Effect of interfacial debonding and matrix cracking on mechanical properties of multidirectional composites

In composites, debonding at the fiber–matrix interface and matrix cracking due to loading or residual stresses can effect the mechanical properties. Here three different architectures — 3-directional orthogonal, 3-directional 8-harness satin weave and 4-directional in-plane multidirectional composites — are investigated and their effective properties are determined for different volume fractions using unit cell modeling with appropriate periodic boundary conditions. A cohesive zone model (CZM) has been used to simulate the interfacial debonding, and an octahedral shear stress failure criterion is used for the matrix cracking. The debonding and matrix cracking have significant effect on the mechanical properties of the composite. As strain increases, debonding increases, which produces a significant reduction in all the moduli of the composite. In the presence of residual stresses, debonding and resulting deterioration in properties occurs at much lower strains. Debonding accompanied with matrix cracking leads to further deterioration in the properties. The interfacial strength has a significant effect on debonding initiation and mechanical properties in the absence of residual stresses, whereas, in the presence of residual stresses, there is no effect on mechanical properties. A comparison of predicted results with experimental results shows that, while the tensile moduli E ₁₁, E ₃₃and shear modulus G ₁₂ match well, the predicted shear modulus G ₁₃ is much lower.     

Fracture and debonding behavior of coated brittle alumina layer on ductile aluminum substrate wire

The fracture and debonding behavior of the Al₂O₃ layer coated on a ductile aluminum substrate wire was studied experimentally and analytically. When tensile strain was applied, the brittle Al₂O₃ coating layer showed multiple cracking perpendicular to the tensile axis. After the multiple cracking, compressive fracture of the Al₂O₃ layer arose in the circumferential direction when the layer was thinner than around 30 μm, while interfacial debonding between the Al₂O₃ layer and aluminum substrate arose when it was thicker. Such a difference in behavior between thin and thick layers could be accounted for by the difference in the layer thickness-dependence of the tensile radial stress at the interface and the compressive hoop stress of the Al₂O₃ layer calculated by the finite element method; the former stress increases while the latter one decreases with increasing layer thickness.     

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.     

Interfacial debonding and slipping of carbon fiber-reinforced ceramic-matrix composites under two-stage cyclic loading

In this paper, the interface debonding and frictional slipping of carbon fiber-reinforced ceramic-matrix composites (CMCs) under two-stage cyclic fatigue loading have been investigated using micromechanics approach. Under cyclic fatigue loading, the fiber/matrix interface shear stress degrades with increasing cycle number due to interface wear. The synergistic effect of interface wear and fatigue loading sequence on interface debonding and frictional slipping has been analyzed. Based on the fatigue damage mechanism of fiber slipping relative to matrix, in the interface debonded region, upon unloading and subsequent reloading, the interface debonded length and interface slip lengths, i.e. interface counter-slip length and interface new-slip length, are determined using the fracture mechanics approach. The relationships between interface debonding, interface slipping, interface wear, cycle number, and different loading sequences are determined. There are two types of fatigue loading sequences considered, i.e. (1) cyclic loading under low peak stress for N₁ cycles, and then high peak stress; and (2) cyclic loading under high peak stress for N₁ cycles, and then low peak stress. The effects of peak stress level, interface wear, cycle number, and loading sequence on interface debonding and frictional slipping of fiber-reinforced CMCs have been analyzed. The fatigue hysteresis loops of cross-ply carbon fiber-reinforced silicon carbide composite corresponding to different cycle number under two-stage cyclic fatigue loading have been predicted.     

