End-notched Flexure Research Articles

Crack growth stabilization in the eccentric three-point end-notched flexure test of solid wood using side-grooved samples

A three-point eccentric end-notched flexure (3EENF) test was conducted on Sitka spruce to characterize the Mode II resistance curve (R-curve). To extend the range for stabilized crack growth, grooves were cut along both side surfaces of the sample to reduce the region around the neutral axis. The R-curve was determined by varying the initial crack lengths, and fracture toughness values were measured at both the onset and during growth. Additionally, the effect of side grooves on stabilizing crack growth in the 3EENF test was investigated by comparing numerical simulation results with those from four-point end-notched flexure (4ENF) tests. The grooves effectively stabilized crack growth, and the stabilization range was equivalent to that of the 4ENF test when the initial crack length was appropriately determined. The grooved sample exhibited behavior indicative of a longer crack than the actual length.

Multi-layer continuum model for adhesive FM 300-2 in end-notched flexure carbon laminate

Multi-layer continuum model for adhesive FM 300-2 in end-notched flexure carbon laminate

Fracture toughness in SPCC/CFRP hybrid laminates: Mode I and mode II perspectives

Hybrid composites using adhesive joints are gaining popularity in various industries as their various material combinations can create certain advantages. This research focuses on examining the mode I and mode II fracture toughness characteristics of the combined laminate between Steel Plate Cold Rolled Commercial (SPCC) metal and Carbon Fiber Reinforced Polymer (CFRP) composite processed using adhesive bonding. SPCC/CFRP hybrid laminate composites were manufactured with a variety of manufacturing options (A, B, and C) to find the most optimal method using two types of epoxy and cyanoacrylate adhesives, with two different bonding processes: secondary bonding and co-bonding. Fracture toughness values were measured through the Double Cantilever Beam (DCB) test for mode I and the End Notched Flexure (ENF) test for mode II. The test results showed that epoxy adhesives in the SPCC/CFRP adhesive joints provided better fracture toughness performance, especially when combined with the co-bonding technique. Specimens from manufacturing option C showed the highest GIC and GIIC values of 83.05 and 254.94 J/m2, respectively. These values increased by 58.98 % and 80.48 % compared to manufacturing options A and B in Mode I. Additionally, the GIIC value for manufacturing option C increased by 78.00 % and 66.76 % compared to manufacturing options A and B. The SPCC/CFRP hybrid laminates showed adhesive failure on the SPCC surface when using epoxy adhesive, whereas adhesive failure occurred on the CFRP surface with cyanoacrylate adhesive for the different manufacturing options.

Traction-separation law for glass/epoxy composite laminates under mixed mode I/II loading condition considering the effects of fiber bridging

This study analyzed the effects of fiber bridging on fracture behavior in glass/epoxy composite laminates under mixed mode I/II loading conditions and proposed new traction-separation laws (TSLs) for this loading condition. To this end, double cantilever beam (DCB), end notch flexure (ENF), and mixed mode I/II bending (MMB) tests were performed under mode I, mode II, and mixed mode I/II loading conditions. Also, finite element analysis (FEA) was employed to simulate these tests. Under mode I loading condition, the presence of fiber bridging increased fracture toughness significantly, which was modeled using a tri-linear TSL. In contrast, under mode II loading conditions, the effect of fiber bridging was negligible, and a bi-linear TSL was sufficient. On this basis, a novel TSL was proposed for mixed modes that considers the effect of fiber bridging under mode I loading conditions and neglects it under mode II loading conditions. This TSL was defined using a tri-linear TSL for mode I and a bi-linear TSL for mode II conditions, along with the B-K fracture criterion. In the bi-linear TSL, the point τb was defined corresponding to the fiber bridging strength (σb) of the tri-linear TSL, with the assumption that τb cannot exceed σb. To analyze the variation in the FEA results with respect to τb, three cases were defined: τb = 0.0001 σb, 0.5 σb, and σb, respectively. FEA results in the first case were observed to be consistent with load–displacement curves obtained from experimental results.

