Stress relaxation in broken fibers in unidirectional composites: modeling and application to creep rupture analysis

This paper describes a model of stress relaxation in broken fibers in unidirectional metal matrix composites reinforced with long brittle fibers. A cylindrical cell with a broken fiber embedded in a power law creeping matrix is employed, and the broken fiber is assumed to have a bilinear distribution of axial stress. Then, on the basis of energy balance in the cell under constant overall strain, a relaxation equation of interfacial shear stress acting on stress recovery segments is derived in a simple form. The relaxation equation is approximated rationally and integrated to obtain an analytical solution, which is shown to agree fairly well with the numerical analysis of Du and McMeeking. (Du, Z.-Z., McMeeking, R.M., 1995. Creep models for metal matrix composites with long brittle fibres. J. Mech. Phys. Solids 43, 701–726.) Moreover, the relaxation equation is combined with Curtin's model (Curtin, W.A., 1991. Theory of mechanical properties of ceramic-matrix composites. J. Am. Ceram. Soc. 74, 2837–2845.), so that rupture time in long term creep is evaluated analytically and explicitly on the assumption of global load sharing. It is shown that the resulting relation represents well the dependence of creep rupture time on applied stress observed experimentally on a unidirectional metal matrix composite.     

Creep-rupture lifetime simulation of unidirectional metal matrix composites with and without time-dependent fiber breakage

A numerical simulation for predicting the axial creep-rupture lifetime of continuous fiber-reinforced metal matrix composites is proposed, based on the finite element method. The simulation model is composed of line elements representing the fibers and four-node isoparametric plane elements representing the matrix. While the fibers behave as an elastic body at all times, the matrix behaves as an elasto-plastic body at the loading process and an elasto-plastic creep body at the creep process. It is further assumed in the simulation that the fibers are fractured not only in stress criterion but time-dependently with random nature. Simulation results were compared with the creep-rupture lifetime data of a boron-aluminum composite with 10% fiber volume fraction experimentally obtained. The simulated creep-rupture lifetimes agreed well with the averages of the experimental data. The proposed simulation is further carried out to predict a possibility of creep-rupture for the composite without time-dependent fiber breakage. It is finally concluded that the creep-rupture of a boron-aluminum composite is closely related with the shear stress relaxation occurring in the matrix as well as time-dependent fiber breakage.     

Analysis for enhancement of composite resistance to matrix cracking and interfacial debonding with rubber-coated reinforcement

An analytical model is presented for a unidirectional composite with a matrix crack straddling across rubber-coated fiber reinforcements. An expression is derived for the energy released in matrix cracking. A penny-shaped matrix crack configuration is chosen as an example. With the aid of Hankel's transform, a linear integral equation is derived and solved numerically for the reinforcement stress and energy release in terms of a parameter λ that depends on the composite material and crack geometry. The maximum stress intensity factor for a matrix crack in the unidirectional composite increases monotonically with λ, attaining the largest value for a crack in a homogeneous matrix material.     

An asymmetrical dynamic model for bridging fiber pull-out of unidirectional composite materials

An elastic analysis of an internal crack with bridging fibers parallel to the free surface in an infinite orthotropic elastic plane is studied. An asymmetrical dynamic model for bridging fiber pull-out of unidirectional composite materials is presented for analyzing the distributions of stress and displacement with the internal asymmetrical crack under the loading conditions of an applied non-homogenous stress and the traction forces on crack faces yielded by the bridging fiber pull-out model. Thus the fiber failure is determined by maximum tensile stress, resulting in fiber rupture and hence the crack propagation would occur in a self-similarity manner. The formulation involves the development of a Riemann-Hilbert problem. Analytical solution of an asymmetrical propagation crack of unidirectional composite materials under the conditions of two moving loads given is obtained, respectively. After those analytical solutions were utilized by superposition theorem, the solutions of arbitrary complex problems could be obtained.     

