Intralaminar Fracture Toughness Research Articles

Dynamic tensile intralaminar fracture and continuum damage evolution of 2D woven composite laminates at high loading rate

The intralaminar tensile failure of 2D woven composites under dynamic tensile load was investigated in this paper. Compact tension samples were tested at high loading rate with an electromagnetic Hopkinson bar system. The strain field was obtained with high-speed imaging and digital image correlation, and the J-integral method was employed to obtain the fracture toughness and corresponding R-curve. The continuum damage evolution of intralaminar failure was then analyzed by tracking the opening near the initial crack tip. It is found that the dynamic intralaminar fracture toughness is decreased by 51% compared to the quasi-static condition, the continuum damage evolution and its dependence on loading rate have been reported as well. The failure mechanisms were studied with thermal imaging and scanned electron microscopy, shorter fibre pull-out length and thinner failure process zone may be responsible for the reduced toughness at high loading rate.

On the use of the Combined Loading Compression fixture to estimate the intralaminar compressive fracture toughness of composites

This study reassesses the constraint effect provided by a Combined Loading Compression (CLC) fixture on notched specimens used to measure the compressive intralaminar fracture toughness of composite materials. An experimental campaign is carried out to determine whether a variation in the specimen gauge section length would result in a significant change in the nominal strength of Double Edge Notch CLC specimens. Following the testing of six sets of different specimen geometries for both a uni-directional thermoplastic and a bi-directional woven thermoset composite, the effect of the gauge length is analysed using the size-effect method. Results show that nominal notched strength variation is minimal, suggesting that the CLC clamp does not effectively constrain the gripped sections against in-plane deformations. This assessment proves that the correction factor used in the determination of the R-curve needs to be computed considering the entire specimen geometry, including the gripped regions. Furthermore, the results reveal that previous characterisation campaigns conducted using end-loaded Double Edge Notch Compression specimens could have led to a significant underestimation of the steady-state fracture toughness.

Modeling fracture of multidirectional thin-ply laminates using an anisotropic phase field formulation at the macro-scale

An equivalent single layer approach to model fracture events of multidirectional balanced thin-ply laminates via the use of the Phase Field method is explored. The inherent anisotropic nature of a multidirectional laminate is taken into account through the use of a structural tensor, defined from scaled directional vectors, which can account for the variation in fracture toughness of the laminates in varying directions. The scaling constants are defined using the lay-up of the laminate and the intra-laminar fracture toughness of the lamina, minimizing the number of input parameters required while also alleviating the structural tensor of a pure numerical and geometric meaning. They have a significant effect in the solution, and are here related to materials properties, not only providing a new perspective on their definition but also allowing the reduction of the number of numerical parameters used to calibrate the anisotropic PF model. The numerical implementation of the proposed formulation is performed using a simple and robust thermal analogy in Abaqus by exploiting the use of an anisotropic conductivity matrix that plays the role of the structural tensor in the anisotropic phase field formulation, which reduces the complexity of the simulations. Experimental results, based on open-hole tension and double edge-notched tension, are reproduced via simulation validating the model for size effects and for the response to off-axis loading. Successful prediction of notch size effects in multidirectional composite laminates is achieved by means of an equivalent single layer approach, incl. the off-axis open-hole tension strengths of a directional thin-ply laminate. All numerical strength predictions were well within acceptable errors of the respective experimental values.

Computational modelling ofthe crushing of carbon fibre-reinforced polymer composites.

