Failure Mechanisms Of Composites Research Articles

Numerical simulation of microstructural failure of natural fibre–hydrogel composites

In this article, we conduct a numerical simulation to investigate the failure mechanism of natural fibre–hydrogel composites under tensile deformation and swelling. Firstly, a physical-based constitutive model is chosen to describe the deformation of the hydrogel matrix. Concurrently, a macroscopic phenomenological hyperelastic constitutive model, incorporated into the material database of Abaqus, is employed to describe the mechanical responses of natural fibres. Then, we implement the model for a numerical analysis. The material parameters of the model for the hydrogel matrix and fibres are determined by a trial-and-error method from the experimental curves of pure hydrogel and fibres; the numerically simulated stress–strain curve of the composites is compared with the experimental one to verify the effectiveness of the simulation. Subsequently, several numerical analyses are performed to discuss the failure mechanism of hydrogel composites caused by the microstructural features of fibres. The findings revealed that fibre protrusion, fibre orientation deviation, and interface strength significantly affect the local failure of the composites during tensile deformation and swelling; the composites’ strength and toughness mainly depend on the cooperation of various microstructural features. These results provide valuable insights into the design of fibre–hydrogel composites.

Effect of grain size on ductility and failure mechanism of fiber-reinforced coral sand cement-based composites

Fiber offers the potential for enhancing the resistance to deformation in engineering cement-based composites (ECC). However, replacing quartz sand in ECC with coral sand containing a large number of internal pores will make the interaction between aggregate, interface transition zone, and cementitious materials more complex. To investigate the influence of coral sand particle size and Polyvinyl alcohol (PVA) fiber content on the compression behaviour and internal microstructure of fiber-reinforced coral sand cement-based composites (FRCSCC), we conducted uniaxial compressive strength tests and real-time measurements of P-wave and S-wave velocities. We tested various mechanical parameters, such as density, elastic modulus, compressive strength, wave velocities, and toughness index. The findings revealed a notable trend in relation to the coral sand particle size. Specifically, as the particle size increased, the compressive strength of FRCSCC decreased by 26 % and the elastic modulus reduced by 11 %. During uniaxial compression, the calculated cumulative voltage energy (CVE) from P-wave and S-wave can be divided into three stages: elastic deformation, microcrack and macrocrack propagation, and main crack formation. Moreover, the increase of coral sand particle size from 0.075 mm to 1.00 mm resulted in the rise of residual stress from 8.7 % to 18.2 %, followed by the increase of toughness index from 2.5 to 3.2. Scanning electron microscope (SEM) images reveal that the main failure modes of PVA fiber in FRCSCC specimens during uniaxial compression are debonding pull-out and tearing. Larger particle sizes of coral sand are associated with uneven fiber dispersion, increased fiber fractures, and diminished ductility of the specimens. The results establish a theoretical foundation for offshore engineering construction.

Tension and Shear Behaviour of Basalt Fiber Bio-Composites with Digital Image Correlation and Acoustic Emission Monitoring.

This research investigates the mechanical behavior and damage evolution in cross-ply basalt fiber composites subjected to different loading modes. A modified Arcan rig for simultaneous acoustic emission (AE) monitoring was designed and manufactured to apply quasi-isotropic shear, combined tensile and shear loading, and pure tensile loading on specimens with a central notch. Digital image correlation (DIC) was applied for high-resolution strain measurements. The measured failure strengths of the bio-composite specimens under different loading angles are presented. The different competing failure mechanisms that contribute to the local reduction in stress concentration are described. Different damage mechanisms trigger elastic waves in the composite, with distinct AE signatures that closely follow the sequence of fracture mechanisms. AE monitoring is employed to capture signals associated with structural damage initiation and progression. The characteristic parameters of AE signals are correlated with crack modes and damage mechanisms. The evolution of AE parameters during the peak load transition is presented, which enables the timely AE detection of the maximum load transition. The combination of DIC and AE monitoring improves understanding of the mechanical response and failure mechanisms in cross-ply basalt fiber composites, offering valuable insights for possible performance monitoring and structural reliability in diverse engineering applications.

Stability and Failure of Thin-Walled Composite Plate Elements with Asymmetric Configurations.

