Fiber-matrix Interfacial Debonding Research Articles

Characterization, quantitative evaluation, and formation mechanism of surface damage in ultrasonic vibration assisted scratching of Cf/SiC composites

Carbon fiber reinforced silicon carbide ceramic matrix composites (Cf/SiC composites) have a wide range of applications in aerospace, nuclear energy, braking systems owing to its excellent mechanical performance. Nevertheless, the hardness, brittleness, heterogeneity, and anisotropy of Cf/SiC composites give rise to difficulties in machining them. In addition, the characterization and formation mechanism of surface damage in the grinding of Cf/SiC composites have not been fully elucidated. The purpose of this paper is to provide a characterization method for surface damage of Cf/SiC composites and an evaluation index for surface edge chipping damage (SECD) through conventional scratching (CS) / ultrasonic vibration assisted scratching (UVAS) tests with single abrasive. Towards revealing the surface damage behavior of Cf/SiC composites during scratching, as well as the impact of fiber orientation on surface damage. The findings indicate that main forms of surface damage of Cf/SiC composites in single abrasive scratching are fiber breakage, fiber fracture-shedding, fiber fracture, fiber-matrix interface debonding, interface fragmentation, matrix cracking, and matrix microcracks. Further, ultrasonic vibration could help to suppress the SECD, and the SECD factor was smallest when scratching along the perpendicular fiber. Furthermore, the fiber orientation can significantly affect the scratching force and cross-sectional area of scratches on Cf/SiC composites via single abrasive scratching. The tangential scratching force was usually smaller as compared to the normal scratching force, and the cross-sectional area of scratches in UVAS is smaller than that in CS. Based on the above findings, this study elucidates the formation and evolution of surface damage after scratching under different fiber orientations, filling the research gap in surface damage under ultrasonic assisted machining of Cf/SiC composites and providing technical guidance for the machining.

Damage evolution in flax fibre composite under creep load

This work aims to reveal the damage mechanisms and evolution in unidirectional flax fibre biocomposites when subjected to creep load. X-ray micro computed tomography and acoustic emission (AE) was used to monitor the failure progress during flexural creep tests. A correlation between the event clusters and directly observed damage modes was established based on coupons with expected failure mechanisms and then validated by computed tomography observations. The damage initiated from matrix cracking in the primary creep stage, and then fibre–matrix interface debonding combined with fibre pull-out occurred sequentially during the steady creep stage. In the tertiary creep stage, the explosive fibre fracture emerged and eventually triggered catastrophic failure. Considerably more AE events were detected during creep tests compared to those in quasi-static tests, which indicates that intensive damage is generated under creep load, and therefore causes the strength degradation. A good agreement was observed between the cumulative number of AE events and the increasing damage volume fraction over time determined by X-ray micro computed tomography during multi-step creep tests.

Influence of nearby fiber on fiber–matrix debonding: Coupled Criterion prediction and debonding shape determination

Fiber–matrix interface debonding in two-fiber specimens under remote tensile loading is studied both experimentally and numerically by means of a coupled stress and energy criterion. Depending on its relative position, the neighboring fiber induces a perturbation of both stress and energy fields at the reference fiber interface which results in asymmetrical debonding initiation and propagation. The determination of the debonding initiation and propagation shape is addressed based on either (i) stress isocontours, (ii) energy isocontours or (iii) the Coupled Criterion (CC). It was found that the debonding initiation configuration can be determined based on stress (respectively energy) isocontours for small (respectively large) enough interface brittleness number. For intermediate brittleness number, the debonding initiation configuration cannot be obtained using neither the stress nor the energy isocontours, but requires a coupling of both aspects. Despite different initiation debonding configurations, the corresponding initiation remote stresses do not differ much, which results in similar debonding configurations after unstable crack propagation following initiation.

