Interfacial Debonding Research Articles

An immersed finite element method for interfacial damage and debonding

An immersed finite element method for interfacial damage and debonding

Effect of Thermal Expansion Mismatch on Thermomechanical Behaviour of Compacted Graphite Iron

Compacted graphite iron (CGI) attracts significant attention in the automotive industry thanks to its suitable thermomechanical properties and cost-effectiveness. A primary fracture mechanism at the microscale for CGI involves interfacial damage and debonding between graphite inclusions and its metallic matrix, which can occur under high-temperature service conditions due to a mismatch in the coefficients of thermal expansion between these two phases. Such microscopic interfacial damage can initiate macroscopic fractures in cast-iron components subjected to thermal loading. While this phenomenon was studied in various composites, there remains a lack of detailed information for CGI, especially related to the complex morphology of its graphite inclusions. This study investigates the influence of graphite morphology and type of matrix on the thermomechanical performance of CGI at high temperatures. A set of three-dimensional finite-element models were developed in the form of unit cells with a single graphite inclusion embedded within a cubic domain of the metallic matrix. Elastoplastic behaviour was assumed for both phases in the numerical simulations. The study is focused on the response of the constituents in CGI to pure thermal loading in order to explore the relationship between graphite morphology and fracture mechanisms. The findings aim to enhance understanding of how graphite morphology affects the behaviours of CGI under high-temperature conditions.

A mode shape sensitivity-based wavelet feature extraction method for interface debonding detection in concrete-filled steel tubes

Abstract The use of concrete-filled steel tube (CFST) composite columns is increasingly prevalent in the construction industry, particularly in high-rise structures. A common issue in CFST columns is interface debonding between the concrete core and the steel tube. If this debonding progresses both superficially and deeply, it can lead to instability and buckling of the column, posing a serious threat to the overall structural integrity. This study presents an innovative and effective method for extracting damage-sensitive features using horizontal, vertical, and diagonal detail coefficients derived from the wavelet analysis of corrected modal signals. The study introduces the total normalized irregularity detection index (NIDIT) as a damage detection metric. The results indicate that NIDIT is highly effective in identifying and detecting debonding regions. NIDIT quantifies the accumulation of irregularities and disturbances in the affected areas, allowing for the detection of concrete surface debonding from the steel tube. The findings show that NIDIT can accurately and efficiently detect damage in middle and end-edge regions, addressing a significant challenge in structural health monitoring with high precision.

Computational analysis of the interfacial debonding in polymer composites: research progress and challenges

Computational analysis of the interfacial debonding in polymer composites: research progress and challenges

Experimental study and finite element analysis on the shear performance of steel-bamboo composite cellular beam

To study the influence of opening ratio on the shear performance of steel-bamboo composite cellular beams (SBCC), taking the opening size as the basic parameter, experimental research was carried out on five test beams. The failure modes and deformation characteristics of the specimens were observed, and the influence and law of the change of hole size on the shear performance of steel-bamboo composite cellular beams were analyzed. Through nonlinear finite element simulation calculation, multi-parameter analysis was carried out on the composite cellular beams, and the contribution of flanges to the shear performance of cellular composite beams was studied. The results show that the integrity of steel-bamboo composite cellular beams is good. The failure is mainly manifested as the fracture of bamboo web at the beam hole area, the buckling of section steel and the debonding and separation of steel-bamboo interface. The opening ratio has a great influence on the shear performance of steel-bamboo composite cellular beams. The thickness of bamboo flange cannot be ignored for the shear contribution of cellular beams. The shear capacity of cellular beams is shared by flanges and webs. The larger the opening ratio, the greater the shear contribution of flanges to composite cellular beams.

A cohesive fracture-enhanced phase-field approach for modeling the damage behavior of steel fiber-reinforced concrete

This study introduces a novel computational framework based on the phase-field fracture/damage model (PFM), providing rapid and accurate predictions of the damage behavior of Steel Fiber Reinforced Concrete (SFRC) material. The framework integrates the interfacial cohesive fracture model with the PFM to depict the interaction between the cementitious matrix and fibers, marking the first demonstration that this model adequately captures both local fracture phenomena between fibers and concrete (such as fiber bridging and interfacial debonding) and mesoscopic stress–strain behavior. Additionally, an enhanced geometric approximation is established based on the spatial distribution density function of fibers and particles, allowing for the transformation of the three-dimensions (3-D) fiber-reinforced material structure into an equivalent two-dimensions (2-D) material. This approach enables the reduction of computational time, a significant limitation of the phase-field method, thereby allowing an in-house code to perform various computations with complex material structures such as SFRC. The effectiveness of the approach is demonstrated through four examples involving variations in the microgeometry and material properties of SFRC structures, ranging from the simplest configurations to real experimental material structures. Extensive Monte Carlo simulations of the model are also employed to provide results closer to reality, which are then compared with recent experimental data and numerical models, demonstrating the efficacy of the proposed computational model.