In the present study, the stability and failure phenomena of thin-walled constructions subjected to axial compression, featuring a central cut-out, and constructed from composite materials were explored. These constructions were fabricated from a carbon-epoxy composite using the autoclave method. The research encompassed experimental assessments on actual specimens alongside numerical analyses employing the finite element approach within the ABAQUS® software. The investigation spanned the entire load spectrum up to the point of structural failure, incorporating both practical trials and simulation analysis. During the practical assessments, the study monitored the post-buckling response and captured acoustic emissions to thoroughly evaluate the composite's failure mechanisms. Additionally, the ARAMIS system's non-invasive three-dimensional scanning was employed to assess deformations. Theoretical simulations utilized a step-by-step failure analysis, initiating with failure onset as per Hashin's theory and proceeding to failure progression based on an energy criterion. The simulation outcomes, particularly concerning the critical and post-critical phases, were juxtaposed with empirical data to identify the composite's vulnerability zones. The comparison underscored a significant concordance between the simulation predictions and the empirical findings.

Thermo-mechanical characterizations and erosion wear studies of fumed silica-reinforced jute/epoxy composites

This study investigates the influence of nano-fumed silica content on thermo-mechanical properties of jute/epoxy composites. The results reveal that jute composites without filler (JJJJ-0) exhibited highest tensile strength (33.01 MPa) and percentage elongation (1.9522%), while composites with 1.5% and 2.5% filler demonstrated the highest tensile modulus (1967 MPa) and flexural modulus (2432.9 MPa), respectively. The observation demonstrates that as the filler content increases in jute composites, tensile strength decreases but flexural strength increases. However, an exception is noted for sample containing excess filler (3.5%), which exhibited the lowest flexural strength (44.36 MPa). The composite with 2.5% filler exhibited the highest flexural strength (53.5 MPa). Thermal analysis indicated that the addition of nanofiller enhanced both the activation energy (Ea) and thermal stability of the jute composites. A four-layer carbon composite without filler (CCCC-0) was also fabricated in order to compare wear and thermal stability performance with jute composites. The wear study was performed at different temperatures and found that JJJJ-3.5 composite exhibited superior wear resistance at ambient temperature, while CCCC-0 composite had better wear resistance at high temperatures. Also, the surface morphology of the eroded surface was examined using a scanning electron microscope (SEM) to study the failure mechanism of composites.

Analyzing the Tensile Strength of Carbon Fiber-Reinforced Epoxy Composites Using LabVIEW Virtual Instrument

Carbon fiber-reinforced polymer composites are widely used materials in the aircraft industry, automotive sector, marine applications, civil engineering, and daily consumer goods, due to their superior mechanical properties at a relatively low density compared to metallic materials. The studied composites are composed of an epoxy resin matrix in which three layers of carbon fiber fabric are embedded, oriented at 0 and 90 degrees. Carbon fiber-reinforced polymer composites were manufactured using the Vacuum Assisted Resin Transfer Molding technique. The tensile failure mechanism in carbon fiber-reinforced polymer composites is an extremely complex phenomenon influenced by numerous factors. This study aims to evaluate the mechanical behavior of carbon fiber-reinforced composites through tensile testing and to compare experimentally obtained results with those calculated using the mixture rule. Additionally, the behavior of the materials under tensile stress was analyzed using the digital image correlation method. Estimating mechanical properties based on the mixture rule is a common practice in the design phase of polymer composites. This study s novelty and originality lie in its anticipation of the tensile strength and modulus of elasticity of the studied composites. This anticipation was achieved using a virtual instrument developed in the LabVIEW graphical programming environment. The experimentally obtained results for the tensile characteristics of the studied materials are suitable for this type of composite. These results were compared with estimates derived from the mixture rule, and the absolute error was determined.

Recent advances in mechanical properties of Mg matrix composites: a review

Magnesium (Mg), with a density of two-thirds of aluminium (Al) and one-fourth of steel, has become one of the most attractive materials for automotive and aerospace industries owing to the obligation to reduce fuel consumption and gas emissions. However, the poor mechanical property of Mg is one of the most significant barriers to its widespread use. The most widely used method to increase the use potential of Mg is the development of Mg matrix composites. This review focuses on the mechanical properties of recent Mg matrix composites. The effect of different reinforcement materials on the mechanical behaviour and failure mechanisms of Mg matrix composites was evaluated in detail.

