Influence of shear properties and fibre imperfections on the compressive behaviour of GFRP laminates

The influence of shear strength properties and fibre misalignment on the compressive behaviour of unidirectional glass fibre-polypropylene laminates has been examined. Tests were conducted between 20°C and 120°C to provide variation in the constitutive behaviour of the polymer matrix and consequently variation in the support provided to the glass fibres. It was found that the laminate loses strength as the operating temperature increases and failure occurs due to fibre microbuckling. At temperatures higher than 50°C the failure mode switches from in-plane to out-of-plane microbuckling. As the test temperature increases the shear strength and stiffness of the resin are considerably reduced; this decreases the amount of side support for the fibres and reduces the strain level at which fibre buckling initiates. Growth of this damage requires little additional load, suggesting that compression strength is controlled by initiation, rather than propagation of microbuckling. Fracture characteristics have been identified using optical and scanning electron microscopy. Recent theoretical models have been employed to predict the compressive stress-strain response and strength.     

Fracture mechanisms and failure analysis of carbon fibre/toughened epoxy composites subjected to compressive loading

This study investigates the failure mechanisms of unidirectional (UD) HTS40/977-2 toughened resin composites subjected to longitudinal compressive loading. A possible sequence of failure initiation and propagation was proposed based on SEM and optical microscopy observations of failed specimens. The micrographs revealed that the misaligned fibres failed in two points upon reaching maximum micro-bending deformation and two planes of fracture were created to form a kink band. Therefore, fibre microbuckling and fibre kinking models were implemented to predict the compressive strength of UD HTS40/977-2 composite laminate. The analysis identified several parameters that were responsible for the microbuckling and kinking failure mechanisms. The effects of these parameters on the compressive strength of the UD HTS40/977-2 composite systems were discussed. The predicted compressive strength using a newly developed combined modes model showed a very good agreement to the measured value.     

Transition in flexural microbuckling mechanisms in unidirectional glass fibre-reinforced thermoplastics

A transition in the mechanism of flexural failure previously observed in low matrix modulus unidirectional glass fibre composites is semi-quantitatively explained by considering the criterion for each of the failure modes. The failure strength for cooperative fibre microbuckling is controlled by the shear modulus of the composite which is linearly related to the Young's modulus of the matrix, while the failure strength for delamination splitting microbuckling is controlled by the composite shear strength which is not as strongly dependent on the Young's modulus of the matrix. Because the critical failure stresses have different dependencies on the matrix modulus, a transition from cooperative fibre microbuckling to delamination splitting microbuckling occurs as the matrix modulus increases. Due to the stress gradient in the beam, the compressive failure behaviour in bending is not the same as in uniform compression. When the failure mode is cooperative fibre microbuckling, the bending strength is higher than expected, especially in the thin beams. In bending, the delamination splitting microbuckling mode does not lead to abrupt splitting of the entire beam, but rather occurs by gradual accumulation of surface damage.     

Co-operative microbuckling of two fibres in a model composite

Cooperative fibre microbuckling, a compressive failure mechanism in unidirectional fibre-reinforced composites, was studied in a model system composed of two polyamide fibres in a transparent silicone matrix. The transparent matrix permitted direct observation of fibre microbuckling during compression. In all cases fibres buckled in a sinusoidal pattern with a critical wavelength characteristic of the fibre diameter and the modulus ratio of the fibre and matrix as observed previously with single fibre composites. At smaller separation distances, the two fibres microbuckled co-operatively in the common plane. At larger separation distances, the fibres microbuckled non-co-operatively in different planes. A stress overlap criterion based on the in-plane shear stress is proposed for co-operative fibre microbuckling.     

Measurement of the static compressive strength of carbon-fibre/epoxy laminates

This paper describes an experimental study of the compressive failure of T800/924C carbon-fibre/efoxy composite laminates. Undirectional laminates loaded parallel to the fibres have compressive strengths that are 70% of the tensile strength and fail by fibre-microbuckling. During microbuckling the fibre debonds from the matrix, and the fibres break in bending. Multidirectional [(±45/0₂)₃]_sm laminates were also tested in compression, and the critical failure mechanism observed was microbuckling of the 0° plies. The failure strain was almost the same as for the undirectional laminate, The failure strain was almost the same as for the unidirectional laminate, which indicated that the ±45° plies have no significant influence on the failure strength of the 0° plies.     

