In situ observation of interfacial debonding process induced by matrix crack propagation in two-dimensional unidirectional model composites

Interfacial debonding behavior is studied for unidirectional fiber reinforced composites from both experimental and analytical viewpoints. A new type of two-dimensional unidirectional model composite is prepared using 10 boron fibers and transparent epoxy resin with two levels of interfacial strength. In situ observation of the internal mesoscopic fracture process is carried out using the single edge notched specimen under static loading. The matrix crack propagation, the interfacial debonding growth and the interaction between them are directly observed in detail. As a result, the interfacial debonding is clearly accelerated in specimens with weakly bonded fibers in comparison with those with strongly bonded fibers. Secondary, three-dimensional finite element analysis is carried out in order to reproduce the interfacial debonding behavior. The experimentally observed relation between the mesoscopic fracture process and the applied load is given as the boundary condition. We successfully evaluate the mode II interfacial debonding toughness and the effect of interfacial frictional shear stress on the apparent mode II energy release rate separately by employing the present model composite in combination with the finite element analysis. The true mode II interfacial debonding toughness for weaker interface is about 0.4 times as high as that for a stronger interface. The effect of the interfacial frictional shear stress on the apparent mode II energy release rate for the weak interface is about 0.07 times as high as that for the strong interface. The interfacial frictional shear stress and the coefficient of friction for weak interface are calculated as 0.25 and 0.4 times as high as those for strong interface, respectively.     

Initial damage induced by thermal residual stress and microscopic failure analysis of carbon-fiber reinforced composite under shear loading

In order to study the mechanical properties and the progressive failure process of composite under shear loading, a representative volume element (RVE) of fiber random distribution was established, with two dominant damage mechanisms – matrix plastic deformation and interfacial debonding – included in the simulation by the extended Drucker–Prager model and cohesive zone model, respectively. Also, a temperature-dependent RVE has been set up to analyze the influence of thermal residual stress. The simulation results clearly reveal the damage process of the composites and the interactions of different damage mechanisms. It can be concluded that the in-plane shear fracture initiates as interfacial debonding and evolves as a result of interactions between interfacial debonding and matrix plastic deformation. The progressive damage process and final failure mode of in-plane shear model which are based on constitute are very consistent with the observed result under scanning electron microscopy of V-notched rail shear test. Also, a transverse shear model was established as contrast in order to comprehensively understand the mechanical properties of composite materials under shear loading, and the progressive damage process and final failure mode of composite under transverse shear loading were researched. Thermal residual stress changes the damage initiation locations and damage evolution path and causes significant decreases in the strength and fracture strain.     

Interfacial debonding behavior of a rigid particle-filled polymer composite

Glass beads, non-modified and modified with coupling agent, were filled separately into high density polyethylene to obtain composite materials with different interfacial adhesion strengths. In situtensile tests reveal the damage mechanisms, which are mainly induced by the interfacial debonding. The interfacial debonding process is observed and studied. The debonding stress is found to be linearly related to the opening angle formed at two poles of the particles. Initial and final opening angles, in addition to the corresponding debonding stresses, are measured. The interfacial fracture energy obtained by using the Griffith fracture theory is found to be 0.028 J m^-2 and 0.058 J m^-2 for mechanical anchorage and physical entanglement across the interface, respectively. The stronger the interfacial adhesion, the smaller is the maximum opening angle and greater the debonding stress.     

Interfacial adhesion and micro-failure phenomena in multi-fiber micro-composites using fragmentation test

Statistical fragments and micro-failure modes in the multi-fiber-reinforced micro-composites were investigated by fragmentation test. The specimen consisted of three fibers using carbon fibers (CFs) and glass fibers (GFs), embedded in the epoxy resin with three-dimensional arrangement. Fracture morphology and micro-failure behavior from the progressive fragmentation of fibers and fiber/matrix interfacial adhesion were observed via polarized-light microscope. The interfacial shear strength of CF/epoxy micro-composites is higher than that of the GF/epoxy micro-composites measured by the single fiber fragmentation test. The results show that fragment number on monofilament demonstrates obvious differences between multi-fiber and single fiber systems, and the location of the breakpoint is determined by the CFs that fracture firstly, indicating clustering fracture modes. This is because stress concentration around the breakpoints influences the stress redistribution on the adjacent fibers. Distinct micro-failure modes were observed in three-fiber and the hybrid systems, where matrix cracks around the CFs and interfacial debonding occurs around the GFs. The mixture of CFs and GFs demonstrates distinctive hybrid effect by the changes of the fragment number and initial fracture strain of fibers in hybrid systems.     