Anisotropy characteristics of electrical conductivity and compressive strength of 3D carbon fiber/epoxy angle-interlock woven composites

Electrical and compressive performances are important in 3D carbon fiber/epoxy angle-interlock woven (AIW) composites for mechanical-electrical coupling behaviors. Here we investigate the electrical conductivity and compressive strength of.3D AIW composites both in in-plane and out-of plane. Four-probe method is conducted to measure the volume resistance along different directions. Damage evolution and failure modes are recorded with a high-speed camera during compressive test. Electrical conductivity and compressive strength exhibit obvious anisotropic characteristics due to fiber orientation and yarn waviness. The curved warp yarns result in the compromise of the X-direction conductivity by extending the current transmission length and increase of the Z-direction conductivity by forming more contact points to expand the current flow paths. Because of different yarn arrangements, the compressive failure mechanisms of 3D AIW composites in the X, Y and Z directions are buckling failure, double shear bands and indirect tensile failure, individually. Yarn undulation in the X-direction causes premature buckling and exhibits elastic-plastic nonlinear response, resulting in the lowest compressive strength and modulus. The 3D AIW composites have the lowest electrical conductivity and highest compressive strength in the Z-direction, which is suitable for high strength stress-sensing elements.

Multiaxial failure behavior and fatigue life prediction of unidirectional composite laminates

Complex coupling mechanisms exist between longitudinal and shear stress on the multiaxial fatigue behavior of composites. A thorough reanalysis of matrix shear failure mechanism under multiaxial fatigue loading is presented. Longitudinal single splitting fracture were analyzed and validated as an independent failure mode under multiaxial loading by analogy to the failure mechanism of natural composites. A new multiaxial fatigue life prediction model was established by double projection on the critical and subcritical fracture planes. Experiments on unidirectional tubular specimens were carried out under combined tension-torsion loadings to separate and identify the multiaxial fatigue failure behavior of composites. The proposed model has been verified using unidirectional laminates subjected to cyclic tension-torsion and off-axis loading, and the results showed that the predicted life is in good agreement with the experimental ones. Applications of three-dimensional digital image correlation (3D-DIC) and microscopy regarding verification in multiaxial damage mechanism are also addressed.

Microstructure and Property Evolution of Diamond/GaInSn Composites under Thermal Load and High Humidity.

As a thermal interface material, diamond/GaInSn composites have wide-ranging application prospects in the thermal management of chips. However, studies on systematic reliability that can guide the practical application of diamond/GaInSn in the high-temperature, high-temperature impact, or high-humidity service environments that are faced by chips remain lacking. In this study, the performance evolution of diamond/GaInSn was studied under high-temperature storage (150 °C), high- and low-temperature cycling (-50 °C to 125 °C), and high temperature and high humidity (85 °C and 85% humidity). The experimental results reveal the failure mechanism of semi-solid composites during high temperature oxidation. It is revealed that core oxidation is the key to the degradation of liquid metal composites' properties under high-temperature storage and high- and low-temperature cycling conditions. Under the conditions of high temperature and high humidity, the failure of Ga-based liquid metal and its composite materials is significant. Therefore, the material should avoid high-temperature and high-humidity environments.

Influence of unidirectional composite failure envelope shape on predicting compressive failure of a laminate with a filled-hole

In recent decades, several computational models have emerged at the mesoscale for predicting the failure development and strength of composite materials. Nevertheless, the intricate failure mechanisms of composites pose a formidable challenge in developing models capable of consistently reproducing diverse sets of experimental data. Furthermore, the absence of standardised multiaxial tests has hindered consensus on failure envelopes and criteria for composites. In this work, an in-house constitutive model implemented in a finite element code is employed to predict the failure strength of several filled-hole compressive carbon/epoxy experimental tests, varying in stacking sequences, sizes, bolt preloads, and other parameters. The influence the selected failure criterion has on the predictions is analysed. The findings indicate a large impact of the failure envelope on both the failure compressive strength and developed failure mechanisms. Therefore, the correct adjustment of the failure criteria can be as relevant as defining accurately the material input parameters. These results emphasise the importance of accurately establishing failure envelopes, rather than overemphasising the development of complex models.

Energy release rate for steady-state fiber debonding in structural battery composites

Structural battery composites are multifunctional materials intended to provide energy storage capacity while maintaining their strength and load bearing capacity under significant mechanical loads. In this study, we investigate the mechanics of carbon fiber debonding, a critical failure mechanism in structural battery composites. The carbon fibers are intended to serve both as an electrochemically active material and to bear mechanical load in the composite system. We derive an analytical solution to the energy release rate for steady-state fiber debonding for different electrochemical and mechanical loading cases with the aid of the classical solution for the Eshelby inclusion problem. The analytical solutions are validated with finite element simulations. We find a higher energy release rate and thus a greater driving force for fiber debonding is caused either by a lower lithium concentration in the fiber and/or by greater transverse mechanical loads such as biaxial tension or shear applied at the far field in the matrix. We find that the model is predictive even for transversely isotropic fibers despite the assumption that the fiber is elastically isotropic in the model. This work can provide guidance for the design of mechanically robust structural batteries.

