Epoxy Laminates Research Articles

Analysis of Mechanical Properties and Thermal Conductivity of Thin-Ply Laminates in Ambient and Cryogenic Conditions

It is widely known that glass–epoxy laminates are renowned for their high stiffness, good thermal properties, and economic qualities. For this reason, composite materials find successful applications in various industrial sectors such as aerospace, astronautics, the storage sector, and energy. The aim of this study was to investigate the mechanical and thermal properties of composite materials comprising two different types of epoxy resin and three different hardeners, both at room temperature and under cryogenic conditions. The samples were produced at IZOERG (Gliwice, Poland) using a laboratory hot-hydraulic-press technique. During cyclic loading–unloading tests, degradation up to a strain level of 0.6% was observed both at room temperature (RT) and at 77 K. For a glass-reinforced composite with YDPN resin (EP_1_1), the highest degradation was recorded at 18.84% at RT and 33.63% at 77 K. We have also investigated the temperature dependence of thermal conductivity for all samples in a wide temperature range down to 5 K. The thermal conductivity was found to be low and had a relative difference of up to 20% among the composites. The experimental results indicated that composites under cryogenic conditions exhibited less damage and were stiffer. It was confirmed that the choice of hardener significantly influenced both properties.

Effect of Nanoclay Addition on Mechanical and Microstructure Properties of E-Glass Fiber and AA2022 Metal Skin Reinforced Epoxy Laminates

Effect of Nanoclay Addition on Mechanical and Microstructure Properties of E-Glass Fiber and AA2022 Metal Skin Reinforced Epoxy Laminates

Basalt Fiber-Reinforced Epoxy Laminates: Improvement in Quasi-Static and Fatigue Properties with Modified Matrices and Fiber Surfaces Using Silica Nanoparticles

Basalt Fiber-Reinforced Epoxy Laminates: Improvement in Quasi-Static and Fatigue Properties with Modified Matrices and Fiber Surfaces Using Silica Nanoparticles

AE based crack size estimates from delamination propagation in fiber reinforced thermoset composites

In previous research it has been shown that micro-crack sizes estimated from acoustic emission (AE) data recorded during Mode I interlaminar delamination propagation in a carbon fiber reinforced PEEK and micro-crack sizes seen in video recordings from simultaneously performed X-ray projection radiography with a contrast agent indicate reasonable agreement. Now the approach of estimating crack sizes from AE data is extended to a carbon and a glass fiber reinforced epoxy laminate, using the same matrix. In a first step sensitivity of the AE measurement is estimated based on recorded AE data and estimated delamination area. Different signal filtering approaches are applied to AE data resulting in different estimated sensitivities. Furthermore, assumed delamination area affects sensitivity. Optical microscopy is used to account for roughness of the delamination area. Depending on the assumed sensitivity, average crack size diameters are either slightly below or above 100 µm in both investigated laminates.

Acoustic Emission based determination of delamination initiation in GFRP laminates

Acoustic Emission (AE) has the potential to identify delamination initiation in quasi-static Mode I fracture tests on glass fiber-reinforced polymer-matrix (GFRP) laminates. It had been shown that a combined AE activity and intensity criterion yields critical Mode I delamination resistance values GIC for an AS4/PEEK carbon fiber thermoplastic composite that are comparable to those from data analysis according to ASTM D5528. However, the AE historic index also allows for detection of delamination initiation under Mode I and Mode II loading of carbon fiber reinforced thermoplastics and thermosets. In the present study, these AE criteria for initiation under Mode I, Mode II and Mixed Mode I/II loading of GFRP epoxy laminates are compared with AE signal energy as additional initiation criterion. Initiation under Mode II and Mixed Mode I/II at a ratio of 4:3 was determined with two different set ups for each Mode. For some test configurations noise signals make unambiguous initiation detection difficult. Determination by means of AE energy or AE activity and intensity yields more conservative GC values compared with the AE historic index or criteria defined in the standards, however, with similar repeatability.