Role of inclusion clusters on fatigue crack initiation in powder metallurgy nickel-based FGH96 superalloy

Inclusion clusters with a size of several tens of micrometers were found to be inclined to early crack initiation, resulting in an abnormally reduced fatigue life. Fatigue tests were conducted to elucidate crack initiation behaviors of inclusion clusters in nickel-based powder metallurgy (P/M) FGH96 superalloy. The inclusion clusters with varying sizes and shapes located at grain boundaries are composed of Al2O3, MgO and ZrO2 particles. The inclusion cluster with large size within 25-35 μm, small average particle distance within 0-4 μm and large orientation relative to loading direction within 35-66° will be more likely to cause crack initiation. In particular, the inclusion clusters with large size and high aggregation degree experience extruding during processing and subsequent heat-treatments due to the difference in thermal expansion coefficient with the matrix behave multiple cracking before fatigue loading, thereby facilitating crack initiation in the surrounding matrix grains. Moreover, as the main cracking part of inclusion clusters, the Al2O3 particles exhibit self-cracking and interface debonding, owing to higher hardness and poorer deformation coordination degree with matrix compared to other component inclusion particles.

Investigation into the effect of impact damage on compression behavior of the omega-stiffened composite panels

Abstract With superior performance and weight-saving potential, composite structures have been increasingly applied in the aerospace industry. The damage process and post-buckling deformation of composite panels under compressive load have been proven to limit the application of composite structures. For the purpose of utilizing the full potentiality of thin-walled composite structures, an experimental investigation was employed to explore the influence of impact damage on the buckling behavior and the load-carrying capacity of omega-stiffened composite panels. Pristine panels and impact-damaged panels were under compressive load until failure. The results showed that the pristine panels had higher compressive stability and ultimate strength, and the existence of impact damage led to a decline in the buckling load and the carrying capacity, which were up to 16% and 27%, respectively. Additionally, the complex stress state caused by the introduced impact damage influenced the buckling response and the damage patterns of the omega-stiffened panels. The pristine panels exhibited typical compression failure mode, with matrix crack and fiber breakage in the stringer and the skin. However, the collapse of the pre-damaged panels was dominated by the debonding of the skin-stiffener interface and the out-of-plane deformation of the skin.

A molecular insight into asphalt-aggregate interfacial debonding: The role of hydrogen bonds in water molecule migration

In this study, molecular dynamics were employed to compare the angles, lengths, and numbers of hydrogen bonds between water molecules and different aggregates. Compared to quartz, calcite has shorter bond lengths, larger bond angles, and a greater number of bonds with water molecules. The differences in hydrogen bonds lead to the formation of a three-layer structure on the calcite surface by water molecules: ordered, relatively ordered, and disordered, while a two-layer structure—relatively ordered and disordered—is formed on the quartz surface. In the ordered layer, water molecules experience the strongest hydrogen bonding, are neatly arranged, and have low diffusion coefficients. In contrast, the disordered layer is characterized by weaker hydrogen bonding, random arrangement, and higher diffusion coefficients. The movement path of water molecules shows that the debonding of asphalt and aggregate is jointly influenced by the migration behavior of both the underlying and upper-layer water molecules. These findings reveal the microscopic mechanism of water molecules forming a wedge shape at the asphalt-aggregate interface from the perspective of hydrogen bonds, explaining why the constraint of water on the Calcite {214} and Calcite {018} surfaces is stronger compared to Calcite {1 0 4}, but the bonding energy with asphalt decays more rapidly.

