frequency f = 5 Hz. The fatigue performances of resistance-welded semi-crystalline (PEKK) and amorphous (PEI) composites were compared and the failure modes of the specimens were described. The stiffness degradation was monitored during the tests in order to evaluate the damage accumulation in the specimens. Linear stress-life (S–N) curves were obtained for all three materials when plotted on a semi-log scale. Interlaminar failure modes, involving tearing of the heating element and damage to the adherends were observed. The indefinite fatigue lives of CF/PEKK and CF/PEI welded specimens were obtained at 25% of their static lap shear strengths. The indefinite fatigue life of the GF/PEI welded specimens was obtained at 20% of the static lap shear strength.     

Hybrid effects in thin ply carbon/glass unidirectional laminates: Accurate experimental determination and prediction

Experimental results are presented which allow the hybrid effect to be evaluated accurately for thin ply carbon/epoxy–glass/epoxy interlayer hybrid composites. It is shown that there is an enhancement in strain at failure of up to 20% for very thin plies, but no significant effect for thicker plies. Hybrid specimens with thick carbon plies can therefore be used to measure the reference carbon/epoxy failure strain. The latter is significantly higher than the strain from all-carbon specimens in which there is an effect due to stress concentrations at the load introduction. Models are presented which illustrate the mechanisms responsible for the hybrid effect due to the constraint on failure at both the fibre and ply level. These results give a good understanding of how variability in the carbon fibre strengths can translate into hybrid effects in composite laminates.     

Fatigue residual strength of circular laminate graphite–epoxy composite plates damaged by transverse load

The research dealt with the relation between damage and tension–tension fatigue residual strength (FRS) in a quasi-isotropic carbon fibre reinforced epoxy resin laminate. The work was organized in two phases: during the first one, composite laminates were damaged by means of an out-of-plane quasi-static load that was supposed to simulate a low velocity impact; in the second phase, fatigue tests were performed on damaged and undamaged specimens obtained from the original composite laminates. During the quasi-static transverse loading phase, damage progression was monitored by means of acoustic emission (AE) technique. The measurement of the strain energy accumulated in the specimens and of the acoustic energy released by fracture events made it possible to estimate the amount of induced damage and evaluate the quasi-static residual tensile strength of the specimens. A probabilistic failure analysis of the fatigue data, reduced by the relative residual strength values, made it possible to relate the FRS of damaged specimens with the fatigue strength of undamaged ones.     

Fatigue life evaluation for carbon/epoxy laminate composites under constant and variable block loading

This paper presents the results of current research on the fatigue life prediction of carbon/epoxy laminate composites involving twelve balanced woven bidirectional layers of carbon fibres and epoxy resin manufactured by a vacuum moulding method. The plates were produced with 3 mm thickness and 0.66 fibre weight fraction. The dog bone shape specimens were cut from these plates with the load line aligned with one of the fibre directions. The fatigue tests were performed using load control with a frequency of 10 Hz and at room temperature. The fatigue behaviour was studied for different stress ratios and for variable amplitude block loadings. The damage process was monitored in terms of the stiffness loss. The fatigue life of specimens submitted to block loading tests was modelled using Palmgren–Miner’s law and taking in to account the stress ratio effect. The estimated and experimental fatigue lives were compared and good agreement was observed.     

Analytical prediction of damage due to large mass impact on thin ply composites

This article presents analytical models for predicting large mass impact response and damage in thin-ply composite laminates. Existing models for large mass impact (quasi-static) response are presented and extended to account for damage phenomena observed in thin-ply composites. The most important addition is a set of criteria for initiation and growth of bending induced compressive fibre failure, which has been observed to be extensive in thin ply laminates, while it is rarely observed in conventional laminates. The model predictions are compared to results from previous tests on CFRP laminates with a plain weave made from thin spread tow bands. The experiments seem to confirm the model predictions, but also highlight the need to include the effects of widespread bending induced fibre failure into the structural model.     

Compression testing of pultruded carbon fibre-epoxy cylindrical rods

The fibre waviness inherent in conventional prepreg laminatessignificantly reduces their compressive strength. This waviness canbe reduced through the use of unidirectional fibre rods. In thiswork, the development of a new test procedure and specimen design isreported that was used to determine the compressive properties ofpultruted T300/828 and IM7/828 carbon fibre-epoxy unidirectionalrods at room temperature. The IM7/828 system demonstrates a highercompressive strength than the T300/828 composite due to strongerfibres used and fewer manufacturing defects. Since the fibres as intension primarily carry the compressive load, the final fracture ofthe rods occurs when the fibres fail. Post-failure examinationreveals that failure of the fibres is microbuckling-induced. This isa bending failure as a consequence of buckling. Other events such asfibre-matrix debonding (splitting) and matrix yielding do not bythemselves cause the final failure, but they facilitate fibrebuckling by reducing the lateral support for the fibres.Microbuckling failure models are used to predict the compressivestrength of the carbon fibre rods; agreement between theory andexperiment is acceptable.     

On the transition from shear-driven fibre compressive failure to fibre kinking in notched CFRP laminates under longitudinal compression

This paper investigates longitudinal compressive failure in notched unidirectional and cross-ply carbon/epoxy specimens. Dedicated test jigs were developed to observe the failure processes at the microscale. In situ and post-mortem fractography reveals two types of failure mechanisms: (i) shear-driven fibre compressive failure and (ii) kink-band formation. The sequence of events leading to failure and the reasons for shear-driven fibre compressive failure or kink-band formation are investigated and discussed. Those findings are discussed further in a separate paper (Gutkin et al., accepted for publication) [1] where an FE micromechanical model is used to investigate numerically the failure mechanisms found in longitudinal compression.