In Situ Microscopy of Fatigue-Loaded Embedded Transverse Layers of Cross-Ply Laminates: The Role of an Inhomogeneous Fiber Distribution

Composites with continuous fiber reinforcement offer excellent fatigue properties but are tedious to characterize due to anisotropy and the interplay of fatigue properties, processing conditions, and the constituents. The global fiber volume content can affect both monotonic and fatigue strength. This dependence can increase the necessary testing effort even when processing conditions and constituents remain identical. This work presents an in situ edge observation method, enabling light microscopy during loading. As a result, digital image correlation can be employed to study local strains at cracking sites on the scale of fiber bundles. The geometric influence on fatigue damage is examined in non-crimp fabrics of glass and carbon fibers. Two epoxy resins (one modified by irradiation) are investigated to verify the geometric influence under changed polymer properties. The microscopy-based image correlation revealed that damage forms at very low global strains of only 0.2–0.3% in glass fiber-reinforced epoxy laminates. For carbon fiber-reinforced epoxy, laminate cracking was found to emanate mainly from regions containing stitching fibers. Across both reinforcements, irradiation treatment led to delayed cracks, emanating from interfaces. This detailed analysis of the damage formation is used as a basis for proposed applications of the in situ strain information.

Anisotropic Thermal Conductivity of Epoxy Laminate Composites Constructed with Three-Dimensional Carbon Fiber Felt

Anisotropic Thermal Conductivity of Epoxy Laminate Composites Constructed with Three-Dimensional Carbon Fiber Felt

Comparison of the in situ compressive behavior of carbon fibers woven ply laminates exposed to one‐sided heat flux: Thermoplastic versus thermosetting composites

AbstractThis study investigates the influence of a combined thermal heat flux (imposed by a cone calorimeter) and a compressive loading on the deformation and damage mechanisms within quasi‐isotropic carbon fibers reinforced thermoplastic (polyetherether ketone [PEEK] and polyphenylene sulfide [PPS]) and thermosetting (epoxy) laminates. First, thermogravimetric Analyses conducted under nitrogen provide valuable information on the thermal decomposition of these materials depending on the matrix nature (580–510°C and 350°C, respectively) which is a key factor to explain the mechanical behavior under fire conditions. Second, under the same testing conditions (creep loading under a 50 kW/m2 heat flux), the time to failure is about 17 times as high (C/PEEK), twice as high (C/PPS) with respect to C/epoxy laminates. At the ply scale, the exposure of thermoplastic matrices (PEEK and PPS) to a 50 kW/m2 heat flux causes softening and thermal decomposition, facilitating the micro‐buckling of fiber bundles in matrix‐rich areas. At the laminates scale, this mechanism ultimately leads to the formation and propagation of plastic kink bands in the transverse direction. In epoxy‐based laminates, the onset of matrix pyrolysis occurs at lower temperatures (350°C) during thermal aggression, and thermal decomposition has started in all the plies of the laminates. Combined with the low ductility of the epoxy matrix, the compressive response is elastic‐brittle and results from the buckling of 0° plies outside the thermally‐damaged area.Highlights Study on the compression of polymer composites exposed to a 50 kW/m2 heat flux. The influence of the matrix nature (thermoplastic vs thermoset) is discussed. Time to failure is about 17 times higher in C/PEEK compared to C/Epoxy. Plastic kink bands propagate in thermoplastic composites at T > Tg. C/Epoxy laminates undergo buckling outside the thermally damaged area.

Crack growth in sandwich-structured foam core graphite epoxy laminate composite using a phase-field modelling approach

The laminated sandwich composites have wide structure-making applications in the automotive and aviation fields due to their lightweight and superior flexural rigidity properties. Making grooves or holes to assemble more than one structure induces crack discontinuities near the stress concentration region in these sandwich structures. The present work examines the effect of crack discontinuities on the mechanical performance and failure process of the sandwich structures under different loading conditions. Phase field method (PFM) has been presented and implemented using in-house developed MATLAB code. The effect of holes, multiple cracks, number of cores, and loading conditions are analyzed for the mechanical and fracture behavior of the structure. Load-carrying capacity, threshold displacement value for crack initiation, crack propagation trajectory, and energy absorption capacity are compared for various crack discontinuities under different loading conditions. Approximately 35% increase in load carrying capacity is observed in equivalent multiple core sandwich structures.

Investigating the relationship between natural frequency and residual strength and stiffness of cross‐ply laminate under cyclic loading

AbstractPredicting the fatigue life of wind turbine rotor blades is a challenging and crucial engineering task. This study investigates the correlation between modal parameters and the degradation of residual strength and tensile modulus in the cross‐ply glass epoxy laminate [0/90]7 used in wind turbine blades under fatigue loading. The tensile and vibration characteristics were assessed, followed by constant amplitude fatigue tests at 35%, 43% and 55% of the ultimate tensile strength, with R = 0.1 and a frequency of 8 Hz. The modal analysis was performed on the cycled specimens at life fractions from 0.05 to 0.70 and residual modulus and strength were obtained. The results establish a well‐defined correlation between these residual mechanical properties and the natural frequency. Normalized residual strength, tensile modulus and natural frequency demonstrated similar behaviors during the fatigue life. An initial rapid decrease in the first tenth of the life fraction was observed, followed by minimal changes up to a life fraction of 0.7. The strong correlation between the first mode natural frequency and both the residual strength and the tensile E‐modulus provides a promising basis for developing accurate fatigue life prediction models for fiber‐reinforced composite structures. © 2024 Society of Chemical Industry.

