Nonlinear shear behavior and interlaminar shear strength of unidirectional polymer matrix composites: A numerical study

Detailed finite element implementation is presented for a recently developed technique (He et al., 2012) to characterize nonlinear shear stress–strain response and interlaminar shear strength based on short-beam shear test of unidirectional polymeric composites. The material characterization couples iterative three-dimensional finite element modeling for stress calculation with digital image correlation for strain evaluation. Extensive numerical experiments were conducted to examine the dependence of the measured shear behavior on specimen and test configurations. The numerical results demonstrate that consistent results can be achieved for specimens with various span-to-thickness ratios, supporting the accurate material properties for the carbon/epoxy composite under study.     

Thermographic detection of adhesive-bond and interlaminar flaws in composites

This paper reports the development of a liquid-crystal passive thermographic technique for the detection of adhesive-bond-line and interlaminar flaws in composite materials. The technique was successfully used for the detection of flaws in three composite systems: E-glass/epoxy, graphite/epoxy and HMC. Thermographic results are compared to ultrasonic C-scan results to assess the relative effectiveness of the new technique. A photomicrographic study was also used to verify the detected flaws and to characterize the type and extent of the actual damage.     

An enhanced beam-theory model of the mixed-mode bending (MMB) test—Part I: Literature review and mechanical model

The paper presents a mechanical model of the mixed-mode bending (MMB) test used to assess the mixed-mode interlaminar fracture toughness of composite laminates. The laminated specimen is considered as an assemblage of two sublaminates partly connected by an elastic–brittle interface. The problem is formulated through a set of 36 differential equations, accompanied by suitable boundary conditions. Solution of the problem is achieved by separately considering the two subproblems related to the symmetric and antisymmetric parts of the loads, which for symmetric specimens correspond to fracture modes I and II, respectively. Explicit expressions are determined for the interfacial stresses, internal forces, and displacements.     

Viscoelastic response of a unidirectional composite containing two viscoelastic constituents

Viscoelastic response of a unidirectional aramid fiber-reinforced epoxy was measured. Procedures to measure all five time-dependent material properties necessary to describe behavior of a transversely isotropic continuous-fiber unidirectional lamina were implemented. The Iosipescu shear method was used to measure in-plane and interlaminar shear viscoelastic response. Applicability of the Schapery single-integral nonlinear viscoelastic constitutive model to describe time-dependent mechanical behavior of a laminated composite material containing two viscoelastic phases was explored. Linear and nonlinear viscoelastic parameters for this two-viscoelastic constituent composite were measured and data summaries are presented in the paper. The time-dependent behavior of this two-viscoelastic constituent composite material was found to be complex, but the Schapery nonlinear viscoelastic model did adequately fit the response of such a composite to uniaxial applied loads.Paper was presented at the 1988 SEM Spring Conference on Experimental Mechanics held in Portland, OR on June 5–10.     

Experimental evaluation of mixed-mode fracture in adhesive bonds

Previous tests have shown that the mode II and mode III fracture energies of adhesive bonds coincide, with the nominal value dictated by post-yield shear deformation in the interlayer. This suggests that the complete mixed-mode fracture behavior may be dellineated by determining the interaction curve in either theG _I -G _II orG _I -G _III plane. A DCB-type specimen capable of delivering the entire opening versus shearing toughness spectrum in a single test was used. A brittle and a ductile epoxy resin were evaluated, with the adhesive thickness varying from a few micrometers up to 0.6 mm. Excluding very thin bonds, the mixed-mode fracture curve was approximately bilinear; when the applied energy release rate in shear,G _s , was relatively small, the total fracture energy equaledG _IC but otherwise, the fracture curve decreased essentially linearly with increasingG _S . In the case of the ductile adhesive, the transition in trends occurred whenG _S was approximately 55 percent of the shearing fracture energy. When the bond thickness was decreased to a few micrometers, the mixed-mode curve displayed a concave shape, with mode interaction occurring promptly. SEM analysis and analytical considerations suggest that this change in mixed-mode behavior was due to the development of a triaxial state of stress in the interlayer. Based on previous fracture studies of the individual fracture modes in adhesive bonds and laminated composites, the present results should be also applicable to mixed-mode interlaminar fracture of laminated composites.Herzl Chai, formerly associated with Polymers Division, Materials Science and Engineering Laboratory, National Institute of Standards and Technology, Gaithersburg, MD 20899     

Progressive fracture of adhesively bonded composite structures

Progressive damage and fracture of adhesively bonded graphite/epoxy composite structures are evaluated via computational simulation. Load induced damage in both the adhesive bond and the adjoining laminate is considered. An integrated computer code is used for the simulation of structural degradation under loading. Damage initiation, growth, accumulation, and propagation to fracture are included in the simulations. Results show in detail the damage progression sequence and structural fracture resistance during different degradation stages. Design implications with regard to damage tolerance of adhesively bonded joints are examined. Influence of the type of loading as well as adhesive thickness on damage initiation and progression for an adhesively bonded composite structure are investigated.     

