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Mechanicalproperties Ofpolymermatrixcomposites-Suhasini
Mechanicalproperties Ofpolymermatrixcomposites-Suhasini
Mechanicalproperties Ofpolymermatrixcomposites-Suhasini
properties of polymer‐matrix
composites
Dr. Suhasini Gururaja
Assistant Professor
Aerospace Engineering, IISc, Bangalore
(Parts of the material for this presentation has been borrowed from lecture notes of Prof. K. Lin
and Dr. Patrick Stickler at University of Washington, Seattle. Some figures have been reproduced
from open literature and used here for purely pedagogical purposes.)
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 1
History
Composite materials as a scientific/engineering discipline is
approximately 60 years old.
Composites have been useful for thousands of years
◦ Animal hair was added to pottery to improve strength
◦ Straw-reinforced clay was used to make bricks (Exodus
5:7)
◦ Bitumen was embedded with papyrus reeds to build boats
◦ Achilles’s shield was a composite laminate design (Homer’s
Illiad, xviii: 468-480)
Composite materials found in nature*:
◦ Wood: cellulose fibers in a lignin mating
◦ Bone: Collagen fibers in an apatite matrix
*Mechanical Design in Organisms, Wainwright et al, 1976.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 2
Introduction
What is a composite material?
Combination of two or more chemically distinct
materials on the macroscopic scale tailored to
achieve improved properties that neither
constituents individually possess.
Classification of composites
◦ Polymer Matrix Composites (PMCs)
◦ Metal Matrix Composites (MMCs)
◦ Ceramic Matrix Composites (CMCs)
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 3
Potential structural advantages of
advanced composites
High Specific Strength (strength/density)
High Specific Stiffness (modulus/elasticity)
Tailored properties in load application direction
Tailored CTE for critical components
Excellent fatigue performance
Depending on resin/matrix combination and design
Corrosion resistant
UV resistant
Good dielectric
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 4
Specific property comparison
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 5
Key Differences between Composites and Metal
Anisotropy
Tailored Properties
Fatigue and Corrosion
Lighting protection
Discontinuous stresses
Delamination
Damage Tolerance
Environmental Effects
Repairability
Reduction in parts counts
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 6
Tailored Properties
Composites Metals
◦ Properties CAN be ◦ Properties CANNOT
tailored be tailored
Properties are represented in
Properties can be tailored by
fixed values that cannot be
combining different tailored
percentages of 0o, 45o, -45o
and 90o plies ◦ Material CANNOT be
optimized
◦ Optimal use of Structural performance can
material only be improved through
Material properties can be changes in geometry, such
tailored per loading as thickness, which adds to
weight
requirements to meet
design allowables while
reducing overall weight
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 7
Fatigue and corrosion
Composites Metals
◦ Better fatigue ◦ Relatively poor fatigue
performance than metals properties in both
in tension (relatively flat tension and
S-N curves) compression (more
◦ Compressive fatigue steep S-N curve)
properties are not as
◦ Poor corrosion
good as those in tension
resistance, especially in
◦ Superior corrosion
a cracked structure
resistance for CFRP
◦ Galvanic corrosion
occurs between CFRP
and Al, Mg, Cd plate and
steel.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 8
Discontinuous Stresses
In-plane strains:
◦ Continuous throughout the
laminate thickness
Constant under uniform
extensional forces
Distributed linearly under
bending
In-plane stresses: Stresses due to Stresses due to
stretching bending
◦ Generally discontinuous
throughout the laminate
thickness because each ply
has different stiffness values
The strain-based design criteria are generally used in industry
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 9
Delamination
Occurs in laminated
composites
Causes local bending
and buckling in
compressively loaded
structures
Can grow under
normal and shear
loads
Careful designs
needed at locations
prone to
delamination
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 10
Damage tolerance/Repairability
Composites Metals
Critical damage Critical damage
◦ Impact, delamination ◦ Fatigue crack, stress corrosion
◦ Compression after Impact (CAI) Damage growth
strength is a key design parameter
◦ Crack growth can be reasonably
Damage growth well predicted using fracture
◦ Complicated by multiple damage mechanics approach
types and failure modes
◦ Refer to FAR 25.571, “Damage
◦ Current design is for “no damage tolerance and fatigue evaluation
growth” of structures”
Damage assessment is more difficult Damage detection techniques are
– surface and internal damage well defined and surface damage
Most repairs are bonded repairs – can be easily found
time consuming and require highly
Most repairs are bolted repairs –
skilled labor
relatively easier and cheaper
Repair materials and adhesives are
time sensitive No shelf life of repair materials
Quality of repair is easier to
control
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 11
Environmental Effects/Thermal Stresses
Composite properties are strongly affected
by moisture, temperature, sunlight,
microbes, release agents, solvents etc.