Mode II fracture properties of parallel neosinocalamus affinis bamboo strand lumber

This study investigates the Mode II fracture properties in the RL and TL planes of parallel neosinocalamus affinis bamboo strand lumber. Eighty End-Notched Flexure (ENF) specimens were designed, varying pre-crack lengths and specimen widths. Digital Image Correlation (DIC) was employed to analyze strain variations during the development of the fracture process zone (FPZ) and crack propagation stages. The Compliance Based Beam Method (CBBM) and equivalent crack length calculations were used to determine the strain energy release rate (GIIC) of PNABSL. R curves and crack growth rate curves revealed that crack propagation in the RL and TL planes. The results indicated that Mode II fracture propagation in both the RL and TL planes of PNABSL predominantly exhibited self-similar cracking, though the fracture surfaces were rough and uneven, with noticeable fiber bridging. The study found that Mode II fracture propagation was less stable in the RL plane compared to the TL plane, which is attributed to the easier fracturing of thick-walled fiber cells in the RL plane. The critical strain energy release rate for PNABSL was determined, offering valuable insights into its fracture behavior.

Prediction of the Interface Behavior of a Steel/CFRP Hybrid Part Manufactured by Stamping.

Carbon fiber-reinforced plastic (CFRP) is a lightweight material. The automotive industry has focused on producing a steel/CFRP hybrid part to reduce overall weight. After manufacturing, delamination can occur at the interface between the CFRP and steel owing to the hybrid part constituting dissimilar materials. However, most studies have focused only on designing the manufacturing processes for the hybrid part or evaluating the adhesive used at the interface. Therefore, it is necessary to predict the behavior of the interface after demolding the hybrid part. This study aimed to predict the interface behavior of a steel/CFRP hybrid part by considering its forming and cohesive properties. First, double cantilever beam (DCB) and end-notched flexure (ENF) tests were performed to obtain cohesive parameters, such as energy release rate of modes I and II (GI, GII). The experimentally obtained properties were applied to the bonding area of the hybrid part. Subsequently, a forming simulation was performed to obtain the stress of the steel blank in the hybrid part. The stress distribution after forming was utilized as the initial condition for spring-back simulation. Finally, the interface behavior of the hybrid part was predicted by a spring-back simulation. The simulation was conducted using the residual stress of steel outer and the cohesive properties on the interface, without the application of any external forces. The cases of spring-back simulation were divided as delamination occurrence and attached state. The simulation results for prediction of delamination occurrence and bonding showed good agreement in both cases with experimental ones. The proposed method would contribute to expanding the manufacturing of the hybrid part by stamping and reducing the manufacturing cost by prediction of delamination occurrence.

Study of Interlaminar Fracture Toughness and Flexural Properties of Carbon Fibre Composites Reinforced with Polyethersulfone/Graphene Oxide Films

Unidirectional carbon fibre reinforced plastic (CFRP) composites were prepared by inserting polyethersulfone (PES) films or polyethersulfone/graphene oxide (GO) films into the composites and used to improve the interlaminar fracture toughness as well as the flexural properties. The effect of low-temperature cycling (35, 70, 105, and 140 cycles between −55 °C and room temperature (25 °C)) on the flexural properties of the specimens was also investigated, and the damage caused to the reinforcement layer was directly detected by comparing the interlaminar images. The results of the double cantilever beam (DCB) test and the end notched flexure (ENF) test were used to verify the optimisation of the interlaminar fracture toughness and flexural properties of the new composite film (PES/GO film). The results show that the performance of PES/GO film under both DCB test and ENF test is superior to that of PES film. Regarding the effect of low-temperature cycling on the specimens, the flexural properties of the specimens containing PES/GO films were improved. Finally, the matrix interface and failure mechanism of the interlayer reinforcement were investigated by scanning electron microscopy (SEM).

Characterization and analysis of conduction welded thermoplastic composite joints considering the influence of manufacturing

Thermoplastic composite welding is a key technology that can help to make the aviation industry more sustainable, while at the same time enable high-volume production and cost-efficient manufacturing. In this work, characterization, testing and analysis of thermoplastic composite conduction welded joints is performed while accounting for the influence of the manufacturing process. Test specimens are designed from welds of a half a meter long welding tool that is developed to weld the stiffened structures of the next-generation thermoplastic composite fuselage. In the design, special attention is paid to the weldability of the laminates, while ensuring fracture occurs only at the welded interface. Two specimen configurations are evaluated for the Double Cantilever Beam and End-Notched Flexure characterization tests. Moreover, Single Lap-Shear specimens are tested in tension and in three-point-bending. Finally, the characterized material properties are introduced in finite element analyses to demonstrate that the cohesive zone modeling approach can be used to conservatively predict the strength of these welded joints. New insights are obtained in the relation between the manufacturing process, the quality of the weld and the mechanical properties of the joints, which are significantly different compared to autoclave consolidated composites.