On the description of anisotropic damage in composite laminates

A general anisotropic damage theory of cracked laminates is formulated here. The deformation of composite laminates is composed of matrix elastic strains, pseudo-elastic damage strains due to cracking and permanent damage strains due to interlaminar slip. The surface of damage initiation is constructed according to the concept of linear elastic fracture mechanics for the virgin material. After the initial damage, a pesudo-elastic damage can be used to describe the damage behaviour if interlaminar slip is negligible. Damage evolution, load induced anisotropy and interlaminar intralaminar interaction for composite laminates are examined; the latter can perturb the normality structure of damage strain rate. Explicit expressions are given for pseudo-elastic (or secant) moduli of the damaging composite laminates, under a non-interacting assumption imposed on the cracks between different families.     

The fracture behaviour of adhesively-bonded composite joints: Effects of rate of test and mode of loading

The present paper discusses the results of an investigation into the effects of test rate and the mode of loading on the fracture energy, G_c, of adhesively-bonded fibre-composite joints. Various carbon-fibre reinforced-polymer (CFRP) matrix composite substrates have been bonded using two different types of automotive structural epoxy-adhesives. They have been tested via loading the bonded joints in mode I (tensile), mode II (in-plane shear) and mixed-mode I/II from slow rates (i.e., of about 10^?5 m/s) up to relatively high rates of test of about 15 m/s. The high-rate tests were photographed using a high-speed digital video camera to record the deformation of the joint and the fracture behaviour. An analysis strategy has been developed for the various modes of loading (i) to account for the observed fracture behaviour, (ii) to circumvent the problems posed by oscillations in the load traces due to the presence of dynamic effects in the faster tests, and (iii) to account for the kinetic energy associated with the moving specimen arms in the faster tests. Based on the analysis strategy developed, the effect of the test rate on the fracture energy, G_c, for the different loading modes for the joints has been ascertained. Furthermore, various different fracture paths were observed in the tests. They were either cohesive, in the adhesive layer, or interlaminar in the composite substrates. The exact fracture path observed was a function of (i) the type of composite substrate, (ii) the type of adhesive, and (iii) the mode of loading employed. However, the nature of the fracture path was found to be quite insensitive to the test rate. Essentially, it was found that joints subjected to mixed-mode I/II loading were more likely to exhibit an interlaminar fracture path in the composite substrates than when loaded in either pure modes I or II. The propensity for a given joint to exhibit such a fracture path via delamination of the composite substrate has been explained by calculating the transverse tensile stresses induced in the loaded composite arms, and comparing this value to the measured transverse tensile strength of the composite. Following this approach, the underlying reasons for the observed fracture path were identified and could be predicted. Also, the proposed scheme provides a route to design against delamination failure occurring in adhesively-bonded fibre-composite test specimens.     

Numerical homogenization of cracking processes in thin fibre-epoxy layers

Discrete microscale fracture processes in thin fibre-epoxy layers are connected to a mesoscale traction-separation law through a numerical homogenization framework. The microscale fracture processes are studied with the finite element method, where cracking within the epoxy and debonding between fibres and epoxy is simulated by placing interface elements furnished with a mixed-mode interface damage model in between the continuum elements modelling the fibres and epoxy. It is demonstrated how the effective traction-separation response and the corresponding microscale fracture patterns under mesoscale tensile conditions depend on the sample size, the fibre volume fraction and the presence of imperfections.     

A novel model of delamination bridging via Z-pins in composite laminates

A new micro-mechanical model is proposed for describing the bridging actions exerted by through-thickness reinforcement on delaminations in prepreg based composite materials, subjected to a mixed-mode (I–II) loading regime. The model applies to micro-fasteners in the form of brittle fibrous rods (Z-pins) inserted in the through-thickness direction of composite laminates. These are described as Euler–Bernoulli beams inserted in an elastic foundation that represents the embedding composite laminate. Equilibrium equations that relate the delamination opening/sliding displacements to the bridging forces exerted by the Z-pins on the interlaminar crack edges are derived. The Z-pin failure meso-mechanics is explained in terms of the laminate architecture and the delamination mode. The apparent fracture toughness of Z-pinned laminates is obtained from as energy dissipated by the pull out of the through-thickness reinforcement, normalised with respect to a reference area. The model is validated by means of experimental data obtained for single carbon/BMI Z-pins inserted in a quasi-isotropic laminate.     