Numerical simulation of fiber–matrix debonding: Inverse identification of interface properties

Fiber-matrix interface debonding is studied by means of single-fiber epoxy-glass fiber specimens under transverse tensile loading. Experimental observations show abrupt debonding initiation between 67 and 83 deg. followed by stable debonding propagation. Similar abrupt debonding initiation is predicted using the coupled criterion (CC). The latter predicts crack initiation considering both stress and energy aspects from which a range of interface shear and opening critical energy release rates (ERR) and strengths can be derived. Depending on these parameters, initiation is found to be either driven by energy solely or by both stress and energy conditions. The loading required for initiation depends on the opening (mode I) critical ERR and tensile and shear strengths. The debonding arrest angle also depends on the shear (mode II) critical ERR. Consequently, a three steps methodology to identify the interface properties is described and an optimum set of parameters is determined by focusing on the stable debonding propagation after initiation using Linear Elastic Fracture Mechanics.

Microscale modelling of lightning damage in fibre-reinforced composites

In this work, three-dimensional (3D) finite element simulations were undertaken to study the effects of lightning strikes on the microscale behaviour of continuous fibre-reinforced composite materials and to predict and understand complex lightning damage mechanisms. This approach is different from the conventional mesoscale or macroscale level of analysis, that predicts the overall lightning damage in composite laminates, thus providing better understanding of lightning-induced thermo-mechanical damage at a fundamental level. Micromechanical representative volume element (RVE) models of a UD composite laminate were created with circular carbon fibres randomly distributed in an epoxy matrix. The effects of various grounding conditions (one-, two-, and four-side grounding), fibre volume fractions ( V f = 55, 60%, and 65%), and peak current amplitudes (10, 20, and 40 kA) on microscopic damage in RVE models were characterised to understand fibre, epoxy matrix, and fibre-matrix interfacial damage associated with a lightning strike. Thermal damage, estimated based on epoxy matrix decomposition temperature, was largely constant up to 20 kA before increasing significantly at 40 kA. Severe thermal damage steadily decreased with increasing V f. Thermo-mechanical damage was predicted using a ductile plasticity model with Drucker–Prager yield criterion for epoxy matrix failure, and cohesive surfaces for fibre-matrix interface debonding. Thermal strain had the largest contribution to thermo-mechanical damage, while dynamic pressure loading was negligible in all RVE models. The RVE model proposed in this work, to the best of the authors’ knowledge, is the first model predicting lightning-induced fibre-matrix interfacial damage.

Self-consistent homogenization-based parametrically upscaled continuum damage mechanics model for composites subjected to high strain-rate loading

This paper develops a Parametrically Upscaled Continuum Damage Mechanics (PUCDM) model for carbon fiber/epoxy matrix composites subjected to high strain-rate loading. The PUCDM model for predicting high strain-rate induced deformation and damage evolution at the macroscopic scale, explicitly incorporates microstructural morphology and micro-inertia in its constitutive coefficients. It is developed using self-consistent homogenization that uses a concurrent multiscale model to account for the effect of micro-inertia and stress wave interaction with the microstructure. The concurrent model embeds a statistically equivalent representative volume element (SERVE) of the microstructure in an exterior domain, whose constitutive and damage response are described by the PUCDM model. Micromechanical modeling for the composite microstructure involves a unified cohesive zone enhanced phase-field damage model for fiber-matrix interface debonding, fiber breakage, and matrix cracking. The PUCDM model parameters for the upscaled domain are determined through micro-macro-scale energy equivalence, along with traction reciprocity and displacement continuity at the SERVE-exterior domain interface that are enforced using a Lagrange multiplier-based approach. Simulations using the concurrent model analyze stress wave propagation and damage evolution in composite microstructures with three different fiber volume fractions at multiple strain rates in the range of 102 − 105 s−1. The fiber volume fraction and spatial distributions affect the overall stiffness and damage evolution in the PUCDM model. Results of the analysis demonstrate the need for representation of micro-inertia, strain rates and microstructure morphology in the PUCDM-based stiffness and damage model parameters for high strain-rates above [Formula: see text].

A CNT-Toughened Strategy for In-Situ Repair of Aircraft Composite Structures.