Finite-element investigations on the influence of material selection and geometrical parameters on dental implant performance

Abstract Dental implants provide functional and aesthetically pleasing dental replacements, but their longevity depends on biomechanical factors, physical characteristics, and patient variability. The present study used finite-element analysis to reveal the biomechanical response and potential modes of failure of dental implant systems subjected to normal occlusal loads. A generalized comparative assessment was carried out to measure the effect of the choice of crown material with zirconia, porcelain-fused-to-metal, and ceramic crowns. Such simulations showed complex patterns of stress distribution and deformation in the implant assembly with significant variation due to the mechanical properties of the crown material. Stiffer zirconia crowns magnified stress concentrations by 12.6, 10.8, 11.4, and 9.1% in the implant fixture, crown, cortical bone, and cancellous bone, respectively, compared with more compliant ceramic crowns. Furthermore, the maximal deformation of both the cortical and cancellous bone induced by zirconia crowns was higher by 21.1 and 19.2%, respectively, compared with the ceramic crowns. These results emphasize that the crown material properties are significant for controlling and modulation biomechanical load transfer, which plays a decisive role in the long-term durability and resistance to failure mechanisms such as interfacial debonding, bone resorption, and fatigue cracking. This study provides valuable information for optimizing implant designs and material selection that may improve clinical results, positively affecting patient satisfaction with dental implant therapy.

Three-dimensional fracture mechanics model of conch shells with hierarchical crossed-lamellar structures

Conch shells, characterized by a highly mineralized hierarchical crossed-lamellar structure that represents the pinnacle of molluscan evolution, exhibit exceptional crack resistance to protect their soft bodies from predatorial attacks. In this paper, we present a three-dimensional fracture mechanics model to establish a correlation between fracture toughness and the crossed-lamellar structure, elucidating the hierarchical crack bridging mechanism of aragonite lamellae. We find that increased fracture toughness is achieved through the energy dissipation contributed by the interfacial debonding of both first-order and second-order lamellae. The conch shells demonstrate outstanding resistance to cracking in two principal directions, featuring a locally stacked structure of flat plates that effectively withstand complex loads. The vertically alternating stacking structure of macroscopic layers of equal thickness inspires a biomimetic design with more balanced mechanical properties, accompanied by enhanced crack resistance observed as the lamellae become thinner. The theoretical results are in good agreement with relevant experimental measurements. This work not only sheds light on the physical mechanisms responsible for the remarkable fracture toughness of crossed-lamellar structures but also provides guidelines for designing high-performance biomimetic structural materials.

Investigations on the influence of thickness and preform structure on the mechanical performance of novel textile composites with woven Kevlar® fabric reinforcement and poly methylmethacrylate (Elium®) matrix

Abstract Elium (novel methyl methacrylate (MMA)) resin is a liquid thermoplastic resin curable at room temperature and a possible replacement for epoxies. The main objective of this work is to evaluate the mechanical characteristics of novel Kevlar fabric reinforced Elium composites with different thicknesses. The plain-woven structure Kevlar/Elium laminates were manufactured with 1.5 mm and 2.5 mm thicknesses through vacuum-assisted resin infusion moulding, where 8 and 12 layers of woven fabrics were used, respectively. The effect of laminate thickness was measured in terms of mechanical (tensile, flexural, shear, and dynamic mechanical analysis (DMA)) and physical (density and fibre volume fraction (FVF)) characteristics. The density of the laminates was found in the range of 1.18–1.31 g cm−3. FVF was 50.69 and 52.27% for 1.5 and 2.5 mm thick laminates, respectively. The composite with 1.5 mm thickness exhibited the highest tensile strength (667.9 MPa) and flexural strength of 330.7 MPa. Conversely, the highest interlaminar shear strength measured for 2.5 mm thick laminate is 16.5 MPa. The DMA analysis recorded the highest storage and loss modulus for 2.5 mm thickness laminates. The fractography analysis confirmed the quantified experimental observation of excessive interface debonding and delamination. Elium composites may be suitable for high-end structural applications, including marine and aircraft structures.

Hygrothermal aging behavior of C/GFRP hybrid rod with bundle‐by‐bundle dispersion

AbstractFiber hybrid with bundle‐by‐bundle dispersion can achieve the high performance of composites, fully understand the hybrothermal resistance of hybrid composites is the key to prove the applications in engineering structures. In the present paper, the hygrothermal resistance performances of new type carbon and glass fiber reinforced epoxy based hybrid rod with bundle‐by‐bundle dispersion produced by pultrusion technology is investigated experimentally. The tests of water absorption and desorption, thermal and mechanical performances are performed to obtain the evolution rules of hygrothermal aging. As a result, the water absorption of hybrid rod confirms to the Fick's diffusion behavior, the serious relaxation of resin matrix and the interfacial debonding of fiber‐resin exposed at high temperature provide more diffusion space for water molecules. Long‐term hydrothermal aging results in the recoverable plasticization of resin matrix and irrecoverable interfacial debonding of fiber‐resin, which brings about the degradation of 6.7%–15.0% for short beam shear strength (SBSS) retention. In addition, the plasticization effect reduces the cross‐linking density of resin matrix, which leads to the degradation of 3.3%–15.6% for glass transition temperature (Tg) retention. The life prediction results show that degradation rate of SBSS is gradually slow down and reached to a stable retention of 85.5%.Highlights Relaxation of resin matrix and interfacial debonding accelerate the diffusion of water molecules. Plasticization and interfacial debonding lead to the degradation of short beam shear strength retention and glass transition temperature. Long‐term life prediction shows that short beam shear strength e retention is 85.5%.