Investigation on the damage mechanisms using acoustic emission method and damping characteristics of hybrid flax‐glass composites

AbstractFiber‐reinforced polymers (FRP) feature high strength‐to‐weight ratio amongst the emerging class of natural composites. This paper presents the impact of the glass fiber on the tensile strength of the flax epoxy laminate. The mechanical behavior and damping characteristics of flax fiber reinforced polymer (FFRP) and the hybrid flax‐glass fiber reinforced polymer (HFRP) are experimentally investigated. Both the flax and hybrid FRPs are made using vacuum infusion process. The specimens without and with holes of 4, 5, and 6 mm in diameter are subjected to tensile test using acoustic emission monitoring and free vibration test. In the former testing, HFRP resulted in higher peak frequencies and cumulative counts. Also, the natural frequency and damping factor of HFRP vary proportionately with the hole size, as identified in the latter tests. Different damage mechanisms during the tensile test revealed that the presence of glass fibers in HFRP increased resistance for certain damage mechanisms.Highlights Adding glass fiber to flax fiber reinforced polymer (FFRP) creates a hybrid FRP (HFRP) with increased resistance to damage and improved damping characteristics. HFRP exhibits a distinction in failure mechanisms compared to FFRP. The study utilizes acoustic emission (AE) to identify various damage mechanisms in the material, providing a more detailed information. The addition of glass fibers in HFRP leads to a more pronounced increase in damping factors.

Effect of moisture on the sensing capabilities of piezoelectric actuator/sensor pairs on flax fibre reinforced composite laminates

The sensitivity of the piezoelectric actuators’ response to the moisture uptake has been investigated on flax fibre reinforced composite laminates. Non-woven flax fabric was impregnated with epoxy and composite laminates were fabricated using hand lay-up and cured in a compression moulding machine. The laminates were initially impacted with a drop-weight impact machine at a low energy level, with the aim to generate an artificial surface crack that will allow the moisture to enter the fibre-matrix interface more effectively. A set of piezoelectric actuators and sensors were adhered on the surfaces of the composite panels in a specific rectangular arrangement to allow for wave capturing at various directions. The wave characteristics of the samples were extracted in pristine stage and then the samples were impacted and immersed in distilled water until saturation. At regular intervals after the water immersion, the panels’ weight was measured using a laboratory scale and the wave propagation characteristics of the materials ware measured in order to investigate the gradual effect of moisture on the capabilities of the actuators and sensors. The propagation of stress waves in the dry and wet samples was investigated and the effect of moisture absorption was examined experimentally using piezoelectric wafers until the saturation was reached. Finally, a continuum damage mechanics layerwise time domain spectral finite element model, both for the composite laminate and the rich resin layers, was also developed to simulate the materials’ performance under impact and evaluate the wave propagation within the material at the dry state.

Experimental investigation of pseudo-ductility in plain weft-knitted epoxy composite laminates under tension

The inherent brittleness of unidirectional fiber-reinforced composites represents a major complication in their broad practical applications. However, exploiting different reinforcement architectures can offer an opportunity for highly desirable ductile fracture nature. This article is aimed at investigating experimentally the tensile behavior of an epoxy laminate reinforced by different layers of plain weft-knitted fabrics. The fabricated laminates were subjected to uniaxial tension in different loading directions, and the corresponding tensile responses were recorded. Basic mechanical properties were characterized and digital image correlation (DIC) was employed to capture surface deformations. Tensile test results demonstrated strong nonlinearity and pseudo-ductility as well as loading-direction dependence in this type of composite laminates. Fracture tests were conducted showing high fracture toughness ranging from 10 to 20 MPa·m1/2. Typical damage modes were characterized using microscopy, which were coupled to a few distinct tensile deformation stages. This work demonstrates that weft-knitted composites are promising in permitting great amounts of pseudo-ductility with clear warning before complete failure. It is also expected to contribute to the understanding of the specific role of weft knit fabrics in composite laminates.

