Delamination Fracture Research Articles

Experimental and numerical investigation on the tensile performances of bonded/bolted hybrid CFRP‐AL joints

AbstractReasonably designed hybrid joints can combine the advantages of both adhesively bonded and bolted joints, and have potential application value in improving the bearing capacity of the joint and ensuring structural safety. However, the failure behavior and damage mechanism of multi‐materials hybrid joints are not fully understood. In this paper, the mechanical performances of bonded, bolted, and hybrid CFRP‐aluminum alloy joints under tensile load were investigated using experiment and simulation methods. Based on the quasi‐static tensile test and fractography analysis, the mechanical behavior and damage mechanism of the three kinds of joints were studied, and the effects of hybrid effects were analyzed. The results demonstrated that there is no obvious co‐bearing effect between the adhesive layer and the bolt within the hybrid joint. Instead, a sequential load transfer behavior was observed. The hybrid joint showed more severe damage compared with the bolt joint, especially the CFRP delamination. Furthermore, a numerical model based on continuous damage mechanics (CDM) was established, the LaRC05 initial failure criterion and linear damage evolution were implemented to predict composite intra‐laminar failure, and the cohesive zone model (CZM) was used to simulate the inter‐laminar delamination and adhesive layer fracture. The model considers in situ effect, shear nonlinearity, and employs the selective parabola algorithm to improve computing efficiency. The comparison between experiment and simulation reveals that the model can accurately predict the mechanical performances of joints and capture the various failure modes.Highlights The performances of bonded, bolted, and hybrid CFRP‐aluminum alloy joints. The CDM model of CFRP includes LaRC05 criterion and stiffness degradation. Effect of damage constitutive models on the failure simulation of CFRP. Damage evolution and failure modes of three types of joints.

Understanding delamination behavior of air electrode in solid oxide electrolysis cells through in situ monitoring of internal oxygen partial pressure

In this study, we monitored the development of internal pO2 in solid oxide electrolysis cells (SOECs) in situ using an embedded probe and a reference electrode. Three types of air electrode cells were compared: LSM (La0.8Sr0.2MnO3−δ) + YSZ (Y0.08Zr0.92O2−δ), LSCF (La0.6Sr0.4Co0.2Fe0.8O3−δ) + GDC (Gd-doped ceria) and LSM + GdCeScSZ ((Gd2O3)0.005(CeO2)0.005(Sc2O3)0.1(ZrO2)0.89). The rate of pO2 increase with the increase in current density was highest in the LSM + YSZ cell, reaching ∼32201 atm at 0.6 A cm−2, resulting in air electrode delamination and intergranular fractures. This physically developed delamination with high pO2 is akin to catastrophic failure, accelerating degradation. The LSCF + GDC cells exhibited a maximum pO2 of ∼12.25 atm and operated stably without increasing pO2 or delamination. In the LSM + GdCeScSZ cells, internal pO2 was substantially suppressed to ∼10−3 atm, with a degradation rate comparable to that of the LSCF + GDC cell. However, the air electrode delaminated without intergranular fractures. This chemically developed delamination without high internal pO2 does not significantly accelerate degradation. These results indicate that the delamination mechanism may vary even with the same LSM electrode, depending on its ionic conduction characteristics.

Research Progress on the Impact Resistance of Basalt Fiber-Reinforced Polymer Composites

Abstract Basalt fibers exhibit excellent properties and have diverse applications. This paper thoroughly investigates the impact resistance of polymer matrix composites reinforced by basalt fibers and analyzes the failure mechanisms during impact, including micro-deformation, delamination, and fiber fracture. Basalt fiber-reinforced resin matrix composites consist of a reinforcement phase, a matrix phase, and an interface phase. To strengthen the material’s resistance to impacts, various approaches have been explored, including optimizing the matrix resin (e.g., selecting vinyl resin and toughening treatments), optimizing the reinforcement phase (e.g., fiber hybridization, morphology optimization, and interlayer hybridization), and improving the interface phase (e.g., coupling agent modification and carbon nanotube grafting). These optimization measures can significantly enhance the impact resistance of basalt fiber-reinforced polymer materials under low-velocity impact loads. Under high-velocity impact loads, increasing the number of laminate layers or employing three-dimensional weaving techniques can significantly improve the material’s impact resistance. These research findings aim to provide a theoretical foundation and practical references for the application of basalt fiber-reinforced polymer materials within the domain of impact resistance.