The use of lightweight carbon fibre-reinforced polymer (CFRP) composites in transportation vehicles has necessitated the need to guarantee that these new materials and their structures are able to deliver a sufficient level of crashworthiness to ensure passenger safety. Unlike their metallic counterparts, which absorb energy primarily through plastic deformation, CFRPs absorb energy through a complex interaction of damage mechanisms involving matrix (polymer) cracking, fibre/matrix debonding, fibre pull-out/kinking/fracture, delamination and inter/intralaminar friction. CFRP is primarily deployed as a laminate and can potentially deliver a higher specific energy absorption than metals. Translating this capability to a structural scale requires careful design and is dependent on geometry, fibre architecture, laminate stacking sequence and damage initiation strategies for optimal uniform crushing. Consequently, the design of crashworthy CFRP structures currently entails extensive physical testing which is expensive and time consuming. This paper reports on progress and challenges in the development of a finite-element computational capability for simulating the crushing of composites for crashworthiness assessments, with the aim of reducing the burden of physical testing. It addresses the 'tyranny of scales' in modelling structures constructed of CFRP composites. Intrinsic to thiscapability is the acquisition of reliable material data for the damage model, in particular interlaminar and intralaminar fracture toughness values. While quasi-static values can be obtained with a reasonable level of confidence, results achieved through dynamic testing are still the subject of debate and the relationship between fracture toughness and strain rate has yet to be satisfactorily resolved. This article is part of the theme issue 'Nanocracks in nature and industry'.

Crack Propagation for Glass Fiber Reinforced Laminates Containing Flame Retardant: Based on Single-Edge Tensile Loading

Research on crack propagation for fiber reinforced composites containing flame retardant is rare. The micro-cracks propagation is a reason for delamination and debonding failure of fiber reinforced composites. To study the crack propagation of continuous glass fiber reinforced epoxy resin laminates that contained ammonium polyphosphate flame retardant (GFRP-APP), the quasi-static single-edge tensile loading (SETL) experiments for the end-notched GFRP-APP specimens were carried out by MTS universal electronic testing machine. The crack propagation of the end-notched 90� GFRP-APP specimen includes two types, both of which belong to opening type (mode I). Namely, one type is mode I multi-cracks propagation without preexisting crack, and the other is mode I fiber bridge propagation with preexisting crack. The intralaminar fracture toughness along fiber direction of GFRP-APP is approximately 8.4 N/mm, which is calculated by area method. The opening displacement-tensile force curves can be divided into three stages for 90� GFRP-APP specimen without crack, i.e., crack gestation, crack birth and crack propagation. However, the 90� GFRP-APP specimen with crack not contains the crack birth stage. Additionally, the microscopic morphology for the fracture face of pure epoxy resin and GFRP-APP, and the phase analysis for GFRP-APP were performed by scanning electron microscope (SEM), X-ray diffraction (XRD) and energy dispersive spectrometer (EDS). As a conclusion, the pores and interfaces in materials were the guiding factors of micro-crack propagation, and the ammonium polyphosphate flame retardant particle contributed extra interfaces.

Dynamic intralaminar fracture toughness characterisation of unidirectional carbon fibre-reinforced polymer composites using a high-speed servo-hydraulic test set-up

This paper presents an experimental investigation on the intralaminar fibre-dominated fracture of unidirectional (UD) IM7/8552 carbon-epoxy composites, loaded under quasi-static (QS) and intermediate strain rates (IR). Dynamic tensile testing is carried out using a previously proposed test methodology involving a high-speed servo-hydraulic test machine, equipped with a slack adapter, and Digital Image Correlation (DIC), with the aim of providing an alternative means to Split-Hopkinson pressure bar testing for the characterisation of similar composite materials at intermediate-to-high strain rates. Three sizes of Double-Edge Notched Tension (DENT) specimens are tested at QS and IR to obtain the mode I intralaminar fracture toughness. The results of the fracture toughness tests compare well with literature data, supporting the proposed methodology. This study is a first step towards standardising a more easily accessible test method for characterising the mechanical properties of fibre-reinforced polymer (FRP) composites over a broad range of dynamic strain rates.