Property reduction factors (knockdown
factors) are used appropriately
Due to mismatch in CTEs, thermal
residual stresses exist in structures.
Thermal stresses must be considered in
composite tool design and manufacturing.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 12
Classifications of reinforcements
Continuous fibers: lengths are in effect infinite -
Unidirectional Tape, Woven or braided Fabric
Whiskers, short fibers, and continuous fibers all have very small
diameters relative to their length (high aspect ratio)
*Prof K. Lin AA532 Notes, University of Washington
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 13
Classifications of reinforcements
Advanced composites
“modern”
◦ Particulates: roughly
spherical particles with
diameters (typically 1-100
mm)
◦ Whiskers: lengths <
10mm
◦ Short (or “chopped”)
fibers: length 10 – 100mm
SMC and Preforms
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 14
Laminate construction
Ready-to-cure part
127 mm ply
on mandrel ~8mm dia
thickness
carbon fiber
Very good quality
Excellent
repeatability
Stacking cut plies
into a desired
sequence *Prof K. Lin AA532 Notes, University of Washington
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 15
Tensile properties of Fiber, Matrix and Composite
600
500 Fiber
Composite
300
200
100
Matrix
0
0 1 2 3 4
Strain (%)
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 16
Manufacturing Methods - Bag Molding Process
• Note:To prevent moisture pickup, prepreg roll on removal from cold storage should be warmed to room
temperature before use.
Overview of Mechanical Properties for PMCs, Dr. Suhasini Gururaja, AE, IISc Bangalore 17
Bag Molding Process
Typical two-stage cure cycle for a carbon fiber-epoxy prepreg :
1. First stage
Increasing temperature up to 130°C (266°F).
Dwelling at this temperature for nearly 60 minutes until the minimum
resin viscosity is reached.
During the temperature dwell, external pressure applied to prepreg stack
that causes excess resin to flow out into bleeders.
2. End of temperature dwell
Autoclave temperature increased to actual curing temp. of resin.
Cure temperature and pressure maintained for 2 hours or more, until
predetermined level of cure has occurred.
At end of cycle, temperature slowly reduced while laminate still under
pressure.
Flow of excess resin from the prepreg is extremely important in reducing the void
content in the cured laminate.
Overview of Mechanical Properties for PMCs, Dr. Suhasini Gururaja, AE, IISc Bangalore 18
Bag Molding Process
Overview of Mechanical Properties for PMCs, Dr. Suhasini Gururaja, AE, IISc Bangalore 19
Mechanical Properties of PMCs
“A material property” is a measurable
constant characteristic of a particular
material, which can be used to relate
disparate quantities of interest.