Effects of alloying elements on microstructure evolution, interfacial structure, and mechanical properties of Al/Cu laminate

Hot press sintering process was employed to fabricate the Al/Cu laminates with pure Al or 6061Al as interlayer, and the effects of alloying elements on microstructure evolution, interfacial structure, and mechanical properties were clarified. A good metallurgical bonding was achieved and intermetallic compounds layers consisting of Al4Cu9, Al2Cu, and AlCu phases formed at the Al/Cu interface. Mg element facilitated the enrichment of Cu atoms and provided the nucleation sites for Al2Cu, resulting in a thicker Al2Cu phase and numerous dispersed Al2Cu particles in 6061Al/Cu laminate. MgAl2O4 phase distributed along 6061Al/Al2Cu interface, and it exhibits a coherent relationship with both 6061Al and Al2Cu, which contributed to enhancing the resistance of dislocation movement and the effectiveness of load transfer. During the tensile deformation of Al/Cu laminate using pure Al as the interlayer, the cracks were more likely to propagate across the Al/Al2Cu interface into the Al layer. When 6061Al was used as interlayer, the overall higher tensile strength was achieved, and the tensile curves showed two distinct stress drops. Moreover, the cracks faced greater resistance when traversing the 6061Al/Al2Cu interface during the expansion, and they tended to extend along the 6061Al/Cu interface, showing a distinct delamination fracture morphology.

Effect of fiber orientation of adjacent plies on the mode I delamination fracture of carbon fiber reinforced polymer multidirectional laminates

AbstractThe extensive use of multidirectional composite laminates requires to understand the delamination behavior at interfaces between plies with different fiber orientations. In this study, double cantilever beam testing was performed to investigate the mode I interlaminar fracture of carbon fiber reinforced polymer laminates with different central interfaces (0//0, 0//+45 and +45//−45). X‐ray microtomography revealed the curved crack front shape that was incorporated to calculate fracture toughness. The fracture toughness varies with the crack length in a typical delamination resistance curve, which can be quantified by an empirical equation. Incorporation of variable fracture toughness into a cohesive zone model can better predict the delamination fracture of the laminate, compared to constant toughness. It was found that the delamination mechanism is independent of central interfaces. However, compared to unidirectional laminates, multidirectional laminates are less resistant to crack initiation, but more resistant to propagation with higher toughness and shorter fiber bridging zone.Highlights Mode I interlaminar fracture of CFRP laminates with different central interfaces was investigated experimentally and numerically. Curved crack front shape was incorporated to calculate fracture toughness. Incorporation of variable fracture toughness into a cohesive zone model can better predict the delamination fracture of the laminate. Multidirectional laminates are less resistant to crack initiation but more resistant to propagation with higher toughness and shorter fiber bridging zone.

Damage evolution and failure mechanism of 2.5D woven composite tubes under quasi-static lateral compression

2.5D woven composites are ideal candidate materials for deep-sea pressure tubes owing to their excellent out-of-plane properties. This paper presents the damage evolution and failure mechanism of 2.5D woven composite tubes under quasi-static lateral compression. To conduct this study, 2.5D woven composite tubes with different thickness-to-diameter ratios, 0.04, 0.07 and 0.10, were designed and prepared. The quasi-static lateral compression tests were carried out in order to evaluate the progressive damage analysis, combining high speed photographic image with acoustic emission technologies. The results show that the increase of the ratio of thickness-to-diameter, the deformation and shear failure of the sample can be inhibited obviously. Due to the enhanced interlayer interaction, the lateral stiffness of the sample is obviously improved, so the lateral bearing stability of the sample is improved. When the peak load of samples with the thickness-to-diameter ratio of 0.1 reached 11.51 kN, it exceeded that of samples with thickness-to-diameter ratios of 0.04 and 0.07 by 450% and 82%, respectively. Furthermore, the failure mechanisms of samples with the thickness-to-diameter ratio of 0.1 were controlled by delamination fracture, whereas that of 0.04 and 0.07 were mainly influenced by shear failure and delamination failure, respectively.