Experimental and Modelling of Lightning Damage to Carbon Fibre-Reinforced Composites under Swept Stroke

Lightning swept stroke creates multiple lightning attachments along an aircraft in flight. This introduces distinct structural damage compared to that from a single-point lightning current injection test in laboratory. This study presents both experimental and numerical studies on lightning damage in carbon fibre-reinforced polymer (CFRP) composites under swept stroke. Coupled electrical–thermal finite element (FE) models were proposed to predict lightning damage to CFRP composites under single-point current injection and swept stroke, respectively. A lightning swept stroke testing method was proposed by embedding a copper wire inside the composites to simulate multiple lightning attachments on the composites. The FE-predicted damage from single-point current injection and swept stroke were comparable to those obtained from the experiments with a deviation less than 23%, demonstrating the effectiveness of the proposed FE model. Finally, the FE model was further utilised to gain insights into the failure mechanism of CFRP composites under swept stroke associated with different skip distances and peak currents. This paper provides an experimental method and a FE model for obtaining the LS damage of CFRP composite by swept stroke.

Multiaxial failure mechanism of 3D triple-twill warp-lining woven composites

3D triple-twill warp-lining woven composites (3DTTWLWC) has promising applications in many fields, but their multiaxial behavior is not clear. Herein, biaxial specimens of 3DTTWLWC are prepared and different experiments are performed. The results show that as the biaxial stress ratios (rbs) increases, the tensile/torsional stiffnesses and strengths decrease/increase and increase/decrease, respectively. Furthermore, under multiaxial-loading, the dominant damage pattern changed gradually from weft yarn breakage in the crack initiation zone to warp and binder yarn pullout in the failure zone. This work provides a reference for the structural design of 3DTTWLWC with significant engineering implications.

Effect of CNT filler and temperature on fracture toughness of epoxy composites reinforced with carbon fabric

AbstractIn present research the fracture behavior of carbon fabric‐epoxy composites (CE composites) was evaluated with the addition of 0.1, 0.2, 0.5, and 0.75 weight percentages of carbon nano tubes (CNTs) at different temperatures. The CE composites with different wt.% of CNT were fabricated using land layup method and cured by hot pressing. The fracture toughness of fabricated composites was evaluated in mode–I condition at different temperature. From the results it was shown that the highest fracture toughness was observed at 0.75 wt.% of reinforcement of CNT functional fillers. The fracture toughness of 0.75 wt.% CNT filled CE composites was increased by 19.73% compared to unfilled CE composites. The fracture toughness of CNT filled CE composites diminishes with increase in temperature and the composite filled with 0.75 wt.% CNT exhibits better fracture toughness than the unfilled CE composite at all the temperatures. The fracture toughness was improved by 57.76% and 71.65% at 40 and 60°C, respectively, at 0.75 wt.% reinforcement of CNT fillers. The fractured surfaces of composites were analyzed using Scanning Electron Microscope (SEM) to study the filler contribution to enhance the fracture toughness and failure mechanism of composites.

Mechanical behaviors of backfill-rock composites: Physical shear test and back-analysis

The shear behavior of backfill-rock composites is crucial for mine safety and the management of surface subsidence. For exposing the shear failure mechanism of backfill-rock composites, we conducted shear tests on backfill-rock composites under three constant normal loads, compared with the unfilled rock. To investigate the macro- and meso-failure characteristics of the samples in the shear tests, the cracking behavior of samples was recorded by a high-speed camera and acoustic emission monitoring. In parallel with the experimental test, the numerical models of backfill-rock composites and unfilled rock were established using the discrete element method to analyze the continuous-discontinuous shearing process. Based on the damage mechanics and statistics, a novel shear constitutive model was proposed to describe mechanical behavior. The results show that backfill-rock composites had a special bimodal phenomenon of shearing load-deformation curve, i.e. the first shearing peak corresponded to rock break and the second shearing peak induced by the broken of aeolian sand-cement/fly ash paste backfill. Moreover, the shearing characteristic curves of the backfill-rock composites could be roughly divided into four stages, i.e. the shear failure of the specimens experienced: stage I: stress concentration; stage II: crack propagation; stage III: crack coalescence; stage IV: shearing friction. The numerical simulation shows that the existence of aeolian sand-cement/fly ash paste backfill inevitably altered the coalescence type and failure mode of the specimens and had a strengthening effect on the shear strength of backfill-rock composites. Based on damage mechanics and statistics, a shear constitutive model was proposed to describe the shear fracture characteristics of specimens, especially the bimodal phenomenon. Finally, the micro- and meso-mechanisms of shear failure were discussed by combining the micro-test and numerical results. The research can advance the better understanding of the shear behavior of backfill-rock composites and contribute to the safety of mining engineering.