Effect of off-axis ply orientation on 0°-fibre microbuckling

The aim of the present work is to study both experimentally and theoretically the compression failure mechanisms in multi-directional composite laminates, and especially the effect of the off-axis ply orientation on fibre microbuckling in the 0°-plies. The critical mechanism in the compressive fracture of unidirectional polymer matrix composites is plastic microbuckling/kinking. In multi-directional composites with internal 0°-plies, catastrophic failure also initiates by kinking of 0°-plies at the free-edges or manufacturing defects, followed by delamination. When 0°-plies are located at the outside, or in the case of cross-ply laminates, failure rather tends to occur by out-of-plane buckling of the 0°-plies. T800/924C carbon-fibre–epoxy laminates with a [(±θ/0₂)₂]_s lay-up are used here to study the effect of the supporting ply angle θ on the stress initiation of 0°-fibre microbuckling. Experimental data on the compressive strength of laminates with θ equal to 30, 45, 60 or 75° are compared to theoretical predictions obtained from a fibre kinking model that incorporates interlaminar shear stresses developed at the free edges at (0/θ) interfaces. Initial misalignment of the fibres and non-linear shear behaviour of the matrix are also included in the analysis.     

The effect of fibre misalignment on the compressive strength of unidirectional carbon fibre/epoxy

The effect of a misalignment angle between the fibres and loading axis of a unidirectional composite is analysed by considering the shear strains induced by the misalignment. It is shown that shear instability in the matrix drastically reduces the predicted compressive strength even for very small misalignments. The same trend is predicted for composites with initial fibre curvatures due to the misalignment angle associated with the curvature. The reduction in compressive strength often attributed to initial fibre curvature may therefore actually be due to fibre misalignment angles. Small misalignments are hard to avoid during the manufacture and testing of unidirectional composites and so these results cast serious doubts on the possibility of measuring a true ultimate compressive strength for this kind of material.     

The failure of composite tubes due to combined compression and torsion

The strength of unidirectional carbon-fibre epoxy laminates has been measured for combined compression and shear loading. Failure was by plastic microbuckling. The axial compressive strength decreased linearly to zero as the shear stress parallel to the fibres was increased from zero to the shear strength. These experimental results support the predictions of Budiansky and Fleck and suggest an average fibre misalignment angle of 2°–3°.     

A Graphical Method Predicting the Compressive Strength of Toughened Unidirectional Composite Laminates

The in-plane shear and compressive properties of unidirectional (UD) HTS40/977-2 carbon fibre-toughened resin (CF/TR) laminates are investigated. Scanning Electron microscopy (SEM) and optical microscopy are used to reveal the failure mechanisms developed during compression. It is found that damage initiates by fibre microbuckling (a fibre instability failure mode) which then is followed by yielding of the matrix to form a fibre kink band zone that leads to final fracture. Analytical models are briefly reviewed and a graphical method, based on the shear response of the composite system, is described in order to estimate the UD compressive strength. Predictions for the HTS40/977-2 system are compared to experimental measurements and to data of five other unidirectional carbon fibre reinforced polymer (CFRP) composites that are currently used in aerospace and other structural applications. It is shown that the estimated values are in a good agreement with the measured results.     

The effect of fibre dispersion on initial failure strain and cluster development in unidirectional carbon/glass hybrid composites

By adding glass fibres to carbon fibre composites, the apparent failure strain of the carbon fibres can be increased. A strength model for unidirectional hybrid composites was developed under very local load sharing assumptions to study this hybrid effect. Firstly, it was shown that adding more glass fibres leads to higher hybrid effects. The hybrid effect was up to 32% for a hybrid composite with a 10/90 ratio of carbon/glass fibres. The development of clusters of broken fibres helped to explain differences in the performance of these hybrid composites. For 50/50 carbon/glass hybrids, a fine bundle-by-bundle dispersion led to a slightly smaller hybrid effect than for randomly dispersed hybrids. The highest hybrid effect for a 50/50 ratio, however, was 16% and was achieved in a composite with alternating single fibre layers. The results demonstrate that thin ply hybrids may have more potential for improved mechanical properties than comingled hybrids.     

