Composite Failure Research Articles

Dynamic compressive impact behavior of CFRP composite under high strain rate loading

Carbon Fiber Reinforced Plastics (CFRP) composite exhibits significant sensitivity to strain rate. In this work, authors investigated the CFRP composite’s dynamic compressive impact behavior under a high strain rate. The vacuum bagging technique was used to fabricate the composite specimens to reduce the presence of voids. Compressive mechanical behavior was examined for the CFRP composite for strain rate ranging from 1384 to 1953 s−1 using a Split Hopkinson Pressure Bar (SHPB) test setup. The experiment aims to investigate the effect of strain rate on stresses, strains, failure strengths, fracture energies, and failure of quasi-isotropic CFRP composites. Furthermore, the specimens’ strength initially increases and achieves its maximum strength, followed by a decrease in strength value. Moreover, an optical microscopic examination reveals that damage in composite laminate grows as the strain rate increases.

Damage behavior and toughening mechanism of SiCf/SiC-Ti3SiC2 composites: A combination of digital image correlation and acoustic emission

Matrix modification is an effective method to improve the mechanical properties of ceramic matrix composites, while the elucidation of corresponding damage mechanism is essential for the design and engineering application of composites. In this work, Ti3SiC2 particles were introduced into SiC matrix to fabricate Ti3SiC2 modified SiCf/SiC (SiCf/SiC-Ti3SiC2) composites by a hybrid technique of slurry suspension impregnation combined with polymer infiltration and pyrolysis. Compared with SiCf/SiC composites, the flexural strength and modulus of SiCf/SiC-Ti3SiC2 composites were increased by 17.8 % and 61.0 %, respectively. The three-point flexural damage behavior and failure mechanism of composites were systematically investigated and compared by the combination of digital image correlation and acoustic emission techniques. Based on the collaborative analysis of in-situ damage process, matrix micro-zone toughness and fracture morphology, the modification effect and toughening mechanism of Ti3SiC2 were revealed. The improved mechanical properties of SiCf/SiC-Ti3SiC2 composite could be ascribed to the more sufficient matrix cracking before composite failure and the increased matrix fracture energy by microcrack deflection. After matrix modification, the failure mechanism was dominated by the gradual propagation and growth of microcracks until the critical crack size, instead of the fast and unstable propagation of main crack.

Performance of glass epoxy composites under combined effect of in‐plane fiber waviness with circular cutout through tensile test, and image processing technique

AbstractPresent study comprehensively explores the phenomenon of in‐plane fiber waviness in glass/epoxy fiber reinforced polymer (GFRP) composites. Utilizing a pioneering technique that employs a semi‐circular bar to induce controlled fiber waviness, coupled with image processing using OpenCV library in Python coding for precise measurement and analysis of in‐plane fiber waviness. This defect is commonly found in components fabricated with fiber‐reinforced composites. During the process of manufacturing fibers may deviate from their intended orientation due to process variables or resin flow dynamics. Understanding in‐plane fiber waviness is crucial due to its impact on mechanical properties of composites. It is essential for optimizing manufacturing processes and ensuring enhanced structural performance in diverse engineering applications through analysis of strength and failure mechanism. A novel study was conducted by introducing a circular cutout within the fiber waviness region to investigate the combined effect of multiple defects. The experimental tensile test reveals that as waviness ratio (WR) increases a significant decrease in its tensile strength and vice versa. The study incorporates scanning electron microscopy (SEM) image analysis to examine composite failure. By advancing the understanding of in‐plane fiber waviness and its implications, this research significantly contributes to ongoing efforts in composite design and optimization.Highlights Adopting a cutting‐edge method to create controlled fiber waviness that makes use of a semi‐circular bar. Image processing with Python code that makes use of the OpenCV package to precisely measure and analyze in‐plane fiber waviness. A new investigation was carried out to examine the combined effect of multiple flaws by creating a circular cutout within the fiber waviness zone.