Assessment of Shear Fracture Energy in Hybrid Composites with Natural and Synthetic Fibers.

Composite materials made with synthetic fibers are extensively employed across a diverse array of engineering structures. However, from an environmental point of view, synthetic fibers do not represent the best choice, since they are not renewable and are not biodegradable as natural fibers. This study investigates the application of adhesive joints with hybrid composites, which combine natural and synthetic fibers, as potential replacements for traditional composites made solely from synthetic fibers. The main focus is on assessing the mechanical performance of these hybrid composites through end-notched flexure (ENF) tests on adhesive joints. Four different configurations of substrates were used, two with only one type of fiber (natural or synthetic) and two hybrids. Digital image correlation (DIC) analysis was conducted to provide detailed insights into the changes in displacement fields for the different configurations tested. The results indicate that adhesive joints with hybrid composites exhibit superior shear fracture energy (GIIC) compared with the joints with purely synthetic fibers. This enhancement in fracture toughness, attributed to the synergistic effects of the natural and synthetic fibers, suggests that hybrid composites could be a viable alternative, offering potential benefits in terms of sustainability and cost without compromising mechanical performance.

A new cohesive-based modelling of moisture-dependent mode II delamination of carbon/epoxy composites

The cohesive zone model (CZM) is widely employed for simulating delamination and debonding behaviour in engineering structures. However, the choice of CZM shape impacts the accuracy of simulation results. Therefore, the selection of a suitable Traction-Separation Law (TSL) with appropriate cohesive parameters is crucial. This study focuses on simulating the mode II delamination of unidirectional carbon/epoxy composites under varying moisture content levels (0%, 2.2%, 3.8%, and 5.3%) using the End Notched Flexure (ENF) test. Trapezoidal TSL (TTSL) with varying pseudo-plasticity parameter (Γ) was implemented and compared. A guideline was proposed in this study to aid in the selection of cohesive parameters, and a relationship between these parameters and moisture content was established. The results indicate that Γ = 0.99 yields a more accurate force-displacement response compared to Γ = 0. The estimated cohesive zone length falls within the range of 2.0–2.4 mm. During crack growth, the analysis reveals that, at the peak force, a region approximately 0.5–0.6 mm ahead of the crack tip undergoes total failure. Simultaneously, damage initiation occurs in the region 2.3–2.4 mm beyond the complete failure zone.

Micromechanical influence of near-surface adherend morphology and bondline fillers on the strain distribution in shear-loaded composite bonds

The near-surface morphology in the joining areas of adherends has a significant impact on the fatigue behavior of adhesively bonded composites. In the production process of composites, numerous opportunities exist for dictating surface morphology through the utilization of different top-layer semi-finished products. For instance, release films and peel ply fabrics can be employed to modulate the thickness and topography of the upper resin layer. These materials are subsequently removed prior to the further processing and assembly of the composites, leaving their negative imprint on the material surface. The resultant structures typically exhibit dimensions on the scale of a few micrometers. Another component in adhesive bonds are fillers, which have diameters in the same size range. Both adherend morphology and fillers influence the macroscopic behavior of the bonded joint. By in situ examining bonded end-notched flexure specimens inside a scanning electron microscope, the adhesive layer and the near-surface region of the adherends can be observed in detail under load. Evaluating these scanning electron microscope images using digital image correlation enables quantitative analysis of the strain distribution within the micrometer range. This allows the identification of the effects the adherend's near-surface morphology and the composition of the bondline (e.g. fillers, meshes) have on the shear strain distribution along bondlines. Consequently, conclusions can be drawn regarding their influence on the service life of adhesive bonds.

Elastic Foundation Solution for the End Notched Flexure (ENF) Mode II Sandwich Configuration

Abstract This paper presents a closed form solution for the energy release rate of face/core debonds in the Mode II end notched flexure (ENF) sandwich configuration. The finite-length sandwich specimen is considered to have a “debonded” region and a “joined” region. In the later, the interface between the top face and the substrate (core and bottom face) is modeled by an elastic foundation, which is a uniform distribution of shear and normal springs. Based on the Timoshenko beam theory, the solution for a general asymmetric sandwich construction is derived. The energy release rate expression is derived via the J-integral. Another closed form expression for the energy release rate is derived from the energy released by a differential spring as the debond propagates. In this closed form solution there is no fitting and everything, including the foundation constants, are given in closed form. Results are produced for a range of face/core stiffness ratios and debond length/core thickness ratios, and are compared with the corresponding ones from a finite element solution. A very good agreement is observed except for small debond lengths vs specimen thickness.