Evaluation on the interfacial fracture toughness of fiber-reinforced titanium matrix composites by push out test

The models for single-fiber push out test are developed to evaluate the fracture toughness G_IIc of the fiber/matrix interface in titanium alloys reinforced by SiC monofilaments. The models are based on fracture mechanics, taking into consideration of the free-end surface and Poisson expansion. Theoretical solutions to G_IIc are obtained, and the effects of several key factors such as the initial crack length, crack length, friction coefficient, and interfacial frictional shear stress are discussed. The predictions by the models are compared with the previous finite element analysis results for the interfacial toughness of the composites including Sigma1240/Ti-6-4, SCS/Ti-6-4, SCS/Timetal 834, and SCS/Timetal 21s. The results show that the models can reliably predict the interfacial toughness of the titanium matrix composites, in which interfacial debonding usually occurs at the bottom of the samples.     

Is there any contradiction between the stress and energy failure criteria in micromechanical tests? Part II. Crack propagation: Effect of friction on force-displacement curves

In micromechanical tests for estimating fiber-matrix interfacial properties, such as the pull-out and microbond tests, fiber debonding from a matrix is often accompanied by friction in debonded areas. In the present study, force-displacement curves, which are usually recorded in these tests, were modeled with taking interfacial friction into consideration. The friction stress was assumed, as a first approximation, to be constant across the interface. Two different approaches to interfacial failure were used: the shear-lag approach with a stress-based debonding criterion (the ultimate interfacial shear strength) and the linear elastic fracture mechanics approach using the critical energy release rate as a condition for crack propagation. The force-displacement curves derived from both models are in good agreement with each other and with experimental micromechanical data. It was shown that any pull-out and microbond experiment comprises four stages: (1) linear loading up to the point where debonding starts; (2) stable crack propagation with friction-controlled debonding; (3) catastrophic debonding; and (4) post-debonding friction. Stable crack propagation was shown to be controlled by both friction and release of residual thermal stresses. An algorithm for estimating both fiber-matrix adhesion and interfacial friction from the microbond and pull-out tests data has been proposed.     

Predicting Interfacial Strengthening Behaviour of Particulate-Reinforced MMC — A Micro-mechanistic Approach

The fracture properties of particulate-reinforced metal matrix composites (MMCs) are influenced by several factors, such as particle size, inter-particle spacing and volume fraction of the reinforcement. In addition, complex microstructural mechanisms, such as precipitation hardening induced by heat treatment processing, affect the fracture toughness of MMCs. Precipitates that are formed at the particle/matrix interface region, lead to improvement of the interfacial strength, and hence enhancement of the macroscopic strength properties of the composite material. In this paper, a micro-mechanics model, based on thermodynamics principles, is proposed to determine the fracture strength of the interface at a segregated state in MMCs. This model uses energy considerations to express the fracture toughness of the interface in terms of interfacial critical strain energy release rate and elastic modulus. The interfacial fracture toughness is further expressed as a function of the macroscopic fracture toughness and mechanical properties of the composite, using a toughening mechanism model based on crack deflection and interface cracking. Mechanical testing is also performed to obtain macroscopic data, such as the fracture strength, elastic modulus and fracture toughness of the composite, which are used as input to the model. Based on the experimental data and the analysis, the interfacial strength is determined for SiC particle-reinforced aluminium matrix composites subjected to different heat treatment processing conditions.     

Stress transfer around a broken fiber in unidirectional fiber-reinforced composites considering matrix damage evolution and interface slipping

A shear-lag model is applied to study the stress transfer around a broken fiber within unidirectional fiber-reinforced composites(FRC) subjected to uniaxial tensile loading along the fiber direction.The matrix damage and interfacial debonding,which are the main failure modes,are considered in the model.The maximum stress criterion with the linear damage evolution theory is used for the matrix.The slipping friction stress is considered in the interfacial debonding region using Coulomb friction theory,in whic...     

