Fatigue crack propagation in microcapsule toughened epoxy

The addition of liquid-filled urea-formaldehyde (UF) microcapsules to an epoxy matrix leads to significant reduction in fatigue crack growth rate and corresponding increase in fatigue life. Mode-I fatigue crack propagation is measured using a tapered doublecantilever beam (TDCB) specimen for a range of microcapsule concentrations and sizes: 0, 5, 10, and 20% by weight and 50, 180, and 460 micron diameter. Cyclic crack growth in both the neat epoxy and epoxy filled with microcapsules obeys the Paris power law. Above a transition value of the applied stress intensity factor, which corresponds to loading conditions where the size of the plastic zone approaches the size of the embedded microcapsules, the Paris law exponent decreases with increasing content of microcapsules, ranging from 9.7 for neat epoxy to approximately 4.5 for concentrations above 10 wt% microcapsules. Improved resistance to fatigue crack propagation, indicated by both the decreased crack growth rates and increased cyclic stress intensity for the onset of unstable fatigue-crack growth, is attributed to toughening mechanisms induced by the embedded microcapsules as well as crack shielding due to the release of fluid as the capsules are ruptured. In addition to increasing the inherent fatigue life of epoxy, embedded microcapsules filled with an appropriate healing agent provide a potential mechanism for self-healing of fatigue damage.published or submitted for publicationis peer reviewe

In situ poly(urea-formaldehyde) microencapsulation of dicyclopentadiene

Microencapsulated healing agents that possess adequate strength, long shelf-life, and excellent bonding to the host material are required for self-healing materials. Ureaformaldehyde microcapsules containing dicyclopentadiene were prepared by in situ polymerization in an oil-in-water emulsion that meet these requirements for self-healing epoxy. Microcapsules of 10-1000 ??m in diameter were produced by appropriate selection of agitation rate in the range of 200-2000 rpm. A linear relation exists between log(mean diameter) and log(agitation rate). Surface morphology and shell wall thickness were investigated by optical and electron microscopy. Microcapsules are composed of a smooth 160-220 nm inner membrane and a rough, porous outer surface of agglomerated urea-formaldehyde nanoparticles. Surface morphology is influenced by pH of the reacting emulsion and interfacial surface area at the core-water interface. High yields (80-90%) of a free flowing powder of spherical microcapsules were produced with a fill content of 83-92 wt% as determined by CHN analysis.published or submitted for publicationis peer reviewe

Retardation and repair of fatigue cracks in a microcapsule toughened epoxy composite -- Part II: In situ self-healing

Successful arrest and retardation of fatigue cracks is achieved with an in situ self-healing epoxy matrix composite that incorporates microencapsulated dicyclopentadiene (DCPD) healing agent and Grubbs??? first generation Ru catalyst. Healing agent is released into the crack plane by the propagating crack, where it polymerizes to form a polymer wedge, generating a crack tip shielding mechanism. Due to the complex kinetics of healing a growing crack, the resulting in situ retardation and arrest of fatigue cracks exhibit a strong dependence on the applied range of cyclic stress intensity DKI. Significant crack arrest and life extension result when the in situ healing rate is faster than the crack growth rate. In loading cases where the crack grows too rapidly (maximum applied stress intensity factor is a significant percentage of the mode-I fracture toughness value), a carefully timed rest period can be used to prolong fatigue life up to 118%. At moderate DKI, in situ healing extends fatigue life by as much as 213%. Further improvements in fatigue life-extension are achieved by employing a rest period, which leads to permanent arrest at this moderate DKI. At lower values of applied stress intensity factor, self-healing yields complete arrest of fatigue cracks providing infinite fatigue life-extension.published or submitted for publicationis peer reviewe

Fracture testing of a self-healing polymer composite

Inspired by biological systems in which damage triggers an autonomic healing response, we have developed a polymer composite materials that can heal itself when cracked. This paper summarizes the self-healing concept for polymeric composite materials and investigates fracture mechanics issues consequential to the development and optimization of this new class of materials. 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 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 recovers as much as 90% of its virgin fracture toughness.published or submitted for publicationis peer reviewe