Polymer Testing 24 (2005) 648–655

www.elsevier.com/locate/polytest
Test Method
Use of split-disk tests for the process parameters
of filament wound epoxy composite tubes
Cevdet Kaynaka,*, E. Salim Erdillerb, Levend Parnasb, Fikret Senelc
a
Department of Metallurgical and Materials Engineering, Middle East Technical University, TR-06531 Ankara, Turkey
b
Department of Mechanical Engineering, Middle East Technical University, TR-06531 Ankara, Turkey
c
Baris Electrical Industry Co., Ankara, Turkey
Received 22 February 2005; accepted 31 March 2005

Abstract
The aim of this study was to investigate processing parameters of continuous fiber reinforced epoxy composite tubes
produced by the filament winding technique. For this purpose, split-disk tests (according to ASTM D-2290 standard) were
performed for the specimens produced with two different epoxy resin systems, five different fiber materials and five different
winding angles. By determining the hoop tensile strength and modulus of these specimens, the effects of three filament-winding
processing parameters; resin type, fiber type and winding angle were evaluated. It is found that use of different epoxy resin
systems has no significant influences, while use of carbon fibers compared to glass fibers and use of winding angles greater than
608 increase the performance of the structures considerably. It is also concluded that split-disk tests are efficient to determine the
performance of these tubular structures which are usually used under internal pressure developing high hoop stresses.
q 2005 Elsevier Ltd. All rights reserved.

Keywords: Split-disk tests; Filament winding; Composite tube; Hoop tensile strength; Hoop modulus of elasticity

1. Introduction and (ii) To verify the accuracy of the completed design

Filament winding is a continuous fiber reinforced
composite production technique in which a resin-impreg-
nated band of continuous fibers is wound over a rotating
mandrel. The process continues with winding of additional
layers until the design requirements are achieved. The
production is completed by curing the filament-wound
product in an oven and the removal of the mandrel. This
method is especially used for hollow tubular structures such
as pipes and pressure vessels which are generally used under
internal pressure leading to high hoop stresses.
Filament-wound composite structures have been tested
to fulfill two main requirements: (i) To provide
the necessary material and strength data for design purposes,
* Corresponding author. Tel.: C90 312 210 5920; fax: C90 312
210 1267.
E-mail address: ckaynak@metu.edu.tr (C. Kaynak).
0142-9418/$ - see front matter q 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.polymertesting.2005.03.012
studies. For these purposes, a test specimen configuration
must be selected on the basis that test results should provide
material properties useful in the design stage.
Three types of testing geometry are commonly used
in testing of filament-wound composite structures; flat
(coupon) specimens, ring specimens and tubular specimens.
Axial, shear, and bending response of each testing geometry
can be determined by applying a suitable type of loading.
Tests involving biaxial/combined loading is also possible. In
addition to these tests, internal pressure and torsion tests can
be applied to the tubular specimens. The following is a
selection of experimental works cited in the literature for the
ring and tubular specimens.
Cohen and his coworkers [1,2] investigated the effect
of winding tension, stacking sequence, winding tension
gradient, and winding time on hoop stress, hoop stiffness,
fiber and void volume fraction distribution through thickness,
and interlaminar shear strength of carbon fiber reinforced
filament wound ring specimens. Hoop strength and hoop
 C. Kaynak et al. / Polymer Testing 24 (2005) 648–655 649

Table 1
Properties of the epoxy resin systems used

Tensile Strength Tensile Modulus Elongation at Curing Schedule

(MPa) (GPa) break (%) (h/8C)
Resin 1: HUNTSMAN MY740/HY918/DY062 61 3.6 2 2/80C2/120
Resin 2: HUNTSMAN LY556/HY917/DY070 80–90 3.2–3.6 3–7 4/80C4/140