Asymmetrical dynamic fracture model of bridging fiber pull-out of unidirectional composite materials

An elastic analysis of an internal crack with bridging fibers parallel to the free surface in an infinite orthotropic anisotropic elastic plane is studied, and asymmetrical dynamic fracture model of bridging fiber pull-out of unidirectional composite materials is presented for analyzing the distributions of stress and displacement with the internal asymmetrical crack under the loading conditions of an applied non-homogenous stress and the traction forces on crack faces yielded by the bridging fiber pull-out model. Thus the fiber failure is ascertained by maximum tensile stress, the fiber ruptures and hence the crack propagation should also appear in the modality of self-similarity. The formulation involves the development of a Riemann-Hilbert problem. Analytical solution of an asymmetrical propagation crack of unidirectional composite materials under the conditions of two increasing loads given is obtained, respectively. In terms of correlative material properties, the variable rule of dynamic stress intensity factor was depicted very well. After those analytical solutions were utilized by superposition theorem, the solutions of arbitrary complex problems could be gained.     

A homogenization theory for time-dependentnonlinear composites with periodic internal structures

A homogenization theory for time-dependent deformation such as creep andviscoplasticity of nonlinear composites with periodic internal structures is developed. To beginwith, in the macroscopically uniform case, a rate-type macroscopic constitutive relation betweenstress and strain and an evolution equation of microscopic stress are derived by introducing twokinds of Y-periodic functions, which are determined by solving two unit cell problems.Then, the macroscopically nonuniform case is discussed in an incremental form using thetwo-scale asymptotic expansion of field variables. The resulting equations are shown to beeffective for computing incrementally the time-dependent deformation for which the history ofeither macroscopic stress or macroscopic strain is prescribed. As an application of the theory,transverse creep of metal matrix composites reinforced undirectionally with continuous fibers isanalyzed numerically to discuss the effect of fiber arrays on the anisotropy in such creep.     

Three-dimensional continuum analysis for a unidirectional composite with a broken fiber

The three-dimensional problem of a periodic unidirectional composite with a penny-shaped crack traversing one of the fibers is analyzed by the continuum equations of elasticity. The solution of the crack problem is represented by a superposition of weighted unit normal displacement jump solutions, everyone of which forms a Green’s function. The Green’s functions for the unbounded periodic composite are obtained by the combined use of the representative cell method and the higher-order theory. The representative cell method, based on the triple discrete Fourier transform, allows the reduction of the problem of an infinite domain to a problem of a finite one in the transform space. This problem is solved by the higher-order theory according to which the transformed displacement vector is expressed by a second order expansion in terms of local coordinates, in conjunction with the equilibrium equations and the relevant boundary conditions. The actual elastic field is obtained by a numerical evaluation of the inverse transform. The accuracy of the suggested approach is verified by a comparison with the exact analytical solution for a penny-shaped crack embedded in a homogeneous medium. Results for a unidirectional composite with a broken fiber are given for various fiber volume fractions and fiber-to-matrix stiffness ratios. It is shown that for certain parameter combinations the use of the average stress in the fiber, as it is employed in the framework of the shear lag approach, for the prediction of composite’s strength, leads to an over estimation. To this end, the concept of “point stress concentration factor” is introduced to characterize the strength of the composite with a broken fiber. Several generalizations of the proposed approach are offered.     

On the effect of fiber creep-compliance in the high-temperature deformation of continuous fiber-reinforced ceramic matrix composites

Creep models for unidirectional ceramic matrix composites reinforced by long creeping fibers with weak interfaces are presented. These models extend the work of Du and McMeeking (1995) [Du, Z., McMeeking, R. 1995. Creep models for metal matrix composites with long brittle fibers. J. Mech. Phys. Solids 43, 701–726] to include the effect of fiber primary creep present in the required operational temperatures for ceramic matrix composites (CMCs). The effects of fiber breaks and the consequential stress relaxation around the breaks are incorporated in the models under the assumption of global load sharing and time-independent stochastics for fiber failure. From the set of problems analyzed, it is found that the high-temperature deformation of CMCs is sensitive to the creep-compliance of the fibers. High fiber creep-compliance drives the composite to creep faster, leading however to greater lifetimes and greater overall strains at rupture. This behavior is attributed to the fact that the greater the creep-compliance of the fibers, the higher the creep rate but the slower the matrix stress relaxation – since the matrix must deform with a rate compatible with the more creep-resistant fibers – and therefore the less the load carried by the main load-bearing phase, the fibers. As a result, fewer fibers fail and less damage is accumulated in the system. Moreover, the greater the creep-compliance of the fibers, the slower the matrix shear stress relaxation – and thus the lower the levels of applied stress for which this effect becomes important. The slower the shear stress relaxes, the slower the “slip” length increases. Due to the Weibull nature of the fibers, the fiber strengths at the smaller gauge length of the slip length are stronger; therefore fewer fibers undergo damage. Hence, high fiber creep-compliance is desirable (in the absence of any explicit creep-damage mechanism) in terms of composite lifetime but not in terms of overall strain. These results are considered of importance for composite design and optimization.     