Intralaminar crack propagation of glass fiber reinforced composite laminate

The intralaminar crack propagation of unidirectional glass fiber reinforced polymer composite (GFRP) laminate has been investigated by quasi-static tensile/compression experiment and complemented by finite element analysis (FEA). The FEA was conducted using a progressive damage model (PDM) -which was executed by the implicit user material (UMAT) and explicit user material (VUMAT) subroutines. Additionally, based on the UMAT implicit algorithm, the intralaminar crack propagation was predicted by the extended finite element method (XFEM). Finally, XFEM was used to simulate the microscopic crack propagation of representative volume element (RVE). The experimental results showed that the intralaminar crack propagation was accompanied by fiber bridging, which was further observed by scanning electron microscopy (SEM). Besides, multi-crack propagation occurred on the specimens without pre-existing crack. The calculated value of intralaminar fracture toughness in stable state was approximately 4.5 N/mm. The PDM revealed the damage status around crack path, stress field at crack tip and the progressive damage mechanical behavior. However, the predicted crack path did not fully agree with those obtained by experiments due to the element delete method. Although the crack propagation process obtained by XFEM was consistent with the experimental result, the damage status could not be observed. The XFEM predictions of the crack state in the RVE was in good agreement with the SEM results; this suggests that crack propagation underpins matrix cracking, interfacial debonding, fiber pulling out, and fiber fracture. In conclusion, using a blended approach by combining the PDM and RVE with XFEM could be a step forward to simulating the intralaminar crack propagation phenomenon in order to gain deeper insights into the micro–macro failure mechanism.

A Modified Compact Tension Test for Characterization of the Intralaminar Fracture Toughness of Tri-Axial Braided Composites.

The application of braided composite materials in the automotive industry requires an in-depth understanding of the mechanical properties. To date, the intralaminar fracture toughness of braided composite materials, typically used for describing post-failure behavior, has not been well-characterized experimentally. In this paper, a modified compact tension test, utilizing a relatively large specimen and a metallic loading frame, is used to measure the transverse intralaminar fracture toughness of a tri-axial braided composite. During testing, a relatively long fracture process zone ahead of the crack tip was observed. Crack propagation could be correlated to the failure of individual unit cells, which required failure of bias-yarns. The transverse interlaminar fracture toughness was found to be two orders of magnitude higher than the reference interlaminar fracture toughness of the same material. This is due to the fact, that intralaminar crack propagation requires breaking of fibers, which is not the case for interlaminar testing.

Fabrication and Thermo-Electro and Mechanical Properties Evaluation of Helical Multiwall Carbon Nanotube-Carbon Fiber/Epoxy Composite Laminates.

The development of advanced composite materials has taken center stage because of its advantages over traditional materials. Recently, carbon-based advanced additives have shown promising results in the development of advanced polymer composites. The inter- and intra-laminar fracture toughness in modes I and II, along with the thermal and electrical conductivities, were investigated. The HMWCNTs/epoxy composite was prepared using a multi-dispersion method, followed by uniform coating at the mid-layers of the CF/E prepregs interface using the spray coating technique. Analysis methods, such as double cantilever beam (DCB) and end notched flexure (ENF) tests, were carried out to study the mode I and II fracture toughness. The surface morphology of the composite was analyzed using field emission scanning electron microscopy (FESEM). The DCB test showed that the fracture toughness of the 0.2 wt.% and 0.4 wt.% HMWCNT composite laminates was improved by 39.15% and 115.05%, respectively, compared with the control sample. Furthermore, the ENF test showed that the mode II interlaminar fracture toughness for the composite laminate increased by 50.88% and 190%, respectively. The FESEM morphology results confirmed the HMWCNTs bridging at the fracture zones of the CF/E composite and the improved interlaminar fracture toughness. The thermogravimetric analysis (TGA) results demonstrated a strong intermolecular bonding between the epoxy and HMWCNTs, resulting in an improved thermal stability. Moreover, the differential scanning calorimetry (DSC) results confirmed that the addition of HMWCNT shifted the Tg to a higher temperature. An electrical conductivity study demonstrated that a higher CNT concentration in the composite laminate resulted in a higher conductivity improvement. This study confirmed that the demonstrated dispersion technique could create composite laminates with a strong interfacial bond interaction between the epoxy and HMWCNT, and thus improve their properties.