Examining the effect of the shear coefficient on the prediction of progressive failure of fiber-reinforced composites

The ultimate damage of composites under tension usually results from fiber damage, which includes both tensile and shear contributions. In this study, the shear coefficient α of the fiber yarn is incorporated into the failure criterion to consider the shear effect of the fiber yarn. An analytical model is then proposed that combines a homogenization method and the enhanced failure criterion to facilitate quick evaluation of the progressive damage and failure of the composite. The sensitivity of α on the behaviors of progressive damage and failure are comprehensively explored for different types of fiber-reinforced composites, including a laminate, a plain weave composite, a two-dimensional triaxially braided composite, and a three-dimensional woven composite. The results indicate that damage and failure behaviors are generally sensitive to the shear coefficient, and composites with more complex textile structure demonstrates greater sensitivity to the α. An analysis of the sensitivity of α for different failure criteria was also conducted, and the results reveal that the Hashin–Hou criterion shows more sensitivity to α than the Chang–Chang criterion, the Hoffman criterion, or the Tsai–Wu criterion. Therefore, the identification of the shear coefficient is significant for exploring the damage and failure behaviors of fiber-reinforced composites.

Damage mechanism identification and failure behavior of 2D needle-punched SiCf/SiC composites based on acoustic emission and digital image correlation

In order to improve the reliability of damage analysis for SiCf/SiC composites, an identification method of damage mechanism was established by combining in-situ acoustic emission (AE) and digital image correlation (DIC). The corresponding failure behavior of 2D needle-punched SiCf/SiC composites during ambient-temperature tensile test was investigated in detail. Through a machine learning k-means algorithm, AE signals could be effectively divided into five clusters: friction and sliding, interface damage, matrix cracking, individual fiber breaks and collective fiber breaks. DIC results show that the surface strain of composites increased non-uniformly during the tensile process, and the architecture of the composites had a significant influence on the initiation and propagation of cracks. To summarize, the tensile process consisted of three stages: the elastic stage, the rapid propagation of matrix cracks, the coordinated fiber fracture within the large strain bands. The failure of composites was dominated by the limited load transferring ability of the interface.

Comparative outcomes of selective laser trabeculoplasty delivered by optometrists compared with ophthalmologists: a UK-based multicentre observational study

BackgroundSelective laser trabeculoplasty (SLT), a National Institute for Care and Health Excellence recommended first-line treatment for open-angle glaucoma and ocular hypertension, is increasingly delivered by optometrists. This retrospective multicentre observational...

Cryogenic mechanical performance and gas-barrier property of epoxy resins modified with multi-walled carbon nanotubes

Type V linerless hydrogen storage vessels made of all-composite face the challenges of cryogenic mechanical failure and hydrogen leakage of composites. The cryogenic mechanical performance and gas-barrier property of the carbon fiber reinforced polymer for Type V vessels are largely determined by the epoxy matrix. Carbon nanotubes are widely used as polymer reinforcement material to enhance the cryogenic mechanical performance and gas-barrier property of epoxy resins. In this work, multi-walled carbon nanotubes (MWCNTs) were dispersed into epoxy resins to prepare MWCNTs-modified epoxy resins. The cryogenic mechanical performance, gas-barrier and thermal properties of the modified resin were then investigated. The experimental findings revealed a 34.34% reduction in the gas permeability coefficient for the nanocomposites containing 0.9 wt% MWCNTs compared with the epoxy matrix. The tensile strength and failure strain at cryogenic temperature (77 K) experienced enhancements of 26.99% and 41.53%, respectively. In addition, the thermal stability and glass transition temperature of the modified resin were improved. As a result, the MWCNTs-modified epoxy resin exhibits improved gas-barrier property in addition to excellent cryogenic mechanical performance, making it ideal for manufacturing Type V linerless hydrogen storage vessels.