Compressive behaviour of unidirectional flax fibre reinforced composites

The compressive strength of unidirectional flax fibre epoxy composites was studied. The compressive strength is influenced negatively by the presence of kink bands in the flax fibres. Improvement of the adhesion between the fibres and the epoxy resin can be achieved easily by removing the thin wax layer which covers the surface of the flax fibres. However, improving the adhesion between fibres and matrix only improves the compressive strength to a very limited extent. Stabilisation of the kink bands present in the fibres and improvement of the compressive properties of the fibres can be achieved by impregnating the fibres with melamine formaldehyde (MF) resin. This results in a large increase in the compressive strength of the resulting composite. The increase in compressive strength is proportional to the amount of MF resin present in the composite. However, the presence of the resin in the fibres lowers their tensile strength, and subsequently the tensile strength of the resulting composite.     

Effect of Moisture and Temperature on the Compressive Failure of CCF300/QY8911 Unidirectional Laminates

CCF300/BMI composites are relevant materials for supersonic aircraft due to their high specific properties. However in aeronautical applications, the composites are exposed to severe environmental conditions, and it is known that hot and humid environments can degrade some aspects of the material performance especially the compressive strength. In this paper, the effect of moisture and temperature on the compressive failure of unidirectional CCF300 carbon fiber reinforced bismaleimide(BMI) matrix composites were studied. Also scanning electron microscope (SEM) was employed for fractographic investigations. It is observed that the plastic deformations at the fiber/matrix and interlaminar interface as well as residual stresses lower the compressive strength of the material. The failure of specimens tested in hot and wet conditions always occurs as a result of out-of-plane microbuckling that is attributed to the reduction of matrix strength. In addition, the fiber microbuckling model, fiber kinking model and combined model were employed for the compressive strength prediction of the UD CCF300/QY8911 composites subjected to different environment conditions. The comparison was done between these models. Results show that the combined model is more suitable for the compressive strength prediction of CCF300/QY8911 composite systems when suffering severe environment conditions.     

Flexural failure mechanisms and global stress plane for unidirectional composites subjected to four-point bending tests

Glass fibre-reinforced epoxy and polyester composites of different fibre/matrix interface strengths exhibited tensile, compressive and shear failure modes in four-point bending tests. The flexural tensile mechanism comprised fibre ridging, transverse matrix cracking and longitudinal matrix cracking; the flexural compressive mode was caused by microbuckling of fibres. The interface strength appeared to affect each of these failure mechanisms, with the flexural tensile mode associated with the strongest and the shear failure mode corresponding to the poorest interface condition. The apparent flexural strength also decreased rapidly as the interface degraded. These phenomena are rationalized by a newly developed ‘global stress plane’, the theoretical basis of which is that the dependency of the interlaminar shear strength on the interfacial shear strength is larger than that of the longitudinal compressive strength, which in turn is larger than that of the longitudinal tensile strength.     

Is there a thickness effect on compressive strength of unnotched composite laminates?

The effect of laminate thickness was investigated on the compressive behavior of unidirectional and crossply composites. A recently developed compression test method for thick composites was used to test specimens from 16 to 200-plies thick. In all cases the stress-strain behavior to failure is nonlinear and failure strength is matrix dominated. Longitudinal compressive failure is triggered by matrix failure accompanied by fiber microbuckling and the compressive strength is greatly degraded by initial fiber misalignment. The longitudinal compressive strength shows a mild trend of decreasing values with increasing thickness. It can be explained that, even if such a trend is significant, increasing size would have a diminishing effect on compressive strength for initial fiber misalignments greater than 1.5 to 2°. This revised version was published online in July 2006 with corrections to the Cover Date.     

Buckling of a fiber bundle embedded in epoxy

Buckling of a fiber bundle embedded in epoxy resin was studied to gain insight into compressive failure mechanisms in unidirectional composites. The fibers used were E-glass, T300 graphite, T700 graphite, and P75 graphite. These fibers were combined with two different resins: Epon 815/V140 and Epon 828/Z. In both resins the failure mode of the bundle was found to be microbuckling of fibers for the first three types of fibers; however, the high-modulus P75 fibers failed in shear without any sign of microbuckling. The strains at which microbuckling occurred were higher than the compressive failure strains of the corresponding unidirectional composites. In the soft resin, Epon 815/V140, fibers buckled at lower strains than in the stiff resin, Epon 828/Z. The buckling strains and the segment lengths followed the trends predicted for a single filament embedded in an infinite matrix.     

