Interlaminar Strength Research Articles

Statistical Analysis of Large Format Additively Manufactured Polyethylene Terephthalate Glycol with 30% Carbon Fiber Tensile Data.

In large format additive manufacturing (LFAM), a keener understanding of the relationship between the manufacture method and material temperature dependency is needed for the production of large polymer parts. Statistical analyses supported by material properties and a meso-structural understanding of LFAM are applied to elucidate tensile data trends. The data from LFAM polyethylene terephthalate glycol with 30% carbon fiber (CF) (PETG CF30%) panels (diagonal, horizontal, and vertical in the x-y print plane) and injection-molded specimens tensile tested at six different testing temperatures (room temperature, 40 °C, 50 °C, 60 °C, 70 °C, and 80 °C) were used for statistical analyses. A standard deviation, a coefficient of variation, and a two-way and one-way analyses of variance (ANOVA) were conducted. The manufacturing method (44.2%) and temperature (47.4%) have a strong effect on the ultimate tensile strength, in which temperature (82.6%) dominates Young's modulus. To explain the difference between the ultimate tensile strength of vertical, diagonal, and horizontal specimens at room temperature, a visual inspection of the specimen failure was conducted and the maximum stress at the crack tip was calculated analytically. The decreased strength in the diagonal specimens resulted from the reliance on interlaminar adhesion strength. Future work will consider the effect of the void space variation on tensile strength variance.

Damage monitoring of glass/epoxy-curved laminates with different stacking sequences using acoustic emission

Delamination is a major concern in the curvature area of a composite laminate due to the flexural stresses occurring between the laminates. This research focuses on the respective merits of different stacking sequences obtained by layering the glass fiber reinforcement at various orientations in an epoxy resin to manufacture a curved laminate. In particular, laminates with stacking sequences, such as Unidirectional [0°]24, Cross-ply [0°/90°]6S, Angle ply [±45°]6S, and Quasi-isotropic laminates [0°/±45°/90°]3S, were tested by performing four-point bending tests. Acoustic emission (AE) monitoring and experimental analysis characterized damage modes, including delamination. AE parameters, such as amplitude, energy, duration, cumulative count, and peak frequency, were utilized to characterize the damage mechanisms of the various stacking sequences. Experimental AE data confirmed that fiber orientation influences delamination resistance and failure mechanisms. Furthermore, compared to other layup sequences, the peak load of cross-ply (Layup B) was found to be greater by 48.7%, 32.87%, and 50.14%. Cross-ply curved laminates also have higher interlaminar tensile strength and curved beam strength than other sequences. They also failed less often due to delamination than other sequences. Finally, scanning electron microscope characterization verified and validated all damage processes found in the AE data collection. As a result, these findings play a significant role in predicting the lifetime, delamination failure, and strength of curved composite laminates.

Interlaminar tensile strength of Alumina-Based Oxide/Oxide ceramic matrix composite at room temperature and 1200 °C using diametral compression test method

The diametral compression test method on circular disks is used in this study to determine the interlaminar tensile strength of an alumina-based Oxide/Oxide ceramic matrix composite at room temperature, 1200 °C, and at room temperature after being thermally aged for 150 h at 1200 °C. Digital image correlation was used in all the tests to measure the full-field strain and observe the progression of interlaminar failure. Post-test fractography was performed to identify the fracture characteristics. All the specimens failed along the disk diameter that coincided with the line of loading, proving the reliability and repeatability of the test method. The thermally aged specimens showed the stiffest response and the highest interlaminar tensile strength. This is attributed to further densification of the matrix due to the thermal aging, confirmed by microstructural characterization. The path of fracture at catastrophic failure traversed the matrix in both the inter-ply and intra-ply regions.