This study aimed to develop an in-situ field-repair approach, especially for aircraft composite structures, to enhance the interlaminar toughness of plain-woven composites (PWCs) by adding multi-walled carbon nanotubes (MWCNTs). MWCNTs were dispersed at each interface between prepreg layers by means of solvent spraying, with a density of 1.58 g/m2. Then, the layers were stacked with the predefined sequence and cured at 120 °C and 1 bar pressure, using a heat-repairing instrument. A standard double cantilever beam (DCB) test was used to investigate the interlaminar toughening effect that was due to the MWCNTs. For comparison, original samples were also prepared. The results indicated that the introduction of MWCNTs can favorably enhance the interlaminar toughness of PWCs in a field-repair approach and the Mode I fracture energy release rate, GIC, increased by 102.92%. Based on the finite element method (FEM) of continuum damage mechanics, the original samples and the MWCNTs toughening specimen under DCB Mode I fracture were modeled and analyzed. The simulation and the experiment were in good agreement. Finally, when the toughening mechanism of MWCNTs was explored with a scanning electron microscope (SEM), we found that a large amount of fiber-matrix (F-M) interface debonding and matrix cracking in mountain shape were the major modes of fracture, accompanied by a small amount of fiber breakage and matrix peeling for the MWCNTs-toughening specimens.

The propagation of fibre–matrix interface debonding during CFRP edge milling process with the multi-teeth tool: A model analysis

The fibre–matrix interface debonding has been considered as one of unsatisfied defects during milling carbon fibre reinforced plastic (CFRP) by multi-teeth tool, which has a special character of propagation in subsurface that still needs to be clearly known. The present paper offered a new model based on beam bending theorem and data from correlated multiple-pass cutting process to precisely describe the mechanism behind such debonding propagation. The validity and accuracy of this model were certified by proposed evaluation methods in the way of experimental results analysis. It can be inferred from results discussion that feed rate and tool radius presented the linear and non-linear proportional relations to debonding degree respectively, but tool radius had a greater impact on variation in debonding degree than feed rate, which can be well described and predicted by such model. This work put a novelty view to further recognize the debonding behaviours during CFRP milling.

Bridging length scales from micro to mesoscale through rate-dependent traction-separation law predictions

Mesoscale models are useful for modeling dynamic impact on fiber reinforced polymer composites . Mesoscale damage can be modeled using cohesive zones , but determining the governing traction-separation laws is a challenge. We developed finite element models with a stochastic fiber-matrix microstructure embedded within a larger mesoscale continuum to study transverse tension and shear loading of unidirectional S-glass/epoxy composite. We included rate-dependent matrix constitutive behavior and failure and rate-dependent fiber-matrix interface debonding, which are important microscale damage mechanisms that comprise mesoscale fracture. With these multiscale models , we simulated mode I and II crack initiation and propagation. We determined mesoscale, mode I and II, rate-dependent cohesive laws from the models using a domain J-integral approach to calculate the fracture energy as a function of crack opening displacement. We explored the effects of loading rate, matrix failure strain, and fiber-matrix interface debonding properties on the traction laws and crack morphologies. Finally, consistent bridging between length scales is demonstrated by comparing energy dissipation of microstructurally-resolved fracture to mesoscale continuum cohesive zone fracture. This work provides a methodology for determining rate-dependent traction-separation laws, derived from accurate micro-mechanics and experimental input, for bridging lengths scales and use in mesoscale models to evaluate ballistic performance of composites.

Characterizing fiber-matrix debond and fiber interaction mechanisms by full-field measurements

An experimental approach is developed and utilized to characterize the fiber-matrix interfacial debonding mechanism and its effect on matrix cracking in unidirectional (UD) fiber composites. Local deformation response at the fiber-matrix interface is first studied by analyzing the strain fields developed in the vicinity of macro fibers in single-fiber samples. A practical approach for the identification of normal cohesive behavior at the fiber-matrix interface is presented and implemented in a finite element model that replicates the experimental findings. Fiber-to-fiber interaction, debond formation, and failure mechanisms in multiple fiber systems are then studied by varying the distance and angle between adjacent fibers in double-fiber samples. The experimental results indicate that the spacing and angular orientation between adjacent fibers affect the interface debond initiation and propagation, as well as subsequent matrix failure mechanisms. It is also shown that compared with fiber spacing, angular distance has a more significant effect on matrix cracking in UD composites under transverse tension. Results presented in this work provide an experimental-based quantitative insight into the mechanics of fiber-matrix interface using in-situ full-field measurements.