Direct Observation of Crystallization of Polybutene-1 Under Low Shear Rate Flow

The isothermal crystallization process of polybutene-1 melt under shear flow was investigated with an optical microscope and a device (shear flow direct observation system, SF-DOS) newly developed by our group. The nucleation rate and growth rate of polybutene-1 were studied under slow shear rates (0–0.1 s^?1) at high crystallization temperature (102–108°C) with the SF-DOS. The nucleation remains heterogeneous. The number of nuclei after long times increased and induction time decreased by increasing the shear rate. Anisotropic and distorted spherulites were observed under shear flow, while the spherulites in the static condition were isotropic. It was clearly observed that the spherulites were rotating under shear. The average growth rates were enhanced by increasing shear rates, which acts as the main factor affecting the overall crystallization kinetics. Finally, the crystallization kinetics were analyzed on the basis of the secondary nucleation theory of Hoffman and Lauritzen. Even under very low shear rates, the product of lateral‐surface free energy σ _s and fold-surface free energy σ _e was found to be reduced as shear rate increased.     

Comparison of fibre/matrix interface strength for a 3D woven SiC/SiC composite

The fibre/matrix interface shear strength, τ _P, was determined by analysis of fibre pullout length distributions for a 3D woven SiC/SiC-based composite that had undergone tensile testing between room temperature and 1300°C in vacuum and air. Data was compared with the fibre/matrix interface shear strength, τ _S, obtained previously for this system by analysis of in situ fibre strength distributions. τ _P was found to follow the same general trend as that of τ _S and this was explained in terms of the carbon-rich fibre/matrix interface region. However, τ _P was smaller than τ _S by a factor of 3-4 for all cases, but the reason for this remains unclear although several tentative suggestions have been put forward.     

Theoretical analysis and numerical simulation of development length of straight steel fiber in cementitious materials

In fiber-reinforced concrete, it is important to choose an appropriate length in each fiber to develop its full yield strength without a failure in the bond strength between the fiber and the concrete. This length is called the fiber development length, L_df. The bond capacity is evaluated between the fiber and the concrete using the pull-out tests. This test evaluates the bond capacity of various types of steel fiber surfaces relative to a specific embedded length. If the steel fiber is smooth and straight, the distribution of tensile stresses will be uniform around the fiber at a specific section and varies along the anchorage length of the fiber and at a radial distance from the surface of the fiber. Pull-out tests can be performed on an embedded straight steel fiber in concrete matrix, in this case, the tensile force, P, is increased gradually and the number of cracks and their spacings and widths is recorded. The bond stresses vary along the fiber length between the cracks. The strain in the steel fiber is maximum at the cracked section and decreases toward the middle section between cracks. If the embedded length of the straight steel fiber is greater than the development length, the steel fiber may yield, leaving some length of the fiber in the concrete. The linear elastic behavior of the fiber-matrix system is interrupted by interface debonding which occurs due to overall weak bonding between the concrete matrix and the surface of the steel fiber. This paper introduces new developed shear lag model and explains simplified method to find the development length of straight steel fiber in concrete matrix using finite element model and analysis of shear lag stresses, where the maximum tension force which is applied on the steel fiber is resisted by another internal force related with the ultimate average bond stress, steel fiber diameter and its yield strength.     

Toughening Effect of Ethylene Propylene DieneTerpolymer-Graft-Styrene-Acrylonitrile Copolymer (EPDM-g-SAN) on SAN Resin

The reaction product EPDM-g-SAN, synthesized by suspension graft copolymerization of styrene (St) and acrylonitrile (AN) in the presence of ethylene-propylene-diene terpolymer (EPDM), was blended with a commercial styrene-acrylonitrile copolymer (SAN resin) to prepare AES blends with high impact strength. The effects of AN mass percentage in the St-AN comonomer mixture (f _AN), EPDM mass percentage in the feed of EPDM and St-AN (f _EPDM) and reaction time on monomer conversion ratio (CR), grafting ratio (GR), and AES notched Izod impact strength were characterized. The notched Izod impact strength of AES containing 15 wt% EPDM reached its maximum with f _AN of 40 wt% and f _EPDM of 45 wt%; this was attributed to the polarity of the SAN copolymer obtained being appropriate with that of the SAN resin matrix. The dependences of GR and the notched Izod impact strength of AES containing 25 wt% EPDM on the reaction time were in rough agreement. The effect of EPDM content on the AES notched Izod impact strength indicated that the brittle-ductile transition of AES occurred for an EPDM content from 12.5 to 15 wt%. TEM and SEM analysis showed that the phase structure of AES exhibited a “salami” like structure, and the toughening mechanism of AES was shear yielding of the SAN resin matrix, which endowed AES with excellent toughness.     

