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    Topik 2 - Failure Modes of Composite Material

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    Razer Pax
    This document outlines key topics related to failure modes in composite materials, including: 1) Different failure mechanisms such as matrix cracking, fiber fracture, and delamination; 2) How material properties like fiber strain to failure influence strength; 3) Techniques for analyzing failure like fractography and fracture mechanics; and 4) Criteria for predicting failure under various stress conditions.

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    Topik 2 - Failure Modes of Composite Material

    Uploaded by

    Razer Pax
    77 views25 pages
    This document outlines key topics related to failure modes in composite materials, including: 1) Different failure mechanisms such as matrix cracking, fiber fracture, and delamination; 2) How material properties like fiber strain to failure influence strength; 3) Techniques for analyzing failure like fractography and fracture mechanics; and 4) Criteria for predicting failure under various stress conditions.

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    Topik 2 - Failure Modes of Composite Material(1)

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    This document outlines key topics related to failure modes in composite materials, including: 1) Different failure mechanisms such as matrix cracking, fiber fracture, and delamination; 2) How material properties like fiber strain to failure influence strength; 3) Techniques for analyzing failure like fractography and fracture mechanics; and 4) Criteria for predicting failure under various stress conditions.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    77 views25 pages

    Topik 2 - Failure Modes of Composite Material

    Uploaded by

    Razer Pax
    This document outlines key topics related to failure modes in composite materials, including: 1) Different failure mechanisms such as matrix cracking, fiber fracture, and delamination; 2) How material properties like fiber strain to failure influence strength; 3) Techniques for analyzing failure like fractography and fracture mechanics; and 4) Criteria for predicting failure under various stress conditions.

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    of 25

    Failure Modes of Composite

    Materials
    Aircraft Materials and Manufacturing Methods II
    (Material Pesawat dan Metoda Manufaktur II)

    This Photo by Unknown Author is licensed under CC BY-NC


    Failure
    Modes of
    Composites
    Material
    Defects
    Strength
    Failure mechanisms
    Outlines
    Fractography
    Fracture mechanics
    Failure criteria
    • Environmental degradation
    • Impact damage
    • Fatigue
    • Cracks from local overload
    In-Service • Debonding
    Defects • Delamination
    • Fiber fracturing
    • Erosion
    • strength = stress at failure
    • failure may be
    • yielding in metals
    • non-recoverable loss of elastic
    Strength response
    • first-ply failure
    • ultimate failure
    • one material can have several
    different strengths
    • Kelly-Tyson equation for UD composites:
    • σc = σfVf + σm*(1-Vf) at high Vf, or
    • σc < σm#(1-Vf) at low Vf
    • where σm* is the tensile stress in the
    matrix
    Strength at the failure strain of the fibre, and
    • σm# is the maximum tensile strength
    of the matrix

    • For small mis-alignments:


    • σc = σfVf / cos2θ = σfVfsec2θ
    • matrix cracking
    • fibre fracture
    • debonding = interface failure
    Failure • delamination = interlayer failure
    • fibre pullout
    mechanisms
    • micro-buckling
    • kink bands
    • cone of fracture
    • The key criterion for composite
    failure is the local strain to failure: ε’
    Failure a.k.a. elongation at break
    and not stress
    strain of
    composites • Note that ε’ for the fibre/matrix
    interface
    i.e. transverse fibres = ~0.25 %
    Matrix cracking max min
    polyester resin ε’ = 0.9-4.0 %

    vinyl ester ε’ = 1.0-4.0 %

    epoxy resin ε’ = 1.0-3.5 %

    phenolic resin ε’ = 0.5-1.0 %

    data from NL Hancox, Fibre Composite Hybrid Materials,


    Elsevier, 1981.
    Fibre fracture
    S/R-glass ε’ = 4.6-5.2 % ….

    E-glass ε’ = 3.37 % ……….…

    Kevlar 49 ε’ = 2.5 % ……………….