Enhancing mode-II delamination resistance of hybrid woven composite materials of glass/Kevlar fabrics by stitching with Kevlar threads

This study analyzes the effects of stitching a hybrid composite beam on its Mode-II delamination to enhance the bonding between a Kevlar-Kevlar interface. The material under investigation is a composite material manufactured from fiberglass and Kevlar fabrics stitched together with Kevlar threads before the infusion of epoxy resin. End-notched flexure tests and multiscale finite element simulations are conducted to validate a glass/epoxy composite with a glass-glass interface. Calibrated simulations are then used to perform a parametric study on stitching parameters, including stitch spacing, pitch, and direction on a composite with a Kevlar-Kevlar interface. The parametric study on Kevlar-Kevlar specimens revealed an average improvement of 17 % in maximum load capacity and 103 % in tangent stiffness in stitched specimens compared to unstitched specimens. Additionally, increasing stitch density up to 0.02 mm−2 significantly enhances mechanical performance, while higher densities do not provide significant additional improvements.

Crack Tip Localization in Adhesively Bonded CFRP-CFRP Joints subjected to Mode II Fatigue Loading

The use of resin-based composite materials in place of metals has gained prominence across various industries. Such composites offer a superior strength-to-weight ratio, addressing the increasing demand for lightweight structures to reduce emissions. As such, structural joining of composite materials is of growing importance. Traditional fasteners, however, not only compromise weight savings, but also introduce weak points within the structure. Adhesive bonding emerges as the most promising joining technology, balancing weight efficiency and performance. However, its broader adoption for primary structural joints is hindered by a lack of standardization of quality control and non-destructive inspection techniques and concerns about long-term reliability. To address this challenge, the “CERTBOND” COST Action initiative (CA18120) was established to investigate adhesive bonding and develop a reliable certification roadmap for bonded primary structures. As part of this initiative, a Mode II fatigue loading Round Robin study was conducted on adhesively bonded CFRP-CFRP End-Notched Flexure specimens. While conducting the fatigue tests, supplementary techniques for estimating the crack tip position were employed. The selected techniques included visual testing (employing two different methods), ultrasonic phased array testing, distributed strain sensing using optical backscatter reflectometry, digital image correlation, and localization by acoustic emission. The present study describes, compares and discusses the results obtained by the cited localization techniques.

A method for modelling arbitrarily shaped delamination fronts with large and distorted elements

The simulation of delamination in layered composites is currently limited for large structures. Typically, the use of Cohesive Zone Modelling leads to a requirement of keeping the elements smaller than 1.0 mm. As an alternative, this article presents an Energy Release Rate-based cohesive method enabling the use of elements significantly larger (up to 5 mm). A novel algorithm is presented to use the Virtual Crack Closure Technique with distorted elements not aligned with the delamination front. When the propagation criterion is met, a cohesive law is introduced to model the progressive crack growth along the newly created crack surface, ensuring to dissipate the correct amount of energy. The method is validated for different propagation tests. Notably, Double Cantilever Beam and End-Notched Flexure tests are accurately modelled with large and distorted elements. Finally, a partially reinforced DCB test demonstrates the ability of the method in representing an evolving delamination front.

Effect of the Atmospheric Plasma Treatment Parameters on the Surface and Mechanical Properties of Carbon Fabric.

The use of Atmospheric Pressure Plasma Jet (APPJ) technology for surface treatment of carbon fabrics is investigated to estimate the increase in the fracture toughness of carbon-fiber composite materials. Nitrogen and a nitrogen-hydrogen gas mixture were used to size the carbon fabrics by preliminarily optimizing the process parameters. The effects of the APPJ on the carbon fabrics were investigated by using optical and chemical characterizations. Optical Emission Spectroscopy, Fourier Transform Infrared-Attenuated Total Reflection, X-ray Photoelectron Spectroscopy and micro-Raman spectroscopy were adopted to assess the effectiveness of ablation and etching effects of the treatment, in terms of grafting of new functional groups and active sites. The treated samples showed an increase in chemical groups grafted onto the surfaces, and a change in carbon structure was influential in the case of chemical interaction with epoxy groups of the epoxy resin adopted. Flexural test, Double Cantilever Beam and End-Notched Flexure tests were then carried out to characterize the composite and evaluate the fracture toughness in Mode I and Mode II, respectively. N2/H2 specimens showed significant increases in GIC and GIIC, compared to the untreated specimens, and slight increases in Pmax at the first crack propagation.

