A delamination gage for carbon fiber composites

A graphite crack gage familiar to fracture testing of nonconductive polymeric materials has been adapted to measure delamination growth in carbon fiber composites. The gage consists of a continuous graphite film whose conductance changes linearly with respect to crack length. The development of an insulation technique so that the electrical film may be applied to carbon fiber composites is described. Further constraints on the gage design occur due to the narrow profiles of conventional delamination specimens. These limitations are reviewed in detail along with appropriate methods for manufacturing and calibration of the gage for delamination experiments. A simple shunt voltage measurement circuit is described along with a derivation of the relationship of crack length to voltage. Two example applications are provided: stable delamination growth in a conventional double cantilever beam (DCB) specimen and dynamic delamination growth in a single-edge-notched (SEN) strip. The electrical delamination length measurements from the DCB tests were found to compare well with the location of the delamination front determined by microscopy and radiography. These results give confidence in dynamic delamination results where growth rates exceeding 1000 m/s were measured. Sample evaluations of delamination toughness are made using the experimental data; compliance methods are used in the case of the DCB analysis, and dynamic finite element methods are used in the case of the SEN strip analysis.     

On the calculation of energy release rate for viscoelastic cracked laminates

IntroductionGenerallyspeaking ,acrackinviscoelasticmaterialswillgrowinsomeunknownspeedeveniftheappliedloadisquasistatic,thusthemaindifficultyisinducedindervingtheenergyreleaserate .Knowledgeoftheconditiongoverningthedelaminationincompositelaminateswithviscoelasticlayersisofparamountimportanceinpracticalapplications.Forexample,inplasticencapsulatedICpackages,theinterfacialdelaminationbetweentheSilicondieandviscoelasticepoxymoldingcompoundunderthethermalloadingisthemainfailuremodeofthestructure…     

Fracture mechanical damage modelling of thermal barrier coatings

Summary The problem of how to avoid damage of TBCs has been approached by calculating the energy release rate of two crack configurations under thermal loading. This has been done for the limiting cases of perfect and lacking heat transfer across the crack. Suitable grading of TBCs is a means of suppressing the tendency to delamination and damage by both decreasing the energy release rate G and increasing its critical value G _c . TBCs can be graded such that delamination cracks would be deflected into depth where G _c is sufficiently high to avoid crack propagation. Received 31 March 1999; accepted for publication 10 June 1999     

Intrinsic coupling of near-tip matrix crack formation to mode III delamination advance in laminated polymeric matrix composites

Laminated carbon/epoxy specimens are loaded in anti-plane shear to investigate the relationship between near-tip matrix crack formation and the apparent mode III delamination toughness. Specimens are tested with different insert lengths to various load levels and examined fractographically. Near-tip matrix cracks are found to initiate and propagate intralaminarly before the onset of planar growth. These cracks are inclined at approximately 45° to the delamination plane and are perpendicular to the direction of maximum near-tip tensile stress. It is found that this represents an intrinsically coupled sequence of events for anti-plane shear loading of continuous fiber laminated polymeric composites when a preexisting delamination is bounded by plies that have their fiber direction aligned with the direction of macroscopic advance. This sequence of events violates the assumptions used in the reduction of data from common mode III tests. It therefore invalidates the associated toughness measurements, and may account for or strongly contribute to the common observation that laminated polymeric composites exhibit an apparent mode III delamination toughness that is dependent on test geometry.     

Dynamic interaction effects of multiple delaminations in plates subject to cylindrical bending

The interaction of multiple delaminations in a laminated composite plate loaded dynamically under plane strain conditions (cylindrical bending) is studied by a simple but accurate model that represents the delaminated plate as a set of Timoshenko beams joined by cohesive interfaces. Behavioral maps are derived, which distinguish conditions under which multiple delaminations tend to propagate with equal lengths from those under which one of them tends to grow as a dominant crack with relatively high velocity. In homogeneous systems, equal length growth is favored when the delaminations are equally spaced through the thickness. While the behavioral maps are similar to those for static loading conditions, significant dynamic effects arise in the details of propagation: the maximum energy release rate depends strongly on the loading rate, duration and profile; dynamic effects and crack-interaction effects are generally coupled; and strong hammering effects (chaotic collisions of sub-laminates) can occur during the free wave motions that arise after the load is removed. The hammering effect can be suppressed by imposing a large-scale bridging mechanism (bridging extending far in the crack wake, as from pins or stitches), whereupon energy release rates tend to show smooth oscillations associated with waves propagating on the scale of the whole specimen. The energy absorbed during failure will depend significantly on whether conditions favor multiple delaminations propagating with equal lengths or a single delamination growing dominantly.     