Fabrication and comparison of interlaminar fracture toughness behaviour of glass epoxy composites with recycled milled Kevlar-carbon hybrid fillers

Current research uses a novel recycled milled carbon (rmCF), recycled milled Kevlar (rmKF), and innovative Hybrid fillers (rmHF) of both to increase glass/epoxy composite laminate delamination resistance. This study examines how crack propagation and fibre orientation affect laminated composite delamination fracture toughness. Recycled milled Fillers in the interlayer increase stiffness, delamination resistance, and fracture toughness by increasing the energy needed to crack the interlaminar domain. Here, Mode I, Mode II, and Mixed Mode (I/II) with GIGII = 25 %, 50 % and 75 % were studied for four different Interface fibre orientations. It appears [06/902/06] increased delamination toughness. Adding the novel recycled milled fillers improved delamination resistance. Among the three fillers, rmCF increased fracture toughness by 271 % and rmHF and rmKF composites had 220 % and 182 % higher fracture toughness. The synergy compensated for Kevlar's lower fracture toughness in the hybrid (rmHF). SEM analysis of fractured surfaces revealed crack deflection, individual debonding, and filler/matrix interlocking, all of which increase fracture toughness on different levels.

Evaluation of mode-I delamination toughness of composites for automotive applications

Abstract With the increasing need for energy efficiency, fiber-reinforced composites are being widely used in the automotive industry. This study investigates the inter-laminar fracture behavior of fiber-reinforced composite double cantilever beam specimens considering a non-zero slope at the root. Experiments were conducted on unidirectional and cross-ply glass fiber reinforced epoxy composite specimens and the critical delamination toughness G I C has been evaluated by the proposed weighted residual equation. The proposed mathematical model requires crack length and the load versus displacement data to evaluate delamination fracture energy. This method accounts the measurement scatter and the rotation at the crack tip. For a particular specimen, the proposed model gives a unique value of critical delamination toughness value. The critical interface failure load estimates utilizing the evaluated delamination toughness agrees well with literature and in-house test results of double cantilever beam specimens.

Tension fracture delamination analysis on a hot rolled Nb-bearing high-strength steel for vehicle wheel application

A comparative analysis was conducted on post-tensile specimens with and without delamination to investigate the causes of tensile delamination in hot rolled steel with a 600 MPa ultimate tensile strength (UTS) for automotive wheel applications. The tensile specimens were sampled from the hot rolled coils in the transverse direction per ASTM A370 standards, and Tensile tests were performed at room temperature with a constant crosshead speed of 0.5 mm/min. The results indicate that normal segregation is not the sole factor contributing to delamination; rather, the presence of Nb lumps within the central segregation area increased the susceptibility to tensile delamination. The statistical analysis indicates that there is a more intense presence of Nb lumps in specimens with tension delamination, tension delamination will occur during specimen stretching when there are Nb lumps with an average size greater than 6.5 μm and a quantity greater than 3 in the central segregation region. Meanwhile, the sources of lumps are also analyzed indicates that these Nb lumps originate from the ferroniobium alloy added during BOF tapping and ladle refining.

A semi-analytical method for determining the mode-I delamination R-curve and fiber bridging traction-separation law of Double-double laminates

Delamination, as one of the most prevalent failure modes of composites, was significantly influenced by the interface angles. In contrast to the limited combinations of interface angles found in traditional laminates, DD laminates, with unique sequence [±Φ/±Ψ]rT and diverse interface angles , urgently required extensive experiments and high-precision simulation analyses to delve into the complexities and unique properties of their interlayer performance. However, the calculation process of current method for determining the R-curve and the bridging traction-separation law was time-consuming. This study proposed a simplified semi-analytical method based on the Euler–Bernoulli beam theory that only required recording initial crack length, final crack length, initial compliance and final compliance. The method validation showed that the deviation between the results obtained from the semi-analytical method and the MBT method averaged no more than 2%. In addition, a tri-linear cohesive zone model based on the delamination fracture micro-mechanism was developed combining semi-analytical method. Both the initial load and ultimate load errors between the simulation and experimental results were within 5 N, showing the accuracy of the model and the semi-analytical method. This method provided a simple and effective way to study the delamination propagation behaviors of DD laminates.