Dynamic tensile intralaminar fracture and continuum damage evolution of 2D woven composite laminates at high loading rate

The intralaminar tensile failure of 2D woven composites under dynamic tensile load was investigated in this paper. Compact tension samples were tested at high loading rate with an electromagnetic Hopkinson bar system. The strain field was obtained with high-speed imaging and digital image correlation, and the J-integral method was employed to obtain the fracture toughness and corresponding R-curve. The continuum damage evolution of intralaminar failure was then analyzed by tracking the opening near the initial crack tip. It is found that the dynamic intralaminar fracture toughness is decreased by 51% compared to the quasi-static condition, the continuum damage evolution and its dependence on loading rate have been reported as well. The failure mechanisms were studied with thermal imaging and scanned electron microscopy, shorter fibre pull-out length and thinner failure process zone may be responsible for the reduced toughness at high loading rate.

Numerical failure modelling of natural fibre composite coupons using X-ray computed tomography based modelling

Natural fibre composites offer versatile applications across industries while being superior in sustainability aspects compared to other composite types. To unlock their full potential, it is essential to understand their complex failure involving fibre failure, matrix cracking, and debonding at the fibre-matrix interface. Efforts to address these challenges focus on advanced numerical models, probing behaviour from micro to macro scales. However, these models face complexities in handling intricate failure modes given the non-uniform nature of natural fibres. To overcome these challenges, image-based modelling using X-ray computed tomography scans is proposed. This work’s novelty lies in integrating detailed microstructure information with a nonlinear calibration procedure to accurately model damage and failure in natural fiber composites. It marks a significant step toward developing a virtual testing model, paving the way for assessing composites with varying fiber content or fiber types.

Concurrent experimental testing and computational micromechanical modeling of a UD NCF GFRP composite ply

The current research work presents a detailed and thoroughly validated computational micromechanical modeling methodology to study the damage initiation and propagation in a uni-directional (UD) glass fiber-reinforced non-crimp fabric (NCF) composite ply. Under the applied transverse tension and compression loads, the effect of various microscale material and geometrical parameters on the ply level stress–strain behavior is studied. To this end, along with the distinctly modeled individual microscale constituents of the UD NCF composite ply (axial fibers, backing fibers, and matrix), the generated RVE (Representative Volume Element) model consists of manufacturing-induced defects and variabilities such as voids as well as the backing fiber’s out-of-plane waviness. The fiber/matrix interface failure behavior in the generated RVE model is simulated using cohesive zone formulations that follow bi-linear traction-separation law. Whereas the hydrostatic pressure-dependent non-linear stress–strain response followed by the fracture of the epoxy matrix is captured using the linear Drucker-Prager plasticity model coupled with the stress triaxiality-based failure criterion. The backing fibers stress–strain and failure behavior is modeled using the linear elastic and isotropic material model in conjunction with the maximum stress criterion.The proposed numerical methodology is thoroughly validated both qualitatively and quantitatively by conducting detailed experiments on a neat epoxy as well as at the composites laminate level. Upon comparing the experimental and computational results, the observed knee or slope change in the bi-linear stress–strain response of the UD NCF composite ply under transverse tension is attributed to the loss of the load-carrying ability of the axial fiber bundle due to fiber/matrix interface debonding followed by the ply splitting. Under the application of transverse compression load, the composite ply failure behavior is governed by the formation of a dominant matrix plastic shear band in the axial fiber bundles, which is in turn triggered by the fiber/matrix interface failure. Under the applied loads in the matrix-dominated direction, the presented research work provides a detailed insight into the microscale damage initiation and propagation in a UD NCF composite ply and its consequent influence on the macroscale stress–strain response.