Mechanical behavior and fracture toughness characterization of high strength fiber reinforced polymer textile composites

The mechanical and fracture behavior of polymer composites are the subject of great interest from many years and still interesting among the researchers. Composites are extremely used for their superior mechanical, thermal and fracture toughness properties in various sectors such as automobile, aerospace and defense applications. In this article, unidirectional and woven high strength glass, carbon and Kevlar fiber reinforced polymer textile composites are taken into consideration for the comprehensive review of mechanical behavior and fracture toughness characterization. Current review work began with the introduction to polymer textile composites with its manufacturing stages, processing techniques and factors affecting the performance under mechanical loading. The mechanical behavior of high strength fiber reinforced polymer (HSFRP) textile composites was discussed in tension, compression, flexural, low velocity and high velocity impact loading with the recent numerical and experimental characterization studies. Textile geometrical modeling and CAE tools are also described for numerical characterization. Under the influence of mechanical loading on composites, failure occurs actually due to the crack initiation and propagation, so it is also required to characterize. Significant elements of fracture mechanics are well described for the better understanding of fracture toughness characterization. Mode-I, Mode-II, Mode-III interlaminar and Mode-I intralaminar fracture toughness characterization are widely explained by considering the effect of filler content, fiber orientation and fiber volume fraction. Fracture toughness characterization techniques and research summery are uniquely presented by considering various factors under one umbrella for better understanding of fracture behavior. Statistical Weibull distribution is also presented for the failure prediction of composites.

High strain rate characterisation of intralaminar fracture toughness of GFRPs for longitudinal tension and compression failure

The elastic parameters, strengths, and intralaminar fracture toughness are determined for an E-Glass polymer composite material system, statically and at high strain rate, adapting methodologies previously developed by the authors for different carbon composites. Dynamic experiments are conducted using tension and compression Split-Hopkinson Bars (SHBs). A unique set of experimental parameters is obtained, and reported together with the experimental set-up, in order to ensure reproducibility. While in-plane elastic and strength properties were obtained by testing one specimen geometry, intralaminar fracture properties required the testing of different sized notched specimens with scaled geometries. This allowed the use of the size-effect method for the determination of the dynamic R-curve. When comparing these results with those previously obtained for a carbon/epoxy material system, it is observed that the dynamic fracture toughness exhibits a much more significant increase in both tension and compression. The obtained results permit the identification of the softening law at different strain rates, allowing its use in any analytical or numerical strength predictive method.

Compressive intralaminar fracture toughness and residual strength of 2D woven carbon fibre reinforced composites: New developments on using the size effect method

This paper presents new developments in the use of the size effect method for obtaining the compressive fracture toughness of 2D woven carbon fibre composites. A modification of the Double Edge Notch Compression (DENC) specimen geometry is proposed, to fit the Combined Loading Compression (CLC) standard fixture, and shown to reduce peak load dispersion. The notch tip diameter sensitivity on the peak load is also investigated, experimentally and numerically, and shown not to have a significant influence on fracture toughness. The use of the CLC fixture also allows for the residual compressive strength of the material to be calculated from post-peak crushing.

Is there a ply thickness effect on the mode I intralaminar fracture toughness of composite laminates?

The apparent crack resistance curves associated with longitudinal tensile failure of carbon fibre reinforced epoxy composite systems with ply thicknesses of 0.075 mm, 0.134 mm and 0.268 mm are determined experimentally from the size effect law of geometrically similar double edge notch tension cross-ply specimens. An increase in notched strength as a function of the ply thickness and a corresponding increase of the measured intralaminar fracture toughness is observed. This increase is shown to be a consequence of the appearance of split cracks in the thicker 0° plies in the vicinity of the notches. The numerical models developed demonstrate that if the notch blunting mechanisms are properly represented, the laminate strength is well predicted for a constant value of the ply intralaminar fracture toughness. This supports the hypothesis that these mechanisms are responsible for the higher strength of the thicker plies, and that the intralaminar fracture toughness of the 0° plies should not be scaled with the ply thickness.