Modified mode I fracture toughness calculation method for composite laminate with large scale fiber bridging

Experimental investigation and theoretical analysis have been carried out in this study to assess the application limitation of the current ASTM D5528 method for Mode I fracture toughness calculation of composite laminate with fiber bridging. It is revealed that additional toughening effect introduced by the fiber bridging is not fully considered in the current method and consequently there are uncertainties associated with the fracture toughness calculated by the current ASTM method. Based on the same principle used in the development of the original ASTM method, a modified method is proposed to extend the applicability of the current method. The modified method is verified with mechanisms based cohesive zone modelling and numerical simulations of the Mode I delamination double cantilever beam tests. The significant improvement of the prediction results compared with experimental results by the modified method over the current method demonstrated its applicability for Mode I delamination fracture toughness calculation of composite laminates with large scale fiber bridging.

The low velocity impact properties of three- dimensional (3D) warp interlock woven composites according to the fabric architecture

Three-dimensional (3D) warp interlock woven composites (3DWIWC) are in demand in various industries due to their excellent delamination resistance, damage tolerance and fracture toughness properties. The 3D warp interlock woven fabric architecture can be defined by numerous fabric parameters such as: the binding and stuffer warp yarns, the woven pattern, the presence of yarn groups, etc. …. The effect of the fabric architecture on the impact behaviour of 3DWIWC made with carbon yarns has not been fully investigated. The binding warp yarns with the weave pattern play the main role in the arrangement of yarns within the final composite. In order to highlight their main influence, the 3D woven composites had been differentiated according to the main fabric architectural parameters, which are the angle and depth of binding warp yarn, presence of stuffer warp yarn and weave pattern of binding warp yarn. Afterward, their low velocity impact properties and damage mechanisms were examined. Thanks to the precise combination of these internal parameters of the fabric architecture, the contact force and absorbed energy values of 3DWIWC could be increased almost %50 and %15, respectively. Moreover, their damage mechanisms could be significantly improved.

Research on Gas Control Technology in Goaf Based on the Influence of Mining Speed

To comprehensively understand the influence of mining speed on gas emissions in goaf during coal seam extraction, enhance gas extraction efficiency in goaf, manage gas emissions at the working face, and ensure safety in the mining production process. This study focuses on the No. 3 mining area of Wangjialing Mine, employing numerical simulations to analyze the evolution of mining-induced fractures and the characteristics of gas distribution in the overburden at varying mining speeds. Furthermore, by integrating actual gas emission and extraction data at the production face, this study examines the quantitative relationship between mining speed and gas emissions in the goaf, identifying optimal regions for high-position borehole layouts and conducting borehole optimization design and investigation. The results of this study indicate that the initial caving step distance of the goaf roof increases with the advancement speed of the working face. Conversely, the maximum height of through fractures in the overburden decreases as the mining speed increases, while delamination fractures are minimally affected by the advancement speed. By categorizing and averaging data on goaf mining speed, the impact of initial and periodic pressure on gas emissions can be effectively mitigated, revealing a linear correlation coefficient of 0.94 between goaf gas emissions and mining speed. At varying mining speeds of the working face, the efficient extraction layer and horizontal distance parameters of gas extraction boreholes in the goaf conform to the linear equation y = ax ± b. Based on the research findings, an optimization design for mining face speed and high-level borehole parameters in the goaf was implemented. The average gas extraction rate of high-level directional boreholes reached 68% throughout the extraction period. Gas emissions at the working face were effectively controlled below 10 m3/min, with the maximum gas concentration at the upper corners and return airflow kept below 0.8%. This effectively managed gas emissions at the working face, ensuring safe production in the mine, providing a theoretical basis for identifying gas-rich areas in the mining-induced overburden, and enhancing gas extraction efficiency at the working face.