Microstructure and mechanical properties of continuous Al2O3 fibre reinforced Ni45Al45Cr7.5Ta2.5 alloy (IP75) matrix composites

Single crystalline Al₂O₃ fibres (sapphire), coated with the NiAl alloy IP75 by physical vapour deposition (PVD), were assembled to fabricate composites by means of diffusion bonding. The microstructure and chemistry of both as-coated fibre and as-diffusion bonded composites were investigated by electron microscopy and microanalysis. The interface shear stress for complete debonding was measured by fibre push-out tests at room temperature, and the composite tensile strength was measured at 900°C and 1100°C. An amorphous layer with a thickness of about 400?nm formed between the fibre and the matrix during the PVD process and was maintained during diffusion bonding. A Laves phase precipitated along NiAl grain boundaries in the IP75 matrix. This caused a lower tensile strength of the IP75/Al₂O₃ composite at high temperatures compared to as-cast monolithic IP75 and rendered the composite useless for structural applications.     

Bonding at Compatible and Incompatible Amorphous Interfaces of Polystyrene and Poly(Methyl Methacrylate) Below the Glass Transition Temperature

Abstract

Films of high‐molecular‐weight amorphous polystyrene (PS, M _w = 225 kg/mol, M _w/M _n = 3, T _g‐bulk = 97°C, where T _g‐bulk is the glass transition temperature of the bulk sample) and poly(methyl methacrylate) (PMMA, M _w = 87 kg/mol, M _w/M _n = 2, T _g‐bulk = 109°C) were brought into contact in a lap‐shear joint geometry at a constant healing temperature T _h, between 44°C and 114°C, for 1 or 24 hr and submitted to tensile loading on an Instron tester at ambient temperature. The development of the lap‐shear strength σ at an incompatible PS–PMMA interface has been followed in regard to those at compatible PS–PS and PMMA–PMMA interfaces. The values of strength for the incompatible PS–PMMA and compatible PMMA–PMMA interfaces were found to be close, both being smaller by a factor of 2 to 3 than the values of σ for the PS–PS interface developed after healing at the same conditions. This observation suggests that the development of the interfacial structure at the PS–PMMA interface is controlled by the slow component, i.e., PMMA. Bonding at the three interfaces investigated was mechanically detected after healing for 24 hr at T _h = 44°C, i.e., well below T _g‐bulks of PS and PMMA, with the observation of very close values of the lap‐shear strength for the three interfaces considered, 0.11–0.13 MPa. This result indicates that the incompatibility between the chain segments of PS and PMMA plays a negligible negative role in the interfacial bonding well below T _g‐bulk.     

On mechanical stability of molybdenum

Investigations of the strength properties of materials under different loading conditions are of practical importance in many engineering applications. The knowledge of elastic moduli as a function of strain is required for determination of strength properties. In the present work, we have determined the elastic moduli of molybdenum through first principles study of the energy changes under three different loading conditions namely ‘uni-axial tensile deformation’ along [0 0 1] direction, ‘uni-axial tensile loading’ along [0 0 1] direction and ‘hydrostatic tensile loading’. The stability conditions for the system are expressed in terms of the elastic moduli and analyzed along the deformation paths corresponding to these three loading modes. The theoretical spall strength (σ_S), tensile strength (σ_T) along [0 0 1] direction and hydrostatic tensile strength (σ_H), are evaluated as a stress at the first onset of the instability for three loading conditions, respectively. The calculated equilibrium volume and elastic moduli are compared with that reported from experimental and other theoretical works.     