Investigating the role of 3D network of carbon nanofillers in improving the mechanical properties of carbon fiber epoxy laminated composite

Carbon fiber epoxy composites are being used in numerous structural applications. However, fracture toughness of these composites is always less than expected. Therefore, potential of nanofillers in improving the fracture toughness of these composites, with, three different morphologies, i.e., Gr (sheet), CNT (tube) and nanodiamond (particle), in a well-connected 3D network is evaluated in this study. Both, interlaminar and intralaminar mode I fracture toughness, revealed improvement of ~260% and ~53%, respectively, with 25Gr:50CNT:25ND CF-epoxy, as compared to CF-epoxy composite. Marking a total improvement of ~1523% over pure epoxy on intralaminar fracture toughness. The composites were also assessed for tensile and interlaminar shear strength. An improvement of ~60% and ~16%, respectively, is noted with the addition of nanofillers. SEM analysis for delaminated and fractured surfaces revealed the toughening mechanism to be the high surface area of nanofillers, offering strong adhesion between matrix and fiber, along with improved matrix toughness.

Mode I intralaminar fracture toughness of 2D woven carbon fibre reinforced composites: A comparison of stable and unstable crack propagation techniques

This paper presents an experimental and numerical comparison of stable and unstable crack propagation techniques used to measure the mode I intralaminar fracture toughness of 2D woven carbon fibre composites. Compact Tension (CT) and Double Edge Notch Tension (DENT) specimens are used for the stable and unstable experimental tests, respectively. The precrack tip radius sensitivity of the scaled DENT specimens is investigated, concluding that the tested tip radii do not substantially affect the measured fracture toughness. The fracture toughness data obtained from the DENT and CT specimens are found to be in good agreement for both tested materials.

An experimental method to determine the intralaminar fracture toughness of high-strength carbon-fibre reinforced composite aerostructures

ABSTRACTCarbon fibres with high tensile strength are being increasingly utilised in the manufacture of advanced composite aerostructures. A Modified Compact Tension (MCT) specimen is often deployed to measure the longitudinal intralaminar fracture toughness but a high tensile strength often leads to premature damage away from the crack tip. We present an approach whereby the MCT specimen is supported by external fixtures to prevent premature damage. In addition, we have developed a novel measurement technique, based on the fibre failure strain and C-scanning, to determine the crack length in the presence of surface sublaminate delamination which masks the crack tip location. A set of cross-ply specimens, with a ((90/0)s)4layup, were manufactured from an IMS60/epoxy composite system Two different data reduction schemes, compliance calibration and the area method, are used to determine the fibre-dominated initiation and propagation intralaminar fracture toughness values. Propagation values of fracture toughness were measured at 774.9 ± 5.2% kJ/m2and 768.5 ± 4.1% kJ/m2, when using the compliance calibration method and the area method, respectively. Scanning Electron Microscopy (SEM) is carried out on the fracture surface to obtain insight into the damage mechanism of high-tensile-strength fibre-reinforced unidirectional composites. The measured tensile fracture toughness value is used in a fully validated computational model to simulate the physical test.

Determination of the crack resistance curve for intralaminar fiber tensile failure mode in polymer composites under high rate loading

This paper presents the determination of the crack resistance curve of the unidirectional carbon-epoxy composite material IM7-8552 for intralaminar fiber tensile failure under dynamic loading. The methodology, proposed by Catalanotti et al. (2014) for quasi-static loading conditions, was enhanced to high rate loading in the order of about 60 s−1. Dynamic tests were performed using a split-Hopkinson tension bar, while quasi-static reference tests were conducted on a standard electromechanical testing machine. Double-edge notched tension specimens of different sizes were tested to obtain the size effect law, which in combination with the concepts of the energy release rate is used to measure the entire crack resistance curve for the fiber tensile failure mode. Digital image correlation is applied to further verify the validity of the experiments performed at both static and dynamic loading. The data reduction methodology applied in this paper is suitable for intralaminar fiber failure modes without significant delamination. Sufficient proof is given that quasi-static fracture mechanics theory can also be used for the data reduction of the dynamic tests. It is shown, that the intralaminar fracture toughness for fiber tensile failure of UD IM7-8552 increases with increasing rate of loading.