Development and Evaluation of a Novel Method for Reinforcing Additively Manufactured Polymer Structures with Continuous Fiber Composites

Additively manufactured polymer structures often exhibit strong anisotropies due to their layered composition. Although existing methods in additive manufacturing (AM) for improving the mechanical properties are available, they usually do not eliminate the high degree of structural anisotropy. Existing methods for continuous fiber (cF) reinforcement in AM can significantly increase the mechanical properties in the strand direction, but often do not improve the interlaminar strength between the layers. In addition, it is mostly not possible to deposit cFs three-dimensionally and curved (variable–axial) and, thus, in a path that is suitable for the load case requirements. There is a need for AM methods and design approaches that enable cF reinforcements in a variable–axial way, independently of the AM mounting direction. Therefore, a novel two-stage method is proposed in which the process steps of AM and cF integration are decoupled from each other. This study presents the development and validation of the method. It was first investigated at the specimen level, where a significant improvement in the mechanical properties was achieved compared to unreinforced polymer structures. The Young’s modulus and tensile strength were increased by factors of 9.1 and 2.7, respectively. In addition, the design guidelines were derived based on sample structures, and the feasibility of the method was demonstrated on complex cantilevers.

Processing and properties of 3D woven SiC/SiC composites with hybrid matrix

3D woven SiC/SiC composites with Sylramic™-iBN SiC fibers have been fabricated by first partially infiltrating 3D woven fiber preforms with SiC by chemical vapor infiltration (CVI) and then by polymer infiltration and pyrolysis (PIP) of SiC-yielding polymer. The influence of fiber architecture on damage evolution and failure mechanisms during tensile loading, in-plane tensile properties, transverse thermal conductivity, and interlaminar tensile strength of the composites has been investigated. Wherever possible, the data are compared with those of 2D woven melt infiltrated (MI), CVI, and (CVI+PIP) hybrid SiC/SiC composites. The composites exhibit 300-hr creep durability at 1482 °C in air at stresses up to 138 MPa and show potential for elevated-temperature applications. Further improvements in composite properties are possible by optimizing composite constituents and fiber architecture.

Preparation and characterization of high load‐bearing needled composite preform based on novel ordered short fiber network needling method

AbstractNeedled preform and its composite using felt and base cloth stacked needled have small fiber volume fraction and relatively weak mechanical properties, which are difficult to meet the service requirements of structural and functional integrated components of high‐speed aircraft. Responding to this issue, this paper proposed a new method for preparing high load‐bearing needled composite preform based on ordered short fiber network needling. The high load‐bearing needled preforms were prepared by designing different structural parameters of ordered short fiber network and forming process parameters, and then preform structure was characterized and mechanical properties were tested. The results showed that using ordered short fiber network as carrier of the short fibers, the formed needled fiber bundles were longer and denser, volume content of needled fiber bundles and mechanical properties of needled preform were greatly improved, and needled fiber bundles volume content of ordered short fiber network reinforced needled preform was 1.5 times and 46.3 times that of half‐cut cloth and felt respectively. Compared with traditional felt needled preform and half‐cut cloth needled preform, the interlaminar peeling strength of the ordered short fiber network reinforced needled preform increased by up to 246.4% and 49.2%, respectively. The tensile strength of ordered short fiber network reinforced needled preform was 12.9% higher than that of half‐cut cloth in X‐axis direction. In addition, the effects of ordered short fiber network structure, short fiber length, areal density and needling density on the needled preform structure and properties were also revealed.Highlights High load‐bearing needled composite preform was prepared based on novel ordered short fiber network needling method. The needled fiber bundles formed by using ordered short fiber network were longer and denser, and their volume content was 46.3 times that of felt needled preform. The interlaminar peeling strength of the ordered short fiber network reinforced needled preform increased by up to 246.4%. The tensile strength of ordered short fiber network reinforced needled preform was 12.9% greater than half‐cut cloth in the X‐axis direction.

Outstanding interlaminar strength of carbon fiber reinforced epoxy resin via graphene oxide chemical bridge bonding

Carbon fiber reinforced polymers (CFRPs) are susceptible to interlaminar failure under high shear stress, which reduces their service life. Herein, we report a strategy to address the interlaminar damage problem of CFRPs by utilizing graphene oxide (GO) as a bridge to chemically bond carbon fibers and epoxy resin. Amino groups were grafted on the surface of carbon fibers to react with GO, then active amino functional groups were introduced onto GO, enabling crosslink with the epoxy resin. The chemical bonding force and mechanical interlocking effect of GO tightly integrated the carbon fibers with the epoxy resin, greatly reducing relative slip under high shear stress. This flexible and robust connection resulted in a significant improvement in the interfacial adhesion strength of CFRPs. The GO content and type of amino reactants were optimized to fabricate CFRPs, and the interlaminar shear strength and transverse fiber bundle tensile strength were increased to 76.36 MPa and 34.2 MPa, which were 46.2 % and 77.2 % higher than those of pre-modification materials, respectively. This research demonstrates that the chemical bonding provided by grafting graphene oxide significantly enhances interlaminar bond strength, thereby extending the service life of CFRPs and offering a promising path for manufacturing high-strength composites.