Insights into freeze-cast hierarchical water–glass foams via in situ time-lapse phase-contrast enhanced microcomputed tomography: Correlating composition, microstructure, and compression failure

We demonstrate how continuous freeze-casting without post-treatment sintering may be successfully employed using a pure water–glass (WG) solution to fabricate hierarchically porous foams lacking a morphology gradient along the freeze direction. By adjusting the water content (dilution) and/or the alkali ratio of the solution, we achieved lamellar structures with sub-features or cellular structures, with porosities spanning ∼65% to 83%. The WG foams exhibit astounding mechanical properties; notably, foams with a relatively low density of ∼0.33 g/cm3 demonstrated the highest compressive strength (5 MPa), due to their microstructure and pore morphology. In situ uniaxial compression tests combined with phase-contrast enhanced micro-computed tomography in a synchrotron revealed bending, buckling, fracture and splitting of the lamellar structures as main failure mechanisms. Our newly developed approach of continuous freeze-casting of pure WG solutions with an improved understanding of the relationship between composition, structure, and failure mechanisms provide a basis for a customized design and manufacture of a wide range of freeze-cast WG-based materials for applications ranging from biomedicine to energy generation and storage.

Differentiating Sensor Changes in a Composite Heart Failure ICD Monitoring Index: Clinical Correlates and Implications

The HeartLogic algorithm integrates data from implantable defibrillator(ICD) sensors to predict heart failure(HF) decompensation: first(S1) and third(S3) heart sounds, intrathoracic impedance, respiration rate, ratio of respiration rate to tidal volume(RSBI), and night heart rate. This study assessed the relative changes in ICD sensors at the onset of HeartLogic alerts, their association with patient characteristics, and outcomes. The study included 568 HF patients carrying ICDs(CRT-D,n=410) across 26 centers, with a median follow-up of 26 months. HeartLogic alerts triggered patient contact and potential treatment. A total of 1200 HeartLogic alerts were recorded in 370 patients. The sensor with the highest change at the alert's onset was S3 in 27% of alerts, followed by S3/S1(25%). Patients with atrial fibrillation(AF) and chronic kidney disease(CKD) at implantation had higher alert prevalence(AF,84% vs. no-AF,58%; CKD,72% vs. no-CKD,59%; p <0.05) and rate (AF,1.51/patient-year vs. no-AF,0.88/patient-year; CKD,1.30/patient-year vs. no-CKD,0.89/patient-year; p<0.05). During follow-up, 247 patients experienced more than one alert; in 85%, the sensor with the highest change varied between successive alerts. Of the 88(7%) alerts associated with HF hospitalization or death, respiration rate or RSBI(11%, p=0.007 vs. S3/S1) and night heart rate(11%, p=0.031 vs. S3/S1) were more commonly the sensors showing the highest change. Clinical events were more common with the first alert(12.6%) than subsequent alerts(5.2%,p <0.001). HeartLogic alerts are mostly triggered by changes in heart sounds, but clinical events are more linked to respiration rate, RSBI, and night heart rate. Recurrent alerts often involve different sensors, indicating diverse mechanisms of HF progression.

A critical appraisal of the Hashin failure criterion

The Hashin criterion is one the most popular failure criteria for fibre reinforce composites. It is critically appraised in this paper. The most significant feature of the criterion is failure modes introduced and the assumption that failure is determined by the traction on the failure plane. For this assumption, there has never been any justification provided in the literature, except the available arguments in the Mohr criterion, where the concept of plane failure as opposed to point failure was first introduced based on this assumption. However, the arguments there were applicable only to isotropic materials and, even so, they are not without exceptions. As contradictions to the assumption in the context of composite failure, three relatively simple cases have been considered in this paper, supported by physical evidence. In each case, failure is observed in a plane on which traction vanishes completely, to which the failure cannot be attributed. The assumption is therefore unfounded both theoretically and physically for anisotropic materials, which dismisses the validity of the Hashin criterion in turn.

Manipulation of mechanical properties and ballistic performance by armor-grade composite processing

For the armor-grade composite, the resin bonding force cannot be too high or too low in order to achieve maximum utilization of high-performance fibers to ballistic impact. This study aims to identify the influence of the resin bonding of armor-grade composite on mechanical properties and ballistic performance. The varied resin bonding force of the panel was manipulated by the composite processing. After resin coating and curing, yarn mobility in fabric was almost fully constrained with 90% reduction, which was benefit for minimizing Backface Signature (BFS) of armor-grade composite. Tensile strength was improved 12.45% for the prepreg (FP/R 15) and 52.87% for the laminate (FL/R 15) due to better synchronous failure of filaments. However, specific energy absorption was degraded during composite processing, such as 10.74 ∼ 27.84% reduction in comparison with the neat fabric. This was because the dominant failure mode was gradually varied from tensile failure of fabric to shear failure of composite.