Mixed-Mode Dynamic Crack Growth in Functionally Graded Glass-Filled Epoxy

Compositionally graded glass-filled epoxy sheets with edge cracks initially along the gradient are studied under dynamic loading conditions. Specimens with monotonically varying volume fraction of reinforcement are subjected to mixed-mode loading by eccentric impact relative to the crack plane. The optical method of Coherent Gradient Sensing and high-speed photography are used to map transient crack tip deformations before and after crack initiation. Two configurations, one with a crack on the stiffer side of a graded sheet and the second with a crack on the compliant side, are examined experimentally. To elucidate the differences in fracture behavior due to functional grading, a homogeneous sample is also tested. The differences in both pre- and post-crack initiation behaviors are observed interms of crack initiation time, crack path, crack speed and stress intensity factor histories. When a crack is situated on the compliant side of the sample, it kinks significantly less compared to when it is on the stiffer side. Crack tip mode mixity histories show small but positive values during crack growth from the stiffer side of the sample towards the compliant side whereas a small but negative mode mixity prevails for the opposite configuration.     

Determination of mixed-mode stress intensity factors, fracture toughness, and crack turning angle for anisotropic foam material

A numerical and experimental investigation for determining mixed-mode stress intensity factors, fracture toughness, and crack turning angle for BX-265 foam insulation material, used by NASA to insulate the external tank (ET) for the space shuttle, is presented. BX-265 foam is a type of spray-on foam insulation (SOFI), similar to the material used to insulate attics in residential construction. This cellular material is a good insulator and is very lightweight. Breakup of segments of this foam insulation on the shuttle ET impacting the shuttle thermal protection tiles during liftoff is believed to have caused the space shuttle Columbia failure during re-entry. NASA engineers are interested in understanding the processes that govern the breakup/fracture of this material from the shuttle ET. The foam is anisotropic in nature and the required stress and fracture mechanics analysis must include the effects of the direction dependence on material properties. Material testing at NASA Marshall Space Flight Center (MSFC) has indicated that the foam can be modeled as a transversely isotropic material. As a first step toward understanding the fracture mechanics of this material, we present a general theoretical and numerical framework for computing stress intensity factors (SIFs), under mixed-mode loading conditions, taking into account the material anisotropy. We present SIFs for middle tension – M(T) – test specimens, using 3D finite element stress analysis (ANSYS) and FRANC3D fracture analysis software. SIF values are presented for a range of foam material orientations. Mode I fracture toughness of the material is determined based on the SIF value at failure load. We also present crack turning angles for anisotropic foam material under mixed-mode loading. The results represent a quantitative basis for evaluating the strength and fracture properties of anisotropic foam insulation material.     

复合材料层合板低速冲击损伤分析的连续介质损伤力学模型

针对复合材料层合板低速冲击损伤问题,提出了一种各向异性材料连续介质损伤力学模型,模型涵盖损伤表征、损伤起始判定和损伤演化法则3 个方面. 通过材料断裂面坐标下的损伤状态变量矩阵完成损伤表征,并考虑断裂面角度的影响,建立了主轴坐标系下的材料损伤本构关系. 损伤起始由卜克(Puck) 失效准则预测,损伤演化由断裂面上的等效应变控制,服从基于材料应变能释放的线性软化行为. 模型区分了纤维损伤和基体损伤,并根据冲击载荷下层内产生多条基体裂纹继而扩展至界面形成层间裂纹(分层) 的试验观察,引入基体裂纹饱和密度参数表征层间分层. 以[0₃/45/-45]_S 和[45/0/-45/90]_4S 两种铺层的复合材料层合板为例,预测了不同冲击能量下复合材料层合板的低速冲击损伤响应参数,试验结果证明了连续介质损伤力学模型的有效性.模型在不同网格密度下的计算结果表明单元特征长度的引入可以在一定程度上降低损伤演化阶段对网格密度的依赖性.      

Nonlinear progressive damage model for composite laminates used for low-velocity impact

In order to effectively describe the progressively intralaminar and interlam- inar damage for composite laminates, a three dimensional progressive damage model for composite laminates to be used for low-velocity impact is presented. Being applied to three-dimensional （3D） solid elements and cohesive elements, the nonlinear damage model can be used to analyze the dynamic performance of composite structure and its failure be- havior. For the intralaminar damage, as a function of the energy release rate, the damage model in an exponential function can describe progressive development of the damage. For the interlaminar damage, the damage evolution is described by the framework of the continuum mechanics through cohesive elements. Coding the user subroutine VUMAT of the finite element software ABAQUS/Explicit, the model is applied to an example, i.e., carbon fiber reinforced epoxy composite laminates under low-velocity impact. It is shown that the prediction of damage and deformation agrees well with the experimental results.     