Intralaminar fracture toughness of UD glass fiber composite under high rate fiber tension and fiber compression loading

Automotive and aeronautical composite structures can be subjected to dynamic loading scenarios (e.g. crash, bird strike). In both industrial areas, energy-based damage models for composite materials, able to predict initiation and evolution of damage of a composite ply under various loading conditions, are increasingly used. These models require the specification of fracture toughness parameters for the main failure modes. In previous works [1],[2], the authors have successfully enhanced a methodology suggested by Catalanotti et al. [3],[4] to measure the fiber failure crack resistance curves of a UD carbon fiber composite under dynamic loading. This methodology uses the relation between the energy release rate, the crack resistance curve and the size-effect law. For the determination of the size-effect law, double-edge-notched specimens of different sizes are tested. In this work, the developed approach is used for the measurement of the fracture toughness for fiber tension and compression failure of a UD glass-epoxy composite under high rate loading. Static tests are performed on an electromechanical test machine. For the high rate tests, split-Hopkinson bars for tensile (SHTB) and compressive (SHPB) loading are used. The results show, that the fracture toughness of the UD glass-epoxy composite, associated with the fiber failure modes, increases with increasing loading rate for tension as well as for compression. The observed strain rate effect on the fracture toughness of the glass-epoxy composite is more pronounced than for the carbon-epoxy composite investigated in [1],[2], in particular for fiber tensile failure.

Strain rate effects on the intralaminar fracture toughness of composite laminates subjected to compressive load

This paper presents an experimental and numerical study focused on the mode-I intralaminar toughness characterization of a woven carbon/epoxy composite loaded in compression and subjected to high strain rates. Simulations for non-standardized Single Edge Notch Bending (SENB) and Double Edge Notch (DEN) specimens were carried out using a continuum damage mechanics based failure model implemented as an user defined material model within ABAQUS software. A Finite Element Model was used in order to produce an optimal specimen for intralaminar fracture toughness tests. A new data reduction scheme based on the numerical evaluation of the strain energy release rate using the J-integral method is proposed to determine the stress intensity factor for composites. The proposed methodology accounts for finite geometry and material anisotropy effects. The dynamic tests were carried out at strain rates of 560s-1,690s-1,770s-1 using an adapted version of the Split Hopkinson Pressure Bar. A high-speed camera was used for monitoring the crack propagation. A Scanning Electron Microscope (SEM) was used to aid the fractographic analyses on the damaged surface of the tested samples searching for the possible failures mechanisms within the material. The experimental results indicated that the composite laminates studied herein are very sensitive to the strain rate effects.

Fracture toughness and crack resistance curves for fiber compressive failure mode in polymer composites under high rate loading

This work presents an experimental method to measure the compressive crack resistance curve of fiber-reinforced polymer composites when subjected to dynamic loading. The data reduction couples the concepts of energy release rate, size effect law and R-curve. Double-edge notched specimens of four different sizes are used. Both split-Hopkinson pressure bar and quasi-static reference tests are performed. The full crack resistance curves at both investigated strain rate regimes are obtained on the basis of quasi-static fracture analysis theory. The results show that the steady state fracture toughness of the fiber compressive failure mode of the unidirectional carbon-epoxy composite material IM7-8552 is 165.6kJ/m2 and 101.6kJ/m2 under dynamic and quasi-static loading, respectively. Therefore the intralaminar fracture toughness in compression is found to increase with increasing strain rate.