Multiple cracking of fiber/matrix composites—Analysis of normal extension

This paper is concerned with the fracture of a fiber embedded in a matrix of finite radius. There is a periodic array of cracks in the fiber along the central axis of the medium. The paper accounts for the cases of axial extension and residual temperature change of the composite medium. Fourier and Hankel transforms are used to reduce the problem to the solution of a system of dual integral equations, which are solved by the singular integral equation technique. Rigorous fracture mechanics analysis, which exactly satisfies all boundary conditions of the problem, is conducted. Numerical solutions for the crack tip field and the stress in the fiber are obtained for various values such as crack radius, crack spacing and fiber volume fraction.     

The analysis of cyclically loaded creeping structures for short cycle times

In a recent paper [1] it was shown that the evaluation of certain bounding solutions for a structure subjected to cyclic loading was equivalent to assuming that the cycle time Δt was short compared with a stress redistribution time. Comparisons between values which are likely to occur in creep design situations indicated that Δt may often be assumed to be small and the bounding solution may be expected to closely approximate the actual stress history. In this paper the solution for the limiting case when Δt → 0 is evaluated for a class of constitutive relationships which may be expressed in terms of a finite number of state variables. Strain-hardening viscous, visco-elastic and Bailey-Orowan equations are discussed and particular solutions for which the residual stresses remain constant in time are derived. The solution for a non-linear visco-elastic model indicates that, for the stationary cyclic state, the constitutive equation need only predict the creep strain over a discrete number of cycles and need not predict the strains during a cycle. This observation should considerably simplify creep analysis.The solution of a simple example demonstrates the similarity between the predicting of the various constitutive relationships for isothermal problems. In fact they provide virtually identical solutions when expressed in terms of reference stress histories. The finite element solution of a plate containing a hole and subjected to variable edge loading is also presented for a viscous material. The solutions show behaviour which is similar to that of the two bar structure.     

The creep deformation of vibrating structures

In a recent paper [1] it was shown that the evaluation of certain bounding solutions for a structure subjected to cyclic loading was equivalent to assuming that the cycle time Δt was short compared with a stress redistribution time. Comparisons between values which are likely to occur in creep design situations indicated that Δt may often be assumed to be small and the bounding solution may be expected to closely approximate the actual stress history. In this paper the solution for the limiting case when Δt → 0 is evaluated for a class of constitutive relationships which may be expressed in terms of a finite number of state variables. Strain-hardening viscous, visco-elastic and Bailey-Orowan equations are discussed and particular solutions for which the residual stresses remain constant in time are derived. The solution for a non-linear visco-elastic model indicates that, for the stationary cyclic state, the constitutive equation need only predict the creep strain over a discrete number of cycles and need not predict the strains during a cycle. This observation should considerably simplify creep analysis.The solution of a simple example demonstrates the similarity between the predicting of the various constitutive relationships for isothermal problems. In fact they provide virtually identical solutions when expressed in terms of reference stress histories. The finite element solution of a plate containing a hole and subjected to variable edge loading is also presented for a viscous material. The solutions show behaviour which is similar to that of the two bar structure.     

Residual strength of a fiber reinforced metal matrix composite with a crack

The residual strength of a cracked unidirectional fiver reinforced metal matrix composite is studied. We propose a bridging model based on the Dugdale strip yielding zones in the matrix ahead of the crack tips that accounts for ductile deformations of the matrix and fiber debonding and pull-out in the strip yielding zone. The bridging model is used to study the fracture of an anisotropic material and its residual strength is calculated numerically. The predicted results for a SiC/titanium composite agree well with the existing experimental data. It is found that a higher fiber bridging stress and a larger fiber pull-out length significantly contribute to the composite's residual strength. The composite's strength may be more notch-insensitive than the corresponding matrix material's strength depending on several factors such as fiber-matrix interface properties and the ratio of the matrix modulus to an ‘effective modulus’ of the composite.     

