Measuring the notched compressive strength of composite laminates: Specimen size effects

Large fibre reinforced composite structures can give much lower strengths than small test specimens, so a proper understanding of scaling is vital for their safe and efficient use. Small size (scale) specimens are commonly tested to justify allowable stresses, but could be dangerous if results are extrapolated without accounting for scaling effects. On the other hand large factors are sometimes applied to compensate for uncertainties, resulting in overweight designs. The most important variables of scaling effects on the strength of composites with open holes have been identified from experimental tests as notch size, ply and laminate thickness. In this study, these have been scaled both independently and simultaneously over a large range of combinations. The specimens are fabricated from commercially available (Hexcel Composites Ltd.) carbon/epoxy pre-impregnated tapes 0.125 mm thick (IM7/8552). The material is laid up by hand in unidirectional [04]ns with n = 2, 3, 4, and 8 (i.e., 2, 3, 4 and 8 mm thick) and multidirectional laminates; two generic quasi-isotropic lay-ups, one fabricated with blocked plies [45n/90n/−45n/0n]s and the other with distributed layers [45/90/−45/0]ns with n = 2, 4 and 8 are examined. It is shown that the critical failure mechanism in these laminates is in the form of fibre microbuckling or kinking. The unnotched compressive strength in unidirectional specimens thicker than 2 mm is found to be limited by the stress concentration developed at the end tabs and manufacturing induced defects in the form of ply waviness, fibre misalignment and voids rather than specimen size (scaling). In the open hole specimens, for both lay-ups, the strength reduction observed is due to hole size effect rather than specimen thickness or volume increase. The open hole (notched) compressive strength results obtained compare favourably to predictions by a linear softening cohesive zone fracture model developed in earlier work by the second author

Fracture mechanisms and failure analysis of carbon fibre/toughened epoxy composites subjected to compressive loading

This study investigates the failure mechanisms of unidirectional (UD) HTS40/977-2 toughened resin composites subjected to longitudinal compressive loading. A possible sequence of failure initiation and propagation was proposed based on SEM and optical microscopy observations of failed specimens. The micrographs revealed that the misaligned fibres failed in two points upon reaching maximum micro-bending deformation and two planes of fracture were created to form a kink band. Therefore, fibre microbuckling and fibre kinking models were implemented to predict the compressive strength of LID HTS40/977-2 composite laminate. The analysis identified several parameters that were responsible for the microbuckling and kinking failure mechanisms. The effects of these parameters on the compressive strength of the LID HTS40/977-2 composite systems were discussed. The predicted compressive strength using a newly developed combined modes model showed a very good agreement to the measured value (c) 2009 Elsevier Ltd. All rights reserve

Matrix cracking in polymeric composites laminates: Modelling and experiments

Composites ability to retain functionality in the presence of damage is a crucial safety and economic issue. Generally the first damage mode in composite laminates is matrix cracking, which affects the mechanical properties of the structure long before its load-bearing capacity is exhausted. In this paper, a detailed analysis of the effect of matrix cracking on the behaviour of cross-ply [0/90]s and unbalanced symmetric [0/45]s glass/epoxy laminates loaded statically in tension is performed. Theoretical predictions of stiffness reduction due to damage are based on the Equivalent Constraint Model (ECM), which takes into account concurrent matrix cracking in all plies of the laminate, although matrix cracking under consideration is developing only within the off-axis ply of the laminates. The longitudinal Young’s modulus predictions are compared to experimentally derived data obtained using laser Raman spectroscopy (LRS). The good agreement between predicted and measured values of the reduced longitudinal Young’s modulus validates the ECM model and proves that its basic assumptions are accurate. Thus, the predictions for all the mechanical properties by the ECM model are within a realistic range, while experimental evidence is required for further validation

Modelling of stiffness degradation due to cracking in laminates subjected to multi-axial loading