Pull-out tests with fibre-metal systems

Fibre pull-out experiments have been carried out to compare the behaviour of reactive and non-reactive fibre-reinforced metal systems. The test samples were made by melting the metal matrix in vacuum and lowering the fibre a known depth into the liquid. In all cases some brittleness appeared to develop, since final interface failure, except with steel-99% AI, was sudden, and the values of the debonding force were quite scattered in all cases. Otherwise the results agreed with earlier observations, i.e. a linear increase in debonding force with increasing embedded length until the force was high enough to break the fibre rather than debond it. Some yielding was noticeable before failure. An elasticity analysis suggested that high shear stresses were needed in some cases to initiate yielding. However, the interface strengths, as indicated by the debonding forces, were no more than about twice the shear yield stresses of the matrices, as indicated by compressive tests on the metals. A reaction layer was observed on steel which was embedded in the aluminum, but this did not appear to reduce the interface strength. With W-Cu, on the other hand, a thin layer of copper was present on the pulled out tungsten fibre, while with SiC-AI, the silicon carbide had some carbon present on the surface, with traces of AI.     

Molecular dynamics simulation of gas diffusion behavior in polyethylene terephthalate/aluminium/polyethylene interface

Molecular dynamics (MD) simulations were performed to estimate the diffusion coefficients of O₂ and H₂O molecules in polyethylene terephthalate/aluminum/polyethylene interface at the temperature of 298 K. It came out that the diffusion coefficient of gasses in the interface is smaller than that of a single polymer, and the diffusion coefficients compare well with experimental data as well as previously published work. Furthermore, the diffusion coefficients of H₂O molecules in the interface are preferable to that of O₂ molecules. Interestingly, the largest diffusion coefficient was detected in the polyethylene terephthalate/aluminum(1 0 0)/polyethylene interface, while the smallest value of the diffusion coefficients was found in the polyethylene terephthalate/aluminum(1 1 1)/polyethylene interface. Calculation and analysis of the interaction between aluminum and polymers indicated that the interaction of polymer/aluminum(1 1 0) has the most interface strength, and crystal density of the metal surface has a definite effect on the planar interface energy. What’s more, the figure of gas molecule concentration is further resulted that the interface make contribution to adsorption of gas molecules. Moreover, the diffusion is belonging to the Einstein diffusion in the multilayer materials, and this work provides some key clues to improve the performance of polymer materials.     

Toughening of Propylene‐ethylene Copolymer/Calcium Carbonate Composites with High‐Density Polyethylene

Propylene‐ethylene copolymer/calcium carbonate (CaCO₃) composites (weight ratio=50/50) toughened with high density polyethylene (HDPE) were prepared using a twin‐screw extruder; the HDPE content in composites was in the range of 0–4 wt.%. The notched impact strength of propylene‐ethylene copolymer/CaCO₃ composites with 1.5 wt.% HDPE was 46% higher than that of propylene‐ethylene copolymer/CaCO₃ composites. Differential scanning calorimetry (DSC) experiments showed that good miscibility between propylene‐ethylene copolymer and HDPE enhanced the interpenetration of the macromolecules located in the interface. It was shown that debonding of the small HDPE particles within the propylene‐ethylene copolymer matrix resulted in the formation of small voids; the subsequent plastic deformation of the propylene‐ethylene copolymer matrix next to the voids thinned the ligaments and led to large energy consumption.     

Interface effect in the silicone rubber/mineral powder composites

Silicone rubber/mineral powder composites have been prepared by surface modification and ultrafinecrashing of mineral powder, mixing and vulcanizing with silicone rubber resin. The surface and interface energy for mineral filler and silicone rubber matrix were investigated. It was found that there is a correlation between W _a/σ_SL (interfacial adhesive work/interfacial tension) and the tensile strength of the corresponding composite, especially for unmodified ultrafine mineral filler. On the other hand, the chemical modification of the surface changes the surface group on the mineral filler and results in improvement of the interfacial interaction between silicone rubber matrix and mineral filler, consequently, altering the reinforcing effect of the mineral filler.     