Key Mechanical properties include:
◦ Stress tensor to strain tensor
◦ Temperature/Moisture to strain tensor
◦ Stress (or strain) to failure/cycles to failure
◦ Crack growth to failure
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 20
Anisotropic behavior
Composites Metals
◦ Anisotropic ◦ Isotropic
Properties are dependent Properties are the same in all
upon directions directions
◦ Inhomogeneous ◦ Homogeneous
Properties are different in Properties are the same in all
different plies directions
◦ Mostly Brittle ◦ Mostly Ductile
Linear stress-strain relation Nonlinear stress-strain
and low strain to failure relation with a large plastic
deformations
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 21
Anisotropic versus isotropic
z
Specimen 2
Specimen 1
y
Specimen 3
x
Three specimens machined at different orientations from a single “parent” block.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 22
Anisotropic versus isotropic
Note: The 1-2-3 coordinate system is the principal material coordinate system
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 25
Principal Material Coordinate System
Note: In this case the principal material coordinate system is not aligned
with the fiber direction
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 26
Anisotropic behavior
PMCs are
anisotropic at the
structural level
One of the most
unusual features of
anisotropic materials
is that they can
exhibit coupling
◦ Coupling between Coupling exists
normal stresses and between sxx and gxy
shear strains
◦ Coupling between
shear stress and
normal strains
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 27
Coupling of bending and stretching deformations
ASTM 3039
- Adhesively bonded tabs
Properties
- Ultimate Tensile Strength
- Ultimate tensile strain
- Modulus of Elasticity
- Poisson’s ratio
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 31
Yielding and Fracture of Composites
Matrix Cracks
◦ Cracks that occur in the polymeric matrix, at some
distance from the fiber/matrix interface.
◦ Matrix cracks generally occur in planes either parallel
or perpendicular to the fiber direction.
Fiber-Matrix Debonding
◦ The crack has formed in the interphase region, and a
(non-planar) crack extends around the periphery of
the fiber.
Fiber Cracks
◦ Cracks that occur in the fiber itself.
◦ Fiber cracks almost always occur in a plane
perpendicular to the axis of the fiber, and extend
across the entire width of the fiber.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 32
Yielding and Fracture of Composites
Viscoelastic behavior: yielding and crack
growth in polymers is a time-dependent
phenomenon called “creep”.
◦ An increase in temperature and/or an
increase in moisture content further
accentuate the time-dependency.
◦ If a tensile stress is applied and held constant
the composite may eventually fail due to slow
crack growth (often called a "creep-to-
rupture" failure).
Chemical aging: polymers aging occurs
due to ultra violate light.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 33
Failure of Multi-angle Composite Laminate
Multi-angle laminates are subject to failure
modes that do not exist in unidirectional
laminates.
◦ The initiation of delamination failures is often
attributed to free-edge stresses.
◦ Free-edge stresses occur whenever adjacent plies
possess differing Poisson ratios or coefficients of
mutual influence.
Pre-existing thermal and/or moisture
stresses occur in multi-angle laminates.
◦ Due to a mismatch in effective thermal expansion
and moisture expansion coefficients from one ply
to the next.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 34
Failure of Multi-angle Composite Laminate
Additional damage mechanisms in
composites include:
◦ Fiber-matrix debonding: a crack forms around the
periphery of a fiber.
Load can no longer be transferred from the
matrix to the fiber.
◦ Fiber micro-buckling: fibers within a ply that
experiences compressive stresses in the fiber direction
buckle.
Reduces the compressive stiffness exhibited
by the ply.
Leads to failure of the fibers due induced
bending stresses.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 35
Failure of Multi-angle Composite Laminate
Failure modes for multiangle laminates.
◦ Matrix cracking/splitting (microcracks).
◦ Delamination.
◦ Fiber fracture.
◦ Fiber/matrix debond.
◦ Fiber “kinking”(microbuckling).
◦ Global laminate buckling.
Failure should be verified experimentally.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 36
Failure of Multi-angle Composite Laminate
Experimental observations of the evolution of damage in a quasi-
isotropic laminate (monotonically increasing uniaxial load, Nxx)
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 37
Failure of Multi-angle Composite Laminate
The 90o plies yield as Nxx increases to a
critical level.
Cracks begin to form in the 90o plies at load
levels above the first-ply failure stress.