Interaction of propagating crack with microstructure in CGI: In situ tensile test and numerical simulation

Compacted graphite iron (CGI) is a double-phase material, in which complex graphite morphology greatly influences crack initiation and propagation. Despite its wide use and considerable past research on the fracture behaviour of CGI, the understanding of the interaction of propagating cracks with CGI's microstructure is still limited. In this study, a novel method is employed that integrates scanning electron microscopy (SEM) and an optical high-speed camera. This approach allows the clear visualisation of microstructures before and after fracture, as well as the calculation of crack-propagation rate during tensile tests. It is also revealed for the first time that in the case of graphite particles situated at a specific distance from the primary crack path, the initiation of secondary micro-cracks, near particles does not occur. A critical distance from the main crack path for crack initiation is analysed. Further, finite-element simulations are developed to study the effect of microstructure on the fracture behaviour of the tested microstructures. A Johnson-Cook (JC) damage model is calibrated and used in all simulations. The crack path and velocity of simulation results are in good agreement with the experimental data, demonstrating that the JC damage model can be used to predict the crack initiation and propagation of CGI. It is found that interface debonding and crack initiation always tend to appear near the tip of vermicular graphite. Thus, large vermicular graphite particles can affect negatively the toughness of CGI. Graphite particles situated farther from the primary crack significantly reduce the likelihood of crack initiation in that specific location. Furthermore, large nodular graphite particles absorb energy and generate secondary cracks, while small graphite particles have little effect on the crack-path direction. The newly discovered fracture mechanisms and simulation results provide new insights for the design and manufacture of metal-matrix composites (e.g., Al/SiC) with optimal mechanical properties.

Questioning the Representativeness of Damage Mechanisms in Single-Fiber Composites via In Situ Synchrotron X-Ray Holo-Tomography.

In fiber-reinforced polymer composites, the fiber-matrix interface controls stress transfer mechanisms, thereby affecting mechanical performance. Interfacial properties are often extracted via single-fiber composite tests. In these tests, the load is transferred from the polymer to the fiber through interfacial shear stresses, necessitating the evaluation of interfacial shear properties. To adopt these properties in the design of industrially relevant composites, one must assume that the damage mechanisms in single-fiber composites are representative of those in multi-fiber composites, consisting of highly aligned, unidirectional plies with high fiber volume fractions. That assumption, however, has never been validated. In this paper, the real-time damage development is monitored in single-fiber and multi-fiber composites using in situ X-ray holo-tomography at 150-nm pixel size. The technique enables the first-ever 3D detection of longitudinal interfacial debonding in carbon and glass single-fiber composites. This mechanism is not detected in multi-fiber composite specimens, suggesting that single-fiber composites are intrinsically unrepresentative of realistic composite behavior.

Experimental and Numerical Investigations of Tensile Properties of SiC Particle‐Reinforced Composites

In this study, experiments and finite element modeling (FEM) are performed to study the tensile mechanical properties of SiC particle‐reinforced 6061 Al‐matrix composites (SiCp/6061Al) at various volume fractions (VFs) of SiCp. The Young's modulus, yield strength, and tensile strength of SiCp/6061Al display an overall upward trend with the increment of the VF of SiCp. The fracture analysis results demonstrate that the fracture of SiCp/6061Al is a hybrid of matrix fracture, reinforcement fracture, and interface debonding. An algorithm is developed to construct the mesostructure of particle‐reinforced composites, based on the random sequential absorption algorithm. The VFs of the particles of the representative volume element (RVE) model constructed using the novel algorithm are as high as 42%. The tensile mechanical properties of SiCp/6061Al are predicted by replacing the irregular particle reinforcements in SiCp/6061Al with spherical particles in the RVE model. Comparisons reveal that the stress–strain curves obtained via experiment and FEM are highly consistent in the elastic‐plastic stage, which verifies the effectiveness and rationality of the novel algorithm.