stiffness of the specimens were obtained by performing
pressurized ring tests on filament-wound ring specimens. It
was shown that composite strength increases for cylinders,
wound without winding gradient, wound in short time, with
high winding tension. However, it was also stated that the
effect of these variables on strength were relatively small,
with effect of winding tension being the largest.
Wang et al. [3] developed ring hoop tension tests
(RHTT) for ring samples with a single reduced section of
area. After determining and evaluating the hoop stress–
strain curves of the samples, they concluded that the ring
hoop tension test is an accurate method to measure
transverse tensile properties of tubular specimens.
Lee and his researchers [4] performed biaxial tests on
cross-ply carbon/epoxy composite tubes under combined
torsion and axial tension/compression up to failure to
investigate the effect of biaxial loading ratios on failure
strength and failure mechanism. In that study, it was
concluded that there is a strong interaction between the axial
stress and the shear stress at failure.
Bai et al. [5] investigated the mechanical behavior of
G558 filament-wound glass fiber reinforced epoxy resin
tubes under three different stress states; pure axial tensile
load, pure internal pressure, and combined loading.
According to the behaviour of the specimens loaded to
twenty to fifty percent of their ultimate tensile strength, they
showed that the main damage initiation mechanisms are
microcracking and delamination. Depending on the loading
levels, one of the mechanisms dominates over the other.
Another experimental study about G558 filament-
wound composite tubes was performed by Caroll et al.
[6]. These glass fiber/epoxy tubes were tested in a biaxial
testing machine with various ratios of axial stress to hoop
stress. The resulting stress/strain curves were analyzed and
biaxial failure envelopes in terms of stress and strain were
constructed. It was shown that the behaviour of the tubes is
complex, and the rate and ratio of biaxial loading affect the
monotonic failure strength, damage accumulation and
failure mode of the specimens.
Further to the works cited above, the purpose of this
study was to determine the effects of three filament winding
processing parameters (resin type, fiber type, winding angle)
by comparing the mechanical performance (hoop tensile
strength and modulus) of various specimens under split-disk
tests which achieves the development of hoop stresses as if
they are under internal pressure.
2. Experimental work
2.1. Process parameters
(i) Matrix resin systems: two different epoxy resin systems
used as matrix material are:
† Resin 1: HUNTSMAN MY740 (Epoxy
Resin)/HY918 (Hardener)/DY062 (accelerator)
system.
† Resin 2: HUNTSMAN LY556 (Epoxy
Resin)/HY917 (Hardener)/DY070 (Accelerator)
system.
Both are hot-curing resin systems suitable for filament
winding. Their mechanical properties and curing
schedules are given in Table 1.
(ii) Fiber reinforcements: five different continuous fiber
reinforcements (three of them glass and two of them
carbon) used for filament winding are:
† Fiber 1: PPG Roving 1084 Glass Fiber (2400 Tex)
† Fiber 2: CAMELYAF WR3 Glass Fiber (2400 Tex)
† Fiber 3: TENAX HTA5331 Carbon Fiber (800 Tex)
† Fiber 4: PPG Roving 1084 Glass Fiber (1200 Tex)
† Fiber 5: FORTAFIL 503 Carbon Fiber (2190 Tex)
Their mechanical properties are given in Table 2.

Table 2
Properties of the fiber reinforcements used

Linear Tensile Tensile Elongation Filament Specific

density strength modulus at break (%) diameter density
(Tex) (MPa) (GPa) (mm) (g/cc)
Fiber 1: PPG Roving 1084 2400 Glass Fiber 2400 2600 75 3.00 15 2.60
Fiber 2: CAMELYAF WR3 Glass Fiber 2400 22
Fiber 3: TENAX HTA 5331 Carbon Fiber 800 3950 238 1.55 7 1.77
Fiber 4: PPG Roving 1084 1200 Glass Fiber 1200 2600 75 3.00 15 2.60
Fiber 5: FORTAFIL 503 Carbon Fiber 2190 3800 231 1.64 6 1.80
650 C. Kaynak et al. / Polymer Testing 24 (2005) 648–655

Fig. 1. Split-disk Test specimen geometry.