Discontinuous interleaving strategies for toughening, damage sensing and repair in multifunctional carbon fibre/epoxy composites

Thermoplastic interleaving is a well-established approach to toughen carbon fibre thermoset laminates, studied over the past five decades. Recently, it has been revisited to create functional smart composites with damage sensing and repair capabilities with a renewed focus on the sustainability and longevity of components. However, the introduction of thermoplastic films within the interlaminar region often lowers fibre volume fraction and performance at elevated temperature, while the addition of impermeable continuous films during manufacture may also limit compatible fabrication methods. Moreover, the incorporation of dielectric thermoplastic films inevitably reduces through-thickness electrical conductivity and prevents accurate damage sensing of delamination in carbon fibre laminates. In this study, strategies of using discontinuous interleaving to improve both fracture toughness and thermomechanical properties of carbon fibre epoxy laminates, with the ability to monitor delamination damage and restore mechanical properties after a short healing step have been explored. Both the interleaving design and the physical properties of the thermoplastic were assessed, which has not been addressed previously. Interleaving high molecular weight thermoplastic with decreasing interleaf width and distance between interleaf zones results in increased fracture toughness (+347 %), by creating a superior toughened interlaminar zone, forcing a migration of delamination into the intralaminar region. A repair efficiency of 77 % was achieved when using a lower molecular weight of thermoplastic; however, the lack of thermoplastic over the entire fracture surface area affects the repairing performance universally. Damage sensing and thermomechanical properties were significantly improved compared to continuous interleaving, demonstrating that discontinuous thermoplastic interleaving strategies offer a favourable combination of toughening, thermal performance and accurate damage sensing for multifunctional high-performance composites.

In situ interlaminar shear behavior of carbon fibers reinforced polymer composites exposed to severe thermal aggressions: PPS versus epoxy laminates

This study investigates the influence of a combined thermal heat flux and a flexural loading on the interlaminar shear behavior of quasi-isotropic carbon fibers reinforced PPS and Epoxy laminates. Regardless the intensity of the heat flux (ranging from 20 to 50 kW/m2), the maximum surface temperature is higher than the onset of thermal decomposition [Formula: see text] in C/Epoxy laminates ([Formula: see text]) whereas the thermal decomposition is reached only for 40-50 kW/m2 heat fluxes in C/PPS laminates ([Formula: see text]). A mechanical bench was specifically designed to study the interlaminar shear behavior of polymer-based laminates during the thermal aggression (imposed by a cone calorimeter). In C/PPS laminates, with respect to the reference values (as received state), the flexural modulus and the apparent ILSS (under 50 kW/m2) decreases by about 80%. In C/Epoxy laminates, with respect to the reference values (as received or virgin state), the flexural modulus and the apparent ILSS (under 50 kW/m2) decreases by about 20% and 50%, respectively. In carbon fiber-reinforced polymer materials, the matrix state is crucial for preserving the cohesion of the fibers network and the bonding of the plies together, a role that seems compromised in C/Epoxy and C/PPS laminates under high heat flux conditions, once the pyrolysis of the matrix has severely degraded the interlaminar properties of the material.

Pressure resistance characterisation of vascular networks embedded in carbon composites for high energy physics applications

In state-of-the-art tracking detectors, lightweight carbon composite structures support the pixel or micro-strip sensors and provide the main thermal path between the silicon and a network of metallic or plastic pipes containing a cooling fluid. Despite the good results obtained with this design approach, the challenges associated with future high energy physics (HEP) experiments demand even lighter and more efficient technologies. In this regard, replacing the existing piping with a network of channels directly embedded in the composite laminates represents a promising solution to improve the thermal coupling, which also offers additional gains in terms of mass and thermo-elastic stability.While some research has been devoted to assessing the mechanical and thermal performance of such laminates, limited information about their resistance to internal pressure is currently available in the literature. This lack of data constitutes an important obstacle for the use of vascular networks in future HEP applications, which the present paper aims to address.Experimental methods were used to investigate the pressure resistance of channels embedded in carbon composite laminates. Modified poly (lactic) acid (PLA) preforms were embedded in carbon-fibre epoxy laminates. A post-cure vaporization technique removed the PLA, thus producing plates with longitudinal channels. Destructive tests were conducted to determine the burst pressure of the plates depending on the lay-up and the cross-section geometry of the channels. Both circular and oblong channels were evaluated, and various reinforcement techniques were explored to enhance the pressure resistance of the laminates. Micro-graphic examinations and X-ray micro-computed tomography were employed to gain a better understanding of the microstructure and the failure mechanisms of the plates.Plates with circular channels measuring 1.75 mm in diameter, embedded in [0/90/0]S laminates and reinforced with 2 mm lay length fuzzy carbon fibre over-braids, achieved burst pressures exceeding 45 MPa. This result, which is approximately an order of magnitude greater than that obtained for the equivalent non-reinforced laminates, demonstrates the enormous potential of this technology for future particle detectors.