Guided Ultrasonic Wave Monitoring of Damage in Anisotropic Composites

Lightweight, carbon fibre reinforced composites are often employed for the manufacture of aerospace components due to their good strength to weight ratio. However, due to poor interlaminar strength, composite components are prone to barely visible impact damage, caused by low velocity impacts, during aircraft operation. Guided-wave-based structural health monitoring (SHM) techniques, using a network of distributed sensors, is an important Structural Health Monitoring (SHM) tool for the detection and localization of in-service impact damage in composite structures. However, the material anisotropy of composite laminates influences guided wave propagation and scattering. These anisotropic effects, if unaccounted for, could lead to inaccurate localization of damage, and potential regions of the structure where guided waves cannot propagate with sufficient amplitude, reducing damage sensitivity. Defect characterization can be improved by considering the scattering characteristics of various damage types for the sparse array signal processing. Guided wave scattering (A0 Lamb wave mode) was investigated around an artificial insert delamination in a quasi-isotropic CFRP panel. Permanent magnets, mounted on an undamaged region of the plate, were also used as scattering targets and compared to the delamination case. Full 3D Finite Element (FE) simulations were performed for both the delamination and magnet cases and compared to wavefield data obtained from non-contact laser Doppler vibrometer (LDV) measurements. Individual ply layers were modelled using unidirectional composite material properties to accurately capture the anisotropy effects. Good agreement was found between the experimental measurements and simulations. Scattered guided wave amplitudes around each damage type show strong directional dependency with energy focusing along the fiber directions of the outer ply layers of the laminate. Distinct scattering behavior was observed for each damage type. Implications of anisotropy and angular scattering on sparse array SHM of different defect types are discussed.

Mechanical Characterization and Production of Various Shapes Using Continuous Carbon Fiber-Reinforced Thermoset Resin-Based 3D Printing.

Continuous carbon fiber-reinforced (CCFR) thermoset composites have received significant attention due to their excellent mechanical and thermal properties. The implementation of 3D printing introduces cost-effectiveness and design flexibility into their manufacturing processes. The light-assisted 3D printing process shows promise for manufacturing CCFR composites using low-viscosity thermoset resin, which would otherwise be unprintable. Because of the lack of shape-retaining capability, 3D printing of various shapes is challenging with low-viscosity thermoset resin. This study demonstrated an overshoot-associated algorithm for 3D printing various shapes using low-viscosity thermoset resin and continuous carbon fiber. Additionally, 3D-printed unidirectional composites were mechanically characterized. The printed specimen exhibited tensile strength of 390 ± 22 MPa and an interlaminar strength of 38 ± 1.7 MPa, with a fiber volume fraction of 15.7 ± 0.43%. Void analysis revealed that the printed specimen contained 5.5% overall voids. Moreover, the analysis showed the presence of numerous irregular cylindrical-shaped intra-tow voids, which governed the tensile properties. However, the inter-tow voids were small and spherical-shaped, governing the interlaminar shear strength. Therefore, the printed specimens showed exceptional interlaminar shear strength, and the tensile strength had the potential to increase further by improving the impregnation of polymer resin within the fiber.