(iii) Winding angle: during the production of specimens
five different fiber winding angles were used: 08,
G258, G458, G658, and 908.
2.2. Specimen fabrication
For all the combinations of each process parameter
mentioned above, tubular specimens were produced by
using a wet winding technique on the filament-winding
facilities of Baris Electrical Industries, Co. (Ankara–
Turkey). Winding operations were performed on a 60 mm
diameter steel mandrel with a three axial, computer
controlled Bolenz and Schafer filament-winding machine.
These wound tubes together with the mandrel were then
placed into temperature-controlled ovens for the curing
operation. After curing, the composite tubes were removed
from their mandrels. Split-disk test specimens were then
produced by cutting these composite tubes.
2.3. Split-disk tests
separation of the two half disk shape components. An
apparent tensile strength rather than a true tensile strength
can be obtained in the test because of a bending moment
imposed during the test at the split between the split disk
test fixtures. The test fixture was therefore designed to
minimize the effect of this bending moment.
2.4. Test procedure
The testing machine used in split-disk tests was an
INSTRON 4206 Universal Testing System with a loading
capacity of 150 kN. The procedure followed during split-
disk tests was as follows:
(i) Reduced section dimensions of the specimens were
measured with digital calipers. For each specimen,
thickness measurements were made at four places, two
of which were in the gage sections. Width of both of
the reduced sections was also recorded. Specimen
reduced section areas were then calculated by using

Determination of hoop tensile properties of filament-

wound composite tubular specimens by split-disk method
was the main objective of this study. The tests were
performed according to ASTM D-2290, ‘Apparent Hoop
Tensile Strength of Plastic or Reinforced Plastic Pipe by
Split Disk Method’. Five specimens were tested for each
process parameter combination. Mainly, the ultimate hoop
tensile strength and hoop tensile modulus of elasticity of the
specimens were determined.
As shown in Fig. 1, test specimens were full-diameter,
full-wall thickness rings, with an inner radius of 60 mm and
an average outer radius of 64 mm. Each specimen involves
two sections of reduced area, which were located 1808 apart
from each other. The specimens were produced free of
machining marks and each were uniform in cross-section.
The test fixture (Fig. 2) involves two half disk shaped
components which were attached to the upper and lower
connecting arms of the test fixture with pins. Split-disk test
specimens were located between the two half disk shape
components and the upper and lower connecting arms, with
the reduced sections aligned perpendicular to the plane of Fig. 2. Test fixture used in split-disk tests.
 C. Kaynak et al. / Polymer Testing 24 (2005) 648–655
the minimum thickness and minimum width
measurements.
(ii) Specimens were mounted on the split disk test fixture
with the reduced sections located at the split in the
fixture, taking care to align the test specimen on the
split disk specimen holder so that it was centered along
the line joining the points of attachment of the fixture
to the test machine.
(iii) Loading rate of the testing machine was set to a
constant level and the test was started. Load and strain
data were taken until the failure of the specimen.
(iv) After obtaining stress–strain curves of all specimens,
arithmetic mean of the measured ultimate hoop tensile
strength and hoop tensile modulus values were
calculated and reported with standard deviations for
each test group.
3. Results and discussion
Besides obtaining hoop tensile properties of the speci-
mens, failure types and their locations were also investi-
gated. Fig. 3 shows dominant failure mechanisms observed
during the tests and their locations on the specimens for
different winding angles. As seen from the photographs,
failure of specimens occurred in the gage section for all
Fig. 3. Dominant failure mechanisms observed and their locations on split-disk specimens. (a) (qZ908) Fiber fracture and fiber-matrix
debonding. (b) (qZ658) Fiber fracture, fiber-matrix debonding and delamination. (c) (qZ458) Delamination and fiber-matrix debonding. (d)
(qZ258) Matrix cracking.
651
winding angles. For specimens having 908 winding angle
(Fig. 3(a)), fiber-matrix debonding parallel to the fibers and
loading axis was followed by fiber fracture. For specimens
having G658 winding angle (Fig. 3(b)), similar mechanism
was observed with the addition of a delamination stage. The
outer layer was observed to be totally damaged.
For the G458 winding angle specimens (Fig. 3(c)), fiber-
matrix debonding occurred more dominantly. Delamination
of G458 layers was also observed for these specimens. In
G258 winding angle specimens (Fig. 3(d)), fiber breakage
was very limited and the specimens failed mainly with a
matrix cracking mechanism.
Fig. 4 shows winding angle dependence of hoop tensile
strength of specimens for the same epoxy resin system
reinforced with five different fibers. As expected, the highest
strength values were obtained for the specimens having a
winding angle of 908, since the fiber direction is parallel to
the direction of loading. Conversely, the lowest strength
values were obtained for the specimens having a winding
angle of 08, where the fiber direction is perpendicular to
the direction of loading. The results for the specimens
having G258, G458, and G608 winding angles exhibited
intermediate performance between these two extremes.
In Fig. 5, hoop tensile strengths of specimens with five
different fibers are compared as a function of winding
angle. Specimens having the same epoxy resin system
(LY556/HY917/DY070) are compared to investigate
652 C. Kaynak et al. / Polymer Testing 24 (2005) 648–655