Fracture testing of a self-healing polymer composite

Inspired by biological systems in which damage triggers an autonomic healing response, a polymer composite material that can heal itself when cracked has been developed. In this paper we summarize the self-healing concept for polymeric composite materials and we investigate fracture mechanics issues consequential to the development and optimization of this new class of material. The self-healing material under investigation is an epoxy matrix composite, which incorporates a microencapsulated healing agent that is released upon crack intrusion. Polymerization of the healing agent is triggered by contact with an embedded catalyst. The effects of size and concentration of the catalyst and microcapsules on fracture toughness and healing efficiency are investigated. In all cases, the addition of microcapsules significantly toughens the neat epoxy. Once healed, the self-healing polymer exhibits the ability to recover as much as 90 percent of its virgin fracture toughness.     

Fiber fracture and strength degradation in unidirectional graphite/epoxy composite materials

An experimental study was conducted to determine the influence of load factor on fiber fracture development and residual strength of fatigue loaded unidirectional graphite/epoxy composite laminated. 8-phy composite laminates with a layer of release cloth imbedded at the middle ply were fatigued at different load levels and were examined for fiber fracture and residual strength at several stages of life based on the average number of cycles to failure (according to S-N data). From the experimental results, it is evident that the number of fiber fractures is nearly constant after the first few percent of the life. It is also suggested that the load level is much more important than the number of cycles of loading in the determination of the state of fiber fracture. This behavior was interrupted at high load levels (S60% S_u where the final fracture was highly affected by the longitudinal matrix splittings. Residual strength is found to be independent of the global fiber fracture density, and to be controlled by local behavior such as matrix cracking, local clustering of fiber fractures, and other local stress concentrations.     

Elastic moduli of transversely isotropic graphite fibers and their composites

This paper demonstrates that it is possible to calculate the complete set of elastic mechanical properties for graphite-epoxy fiber-reinforced materials at any fiber-volume fraction by modifying equations previously developed to include transversely isotropic graphite-fiber properties. Experimental verification of the modified equations is demonstrated by using these equations to curve fit elastic-property data obtained ultrasonically over a range of fiber-volume fractions. Material systems under consideration are T300/5208, AS-3501 and Modomor II/LY558 graphite epoxy. Using the modified equations it is possible to extrapolate for fiber properties. From Modomor II/LY558 ultrasonic data, it is shown that five out of seven extrapolated graphite-fiber properties are consistent with the assumption that graphite fibers are transversely isotropic. Elastic properties for T300/5208 and AS-3501 are ultrasonically evaluated by propagating stress waves through six individual specimens but at various angles from a block of unidirectional material. Particular attention is devoted to specimen dimensions. To demonstrate the need for accurately calculating or experimentally measuring all lamina elastic properties, a brief discussion is included on the effect that variations in lamina elastic properties have on calculating interlaminar stresses.     

An experimental study of dynamic delamination of thick fiber reinforced polymeric matrix composites

Dynamic delamination of thick fiber reinforced polymeric matrix composite laminates is investigated using optical techniques and high-speed photography. The laminates used in this work are graphite/epoxy fiber reinforced, 65 percent fiber volume fraction, composite plates consisting of 48 plies (6 mm plate thickness). Two different laminate layups are tested: a quasi-isotropic arrangement and a unidirectional arrangement. The experimental setup consists of 152 mm×152 mm square plates impact loaded in an outof-plane configuration using a high-speed gas gun. Impact speeds range from 1 m/s to 30 m/s. Real-time imaging of the laminate out-of-pane displacement is performed using the lateral shearing interferometer of coherent gradient sensing (CGS) in conjunction with high-speed photography. Onset of dynamic delamination can be observed, and quantities such as delamination speeds (in some cases up to 1800 m/s) are measured and reported. A brief comparison is made with dynamic fracture experiments of the same material conducted in a separate study.     

Effects of electric/magnetic impact on the transient fracture of interface crack in piezoelectric-piezomagnetic sandwich structure: anti-plane case

Due to the incompatibility of the interlaminar deformations,the interface debonding or cracking usually happens in a layered magnetoelectric(ME)structure under an applied load.In this paper,the transient responses of the anti-plane interface cracks in piezoelectric(PE)-piezomagnetic(PM)sandwich structures are studied by the standard methods of the integral transform and singular integral equation.Discussion on the numerical examples indicates that the PE-PM-PE structure under electric impact is more likely to fracture than the PM-PE-PM structure under a magnetic impact.The dynamic stress intensity factors(DSIFs)are more sensitive to the variation of the active layer thickness.The effects of the material constants on the DSIFs are dependent on the roles played by PE and PM media during the deformation process.