Role of weak interface to retain high strength of fiber in monofilamentary SiC fiber/titanium-aluminide composite

The tensile strength of monofilamentary weakly bonded SiC fiber/γ-TiAl intermetallic compound matrix composite, prepared by the sputtering method, was measured and analysed using a fracture mechanical technique. The main results are summarized as follows: (1) The fracture of TiAl occurred prior to that of fiber, resulting in formation of circumferential cracks on the fiber. Interfacial debonding occurred during tensile test, resulting in long pull-out of the fiber. (2) The strength of the fiber in the TiAl matrix was nearly the same as that of the bare fiber. (3) The fracture mechanical analysis showed that (i) the interfacial debonding grows unstably upon initiation and (ii) the stress distribution in the fiber in the cross-section, where the matrix is fractured, approaches to that of bare fiber with increasing debonded length. The reason why the fiber strength was maintained in spite of the formation of cracks on the fiber surface due to the premature fracture of the matrix was accounted for by the fully blunted crack-tip from the above calculation result.     

INVESTIGATION OF STATIC AND DYNAMIC FRACTURE TOUGHNESS OF SHORT CERAMIC FIBER REINFORCED POLYPROPYLENE COMPOSITES

Short ceramic fiber reinforced polypropylene composites have been investigated to determine their static and dynamic fracture toughness for different reinforcing fiber contents. The composites were reinforced with fibers produced by a carding technique combined with needle-punching. Static fracture toughness (K _c) was measured on single-edge notched tensile (SEN-T) specimens, while dynamic fracture toughness (K _d) was tested by impact strength Charpy specimens. Specimens in both cases were cut transverse (T) and in longitudinal (L) directions. Test results show that dynamic fracture toughness is larger than the static one. During loading of SEN-T specimens the burst-type acoustic emission (AE) signals were monitored. From AE signals it can be concluded that the main damage form is the pull-out in the T specimens, and debonding in L ones. These results were supported by scanning electron microscopy micrographs taken from fracture surfaces.     

Enhancing the interfacial strength of glass/epoxy composites using ZnO nanowires

This paper investigated the application of ZnO nanowires (ZnO NW) to enhance the interfacial strength of glass/epoxy composites. ZnO NW were grown on glass fibers by hydrothermal method, tensile properties of bare and ZnO NW coated fibers were measured by single fiber tensile testing, wettability of fiber with resin was studied by contact angle measurements and finally the interfacial strength and mechanisms were determined by single fiber fragmentation testing of glass/epoxy composites. The surface coverage of ZnO NW on glass fibers was fairly uniform without formation of major clusters. The coating of ZnO NW slightly reduced the tensile strength and improved the tensile modulus of fibers. Wettability tests showed reduction in contact angles for ZnO NW coated fibers because of enhanced wetting and infiltration of epoxy resin into nanowires. In fragmentation testing of microcomposites, smaller and concentrated interfacial debonding zones for ZnO NW coated fibers indicated good stress transfer and strong interfacial adhesion. A new form of crossed and closely spaced stress patterns were observed for nanowires of high aspect ratios. The interfacial strength of ZnO NW coated fibers increased by at least 109% and by 430% on average, which was attributed to the increased surface area and mechanical interlocking provided by ZnO NW.     

Effect of matrix yield properties on fragmentation behavior of single fiber composites

Experimental and theoretical investigations have been conducted to study the dependence of fiber fragmentation behavior on matrix yielding properties. The cured Epikote 828 resins with two types of curing agents have almost similar elastic moduli, but different tensile yield strengths. The interfacial chemistry between fiber and epoxy resin is unchanged due to the same constituent of the epoxy resin. The experimental results indicate that the fragmentation behavior of the fibers embedded in the matrix is significantly different for the tested glass fiber treated by γ-glycidoxypropyltrimethoxysilane. The average fragment length decreased with increasing tensile yield strength of resin, which suggests that the interfacial shear strength determined in the fragmentation test should be different depending on the tensile yield strength of resin used. The important phenomenon observed is the transition of the micro-damage mode from matrix crack to interfacial debonding. An elastoplastic shear-lag model was used to calculate the shear stress and fiber tensile stress distributions considering different plastic behaviors of the matrices. The theoretical results indicate that the plastic behavior of the matrix has a large influence on stress transfer. Based on elastic and plastic properties of the matrix, the fiber fragmentation behavior in the matrix is predicted. Experimental and theoretical results are favorably compared.     