As the effective stress is further increased,
cracks eventually begin to form within the
±45 plies
As the effective stress is increased further,
delaminations begin to develop.
Matrix cracks begin to form between plies,
and these new matrix cracks lie within
planes that are parallel to the x-y plane
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 38
Failure of Multi-angle Composite Laminate
The delaminated regions grow in size as the stress is
increased and eventually coalesce, such that a delaminated
region may extend across the entire width of the specimen.
At still higher effective stress levels matrix cracks begin to
form within the 0ºplies (often referred to as “splitting”).
These cracks lie within a plane perpendicular to the x-y
plane.
Final laminate fracture is precipitated by fiber failures within
the 0ºplies.
The effective stress level at which final fracture occurs is
often called the last-ply failure stress.
◦ At final fracture the laminate fractures into fragments.
◦ Extensive and pre-existing matrix cracks and delamination that
occurred at lower stress levels.
◦ Large amount of energy release associated with fiber failure.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 39
Failure of Multi-angle Composite Laminate
Reifsnider et al s smax
studied damage sm sa
progression of multi- Ds
angle composite 0
laminates under fatigue
loading. smin
◦ Material:
graphite/epoxy. Nxx
◦ Layup: [0/±45/90]s
◦ Tension-tension
fatigue spectrum.
σmax= 0.62 σult
σmin= 0.062 σult
R = (σmin/ σmax) = 0.1
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 40
Failure of Multi-angle Composite Laminate
◦ Delaminations.
◦ Matrix cracks 0ºplies (splitting).
Significant reduction in
◦ Fiber failure. stiffness.
◦ Final fracture.
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 41
Failure of Multi-angle Composite Laminate
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 42
Constant Life Diagrams
0o 45o
90o
ASTM E739-91
SMC R27
Fatigue behavior of these four
SMC R37
Compression molded composites
Preform R25 shall be presented
Preform R40
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 44
Composite Material Composition
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 45
Compression Molding Process
SMC Preform
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 46
Burn out Virgin Sample
SMC R-27 SMC R-37
y
x
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 47
UTS and tension-tension Fatigue Test Setup
Ambient air
thermocouple Fatigue specimen
thermocouple
Knee
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 49
Specimens after UTS Experiments
SMC-R27
SMC-R37
Preform-R25
30 mm
Preform-R40
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 50
Temperature versus Frequency
45
40
35
30
25
20
Deg C
15
10 HZ
10
5 5 HZ
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65
Minutes
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 51
Stress life plots
160 R = 0.05, Room Temp
140 y = -5.495ln(x) + 125.98
100
80
y = -4.676ln(x) + 101.27
60
40
y = -3.501ln(x) + 82.985
20
0
0.1 10 1000 100000
Log Cycles
SMC-R37 Preform-R40 SMC-R27 Preform-R25
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 52
Tensile Modulus degradation
15000 15000
Tensile Modulus (MPa)
60% UTS
50% UTS
10000 40% UTS 10,000
30% UTS
70% UTS
60% UTS
5000 5,000 50% UTS
40% UTS
(c) Preform-R25 (d) Preform-R40 30% UTS
0 2 4 6 0 2 4 6
10 10 10 10 Log Cycles 10 10
Log Cycles 10 10
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 53
Fractography - 70% UTS fatigue test (R = 0.05)
Fiber bundle
Pull-out
Matrix fracture
surface
SMC-R27
Fiber
fracture
SMC-R37
Fiber
bundle
damage
Preform-R25
Preform-R40
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 54
Low-Velocity Impact
Effect of LVI on residual compression and tensile strengths of HTA/913 and HTA/982 CFRP laminates and E-glass/913
(normalized wrt undamaged material). [(±45,02)2]s (Courtesy: Brian Harris, Fatigue in Composites, CRC Press, 2003.)
Overview of Mechanical Properties for PMCs Dr. Suhasini Gururaja, AE, IISc Bangalore 55