Ductile–brittle transitions in the fracture of plastically-deforming,adhesively-bonded structures. Part I: Experimental studies

Rate effects for adhesively-bonded joints in steel sheets failing by mode-I fracture and plastic deformation were examined. Three types of test geometries were used to provide a range of crack velocities between 0.1 and 5000 mm/s: a DCB geometry under displacement control, a wedge geometry under displacement control, and a wedge geometry loaded under impact conditions. Two fracture modes were observed: quasi-static crack growth and dynamic crack growth. The quasi-static crack growth was associated with a toughened mode of failure; the dynamic crack growth was associated with a more brittle mode of failure. The experiments indicated that the fracture parameters for the quasi-static crack growth were rate independent, and that quasi-static crack growth could occur even at the highest crack velocities. Effects of rate appeared to be limited to the ease with which a transition to dynamic fracture could be triggered. This transition appeared to be stochastic in nature, it did not appear to be associated with the attainment of any critical value for crack velocity or loading rate. While the mode-I quasi-static fracture behavior appeared to be rate independent, an increase in the tendency for dynamic fracture to be triggered as the crack velocity increased did have the effect of decreasing the average energy dissipated during fracture at higher loading rates.     

A crack tip tracking algorithm for cohesive interface element analysis of fatigue delamination propagation in composite materials

A novel approach is proposed for the use of cohesive elements in the analysis of delamination propagation in composite materials under high-cycle fatigue loading. The method is applicable to delamination propagation within the Paris-law regime and is suitable for the analysis of three-dimensional structures typical of aerospace applications. The major advantages of the proposed formulation are its complete independence of the cohesive zone length – which is a geometry-dependent parameter – and its relative insensitivity to mesh refinement. This is only possible via the introduction of three nonlocal algorithms, which provide (i) automated three-dimensional tracking of delamination fronts, (ii) an estimation of direction of crack propagation and (iii) accurate and mesh-insensitive integration of strain energy release rate. All calculations are updated at every increment of an explicit time-integration finite element solution, which models the envelopes of forces and displacements with an assumption of underlying constant cyclic loading. The method was implemented as a user-defined subroutine in the commercial finite element software LS-Dyna and supports the analysis of complex three-dimensional models. Results are presented for benchmark cases such as specimens with central cut plies and centrally-loaded circular plates. Accurate predictions of delamination growth rates are observed for different mesh topologies in agreement with the Paris-laws of the material.     

INFLUENCE OF LOADING RATE ON DYNAMIC FRACTURE BEHAVIOR OF FIBER-REINFORCED COMPOSITES

The effect of loading rate on the dynamic fracture properties and the failure mechanisms of glass fiber-reinforced composite materials under mode I fracture is studied. Dynamic reflective caustic experiments are carried out for two loading rates. By measuring the characteristic dimensions of the shadow spots during the caustic experiments, the dynamic SIFs are calculated for different loading rates. The experimental results indicate that the dynamic fracture toughness Kid increases remarkably with increasing loading rate, and the crack grows faster under the high-velocity impact. Moreover, by examining the crack growth routes and the fracture surfaces, it is shown that the loading rate also greatly affects the failure mechanisms at micro-scale.     

Closure effects in delaminated graphite epoxy laminate under compression

Flaws in composite laminates may result in a severe loss of static and dynamic strength. Such flaws may be inherent or gained by misadventure. The extent of this loss can be influenced by several factors including loading, laminate stacking sequence, lamina properties, flaw size and damage type.In this study, the free-edge delamination of a laminated composite under compression loading is investigated. Computational, analytical and experimental tests are performed on a graphite/epoxy laminate AS4/3501-6 containing near surface edge defects and the crack opening behaviour is investigated.The computational analysis consists of a three dimensional finite element model where the plies can be catered for individually and interply delamination modelled. In the experimental investigations, a delamination is simulated by inserting teflon film at appropriate locations during the lay-up process.     

A Novel Method for Dynamic Short-Beam Shear Testing of 3D Woven Composites

A new test method for performing dynamic short-beam shear tests using a momentum trapped Hopkinson pressure bar is proposed. Angle-interlock 3D woven composite specimens were tested under quasi-static and dynamic loading conditions to determine the effect of loading rate on damage evolution. The equilibrium condition in the composite specimen under dynamic loads was verified using finite element analysis of the experiment. A high speed camera was used to capture delamination initiation and propagation during both quasi-static and dynamic experiments. Analysis of the load-deflection curves and the high speed images revealed a good correlation between the modes of damage initiation and propagation with the features in the loading response. The apparent inter-laminar shear strength and the bending stiffness increased with rate of loading. While the damage was observed to propagate at a relative steady rate during quasi-static loading, the high rate of energy input during dynamic loading resulted in a rapid propagation of damage and a subsequent loss of stiffness in the composite as noted in the load-deflection curve.     