Crack propagation in amorphous polymers and their composites

The fracture energy of a polymer depends strongly on the viscoelastic responses of the material, and therefore is a function of temperature and crack velocity. The toughness of a composite is determined by the way in which the reinforcing filler modifies the energy dissipating mechanisms of the polymeric matrix.

The fracture toughness of a variety of polymeric glasses and their composites with glass beads, glass fibers, and rubber particles was measured. The velocity of rapidly moving cracks and the crack propagation rates under controlled loading conditions were also measured.

It was found that the crack propagation velocities in unfilled and glass bead filled materials were controlled by the longitudinal stress waves in the matrix and that the only effects of the glass beads were to blunt the crack tip and limit the viscous deformation. The effect on fracture toughness was relatively small and either positive or negative, depending on which of the above two factors dominated.

The presence of rubber particles as a second phase lowered terminal crack propagation velocities and greatly increased the fracture toughness, indicating a crack retarding effect of the rubber particles. This is related to the induction of crazes in the matrix by the rubber phase.

Glass fibers had a tendency to bridge the tip of a propagating crack, thereby greatly increasing the fracture toughness. In this case the work of fracture comes from a combination of the elastic strain energy stored in the fibers, the energy dissipated in debonding the fibers from the matrix, and the fracture energy of the matrix itself.     

Measurement of fiber/matrix interface properties of C/C composites by single fiber and fiber bundle push-out methods

Interfacial fracture stresses of carbon/carbon composites were measured by indentation methods. Two types of test methods, namely, single fiber push-out, and bundle fiber push-out tests were conducted. Both methods successfully gave fiber/matrix interface mechanical properties, especially debonding behavior. However, when the interface was strong, the single fiber push-out test encountered technical difficulty in processing the extremely thin specimen required to realize the fiber push out. On the other hand, the bundle fiber push-out test gave a good estimation of interfacial fracture stresses.     

Effects of residual stress and interfacial frictional shear stress on interfacial debonding at notch-tip in two-dimensional unidirectional composite

A calculation method based on the shear lag approach was presented to get an approximate estimate of influences of residual stresses and frictional shear stress at the debonded interface on the interfacial debonding behavior at the notch-tip along fiber direction in two-dimensional unidirectional double-edge-notched composites. With this method, the energy release rate for initiation and growth of debonding as a function of composite stress were calculated for some examples. The calculation results showed in outline how much the tensile and compressive residual stresses in the matrix and fiber along fiber direction, respectively, act to hasten the initiation and growth of the debonding when the final cut element in the notch is matrix, while they act to retard them when the final cut element is fiber, and how much the frictional shear stress at the debonded interface reduces the growth rate of the debonding.     

A study of TiB2/TiB gradient coating by laser cladding on titanium alloy

TiB₂/TiB gradient coating has been fabricated by a laser cladding technique on the surface of a Ti–6Al–4V substrate using TiB₂ powder as the cladding material. The microstructure and mechanical properties of the gradient coating were analyzed by SEM, EPMA, XRD, TEM and an instrument to measure hardness. With the increasing distance from the coating surface, the content of TiB₂ particles gradually decreased, but the content of TiB short fibers gradually increased. Meanwhile, the micro-hardness and the elastic modulus of the TiB₂/TiB coating showed a gradient decreasing trend, but the fracture toughness showed a gradient increasing trend. The fracture toughness of the TiB₂/TiB coating between the center and the bottom was improved, primarily due to the debonding of TiB₂ particles and the high fracture of TiB short fibers, and the fracture position of TiB short fiber can be moved to an adjacent position. However, the debonding of TiB₂ particles was difficult to achieve at the surface of the TiB₂/TiB coating.     