Synergistic effect of acidic environmental exposure and fatigue loads on FRP tendons

The synergistic effect of acidic environmental exposure and fatigue loads on fiber-reinforced polymer (FRP) tendons was investigated in this study. The fatigue behavior of basalt FRP tendons under cyclic loads and exposed to air, water, and acid was evaluated. Three types of fatigue tests, that is, air, water spraying, and acid spraying tests, were performed at 40 °C. Another set of preconditioned specimens was prepared by immersing in an acid solution without stress for a designated period. Fatigue stresses of 25%fu–65%fu (where fu is the tensile strength) were applied at a stress ratio of 0.5. The failure mechanism was analyzed at macroscopic and microscopic scales. The results showed that water spraying had the most negligible impact on fatigue behavior, and the acid spraying specimens exhibited 58% faster degradation than the water spraying specimens. Moreover, the synergistic effect of the acid and cyclic stress facilitated the failure process of the acid spraying specimens by 43% compared to the preconditioned specimens. The internal pressure generated by the ingress liquid accelerated resin cracking and fiber–matrix interface debonding. Furthermore, the synergistic effect of the acid and fatigue loads accelerated degradation, owing to the combined effect of internal pressure and chemical corrosion.

Non-linear mean-field modelling of UD composite laminates accounting for average asymmetric plasticity of the matrix, debonding and progressive failure

As an effective and accurate method for modelling composite materials, mean-field homogenization is still not well studied in modelling non-linear and damage behaviours of UD composites. Investigated micro FE-simulations show that the matrix of UD composites exhibits different average plastic behaviour, named as average asymmetric matrix plasticity (AAMP), when the composite behaves different under shear, longitudinal and transverse loadings. In this study, a non-linear mean-field debonding model (NMFDM) combining a mean-field model and a fibre–matrix interface debonding model, is developed to simulate UD composites under consideration of AAMP, fibre–matrix interface damage and progressive failure. AAMP is considered by using so-called stress mode factor, which is expressed in terms of basic invariants of the matrix deviatoric stress tensor and is used as an indicator for detection of differences in the loading mode. The material behaviour of UD composites with imperfect interface is assumed identical as for perfect interface and stiffness reduced fibres. Progressive failure criteria are established with consideration of fibre breakage and matrix crack for different fibre orientations. As a representative example for the NMFDM, a C30/E201 UD composite is studied. To verify the model, experiments are conducted on polymers, carbon fibres and UD CFRPs. Finally, the model is applied to simulate a perforated CFRP laminate, which shows excellent prediction ability on deformation, debonding and progressive failure.

Investigation of a critical separation criterion for mode I-Governed fracture of basalt fiber/polypropylene rods via a modified double cantilever beam test

A new approach using a modified double cantilever beam test was proposed for evaluating the mode Ⅰ-governed critical energy release rate representative of unidirectional composite rods, defined here as the mode Ⅰ critical separation energy, SEⅠC. This approach was used to characterize basalt fiber reinforced polypropylene rods. The relation between load and displacement is obtained from loading-holding-unloading tests, where apparent crack length—defined as the straight-line distance between the loading axis and crack tip—is measured at the end of holding time of each cycle; the start of crack propagation is confirmed by in-situ digital microscope observation. Scanning electron microscope observation of fracture surface reveals matrix crack growth and fiber–matrix interfacial debonding. The linear relation between apparent crack length and cube root of compliance is obtained, and the SEⅠC calculated by the compliance method is 1.5 ± 0.5 kJ/m2.

Per-phase spatial correlated damage models of UD fibre reinforced composites using mean-field homogenisation; applications to notched laminate failure and yarn failure of plain woven composites

A micro-mechanical model for fibre bundle failure is formulated following a phase-field approach and is embedded in a semi-analytical homogenisation scheme. In particular mesh-independence and consistency of energy release rate for fibre bundles embedded in a matrix phase are ensured for fibre dominated failure. Besides, the matrix cracking and fibre-matrix interface debonding are modelled through the evolution of the matrix damage variable framed in an implicit non-local form. Considering the material parameters of both fibre and epoxy matrix phases identified from manufacturer data sheets, it is shown that the failure strength of a ply loaded along the longitudinal direction is in agreement with the reported values. Finally, the multi-damage homogenisation framework is applied to model, on the one hand, the failure of a notched laminate, in which case the failure modes are observed to be in good agreement with experiments, and, on the other hand, the failure of yarns in a plain woven composite unit-cell under uni-axial tension.