Effect of the silicon-carbide micro- and nanoparticle size on the thermo-elastic and time-dependent creep response of a rotating Al–SiC composite cylinder

The history of stresses and creep strains of a rotating composite cylinder made of an aluminum matrix reinforced by silicon carbide particles is investigated. The effect of uniformly distributed SiC micro- and nanoparticles on the initial thermo-elastic and time-dependent creep deformation is studied. The material creep behavior is described by Sherby’s constitutive model where the creep parameters are functions of temperature and the particle sizes vary from 50 nm to 45.9 μm. Loading is composed of a temperature field due to outward steady-state heat conduction and an inertia body force due to cylinder rotation. Based on the equilibrium equation and also stress-strain and strain-displacement relations, a constitutive second-order differential equation for displacements with variable and time-dependent coefficients is obtained. By solving this differential equation together with the Prandtl–Reuss relation and the material creep constitutive model, the history of stresses and creep strains is obtained. It is found that the minimum effective stresses are reached in a material reinforced by uniformly distributed SiC particles with the volume fraction of 20% and particle size of 50 nm. It is also found that the effective and tangential stresses increase with time at the inner surface of the composite cylinder; however, their variation at the outer surface is insignificant.     

The effect of fiber damage on the longitudinal creep of a CFMMC

Fiber failures which may exist in a continuous fiber composite before the composite is loaded or generated while the composite is loaded, introduce an additional strain component not included in existing continuous fiber models. Equations are developed which can be used to calculate the magnitude of this additional strain. A Finite Element Model (FEM), in the form of a Representative Volume Element (RVE), calculates the stress field surrounding a fiber break. Statistical analysis is used to infer the behavior of a large composite sample from the stress analysis of a single break. The creep strain, the time to failure, and time-dependent composite strength can all be calculated by combining the FEM results, the statistical analysis model, and knowledge of the initial average fiber length. Important variables included in the calculation are process-related parameters such as the fiber-matrix interface strength and roughness.     

Effective longitudinal shear moduli of periodic fibre-reinforced composites with functionally-graded fibre coatings

This paper presents a homogenization method for unidirectional periodic composite materials reinforced by circular fibres with functionally graded coating layers. The asymptotic homogenization method is adopted, and the relevant cell problem is addressed. Periodicity is enforced by resorting to the theory of Weierstrass elliptic functions. The equilibrium equation in the coating domain is solved in closed form by applying the theory of hypergeometric functions, for different choices of grading profiles. The effectiveness of the present analytical procedure is proved by convergence analysis and comparison with finite element solutions. The influence of microgeometry and grading parameters on the shear stress concentration at the coating/matrix interface is addressed, aimed at the composite optimization in regards to fatigue and debonding phenomena.     

A multi-scale framework for layered composites with thermo-rheologically complex behaviors

A multi-scale modeling framework is proposed for generating the effective nonlinear thermo-viscoelastic responses of multi-layered and thick-section composites. The modeling framework is demonstrated for multi-layered composite systems consisting of two alternating fiber-reinforced polymeric layers: unidirectional fiber (roving) and continuous filament mat (CFM). The viscoelastic behavior of the polymeric matrix is considered as stress-dependent and thermo-rheologically complex. Two simplified 3D micromechanical models with periodic boundary conditions are formulated for the roving and CFM. In addition, a sublaminate model is developed for the 3D effective homogenized through-thickness response of the roving and CFM layers. This framework provides an effective time-dependent material response while simultaneously recognizing the corresponding deformation at the microconstituents under overall thermo-mechanical loadings at the macro-level. Stress correction algorithms are developed at each scale to enhance computational efficiency and accuracy. Short-term (30 min) creep tests on off-axis multi-layered specimens are also conducted under combined stresses and temperatures to calibrate in-situ fiber and matrix properties and verify the predictions of the multi-scale framework. A time-shifting method is applied to create long-term material behaviors from the available short-term creep data. Verification of the multi-scale material framework is also done for the overall long-term responses. Finally, long-term structural analyses under thermo-mechanical loadings are conducted by integrating the multi-scale material framework to finite element (FE) structural analyses.     

Statistical Assessment of Tensile Static,Creep and Fatigue Strengths for Unidirectional CFRP

Background

The tensile strength along the longitudinal direction of unidirectional carbon fiber reinforced plastics (CFRPs) constitutes important data for the reliable design of CFRP structures. Our earlier reports proposed the formulations for the statistical static, creep, and fatigue strengths of CFRP based on Christensen’s model of the viscoelastic crack kinetics.