Effects of voids on postbuckling delamination growth in unidirectional composites

This work examines the effects of manufacturing induced voids on the postbuckling behavior of delaminated unidirectional composites. In the finite element model developed, a through-width delamination is introduced close to one surface of a flat panel, and a void is placed in the delamination plane ahead of each delamination front. The panel is subjected to compression in the fiber direction. The postbuckling delamination growth is studied by calculating the strain energy release rate (SERR) using the virtual crack closure technique. Local stress analyses of the region near the delamination front are also performed to further investigate the void effects. It is found that although the presence of void does not significantly alter the postbuckling transverse displacement of the delaminated panel, the induced stress perturbation by the void affects the SERR. The Mode II SERR as well as the total SERR increase depending on the size of the void and its distance from the delamination front. Since the Mode I SERR shows non-monotonic behavior with the applied load, the effects of voids are studied on its maximum value.     

Generating dynamic crack growth resistance curves for fiber-reinforced concrete

Fiber-reinforced concrete is known to have a greater resistance to impact and impulsively applied loads than its plain counterpart. However, the exact mechanisms that contribute to this enhanced resistance are not known, and fundamental fracture tests are necessary to develop such an understanding. To this end, an instrumented drop weight impact machine was configured to perform dynamic fracture studies on fiber-reinforced concrete specimens. Cracks were allowed to open in Mode I under high rates of loading using contoured double cantilever beam specimens. The paper describes the test apparatus, instrumentation, calibration, and the data analysis. The technique was applied to investigate dynamic crack growth in two types of fiber-reinforced concrete composites: one with steel macrofiber and the other with polypropylene macrofiber. Companion tests were performed under quasi-static conditions. Test data indicate that the proposed technique can be successfully applied to study dynamic crack growth in cement-based composites and to further enhance their properties.     

Impact and high strain rate delamination characteristics of carbon fibre epoxy composites

Delamination mechanisms and energy dissipation of carbon fibre epoxy composites under impact and high strain rate conditions are studies in terms of a new experimental set-up. The test set-up is designed to separate the Mode-I, -II and mixed mode delamination resistance so that relevant mechanisms can be studied in greater detail. The impact specimens consist of 18 × 18 mm laminated composite pieces bonded to steel bars to form the impact specimens with the normal Charpy and Izod specimen geometry. The impact energy dissipation is recorded and taken as a dynamic delamination toughness measurement, and the transition from the pure Mode-I to Mode-II through the mixed mode delamination is measured. Detailed delamination surface examinations by scanning electron microscopy (SEM) show that different failure mechanisms are involved in the dynamic and usual quasi-static delamination processes. The influence of chopped Kevlar fibres used as low cost interlaminar reinforcement on the energy dissipation is also studied.     

Transient response of an insulating crack between dissimilar piezoelectric layers under mechanical and electrical impacts

Summary  The dynamic response of an interface crack between two dissimilar piezoelectric layers subjected to mechanical and electrical impacts is investigated under the boundary condition of electrical insulation on the crack surface by using the integral transform and the Cauchy singular integral equation methods. The dynamic stress intensity factors, the dynamic electrical displacement intensity factor, and the dynamic energy release rate (DERR) are determined. The numerical calculation of the mode-I plane problem indicates that the DERR is more liable to be the token of the crack growth when an electrical load is applied. The dynamic response shows a significant dependence on the loading mode, the material combination parameters as well as the crack configuration. Under a given loading mode and a specified crack configuration, the DERR of an interface crack between piezoelectric media may be decreased or increased by adjusting the material combination parameters. It is also found that the intrinsic mechanical-electrical coupling plays a more significant role in the dynamic fracture response of in-plane problems than that in anti-plane problems. Received 4 September 2001; accepted for publication 23 July 2002 The work was supported by the National Natural Science Foundation under Grant Number 19891180, the Fundamental Research Foundation of Tsinghua University, and the Education Ministry of China.     