    HS-carbon ε’ = 1.12 % …………………

    UHM-carbon ε’ = 0.38 % …………………..


    data from NL Hancox,
    Fibre Composite Hybrid Materials, Elsevier, 1981.
    Fibre-matrix debonding

    a b
    • Crack can run
    • through (not shown), or
    • around the fibre
    • ~12000 carbon or 1600 glass UD fibres / 1 mm2
    Fibre-matrix
    debonding:
    Fibre pullout Fibre
    • as parts of fractured composite separate, fracture
    fibres which have debonded
    fail remotely from principal fracture plane.
    • relaxed fibre expands radially
    • energy absorbed by frictional forces
    as fibre pulls from the opposite face
    • debonding and pullout absorb high
    energies and result in a tough material
    • one layer is a lamina (plural = laminae)
    • several layers in a composite is a
    laminate
    • separation of the layers is delamination
    Delamination
    of layers • to avoid delamination
    • 3-D reinforcement (often woven or
    stitched)
    • Z-pinning
    • debonding (fibre/matrix separation)
    and delamination (layer separation)
    both create internal defects
    Stress which scatter light
    • the consequence is that the laminate
    whitening changes from transparent to opaque,
    of GFRP referred to as “stress whitening”
    • similar effects may be seen in other
    composites (e.g. at stitches in NCF
    CFRP)
    Micro-buckling

    In bending tests, failure occurs due to:


    • stress concentration
    at the loading roller
    • and poor
    fibre/matrix adhesion
    • local microbuckling
    Kink bands (HM
    fibre composites)
    • Compressive load causes buckling
    followed by
    co-operative failure of a group of
    fibres to produce short lengths of
    parallel mis-oriented fibre
    • Image from
    • http://coeweb.eng.ua.edu/
    aem/people/samit/
    nanoclay.htm
    Cone of fracture (CFRP)
    • the impacted face shows no sign of damage
    • delamination occurs in a cone
    • fibre spalling from the back face
    • known as BVID
    • barely visible impact damage
    • difficult to detect unless reported
    Ballistic impact
    • energy absorbing mechanisms
    • compression at projectile CSA
    • compression beyond projectile CSA
    • shear plugging
    • tension of primary yarns
    • tension of secondary yarns
    • cone of fracture
    • matrix cracking
    • fibre fracture
    • debonding
    • delamination
    • friction … after Akella and Naik, Composite armour – a review
    J.Indian Inst. Sci, 2015, 95(3), 297-312.
    Fractography
    • use of optical or electron microscopes
    to image the fracture surface:
    Fracture mechanics
    • stress intensity factor (Pa.m1/2 )
    • fracture toughness
    (critical stress intensity factor, Pa.m1/2 )
    • separate parameters in each plane

    • mode

    JG Williams,
    Fracture mechanics of composite failure, Proc IMechE Part C:
    Journal of Mechanical Engineering Science, 1990, 204(4), 209-218.
    Design to avoid failure
    • beware first ply failure
    dependent on laminate stacking sequence

    • failure index (FI) of >1 = failure


    dependent on the failure criteria selected
    • reserve factor (RF) <1 = failure
    for Tsai-Hill failure criteria, RF =1/√(FI)
    Failure criteria
    • failure occurs at critical value of
    local uni- or bi-axial stress reaches :
    • σi ≥ σi' or ij ≥ ij' (' indicates failure condition)
    • criteria include
    • von Mises yield criterion:
    • critical distortional strain energy
    • Tresca yield criterion:
    • maximum shear stress
    • Tsai-Hill criterion:
    • an envelope in stress space
    • … and many others,
    • getting more complex/sophisticated
    Failure criteria
    • those above plus many other criteria
    • no agreement !
    (see MJ Hinton, AS Kaddour and PD Soden,
    Failure criteria in fibre reinforced polymer composites: the world-
    wide failure exercise,
    Elsevier, Amsterdam, 2004. ISBN 0-08-044475-x).
    • Hashin’s early assumption:
    • "It may be argued that in the event
    that a failure plane can be identified,
    [then] the failure is produced by the
    normal and shear stresses on that plane"!
    Summary of lecture
    • strength
    • failure mechanisms
    • fractography
    • fracture mechanics
    • failure criteria

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