Multiaxis three-dimensional (3D) glass fiber preform/cementitious matrix concrete composites: Experimental characterizations by panel test

Multiaxis three-dimensional (3D) alkali-resistant continuous glass fiber/cementitious matrix concrete composites were developed using the “winding and molding” method. The panel properties of the concretes were experimentally investigated and compared with the neat concrete. The experiment revealed that the load-bearing capability, strength and energy absorption properties of the multiaxis three-dimensional concretes were significantly influenced by the placement and orientation of the reinforcement fiber. The newly developed concrete composite was found to have the strain hardening behavior which attributed to an improved energy absorption performance of the concrete. It was also identified that four directional glass structure (ARG-4D) demonstrated somewhat better energy absorption performance compared to that of the biaxial (ARG-2D) and uniaxial (ARG-1D) structures because of the fiber orientation in the multiaxial direction in the concrete. Further investigation of the fractured four directional glass fiber/cementitious matrix concrete (ARG-4D) showed that the fiber-matrix interfacial debonding in each yarn set, local matrix breakages, yarn bridging due to tensile strengthening, tensile pull-out of outer filament and stick-slip frictions between the filament TOWs and the cementitious matrix were the principal fracture mechanisms. The micro-cracks occurred in multiaxis concretes were restricted by the multiaxis 3D fiber architecture. The multiaxis three-dimensional alkali-resistant continuous glass fiber/cementitious concrete can be considered as the damage tolerant structures with regard to neat concrete.

Study on interfacial debonding stress and damage mechanisms of C/SiC composites using acoustic emission

Among ceramic matrix composites (CMCs), carbon fiber-reinforced silicon carbide matrix (C/SiC) composites are widely used in numerous high-temperature structural applications because of their superior properties. The fiber–matrix (FM) interface is a decisive constituent to ensure material integrity and efficient crack deflection. Therefore, there is a critical need to study the mechanical properties of the FM interface in applications of C/SiC composites. In this study, tensile tests were conducted to evaluate the interfacial debonding stress on unidirectional C/SiC composites with fibers oriented perpendicularly to the loading direction in order to perfectly open the interfaces. The characteristics of the material damage behaviors in the tensile tests were successfully detected and distinguished using the acoustic emission (AE) technique. The relationships between the damage behaviors and features of AE signals were investigated. The results showed that there were obviously three damage stages, including the initiation and growth of cracks, FM interfacial debonding, and large-scale development and bridging of cracks, which finally resulted in material failure in the transverse tensile tests of unidirectional C/SiC composites. The frequency components distributed around 92.5 kHz were dominated by matrix damage and failure, and the high-frequency components distributed around 175.5 kHz were dominated by FM interfacial debonding. Based on the stress and strain versus time curves, the average interfacial debonding stress of the unidirectional C/SiC composites was approximately 1.91 MPa. Furthermore, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDXS) were used to observe the morphologies and analyze the chemical compositions of the fractured surfaces. The results confirmed that the fiber was completely debonded from a matrix on the fractured surface. The damage behaviors of the C/SiC composites were mainly the syntheses of matrix cracking, fiber breakage, and FM interfacial debonding.