A thermomechanical cohesive zone model for bridged delamination cracks

The coupled thermomechanical numerical analysis of composite laminates with bridged delamination cracks loaded by a temperature gradient is described. The numerical approach presented is based on the framework of a cohesive zone model. A traction-separation law is presented which accounts for breakdown of the micromechanisms responsible for load transfer across bridged delamination cracks. The load transfer behavior is coupled to heat conduction across the bridged delamination crack. The coupled crack-bridging model is implemented into a finite element framework as a thermomechanical cohesive zone model (CZM). The fundamental response of the thermomechanical CZM is described. Subsequently, bridged delamination cracks of fixed lengths are studied. Values of the crack tip energy release rate and of the crack heat flux are computed to characterize the loading of the structure. Specimen geometries are considered that lead to crack opening through bending deformation and buckling delamination. The influence of critical mechanical and thermal parameters of the bridging zone on the thermomechanical delamination behavior is discussed. Bridging fibers not only contribute to crack conductance, but by keeping the crack opening small they allow heat flux across the delamination crack to be sustained longer, and thereby contribute to reduced levels of thermal stresses. The micro-mechanism based cohesive zone model allows the assessment of the effectiveness of the individual mechanisms contributing to the thermomechanical crack bridging embedded into the structural analysis.     

含分层损伤复合材料层合板分层扩展研究

采用基于Ｍｉｎｄｌｉｎ－阶剪切理论的四节点板单元,分析了含椭圆分层合板分层扩展行为。利用虚裂纹闭合技术计算分层前缘处的总能量释放率,并采用总能量释放率准则作为扩展准则,结合自适应网格移动技术,并考虑了分层前缘闭合接角效应,对 合材料层合板的分层扩展行为进行了模拟分析。结果表明,初始分层形状对其扩展有方式有限大影响。     

Dynamic crack kinking from a PMMA/Homalite interface

The behavior of a pre-existing, dynamically loaded, interfacial crack kinking away from the interface separating two materials was experimentally investigated under dynamic loading conditions. Dynamic fracture experiments were performed on pre-cracked bimaterial panels of PMMA bonded with Homalite-100 impact loaded using a high-speed gas gun. By varying the location of impact, a large range of mixed mode loading at the crack tip was produced. Information about the stress state surrounding the crack tip was obtained through use of the lateral shearing interferometer of coherent gradient sensing in conjunction with high-speed photography. The high-speed interferogram corresponding, to the time of crack initiation was analyzed in each case to find the preinitiation mode mixity at the crack tip. Measurement of both the local initiation mode mixity and the crack kink angle allows for possible extension of existing quasi-static interface crack kinking criteria, such as maximum opening stress or maximum energy release rate, to the case of dynamic loading. It was found that for bimaterial systems with small material property mismatch, such as the PMMA/Homalite system, the maximum opening stress criterion accurately predicts the relation between crack tip mode mixity and resulting kink angle for small initial crack kinking speeds.     

A novel technique for time-resolved detection and tracking of interfacial and matrix fracture in layered materials

A novel experimental technique is developed for time-resolved detection and tracking of damage in the forms of delamination and matrix cracking in layered materials such as composite laminates. The technique is non-contact in nature and uses dual or quadruple laser interferometers for high temporal resolution. Simultaneous measurements of differential displacement and velocity at individual locations are obtained to analyze the initiation and progression of interfacial fracture and/or matrix cracking/delamination in a polymer matrix composite laminate system reinforced by graphite fibers. The measurements at multiple locations allow the speeds at which interfacial crack front (mode-I) or matrix cracking/delamination front (mode-II dominated) propagates to be determined. Experiments carried out use three-point bend configurations. Impact loading is achieved using a modified Kolsky bar apparatus with a complete set of diagnostics for load, deformation, deformation rate, and input energy measurement. This technique is used to characterize the full process of damage initiation and growth. The experiments also focused on the quantification of the speed at which delamination or damage propagates under primarily mode-I and mode-II conditions. The results show that the speed of delamination (mode-I) or the speed of matrix cracking/delamination (primarily mode-II) increases linearly with impact velocity. Furthermore, speeds of matrix failure/delamination under primarily mode-II conditions are much higher than the speeds of mode-I crack induced delamination under mode-I conditions.     

Remarks on the energy release rate for an antiplane moving crack in couple stress elasticity

This paper is concerned with the steady-state propagation of an antiplane semi-infinite crack in couple stress elastic materials. A distributed loading applied at the crack faces and moving with the same velocity of the crack tip is considered, and the influence of the loading profile variations and microstructural effects on the dynamic energy release rate is investigated. The behavior of both energy release rate and maximum total shear stress when the crack tip speed approaches the critical speed (either that of the shear waves or that of the localized surface waves) is studied. The limit case corresponding to vanishing characteristic scale lengths is addressed both numerically and analytically by means of a comparison with classical elasticity results.