Interlaminar tensile properties of raw and carbon fiber‐wrapped additively manufactured polyetherimide

AbstractHigh‐performance engineering thermoplastics are important emerging materials, particularly when processed using additive manufacturing technologies. One of the most important among these is polyetherimide, also known as PEI or ULTEM. Using the fused filament fabrication (FFF) additive manufacturing (AM) process to form this material is a good option, but it is difficult to control the properties in some cases due to the very high processing temperature compared with most engineering thermoplastics. One way to “even‐out” the properties is to wrap the specimens in continuous glass or carbon fibers embedded in a thermosetting matrix, as this allows strategic placement and orientation of reinforcement. This also complements the natural structure of the FFF‐manufactured materials, helping to minimize the amount of additional weight that needs to be added to a part. To further knowledge in this area, the present study explored and compared the interlaminar tensile strength of FFF‐processed PEI/ULTEM 9085 specimens and compared them with ones wrapped in carbon fibers with a 2‐part resin matrix. Experiments were performed in accordance with the guidelines given in the ASTM D6415 standard and replicated five times. Variations were introduced in thickness of the specimen and raster angle during the manufacturing process to identify the significant impact of the failure. The results show a fall in interlaminar tensile strength with increasing specimen thickness and a very large effect from natural printing defects in the samples. The carbon fiber wrap decreased the ILTS but made the results far more consistent between experimental runs. This study provides a good, replicated dataset on the performance of raw and fiber‐wrapped FFF‐processed ULTEM 9085 and gives insights into the structural behavior of the material that will be useful for use in design decisions and material selection.Highlights Polyetherimide, also known as PEI/ULTEM, is a high‐performance engineering thermoplastic. Explored the interlaminar tensile properties (ILTS) of this material using ASTM D6415. Raster angle, thickness, and use of fiber wrap were experimental parameters. Fiber wrap was found to have little effect on strength but made results more consistent. Results are useful for material selection and design decisions using PEI.

Assessment of crack suppression in glass/epoxy curved laminates by incorporating micro and nanofillers

AbstractThe design of structures with a large radius of curvature is challenging because fiber‐reinforced composite materials have low resistance to delamination in the direction perpendicular to their thickness. These structures are commonly found in a wide variety of structural components that are used in the wind turbine and aviation industries. The objective of this study is to conduct an experimental investigation into the efficacy of incorporating milled glass fiber, cellulose nanoparticles, and carbon nanoparticles as fillers into an epoxy matrix to improve the resistance to delamination of glass/epoxy curved laminates and thereby inhibit crack growth. In contrast to the baseline samples, curved samples containing 3% cellulose nanoparticles demonstrated enhanced curved beam strength and interlaminar tensile strength by 4.95% and 3.82%, respectively. Additionally, filler‐loaded samples exhibited reduced delamination and fracture propagation damage compared with baseline samples. The adhesion between the epoxy matrix and infill was investigated by means of Fourier transform infrared analysis. In addition, live photographic images and fractured micrographs were correlated with mechanical findings in order to assess delamination suppression and damage processes in both the arm and arc directions.

Reusing uncured Fiber-reinforced thermoset composite Prepreg waste with water-soluble PVA backing film

One challenge in reusing uncured composite prepreg waste is the removal of the backing film. Ensuring that no backing film remains during the reuse of composite prepreg material is crucial, as the presence of backing film in the laminate can contaminate the part, leading to defects such as delamination. Manual removal of the backing film from the leftover uncured composite prepreg is a labor-intensive task, and ensuring there is no remaining backing film in the prepreg waste can be challenging. To address these issues, the authors implemented a water-soluble polyvinyl alcohol (PVA) film as the backing material for the prepreg, allowing less labor-intensive removal of the PVA backing film by soaking the prepreg in water before reusing. In this study, 20 μm thick 100% PVA film was utilized as backing material for carbon fiber-reinforced thermoset composite prepreg. The performance of the PVA film as a prepreg backing material was assessed, and the process of removing the backing film was demonstrated. To investigate the impact of the backing film removal process on the mechanical properties of the reused prepreg, tensile and double cantilever beam (DCB) tests were conducted. The results indicated that the PVA backing removal and drying processes did not show any significant influence on the tensile properties and interlaminar strength of the reused composite prepreg. Furthermore, this study demonstrated the recycling of the PVA solution used in the backing removal process to produce new PVA film. The application of PVA as a backing film not only simplified the backing film removal for reused prepreg but also established a sustainable closed-loop recycling system for prepreg backing film.