Utilizing concrete pillars as an environmental mining practice in underground mines

Ground control is an integral element of mine design and worker safety. The use of concrete pillars for underground mines is of paramount importance to maintaining the economic and operational security of structures. This paper deals with the use of fiber-reinforced concrete (FRC) as pillars via laboratory and field tests. The strength performance of prepared concrete reinforced with glass, polypropylene and polyacrylonitrile fibers was researched by a mechanical press and a computed tomography (CT) tool. Samples were tested for fiber volume fractions of 0, 0.4, 0.8 and 1.2 wt%, respectively. Results have indicated that, with the addition of fibers, the strength was improved first due to a bridging effect and then decreased due to a pull-out effect. Compared to the reference sample, the absorbed energy prevents FRC from deterioration by mechanisms of matrix cracking, fiber-matrix interface debonding and fiber rupture. The peak strains of FRC linearly rise with increasing fiber. The gray value distribution curves have also good correspondence with 2D CT pore and crack distributions, which reveal that gray value processing could depict the structural behavior of concretes reinforced with or without fiber. Theoretical analyses show that the pillar remains stable for sustainable mining. Besides, the location and size of FRC pillars are suitable for numerical calculations of the trial stope. The findings of this study can offer a key reference for the orebody pillar recovery in underground mines.

Micromechanical progressive damage analysis of inter- and intra-layer failures in fiber-reinforced composite laminates

We analyze progressive damage and failure of composite laminates by using a micromechanical bridging model and compare numerical and experimental results for three fracture problems, namely, the four-point bending, the simple tension, and the simple tension of a laminate with an open hole at its centroid. These problems involve fiber–matrix interface debonding, constituents’ damage, interlayer delamination, and localized damage due to stress concentration. Macroscopic constitutive equations of unidirectional lamina, derived from those of the fiber and the matrix by using the bridging model with the fiber material assumed to be linearly elastic and the matrix to be elasto-plastic obeying the Drucker–Prager yield criterion, are employed. Strains in each constituent of the composite are assumed to be infinitesimal for the additive decomposition of strains into elastic and plastic parts to be valid, and the incremental plasticity theory is used. Stresses in the two constituents are found from their values in the homogenized material by using a dehomogenization technique. The intra-layer damage is assumed to initiate at a material point when the failure criterion for either the fiber or the matrix is satisfied. Young’s modulus of a constituent is degraded by following a Weibull distribution. A finite element is deleted when an energy-based failure criterion is satisfied in it, and the analysis is continued till the structure fails. The delamination between adjacent plies is simulated by including a thin resin layer at the interface and studying failure initiation and propagation in it. The computed reaction force versus the displacement curves and the failure patterns in the three problems are found to agree with the corresponding experimental data.

Experimental and numerical multi-scale approach for Sheet-Molding-Compound composites fatigue prediction based on fiber-matrix interface cyclic damage

In this paper, a multi-scale approach is proposed to predict the stiffness reduction of a Sheet-Molding-Compound (SMC) composite submitted to low cycle fatigue (until 2.105 cycles). Strain-controlled tensile fatigue tests (R = 0.1) are carried out at various strain ranges. Damage is investigated at both macroscopic and microscopic scales through the evolutions of Young’s modulus and SEM observations, after interrupted fatigue tests at different lifetime periods. The results show that the fatigue degradation of the composite is mainly controlled by fiber-matrix interface debonding. A quantitative analysis allows determining the threshold and kinetics of the fiber-matrix interface damage during cyclic loading as a function of the orientation of fibers. Moreover, a fiber-matrix interface damage criterion, taking into account the local cyclic normal and shear stresses at the interface, is introduced in the Mori and Tanaka approach in order to predict the loss of stiffness. The parameters of this local criterion are identified by reverse engineering on the basis of the experimental results described above. Finally, the predicted loss of stiffness is very consistent with the experimental results.

Prediction of debonding growth in two-dimensional RVEs using an extended interface element based on continuum damage mechanics concept

In the present study, a new interface model based on continuum damage mechanics (CDM) is developed to investigate the fiber-matrix interfacial debonding in the composite material. This model differs from Voronoi cell finite element and cohesive zone element method. To this purpose, a 2D classical elasticity formulation with non-interactive strength-based criteria and complex variable method with non-interactive energy-based criteria are applied for the analysis of the debond onset and propagation in an RVE with a single fiber, respectively. Then, the CDM approach is used to bridge between analytical and numerical methods. The developed model based on CDM is implanted into ANSYS commercial software to compare the accuracy of the proposed method with the obtained results by the cohesive zone model in RVEs containing single and multiple fibers. The admissible matching between the obtained stress-strain responses reveals the capability of the proposed approach to predict the fiber-matrix debonding as a primary damage mode in composite materials.