Study on the fracture behavior and toughening mechanisms of continuous fiber reinforced Wf/Y2O3/W composites fabricated via powder metallurgy

Tungsten (W) is a promising candidate material for the plasma facing components in fusion reactors. However, it has issues regarding the intrinsic brittleness. Tungsten fiber reinforced tungsten composites (Wf/W) have been developed based on the concept of extrinsic toughening mechanisms and they show a pseudo-ductile behavior during the fracture process. In the present work, continuous fiber reinforced Wf/Y2O3/W composites were fabricated via a powder metallurgy (PM) process, and the microstructure and mechanical properties were characterized. The fracture behavior and toughening mechanisms were analyzed in detail combining the results of experiments and numerical simulation. The Wf/Y2O3/W composites is toughened by multiple mechanisms such as fiber bridging, crack bending and deflection, interface de-bonding and plastic deformation of fiber. The energy dissipation by interface de-bonding can be neglected. However, it is a necessary factor to ensure any extrinsic toughening mechanisms. The main contribution of the energy dissipation while composite failure is the plastic deformation of fibers.

A multiscale modeling for progressive failure behavior of unidirectional fiber-reinforced composites based on phase-field method

The effective macroscopic properties of composites are determined by the intricate interactions among the individual components within their microstructure. Preserving these microscopic details during the failure simulation of macrostructures presents significant challenges. This work proposes a multiscale modeling framework to numerically predict the macroscopic fracture properties of unidirectional fiber-reinforced composites based on micromechanical analysis. In this study, 2D representative volume elements (RVEs) combined with the phase-field method are utilized to simulate fiber-reinforced composites under transverse loadings. A series of representative loading conditions are employed to investigate cracking patterns and to construct failure strength envelopes of the composites subjected to different multiaxial proportional loadings. By extracting the softening curve from the uniaxial tensile simulation of the RVE and fitting it with a tenth-order polynomial, the homogenized cohesive law, combined with the phase-field method, is applied to the damage analysis of macroscopic heterogeneous materials. The homogenized model of unidirectional fiber reinforced composites is numerically validated through simulations of a 2D flat plate. The simulation results demonstrate the excellent potential of the proposed multiscale modeling framework to accurately and efficiently predict the progressive failure and fracture behavior of fiber-reinforced composites in engineering applications.

Enhanced LaRC05 failure criteria for investigating low-velocity impact on fiber-reinforced composites: An experimental and computational study

A finite element model was developed using both continuum and discrete damage modeling techniques to provide detailed predictions for ply-by-ply damage progression in composite laminates during low-velocity impact (LVI) events. A new fiber failure model was incorporated into the LaRC05 failure criteria to predict fiber pull-out and fiber crushing during the fiber damage evolution. In addition, the selective range golden section search (SRGSS) algorithm was implemented to efficiently predict fiber breakage, pull-out, splitting, kinking and crushing, and matrix cracking. The delamination was captured by cohesive element layers embedded between every adjacent composite ply. The interactions of intralaminar matrix cracking and delamination were modeled by deploying cohesive elements within each composite ply. The prediction results were validated by 30 J and 75 J drop-weight tests with different-sized impactors, as well as X-Ray CT inspections on 254 mm by 304.8 mm [0/45/90/-45]4s IM7/977–3 laminates. The model predicted the maximum deflection and contact duration with <2 % error, and the peak load, damaged areas, and absorbed energy with <8 % error. The matrix fracture plane and the fiber kink band angle were found with 1° precision 48 % faster via the SRGSS algorithm. The detailed sequences of damage occurrence were predicted by analyzing the energy dissipation histories through various damage modes. Although this modeling methodology was developed for LVI scenarios, it has broad applications for predicting failures in composites.