Multiscale damage and low-velocity impact study of three-dimensional woven composites

Three-dimensional woven composites address the limitation of weak interlaminar strength found in traditional laminated composites and offer superior resistance to out-of-plane impact. However, the complex material composition and structural intricacies necessitate investigation into their damage mechanisms. This study introduces novel and reliable microscale and mesoscale Representative Volume Element (RVE) models for three-dimensional woven composites, developed through advanced CT scanning and comprehensive multi-directional tensile and shear experiments. The research explores the impact of fiber volume fraction on yarn mechanical properties using the microscale RVE model, yielding precise macroscale homogenization parameters through the mesoscale RVE model. Furthermore, a macro-meso model tailored for low-velocity impact scenarios is established, significantly enhancing computational efficiency without compromising accuracy, thus providing support for further research on the impact properties of three-dimensional woven composites.

Enhanced mechanical properties of continuous carbon fiber reinforced polyether-ether-ketone composites via infrared preheating and high fiber volume fraction

The field of additive manufacturing encounters an innate challenge regarding insufficient interlayer adhesion and anisotropy, which consequently constrains the mechanical properties of printed materials. Continuous fiber-reinforced thermoplastic composite (CFRTP) printing allows ultra-high mechanical properties using a material extrusion (ME) platform but is still significantly affected by the mentioned inherent challenges. The expansion of the usage spectrum for composites manufactured with additive methods depends on overcoming these challenges. Achieving higher fiber volume fractions is a primary method for enhancing the mechanical properties of CFRTP parts. However, it has been proven that high fiber volume fractions can adversely affect mechanical properties due to lower impregnation and reduced interlayer strength. In this study, a high fiber volume fraction of 50 % was utilized, and interlayer strength was further improved by employing an infrared heater to preheat the previous layers. This approach resulted in better interlaminar strength and overall mechanical properties, demonstrating the effectiveness of infrared heating in mitigating the challenges associated with high fiber volume fractions. The infrared heater was positioned in a rotating printing head so it could continuously stay in front of the print path. Mechanical tests showed a flexural strength of 1304 MPa and tensile strength of 995 MPa, with high fiber volume fraction and infrared assistance. As far as we know, these values represent the highest achieved in the literature for CFRTP printing without any post-processing. Optical images and differential scanning calorimeter (DSC) tests were used to investigate the microstructure and thermal properties of the printed samples.

Research on foldable two-matrix 3D braided composites: Manufacturing and bending progressive damage

Research on foldable two-matrix 3D braided composites: Manufacturing and bending progressive damage

Structural Health Monitoring of Fiber Reinforced Composites Using Integrated a Linear Capacitance Based Sensor.

The demand for fiber-reinforced polymers (FRPs) has significantly increased in various industries due to their attributes, including low weight, high strength, corrosion resistance, and cost-efficiency. Nevertheless, FRPs, such as glass and Kevlar fiber composites, exhibit anisotropic properties and relatively low interlaminar strength, rendering them susceptible to undetected damage. The integration of real-time damage detection processes can effectively mitigate this issue. This paper introduces a novel method for fabricating embedded capacitive sensors within FRPs using a coating technique. The study encompasses two types of fibers, namely glass and Kevlar fiber/epoxy composites. The physical vapor deposition (PVD) technique is employed to coat bundle fibers with conductive material, thus creating embedded electrodes. The results demonstrate the uniform distribution of nanoparticles of gold (Au) along the fibers using PVD, resulting in a favorable resistance of approximately ≈100 Ω. Two sensor configurations are explored: axial and lateral embedding of the coated yarn (electrodes) to investigate the influence of load direction on the coating yarn. Axial-sensor configuration specimens undergo tensile testing, showcasing a linear response to axial loads with average sensitivities of 1 for glass and 1.5 for Kevlar fiber/epoxy composites. Additionally, onset damage is detected in both types of fiber composites, occurring before final fracture, with average stress at the turning point measuring 208 MPa for glass and 144 MPa for Kevlar. The lateral-sensor configuration for glass fiber-reinforced polymer (GFRP) exhibits good linearity towards strain until failure, with average gauge factors of 0.25 and -2.44 in the x and y axes, respectively.