Funding Financial support of this research by the Engineering and Physical Sciences Research Council (EPSRC/GR/L51348) and the British Ministry of Defence is gratefully acknowledged.Peer reviewedPostprin

A study on the compressive strength of thick carbon fibre-epoxy laminates

This paper describes an experimental study that examines the effect of specimen size on the axial compressive strength of IM7/8552 carbon fibre/epoxy unidirectional laminates (UD). Laminate gauge length, width and thickness were increased by a scaling factor of 2 and 4 from the baseline specimen size of 10 mm x 10 mm x 2 mm. In all cases, strength decreased as specimen size increased, with a maximum reduction of 45%; no significant changes were observed for the axial modulus. Optical micrographs show that the failure mechanism is fibre microbuckling accompanied by matrix cracking and splitting. The location of failure in most specimens, especially the thicker ones, is where the tabs terminate and the gauge section begins suggesting that the high local stresses developed due to geometric discontinuity contribute to premature failure and hence reduced compressive strength. Two generic quasi-isotropic multi-directional (MD) lay-ups were also tested in compression, one with blocked plies [45n/90n/-45n/0n]s and the other with distributed plies [45/90/-45/0]ns with n=2, 4 and 8. The material used and test fixture was identical to that of the unidirectional specimens with three different gauge sections (30 mm x 30 mm, 60 mm x 60 mm and 120 mm x 120 mm) to establish any size effects. Strength results showed no evidence of a size effect when the specimens are scaled up using distributed plies and compared to the 2 mm thick specimens. All blocked specimens had similar compressive strengths to the sub-laminate ones apart of the 8 mm specimens that showed a 30% reduction due to extensive matrix cracking introduced during the specimen's cutting process. The calculated unidirectional failure stress (of the 0° ply within the multidirectional laminate) of about 1710 MPa is slightly higher than the average measured value of 1570 MPa of the 2 mm thick baseline unidirectional specimen, suggesting that the reduced unidirectional strength observed for the thicker specimens is a testing artefact. It appears that the unidirectional compressive strength in thicker specimens (>2 mm) is found to be limited by the stress concentration developed at the end tabs and manufacturing induced defects

Predicting residual stiffness of cracked composite laminates subjected to multi-axial inplane loading

Funding This research arises from work carried out under EPSRC/GR/L51348 grant. Acknowledgments Financial support from UK’s Engineering and Physical Sciences Research Council is gratefully acknowledged.Peer reviewedPostprin

Internal instability as a possible failure mechanism for layered composites

Funding Financial support of part of this research by The Royal Society, The Royal Society of Edinburgh, The Royal Academy of Engineering and The Carnegie Trust for the Universities of Scotland is gratefully acknowledged.Peer reviewedPostprin

The effect of z-binding yarns on the electrical properties of 3D woven composites

Electrical resistance monitoring (ERM) has been used to study the effect of the z-binding yarns on the initial electrical resistance (ER) and its change of three architectures of 3D woven carbon fibre composites namely (orthogonal “ORT”, layer-to-layer “LTL” and angle interlock “AI”) when tested in tension. Specimens are loaded in on-axis “warp” and off-axis “45°” directions. In-situ ERM is achieved using the four-probe technique. Monotonic and cyclic “load/unload” tests are performed to investigate the effect of piezo-resistivity and residual plasticity on resistance variation. The resistance increase for the off-axis loaded specimens (∼90%) is found to be higher than that of their on-axis counterparts (∼20%). In the case of cyclic testing, the resistance increase upon unloading is irreversible which suggests permanent damage presence not piezo-resistive effect. At the moment, it is difficult to obtain a direct correlation between resistance variation and damage in 3D woven composites due to the complexity of the conduction path along the three orthogonal directions, however this study demonstrates the potential of using ERM for damage detection in 3D woven carbon fibre-based composites and highlights the challenges that need to be overcome to establish ERM as a Structural Health Monitoring (SHM) technique for such material systems