Image-Based Peridynamic Modeling-Based Micro-CT for Failure Simulation of Composites

By utilizing computed tomography (CT) technology, we can gain a comprehensive understanding of the specific details within the material. When combined with computational mechanics, this approach allows us to predict the structural response through numerical simulation, thereby avoiding the high experimental costs. In this study, the tensile cracking behavior of carbon–silicon carbide (C/SiC) composites is numerically simulated using the bond-based peridynamics model (BB-PD), which is based on geometric models derived from segmented images of three-dimensional (3D) CT data. To obtain results efficiently and accurately, we adopted a deep learning-based image recognition model to identify the kinds of material and then the pixel type that corresponds to the material point, which can be modeled by BB-PD for failure simulation. The numerical simulations of the composites indicate that the proposed image-based peridynamics (IB-PD) model can accurately reconstruct the actual composite microstructure. It can effectively simulate various fracture phenomena such as interfacial debonding, crack propagation affected by defects, and damage to the matrix.

Performance Evaluation of Pebble Concrete for Pavement: A Study on the Sucre Highway Project

Bolivia has abundant pebbles, while the supply of crushed stone is limited and unstable. Thus, the resource utilization of local pebble as a coarse aggregate and the guarantee of concrete durability are the key scientific issues in the Sucre Highway Project. In this paper, a comparative analysis was conducted of the performance of crushed stone concrete and pebble concrete. Additionally, the impact of fly ash on the water permeability resistance of concrete was investigated. The results indicate that the apparent density, bulk density, and void ratio of pebbles are lower than those of crushed stone, and the aggregate gradation of pebbles is dispersed. The type of aggregate is the primary factor influencing the splitting tensile strength of concrete, with the main failure modes of pebble concrete being slurry cracking, aggregate crushing, and interface debonding. While aggregate and fly ash have a minor effect on compressive strength, they significantly impact flexural tensile strength; however, all concretes meet the requirements for extra-heavy, very heavy, and heavy traffic load levels. In terms of impermeability, fly ash effectively mitigates the negative impact of aggregate type on the impermeability of concrete. These findings support the application of pebble concrete in the highway project.

Decreasing propagation rate of interfacial debonding between a single carbon fiber and epoxy matrix under cyclic loading

The interfacial debonding of a single carbon fiber transversely embedded in a dumbbell-shaped epoxy sample was generated under cyclic loading, and images were captured using synchrotron radiation X-ray computed tomography. A fatigue testing machine driven by a piezoelectric actuator placed along the beamline for in situ observation was developed for precise alignment. Interfacial debonding was initially observed under a static tensile load and was confirmed to be almost of the same length at both ends of the carbon fiber, implying negligible bending deformation due to inclination. Cyclic loads were then applied to the sample to capture the progressive debonding. The propagation rate of the interfacial debonding decreased as the number of cycles increased. Another sample with a single carbon fiber aligned parallel to the loading direction was prepared following a single-fiber fragmentation test. Interfacial debonding was clearly observed around the fiber breakage. Cyclic loads were also applied to this sample; however, no progression of the interfacial debonding was evident. Degradation of the interfacial strength between the carbon fiber and epoxy matrix was not confirmed under cyclic loading within the elastic deformation range.

Three-point bending damage detection of SiC coated C/C composites based on acoustic emission

In this study, the three-point bending process of needled C/C composites, pack cementation SiC coated-C/C composites (PC-SiC-C/C) and chemical vapor deposition SiC coated-C/C composites (CVD-SiC-C/C) were monitored by the acoustic emission (AE) technology. To study the bending damage evolution process of three kinds of composite materials, the K-means algorithm was used to analyze the AE characteristic parameters. The damage type was analyzed by combining the electron microscope image of the sample fracture. The findings revealed that C/C composites and CVD-SiC-C/C composites contain three distinct types of damage: matrix cracking, carbon fiber-pyrolytic carbon interface debonding, and fiber fracture under three-point bending loading. PC-SiC-C/C composites has two additional damage: coating cracking and pyrolytic carbon-SiC interface debonding. The various damages could be identified by different AE signals: matrix cracking (175.781–421.875 KHz), carbon fiber-pyrolytic carbon interface debonding (70.312–164.062 KHz), fiber fracture (2.929–46.875 KHz), coating cracking (375–585.937 KHz), pyrolytic carbon-SiC interface debonding (169.921–257.812 KHz). The cumulative AE energy shows that the order of damage types of the three composites during the three-point bending loading is different.