Revealing the failure mechanism of industrial Fe-25Cr-20Ni stainless steel plate: Fine-grained segregation band and brittle phase induced delamination cracking

The use of heat-resistant stainless steel thick plates in industrial production often presents challenges due to the presence of uneven microstructure and segregation, which can pose a persistent challenge for the prolonged safe operation of critical components made from such materials. This study aimed to investigate the fracture mechanism of an industrial Fe-25Cr-20Ni stainless steel plate at room temperature through uniaxial tensile experiments and fully reversed strain-controlled tension-compression fatigue experiments. Delamination cracks were observed on the fracture surfaces of both experiments. The specimens with fracture delamination were systematically studied by detailed microstructural evolution, and the failure mechanism and main reasons of fracture delamination were analyzed. The results show that the fracture delamination is related to the fine-grained segregation band (FGSB) consisted of fine grains and sigma phase located at the center of the thickness of the stainless-steel plate. The FGSB demonstrates low transgranular and intergranular fracture modes and exhibits bamboo knobs crack during plastic deformation, leading to a mixed fracture mode of ductile and brittle fracture. Furthermore, FGSB, as an anisotropic microstructure, which has a high stress concentration with nearby grains during plastic deformation. The sigma phase fracture and the weakening of the interface strength of the microstructure in FGSB provide a potential initiation site for fatigue crack initiation, thereby contributing to the possibility of aggravating fatigue damage and deteriorating fatigue performance. It is concluded that FGSB, as a metallurgical defect in stainless steel plates, is responsible for delamination failure.

Failure characteristics and fracture mechanism of overburden rock induced by mining: A case study in China

This study employs similar simulation testing and discrete element simulation coupling to analyze the failure and deformation processes of a model coal seam's roof. The caving area of the overburden rock is divided into three zones: the delamination fracture zone, broken fracture zone, and compaction zone. The caving and fracture zones' heights are approximately 110 m above the coal seam, with a maximum subsidence of 11 m. The delamination fracture zone's porosity range is between 0.2 and 0.3, while the remainder of the roof predominantly exhibits a porosity of less than 0.1. In addition, the numerical model's stress analysis revealed that the overburden rock's displacement zone forms an 'arch-beam' structure starting from 160 m, with the maximum and minimum stress values decreasing as the distance of advancement increases. In the stress beam interval of the overburden rock, the maximum value changes periodically as the advancement distance increases. Based on a comparative analysis between observable data from on-site work and numerical simulation results, the stress data from the numerical simulation are essentially consistent with the actual results detected on-site, indicating the validity of the numerical simulation results.

Impact and torsional behavior of additive layer-manufactured biopolymer: An advancement for orthopedic applications.

Distal ulna locking bone plates (DLBPs) are commonly employed in the treatment of distal ulna fractures. However, commercially available metallic bone plates experience stress shielding and lack corrosion resistance. Poly lactic acid (PLA) is highly favored biopolymer due to its biocompatible and bioabsorbable nature with human tissues. The use of additive layer manufacturing (ALM) is gaining attention for creating customized implants with intricate structures tailored to patient autonomy. ALM-based PLA bone plates must provide high resistance against impact and torsional forces, necessitating the adjustment of printing process parameters. This study focuses on examining the influence of key printing parameters, on the impact strength and torque-withstanding capability of DLBPs. Experimental results, along with microscopic images, reveal that an increase in infill density (IF) and wall thickness imparts strong resistance to layers against crack propagation under impact and torsional loads. On the contrary, an increase in layer height and printing speed leads to delamination and early fracture of layers during impact and torsional testing. IF significantly contributes to improving the impact strength and torque-withstanding capability of DLBPs by 70.53% and 80.65%, respectively. The study highlights the potential of the ALM technique in developing DLBPs with sufficient mechanical strength for biomedical applications.