Estimation of fracture behavior of CFRP/CFRP adhesively bonded joints under mixed-mode conditions using a cohesive zone model

Finite element (FE) simulations of adhesively bonded composite joints were conducted using the cohesive zone model (CZM). To clarify the effect of fracture criteria on the accuracy of the CZM simulation, two types of mixed-mode criteria including the ­linear summation model of Modes I and II energy release rates, G I / G IC + G II / G IIC = 1 , and the nonlinear power-law, ( G I / G IC ) n + ( G II / G IIC ) n = 1 , were employed. A CZM formulation using the power-law fracture criterion was developed in this study. The load–displacement curves calculated by the two models were compared with the experimental results obtained from mixed-mode Fernlund–Spelt-type double cantilever beam tests, and the Mode II end-notched flexure (ENF) tests. Calculations using the nonlinear fracture criterion were closer to the experimental results. Consequently, it is concluded that nonlinear fracture modeling is of vital importance for accurate strength analysis of mixed-mode adhesive joints.

Introducing a nano-scale surface morphology parameter affecting fracture properties of CNT nanocomposites

Carbon Nanotube (CNT) particles and membranes improve interlaminar fracture toughness of nanocomposites. The novelty of this study is to introduce the effect of a new nanoscale parameter - CNT network (bundle) size to interphase thickness ratio - on modes I and II interlaminar fracture toughness of CNT Polymer Nanocomposites (PNCs). This investigation includes the stochastic distribution function of CNT bundle size, interphase thickness, and modes I and II fracture toughness of PNCs based on an extensive experimental study at the nano- and macro-scales. The Atomic Force Microscopy PeakForce Quantitative Nanomechanics Mapping technique was used to collect 500 datasets for a low-weight percentage of CNT PNC and 180 datasets for a high-weight percentage of CNT PNC. Each dataset included CNT bundle size and interphase thickness at the nanoscale. Double cantilever beam and end-notched flexure experiments were conducted to collect 600 modes I and II fracture toughness data. Two-, three-, and four-parameter Weibull models were used to simulate the nano- and macro-scale material properties of CNT PNCs. Results indicate that (i) a lower CNT bundle size to interphase thickness ratio improves fracture toughness, and (ii) a four-parameter Weibull model is the most efficient model for simulated data.

Failures of laminates under nonpenetrative impacts

Various failures of laminates under low-velocity impacts without penetration are simulated systematically with a limited number of inputs, all measurable following existing standards without any data calibration. No iteration is required to determine any of the failures investigated in this work. Any two adjacent lamina (primary) layers are inserted with a matrix (secondary) layer, whose stresses are modified through two modification coefficients (MCs). The MCs are determined through peak loads of double cantilever beam and end-notched flexure tests on unidirectional laminates, and their weak sensitivity to sample dimensions is shown. Delamination is reproduced by deleting failed secondary-layer elements. The homogenized stresses of fiber and matrix obtained by Bridging Model are converted into true values through the author’s true stress theory to estimate constituent-induced intralaminar failures, such as fiber breakage, matrix crack and interface debonding, against the monolithic fiber or matrix strengths measured independently. Primary- layer elements attaining a fatal failure (fiber breakage or matrix crack accompanied with a critical strain condition) are deleted before an impact termination corresponding to separation of the impactor from target. The predicted delamination areas and impact force, displacement and energy histories for the laminates of three lamination angles under different impact energies agree well with our measured counterparts, validating the efficiency of the simulation.

Energy release rate in bimaterial specimens tested in pure modes I and II

New closed-form analytical expressions of the energy release rate of a bimaterial cracked specimen are derived, when it experiences pure mode I in an asymmetric double cantilever test, and pure mode II in an asymmetric end-notched flexure test. The analysis is based on the strain coenergy and on the laminated beam theory. The results of the analytical approach are compared with those obtained using the finite element method in two ways: by the virtual crack closure technique at a test point and by cohesive elements during a virtual delamination test. The agreement is excellent in both cases.