Microstructure evolution and properties of Al/Al–Mg–Si alloy clad wire during heat treatment

In this paper, heat treatment was carried out on Al/Al–Mg–Si alloy clad wire, and microstructure evolution and properties of Al/Al–Mg–Si alloy clad wire during heat treatment were investigated. During solution, contents of Mg and Si in inner matrix increased due to dissolution of primary Mg₂Si, and they also increased in outer matrix because Mg and Si diffused across the interface. Tensile strength of the clad wire increased firstly and then decreased, and elongation continuously increased, while conductivity continuously decreased with the increase in solution time. In aging process, Mg₂Si precipitated in both inner core and outer layer, and the content and average diameter of the precipitate increased with the increase in aging time. The content of precipitate was higher, and the average diameter was bigger in inner core. Tensile strength of the clad wire increased firstly and then decreased with the increase in aging time, and the elongation continuously decreased, while the conductivity continuously increased. The peak tensile strength of 202 MPa occurred at 8 h, when the corresponding elongation was 20 % and the conductivity reached 56.07 %IACS. Even tensile strength of the prepared clad wire approximately equaled to that of Al–0.5Mg–0.35Si alloy 203 MPa, the conductivity was obviously improved from 54.2 to 56.07 %IACS.     

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.     

Stress field calculation around a particle in elastic–plastic polymer matrix under multiaxial loading as basis for the determination of adhesion strength

The stress distribution around a single particle coated with an elastic interphase embedded within an elastic–plastic polymer matrix under multiaxial load was considered. The specimen has a curved (necked) geometry, which causes multiaxial local stresses in the neighbourhood of the particle. The motivation for the calculations is to determine the maximum radial stress (debonding strength) at the particle surface as a function of applied load. The effect of the particle size on failure initiation is considered. Assuming that the normal stress at the interface is responsible for debonding, the adhesion strength can be determined from the critical load at debonding initiation. Because of the matrix yielding, the relation between the applied load and the maximum radial stress at the particle/interphase interface is a non-linear one. Using this relation, the determination of interfacial strength will be possible by a tensile test.     

Ultrasonic semi-solid coating soldering 6061 aluminum alloys with Sn–Pb–Zn alloys

In this paper, 6061 aluminum alloys were soldered without a flux by the ultrasonic semi-solid coating soldering at a low temperature. According to the analyses, it could be obtained that the following results. The effect of ultrasound on the coating which promoted processes of metallurgical reaction between the components of the solder and 6061 aluminum alloys due to the thermal effect. Al₂Zn₃ was obtained near the interface. When the solder was in semi-solid state, the connection was completed. Ultimately, the interlayer mainly composed of three kinds of microstructure zones: α-Pb solid solution phases, β-Sn phases and Sn–Pb eutectic phases. The strength of the joints was improved significantly with the minimum shear strength approaching 101 MPa.     

Enhanced interface interaction between modified carbon nanotubes and magnesium matrix

Carbon nanotube (CNT)/metal interface interaction is critical to the mechanical properties of CNT-reinforced metal matrix composites (MMCs). In this paper, in order to realize the chemical modification of the interface interaction between CNTs and Mg matrix, different types of defects (monovacancy, carbon and oxygen adatoms, as well as p-type boron and n-type nitrogen substitution) are introduced in CNTs to investigate the effect of the defects on the interface interaction (E_ib) between CNT and Mg (0 0 0 1) surface. Moreover, two models (adsorption model and interface model) are compared and validated to investigate the interface interaction. It is revealed that the CNT with the carbon adatom has the highest E_ib with the Mg (0 0 0 1), and the effect of boron doping on E_ib is superior to the intermediate oxygen which has already been proved experimentally in the enhancement of the interface interaction in MMCs. In terms of the electronic structure analysis, we reveal the micro-mechanism of the increase of E_ib under the action of different types of defects, and propose that the presence of holes (boron dopant) and the unsaturated electrons in CNTs can generate the chemical interaction between CNT and Mg matrix effectively. Our results are of great scientific importance to the realization of robust interfacial bonding between CNTs and Mg matrix via the reinforcement modification, so as to enhance the mechanical properties of CNTs reinforced Mg matrix composites.