Mechanical behaviour and macro-micro failure mechanisms of frozen weakly cemented sandstone under different stress paths

Significant unloading failure zones in artificial freezing shaft sinking projects in western China are primarily caused by stress release. To investigate the deformation and failure mechanisms of frozen weakly cemented sandstone (FWCS), three groups of triaxial unloading tests were conducted under different initial principal stresses (σ₃ = 3, 6, and 10 MPa) with an unloading rate of 0.05 MPa/s. Scanning electron microscopy (SEM) was employed to examine the micro-fracture characteristics of the failure surfaces. The results revealed that, compared to traditional triaxial and room-temperature triaxial compression tests, the strength and plastic deformation characteristics of FWCS are significantly weakened under unloading conditions. However, lateral deformation, particularly volumetric strain, increased markedly, exhibiting pronounced dilatancy characteristics, especially along stress path III (i.e., post-peak axial stress loading with confining pressure unloading). Unloading leads to a reduction in cohesion and an increase in the internal friction angle of FWCS, with the most significant changes observed along stress path IV (i.e., pre-peak constant axial displacement loading with confining pressure unloading). Macroscopic and microscopic analyses indicate that the failure mechanism of FWCS under complex unloading stress paths is driven by the rapid accumulation of energy caused by unloading, which results in the development and propagation of axial and circumferential cracks, widespread particle breakage, and the formation of inter-granular and trans-granular fractures, as well as shear scratches at the micro level, ultimately manifesting macroscopically as shear-tensile composite failure.

Failure analysis and structural optimization of unequal-parameter metal bellows in resistance to bending and torsional composite deformation

In practical engineering applications, metal bellows are subjected to complex environmental conditions, and they usually deform under the combined effects of tension, bending and torsion. In this paper, the bending and torsion composite deformation of unequal parameter metal bellows arranged alternately by large wave and wavelet is studied. Firstly, the finite element model of metal bellows is constructed, and the finite element simulation analysis of its mechanical properties is carried out. Taking the simulation results as samples, the multi-objective structural optimization of unequal parameter metal bellows under the condition of bending and torsion composite deformation is carried out. Combined with the bending-torsion composite deformation test and fracture microscopic characterization, the bending-torsion composite deformation characteristics and fracture failure mechanism of equal-parameter metal bellows (EPMB) and unequal-parameter metal bellows (Un-EPMB) were compared and analyzed. The results show that under the same deformation conditions, compared with the EPMB, the elastic limit bending line displacement and elastic limit torsion angle displacement of Un-EPMB are increased by 52.94 %, and the bending and torsional stiffness are greatly improved, moreover, the alternating waveform arrangement led to relatively gradual stress transfer through the Un-EPMB during the bending-torsion composite deformation process, thereby reducing stress concentration. Thus, the Un-EPMB exhibited more favorable mechanical properties. Unlike in the EPMB, which underwent fracture along the grain boundary, the cracks in the Un-EPMB appeared in the middle layer and propagated to both sides in a wavelike pattern. The dimples were distributed in the middle layer of the fracture, which indicates ductile behavior.

Development and experimental verification of an advanced 3D elastoplastic progressive damage model for composite materials

This study develops a sophisticated three-dimensional elastoplastic progressive damage finite element analysis (FEA) model for stiffened composite materials under axial compression. The model integrates the Hashin and Ye criteria to capture the inception of damage within the composite and introduces a cohesive zone model (CZM) to simulate debonding between stiffeners and panels. Furthermore, damage evolution based on energy release rate and plastic flow rules grounded in Hill’s criteria are employed to thoroughly explore the progressive failure behavior of stiffened composite materials. Implemented within Abaqus/Explicit through user-defined ‘VUMAT’ subroutines, the model ensures computational accuracy and reliability. Comparative evaluations against standard linear elastic progressive damage models demonstrate a statistically significant improvement of at least 5% in predicting ultimate load capacities. Additionally, this model accurately captures different failure modes, providing a nuanced understanding of stiffened composite material failure under compressive loads.