Compression and hydrothermal ageing after impact of carbon fibre reinforced epoxy laminates

This paper proposes a new methodology for the assessment of seawater ageing effects on impact-damaged composite laminates. CF/Epoxy laminates which were unimpacted, and impacted at 30 J, 60 J, and 90 J by hemispherical and conical impactors were subject to 4 months hydrothermal ageing in renewed natural seawater at 60 +/-2 °C. The majority of water uptake by impacted laminates (0.05 wt% − 0.3 wt%) occurred in the first 24 h and is believed to be held in damage cavities by capillary mechanisms. The increase in diffusive water uptake rate by the matrix due to impact damage was only small, at less than 0.008 wt%.mm.hr−0,5, compared with the total diffusive water uptake rate of 0.1 wt%.mm.hr−0,5. Hydrothermal ageing reduced the residual compressive strength of pristine laminates by 25 % and impact-damaged laminates by 8 % to 16 % for impacts between 30 J and 90 J.

Mechanical properties and damage development in glass-fiber epoxy laminates subjected to tensile loading at sub-zero temperatures

In various structural applications polymer composites are exposed to sub-zero and even cryogenic temperatures which may initiate of microstructural damage. To anticipate these events, one needs to understand the behavior of composites in a sub-zero environment. This study focuses on damage initiation and accumulation, and its influence on the properties of cross-ply glass fibers epoxy composites at sub-zero temperatures. The effect of bromine modification of epoxy, and the dissolution in an organic solvent on the mechanical performance of the produced composite is also investigated. To evaluate the influence of a sub-zero environment on the mechanical performance of glass fiber epoxy laminates, tensile tests in a sub-zero environment of unconditioned specimens were carried out. The quasi-static tensile tests were performed to measure the elastic modulus of the composites while loading-unloading experiments were performed to monitor the initiation (and accumulation) of microstructural damage and its influence on the stiffness of glass fiber epoxy laminates. The results of cryogenic damage and fracture in the laminates are discussed with a focus on the degradation of properties of glass fiber crucial for their use in structural applications: strength and stiffness.

Basalt fabric/(3-aminopropyl) triethoxysilane modified epoxy laminates reinforced with nano-silica, OMMT and GNP: mechanical and dynamic mechanical studies

Basalt fabric/(3-aminopropyl) triethoxysilane modified epoxy laminates reinforced with nano-silica, OMMT and GNP: mechanical and dynamic mechanical studies

Mechanical properties: Lifespan and retention forecast for jute fiber woven fabric reinforced epoxy matrix composite

AbstractPolymer composites bonded with natural fibers are extensively used for a range of engineering purposes. Preserving their mechanical strength and estimating their maximum service life are thus essential for efficient usage. The primary goals of this effort are to analyze and forecast the longest possible life span of composites. To do this, Fick's law and the Arrhenius principle are employed to analyze the diffusion coefficient and activation energy. Compression molding technology and a manual technique for layup were employed to make the composites reinforced with epoxy laminate and woven mats of jute fiber (JRC). Three layering patterns were used to prepare the laminated composite: 45° angle‐ply laminate [0°/+45°/0°/−45°/0°], 0° balanced laminate [0°/0°/0°/0°/0°/0°], and 30° angle‐ply laminate [0°/+30°/0°/−30°/0°]. In order to examine how aging affected the composites' mechanical properties, the materials were immersed in water for 10, 20, 30, and 40 days throughout the study. The study's conclusions showed that the composite samples' weight rose with age. It was possible to make precise predictions about strength retention by comparing the mechanical characteristics of aged (wet) and unaged composites. It was discovered that the strongest composites were those with a 45‐degree stacking pattern. The activation energy of composites with a 45° angle‐ply laminate layering pattern is maximum, according to the Arrhenius principle. Additionally, using an electron microscope with scanning capabilities (SEM), it was possible to determine the fiber matrix and the tensile cracked surface contact connection.Highlights The widespread usage of polymer composites with natural fibers in engineering applications. Preservation of mechanical strength and predicting the maximum service life of these composites show how important these materials are for engineering efficiency. Fick's rule and the Arrhenius principle are used to analyze diffusion coefficient and activation energy. Laminated composites are made using 45° angle‐ply, 0° balanced laminate, and 30° angle‐ply layering patterns. The impact of simulated aging on composite mechanical characteristics by water immersion for varied periods.