A theoretical framework for the compressive properties of aligned fibre composites

New experimental results have made necessary the reformulation of the theory for compressive strength. The new theory is based on the precept that a number of different mechanisms can cause composite failure. The active one in a particular situation is that which gives the lowest failure stress. Thus composite strength can be dominated by fibre strength when the fibres are ductile, or controlled by matrix yielding when the matrix is soft. Lack of linearity in the fibres has a very important effect also, as does the adhesion between the matrix and the fibres. Modulus is affected as well as strength. Governing equations are developed for six different mechanisms and the agreement with experiment is very good. It is concluded that to make composites with good compressive properties the fibres should be hard, as straight as possible and well bonded to the matrix. The matrix should have a high yield stress, tensile strength and compressive strength. Hybridization is useful to improve the compressive strength of Kevlar composites, but should be avoided with brittle fibre systems due to unfavourable “hybrid effects”.     

Experimental verification of a microbuckling model for the axial compressive failure of high performance polymer fibres

A previously derived theoretical compressive strength for fibres composed of uniaxially oriented and extended polymer chains was compared with the measured strengths of several high performance fibres. For failure initiated by elastic microbuckling of polymer chains or fibrils, the maximum fibre strength is predicted to be equal to the minimum longitudinal shear modulus of the fibre. An excellent linear correlation between measured strengths and torsion moduli was obtained for four liquid-crystalline polymer fibres and high modulus graphite fibres. The correlation shows that measured strengths are 30% of the corresponding torsion moduli for all these fibres. A high modulus, high strength polyethylene fibre exhibited a compressive strength-torsion modulus ratio that was lower than the value 0.3 obtained for the other fibres examined in this study.     

Hygrothermal ageing effects on the static fatigue of glass/epoxy composites

A study of the effects of water ageing on the static fatigue behaviour of unidirectional glass/epoxy composites is presented. The failure mechanisms associated with fatigue damage were investigated under three-point bending loading. Depending on the ageing temperature, two failure features were identified: either fibre microbuckling on the compressive side of the specimen, or progressive cracking on the tensile side. Microbuckling has been found to be related to the reversible plasticization of the epoxy matrix, as measured by dynamic mechanical thermal analysis. On the other hand, tensile failure was associated with an irreversible weakening of the fibres and interfaces at elevated ageing temperatures. Some similarity is identified between damage processes in static and dynamic bending fatigue.     

On longitudinal compressive failure of carbon-fibre-reinforced polymer: from unidirectional to woven, and from virgin to recycled

Modelling the longitudinal compressive failure of carbon-fibre-reinforced composites has been attempted for decades. Despite many developments, no single model has surfaced to provide simultaneously a definitive explanation for the micromechanics of failure as well as validated predictions for a generic stress state. This paper explores the reasons for this, by presenting experimental data (including scanning electron microscopic observations of loaded kink bands during propagation, and brittle shear fracture at 45° to the fibres) and reviewing previously proposed micromechanical analytical and numerical models. The paper focuses mainly on virgin unidirectional (UD) composites, but studies for woven and recycled composites are also presented, highlighting similarities and differences between these cases. It is found that, while kink-band formation (also referred to in the literature as microbuckling) is predominant in UD composites under longitudinal compression, another failure mode related to the failure of the fibres can be observed experimentally. It is also shown that the micromechanics of the failure process observed in UD composites is similar to that in other fibre architectures, hence encouraging the adaptation and application of models developed for the former to the latter.     

Compression fracture of unidirectional carbon fibre-reinforced plastics

The effect of volume fraction and tensile strength of fibres, temperature and stress concentrators on the compression strength and fracture mode of unidirectional CFRP was studied. The cause of kinking is different for composites reinforced by low-(<3 GPa) and high-strength fibres. If fibre strength is high, the kink is initiated by composite splitting followed by fibre bend fracture in the tip of the split. In the case of low-strength fibres, kinking is initiated by compressive fracture of the fibres. The effect of stress concentrators on the CFRP compressive strength is described by linear fracture mechanics. In the presence of defects, fracture is a result of the emergence of splits near a hole. As the critical stress of splitting growth initiation reduces in proportion to the square root of the defect size, the Griffith criterion describes the composite compressive fracture. At elevated temperature, failure is caused by fibre buckling. The fracture band in this case is oriented perpendicular to the fibre direction. Carbon fibre compressive strength may be measured by the loop method. Bending a strand of carbon fibres glued to the elastic beam gives a fibre-controlled upper limit of the composite compressive strength.