Objective

This study is concerned with the statistical assessment of the tensile static, creep, and fatigue strengths of unidirectional CFRPs by using the proposed formulations and the characterization of the long-term strengths of unidirectional CFRPs.

Method

First, the proposed formulations for the time-dependent and temperature-dependent statistical static, creep, and fatigue strengths of CFRP are introduced. Second, the tensile static, creep and fatigue strengths of unidirectional CFRP are measured statistically at various temperatures using resin-impregnated CFRP strands as tensile test specimens by measuring the viscoelasticity of the matrix resin. Finally, the master curves showing the long-term life of these strengths are constructed by substituting these measured data into the formulations.

Results

The results clarify that the formulations are applicable with high reliability over wide ranges of time and temperature for the statistical tensile static, creep and fatigue strengths of unidirectional CFRP except above the glass transition temperature of the matrix resin. Therefore, the fatigue strength degradation phenomena of unidirectional CFRPs can be expressed by the time- and temperature-dependent part due to the viscoelastic behavior of the matrix resin and the number of load cycle-dependent parts.

Conclusions

The long-term life prediction of unidirectional CFRPs under static, creep and fatigue tension loadings can be determined by ascertaining the mechanical properties of the CFRP and matrix resin in the proposed formulations.

     

Uncertainties of unidirectional composite strength under tensile loading and variation of environmental condition

A probabilistic strength model is developed for unidirectional composites with fibers in hexagonal arrays. The model assumes that, a central core of broken fibers surrounded by unbroken fibers which are subjected to unidirectional tensile loading. The proposed approach consists in using a modified shear lag model to calculate the ineffective lengths and stress concentrations around fiber breaks. The main feature in the model lies in incorporating the variation of composite properties due to temperature and moisture, in order to predict degradation of fibers and matrix characteristics. The strength degradation is often seen as a result of changes in ineffective lengths at fiber breaks, leading to stress concentrations in intact neighboring fibers. As fiber breaks are intrinsically random, the variability of input data allows us to describe the probabilistic model by using the Monte-Carlo method. The sensitivities of the mechanical response are evaluated regarding the uncertainties in design variables such as Young’s modulus of fibers and matrix, fiber reference strength, shear yield stress, fiber volume fraction and shear parameter defining the shear stress in the inelastic region.     

On Brinell and Boussinesq indentation of creeping solids

As an alternative to traditional tensile testing of materials subjected to creep, indentation testing is examined. Axisymmetric punches of shapes defined by smooth homogeneous functions are analysed in general at power law behaviour both from a theoretical and a computational point of view. It is first shown that by correspondence to nonlinear elasticity and self-similarity the problem to determine time-dependent properties admits reduction to a stationary one. Specifically it is proved that the creep rate problem posed depends only on the resulting contact area but not on specific punch profiles. As a consequence the relation between indentation depth and contact area is history independent. So interpreted, the solution for a flat circular cylinder (Boussinesq) is not only of intrinsic interest but serves as a reference solution to generate results for various punch profiles. This is conveniently carried out by cumulative superposition and in particular ball indentation (Brinell) is analysed in depth. A carefully designed finite element procedure based on a mixed variational principle is used to provide a variety of explicit results of high accuracy pertaining to stress and deformation fields. Universal relations for hardness at creep are proposed for Boussinesq and Brinell indentation in analogy with the celebrated formula by Tabor for indentation of strain-hardening plastic materials. Quantitative comparison is made with a diversity of experimental data attained by earlier writers and the relative merits of indentation strategies are discussed.     

Anti-plane shear waves in a fibre-reinforced composite with a non-linear imperfect interface

The propagation of non-linear elastic anti-plane shear waves in a unidirectional fibre-reinforced composite material is studied. A model of structural non-linearity is considered, for which the non-linear behaviour of the composite solid is caused by imperfect bonding at the “fibre–matrix” interface. A macroscopic wave equation accounting for the effects of non-linearity and dispersion is derived using the higher-order asymptotic homogenisation method. Explicit analytical solutions for stationary non-linear strain waves are obtained. This type of non-linearity has a crucial influence on the wave propagation mode: for soft non-linearity, localised shock (kink) waves are developed, while for hard non-linearity localised bell-shaped waves appear. Numerical results are presented and the areas of practical applicability of linear and non-linear, long- and short-wave approaches are discussed.