Synergistic toughening by a layered microstructure and texture of Si-enriched ferritic/martensitic(F/M) heat resistant steel

In order to achieve favorable heat corrosion resistance, it is effective to add high Si contents to F/M heat resistant steel. Unfortunately, the high Si content results in a significant deterioration of impact toughness. Determining how to balance heat corrosion resistance and impact toughness has been a challenge. In this paper, we optimize austenite isothermal hot-rolling (AIHR) technique to the 10Cr1SiY F/M dual-phase heat resistant steel with 1% Si(wt.), to obtain layered microstructure with thread-like δ-ferrite. This decreases ductile-brittle transition temperature (DBTT) from 149 °C to 15 °C, and increases impact energy from 8 J to 107 J, compared to the quenched and tempered steel with the same chemical composition. According to the instrumented Charpy impact tests, higher impact energy derives from the absorbing energy during crack propagation, accounting for 94.9% of the total absorbing energy. The weak interfaces in the layered microstructure effectively deflect cracks, while the {110} slip plane induced by strong textures from multi-pass rolling promoted dislocation slip, thus rendering plastic deformation and weakening the crack tip stress; synergistic interaction is responsible for the improved toughness, resulting in the delamination fracture of the steel. The reduced grain size and M23C6 phases also contributes to the improved toughness.

Dual-scale numerical analysis of delamination in composite materials with varied fiber orientations at the interface

What is the relationship between the fiber orientation at delamination interface and the interlaminar fracture toughness of the composite? The answer is inconclusive based on experimental results. The conflicting observations stem from inconsistencies and inaccuracies in characterization techniques. As an alternative approach to circumvent the experimental challenges, the present study proposes a numerical dual-scale model for delamination, incorporating both micro- and meso-scale features. The model investigates two different fiber orientations at the mid-thickness interface: 0°/0° and 90°/90°. Comparative analyses demonstrate the importance of including a refined region with micromechanics to accurately predict the crack path during delamination. The results exhibit agreement with the literature models and enable estimation of early-initiation fracture toughness, considering delamination interacting with the microstructure while simulating a double cantilever beam specimen with reduced width. The approach provides a deeper understanding of delamination behavior and fracture toughness estimation, contributing to improving composite characterization techniques and design strategies.

Electrothermal Instabilities in Barium-Titanate-Based Ceramics

An electrothermal analysis for barium-titanate-based ceramics is presented, combining the Heywang–Jonker model for the electric resistivity with a heat dissipation mechanism based on natural convection and radiation in a one-dimensional model on the device level with voltage as the control parameter. Both positive-temperature-coefficient (PTC) and negative temperature coefficient (NTC) effects are accounted for through the double Schottky barriers at the grain boundaries of the material. The problem formulated in this way admits uniform and non-uniform multiple-steady-state solutions that do not depend on the external circuit. The numerical bifurcation analysis reveals that the PTC effect gives rise to several multiplicites above the Curie point, whereas the NTC effect is responsible for the thermal runaway (temperature blowup). The thermal runaway phenomenon as a potential thermal shock could be among the possible reasons for the observed thermomechanical failures (delamination fracture). The theoretical results for the NTC regime and the thermal runaway are in agreement with the experimental flash sintering results obtained for barium titanate, and 3% and 8% yttria-stabilized zirconia.

Effect of nanosecond laser pulse width and energy on damage characteristics in carbon fibre reinforced plastic (CFRP) laminates

AbstractThis study explores the effects of laser pulse width and energy on CFRP laminates damage in laser bond inspection technology. Three testing programs were used, including varying laser energy while keeping pulse width constant, altering pulse width while maintaining constant power density, and modifying pulse width while keeping energy constant. The results show that when the pulse width remains constant, increased laser energy has a minimal effect on the initial damage location but leads to gradual interlayer delamination and fiber fracture propagation toward the impact surface. With constant laser energy, a specific threshold for pulse width is observed. When the laser pulse width is below this threshold, it exhibits a positive correlation with the damage characteristics of CFRP laminates, whereas when it exceeds this threshold, it shows a negative correlation. Power density correlates with damage when pulse width is constant, but there is no direct correlation when pulse width varies.Highlights CFRP laminates underwent laser shock tests with varying pulse widths. Power density is positively correlated with damage under specific conditions. There exists a specific threshold for laser pulse width. In single‐sided laser shock, initial damage spreads within a specified range.