Adaptive phase-field modeling of fracture in orthotropic composites

An adaptive phase-field method is developed and applied to model fracture propagation in orthotropic composites. The proposed approach extends the work of Muixí et al. (2020) to orthotropic composites through following modifications: (a) elastic tensor is evaluated in the global coordinate system from a given engineering stiffness matrix in the principal material coordinates, (b) strain energy density is additively decomposed into fiber and matrix-dominated modes, and (c) a penalized second-order structural tensor is introduced in the phase-field equation facilitating preferential damage growth along the fiber orientation. The developed approach is validated through several benchmark examples and available experimental results.Several numerical failure experiments are conducted varying fiber orientation, adhesive layer thickness, shear modulus, and fracture toughness. A large increase in ductility and peak-load carrying capacity is observed for laminate configurations where the fibers are oriented such that the principal material coordinates and the global coordinates are aligned. An increase in the adhesive layer’s fracture toughness increases the macroscopic ductility and prevents catastrophic failure of laminate. The results of this study provide valuable insights into the failure mechanisms in orthotropic composites.

The effects of moisture content on the bonding interfacial properties of glued bamboo

Glued bamboo is often used in outdoor environments where humidity changes constantly. It is necessary to investigate the effects of changing moisture content, induced by environmental humidity, on the bonding performance of glued bamboo. In this study, glued bamboo was processed using Moso bamboo and phenol-formaldehyde (PF) resin with three typical assembling structures: outerlayer-outerlayer (A-A), outerlayer-innerlayer (A-B), and innerlayer-innerlayer (B-B). The microstructures of the bonding interphase were observed using fluorescence microscopy and scanning electron microscopy (SEM). The moisture content (MC) and thickness swelling (TS) of glued bamboo were measured after conditioning under different environmental humidity levels. The lap-shear test (LShT) and digital image correlation (DIC) were used to study the bonding performance of glued bamboo. Results indicated that PF resin penetrated more easily into the bamboo innerlayer due to the presence of more parenchyma cells on the inner side. When conditioned under different humidity environments, both MC and TS increased with rising humidity. Bonding strength decreased significantly with increased MC, especially for specimens with A-A and A-B structures. However, energy absorption was better when specimens were conditioned at 95% relative humidity (RH). Strain distribution was more uniform in specimens conditioned in high humidity environments. After soaking in water, shear strain was minimal due to the low strength of glued bamboo. The influence of MC on the bonding interfacial properties of glued bamboo, as indicated in this paper, will contribute to understanding the failure mechanism of bamboo-based composites for outdoor use.

Modelling intralaminar damage mechanisms in fibre reinforced polymers at finite strains

An approach to predict intralaminar failure mechanisms in laminate fibre-reinforced composites, at finite strains, is proposed. Transverse matrix cracking is described by a smeared crack model, activated by an invariant-based failure criterion, where an embedded cohesive crack is considered in the continuum description. A deformation gradient decomposition based on homogenisation considerations is developed for a more objective finite strain kinematic description of transverse cracks. The local equilibrium problem is established in the reference configuration to naturally include re-orientation of the fracture plane, and the employed cohesive law is able to deal with non-monotonic loading. Moreover, a continuum damage model formulated in terms of the Green–Lagrange strain tensor is used for longitudinal failure. The simulation of an open-hole multi-directional specimen subjected to tension illustrates the ability of the proposed constitutive equations to capture experimental observations.

Tensile, Fatigue and Impact Properties of the AA 2618/AL2 O3P Composites

In this paper, the tensile properties (at RT and 200°C), high cycle fatigue and impact behaviour of the 2618 aluminium alloy reinforced with 5% wt. of Al2O3 particles (AA 2618/Al2O3p/5P) and 10% wt. of Al2O3p particles (AA 2618/Al2O3p /10P) were studied. The Composites were prepared by two-step mixing of stir casting method followed by forging. A significant increase in tensile strength of the MMCs, with respect to the unreinforced alloys was evidenced by the tensile test while the elongation to fracture decreased. Tensile property at 200°C is higher than the unreinforced counterpart. The high cycle fatigue tests showed that fatigue life is comparable to the monolithic alloy. The SEM analysis of the fracture surfaces showed that the presence of secondary precipitates played a significant role in the mechanism of failure in composites by promoting void nucleation at the particle-matrix interfaces, interfacial decohesion and also the failure of the particles. The impact strength is reduced with respect to the unreinforced alloy.