Advanced adhesive repairs and reinforcements for curved glass/epoxy composite laminates

This study investigates the repair of damaged curved glass/epoxy composite laminates through various adhesive reinforcements and adhesively bonded external patches. The experimental procedures involve fabricating laminates, conducting four-point bending tests, quasi-static indentation tests, and optimizing damaged areas. Results demonstrate the influence of repairs on curved beam strength and interlaminar tensile strength. Adhesive repairs with chopped fiber reinforcement outperform plain epoxy and particle fiber-reinforced repairs, preserving 51.28% of curved beam strength. Adhesively bonded external patches, both single and double, with chopped fiber reinforcement exhibit significant strength recovery 72.08% and 80.78% compared to virgin samples. The study emphasizes the effectiveness of adhesively bonded external patches, particularly those with chopped glass fiber reinforcement, in enhancing curved beam strength and interlaminar tensile strength. This research provides valuable insights for repairing angled structures, such as those in airplane components, showcasing potential applications of these techniques for structural maintenance.

Progressive failure simulation of angled composite beams subject to flexural loading

Laminated composite structures, while offering weight savings compared with their metal counterparts, are susceptible to ply separation, (i.e., delamination mode of failure) due to the lack of through-thickness fiber reinforcements. In this paper, numerical simulations are used to gain an enhanced understanding of angled composite beam delamination when subjected to four-point bending consistent with the ASTM D-6415 test standard, with an expectation that the learning gained from this work is extensible to laminated composite components in general. While illustrating mesh sensitivity, manufacturing and frictional effects, four items of interest are examined: (1) the undamaged state/pre-peak load response, (2) the through-thickness peak tensile capability, (3) the post-peak load drop, and (4) the subsequent post-peak damaged response. A Finite Element Analysis (FEA) model is developed that incorporates the Smeared Crack Approach (SCA) to capture progressive failure modes within the element formulations directly, effectively eliminating the need for a priori specification of discrete delamination zones. The ability to incorporate failure directly within the element structure is particularly notable where laminates may not realistically permit a high number of interface layers or where geometry may be complex. Leveraging experimental data of curved composite laminates subject to four-point bending, the proposed approach successfully predicts the correct behavior throughout the damage progression. Additionally, this study offers an insight into effects of manufacturing-induced imperfections and frictions between the specimen and fixture on the prediction of inter-laminar strength of a curved composite part.

Influence of Stitch Angle on the Flexural Response of Composite Structures

Utilizing lightweight composites in aerospace vehicles plays a pivotal role in sustainability by improving fuel efficiency and mitigating emissions. However, due to their low interlaminar strength, delaminations and microcracking degrade their strength and stiffness properties. Through-thickness stitching improves the interlaminar strength, thus increasing the delamination tolerance of composite structures. Therefore, in this study, the influence of repeated periodic stitching patterns, stitched at three different angles (0, 45, and 90°) w.r.t. the transverse direction, on the flexural properties of stitched composites is investigated. The strain distributions of these specimens were obtained using a single continuous optical fiber bonded to the tensile surface of the specimens. The results show that stitching at a 45° angle produced lower strains and higher flexural strength and bending modulus when compared to the stitched and unstitched laminates. An increase of 32.3 and 47.4% in the flexural strength and bending modulus were obtained, respectively, with reference to the unstitched laminates. The failure morphology of specimens was also analyzed using optical microscopy and revealed that the stitch seams arrested delaminations. However, due to the 45° angle, the damage progressed along a longer distance, thus resulting in an increased ultimate failure load.

A new method for obtaining the in situ interfacial shear strength of the 3D woven composite

The interfacial strengths have significant effects on the accuracy of numerical simulations for the 3D woven composite (3DWC). However, obtaining the in situ interfacial strengths of the 3DWC currently presents substantial challenges. Furthermore, it remains questionable whether the interlaminar strength of laminate composites can represent the interfacial strength of the 3DWC. This paper proposes an in situ experiment-simulation (ISES) method to determine the shear strength of the interface within the 3DWC. For this purpose, several novel off-axis tensile specimens were designed with a simplified and continuous interface structure. A corresponding full-scale finite element (FE) model based on the mesoscale structure of the specimen was established, employing the cohesive zone model to describe the interface mechanical behavior. The in situ interfacial shear strength of the 3DWC was then obtained using the proposed ISES method.