Influence of material processing and interface on the fiber fragmentation process in titanium matrix composites

The objective of this work is to study the effect of composite processing conditions on the nature of the fiber–matrix interface in titanium matrix composites and the resulting fragmentation behavior of the fiber. Titanium matrix, single fiber composites (SFCs) were fabricated by diffusion bonding and tensile tested along the fiber axis to determine their interfacial load transfer characteristics and the resulting fiber fragmentation behavior. Two different titanium alloys, Ti-6Al-4V (wt%) and Ti-14Al-21Nb (wt%), were used as matrix material with SiC (SCS-6) fibers as reinforcement. The tensile tests were conducted at ambient temperature and were continuously monitored by acoustic emission. It was observed that the Ti-6Al-4V/SCS-6 composite system exhibited a greater degree of fiber–matrix interfacial reaction, as well as a rougher interface, compared to Ti-14Al-21Nb/SCS-6 composites. Acoustic emissions during tensile testing showed that most of the fiber fractures in Ti-6Al-4V/SCS-6 occurred at strains below ～5% and the fragmentation ceased at ～10% strain corresponding to specimen necking. In contrast, the Ti-14Al-21Nb/SCS-6 composite deformed without necking and fiber fractures occurred throughout the plastic range until final fracture of the specimen at about 12% strain. The markedly different fragmentation characteristics of these two composites were attributed to differences in the fiber–matrix interfacial regions and matrix deformation behavior.     

Mechanical properties of flat braided composite with flexible interphase

Textile composites have been used extensively as industrial materials because of the excellent mechanical properties resulting from the continuously oriented fiber bundle. In a study of the mechanical properties, it is important to consider the fiber/matrix interface property as for other composite materials. In a recent study, the fiber/matrix interface is regarded as an interphase that has its own material constants and thickness; consequently, the mechanical properties of a composite can be controlled by specifically designing the interphase. In this study, we applied this concept to braided composites with flexible resin as interphase for the purpose of designing the interphase. In a static tensile test, though there were no improvements in Noncut specimens (normal braided composites), but a Cut specimen (each side of the Noncut specimen was cut) with flexible interphase was improved in fracture load and displacement. The observation of the specimen edge was carried out and it was confirmed that the progress of debonding at the fiber bundle intersection was interrupted by a flexible interphase, and a matrix crack did not occur in the Cut specimen with flexible interphase. In a fiber bundle pull-out test, it was confirmed that debonding progressed not into the fiber/resin interface but into the flexible interphase in the specimen with flexible interphase, and the interfacial property at the fiber bundle intersection was improved.     

Mode I and Mode II interlaminar fracture toughness of CFRP/magnesium alloys hybrid laminates

The fiber metal laminates (FML), consisting of carbon fiber reinforced polymer prepregs and magnesium alloys sheets, were introduced, and the Mode I (peel) and Mode II (shear) interlaminar fracture toughness of the FMLs were investigated. The results show that the Mode I interlaminar toughness (0.23 kJ/m²) of the FMLs is much lower than the Mode II interlaminar toughness (5.81 kJ/m²), due to the fact that the effects of mechanical interlock to hinder crack propagates is smaller under Mode I loading conditions than under Mode II. The FMLs mainly show adhesive failure and interfacial failure under Mode I loading conditions, while for Mode II loading, it exhibits a degree of epoxy cohesive failure except the adhesive failure and interfacial failure.     

Interface Separation in Residually-Stressed Thin-Film Structures

Plasticity is a significant contributor to the interfacial fracture resistance of multilayer thin-film structures containing ductile layers. Salient parameters affecting plasticity contributions to interfacial fracture energy including the ductile layer thickness, yield strength, and the maximum cohesive stress governing interface separation, have been reported. However, the effects of residual stresses in the thin-film layers on such plasticity contributions have not been considered. We explore the effect of residual stresses on debonding with particular attention to the relationship between the stress state in both ductile and elastic layers and the resulting macroscopic debond energy. Using multiscale simulations it is shown that residual thin-film stresses can alter plasticity in the ductile layer and significantly influence the macroscopic fracture energy. A simple yield-based model to account for this behavior is proposed.