Fig. 4. Hoop tensile strength vs winding angle curves for the specimens having the same epoxy resin system (LY556/HY917/DY070) reinforced
with (a) Fiber 1, (b) Fiber 2, (c) Fiber 3, (d) Fiber 4, and (e) Fiber 5.

the effect of fiber type on mechanical performance.
According to this figure, it can be stated that the specimens
produced by carbon fibers showed better mechanical
performance compared to the ones reinforced with glass
fibers. This result became more dominant as the winding
angle of specimens approached the direction of loading
(908). Highly anisotropic behavior of the carbon fiber system
can also be seen in the same figure, such that a sharp decrease
of hoop tensile strength was detected when the winding
direction of the fibers was altered from the direction of
loading.
Among the specimens reinforced with glass fibers, the
one reinforced with PPG 1200 Tex glass fiber (Fiber 4)
showed better performance. This result can be explained
by the effect of the low linear density of Fiber 4. As the
linear density of fibers decreases, the diameters of the
fiber bundles used during the winding operation
decreases, which cause the fiber bands to crisscross
more efficiently by creating a weaving effect. The same
result can also be seen by comparing the strength results
of carbon fiber reinforced specimens. The specimen
produced with low linear density carbon fibers (Fiber 3)
showed better mechanical performance compared to
 C. Kaynak et al. / Polymer Testing 24 (2005) 648–655 653

Fig. 5. Comparison of hoop tensile strengths of specimens with five different fiber types as a function of winding angle.

the one produced with high linear density carbon fibers
(Fiber 5).
In Fig. 6, hoop tensile strengths of specimens with two
different epoxy resin systems are compared for each fiber
type. The specimens having the same winding angle (G658)
are compared to evaluate the effect of epoxy resin system on
the mechanical performance. According to this figure, it can
be stated that the effect of epoxy resin system on hoop
tensile strengths of specimens is negligible.
Similar to the strength results of split-disk tests, winding
angle dependence of hoop tensile modulus of elasticity of
specimens is evaluated in Fig. 7.
This figure shows that a similar distribution of hoop
tensile modulus of elasticity is obtained with the strength
results given in Fig. 4. However, the calculated hoop tensile
modulus of elasticity of carbon fiber reinforced specimens is
almost 2–3 times greater than that of glass fibre reinforced
ones when the winding angle is greater than G658. This
result can be better observed from Fig. 8 which shows the
comparison of hoop tensile modulus of elasticity of
specimens with five different fibers as a function of winding
angle.
4. Conclusions
This study was aimed at satisfying the requirements of
experimental data for the characterization of filament-
wound epoxy composite tubes. For this purpose, many

Fig. 6. Comparison of hoop tensile strengths of specimens with two different epoxy resin systems as a function of fiber type under the same
winding angle of G658.
654 C. Kaynak et al. / Polymer Testing 24 (2005) 648–655

Fig. 7. Hoop tensile modulus of elasticity vs winding angle curves for the specimens having the same epoxy resin system
(MY740/HY918/DY062) reinforced with (a) Fiber 1, (b) Fiber 2, (c) Fiber 3, (d) Fiber 4, and (e) Fiber 5.

Fig. 8. Comparison of Hoop Tensile Modulus of Elasticity of specimens with five different fibers as a function of winding angle.
 C. Kaynak et al. / Polymer Testing 24 (2005) 648–655
different testing groups were defined by considering five
different fibers, two different epoxy resin systems and five
different winding angles. Split-disk tests were performed for
each group and the following conclusions were obtained:
† Hoop tensile stress–strain curves were generally linear
up to the point of failure. For the specimens having
08 winding angle, deviation from linearity was detected
as the failure occurred predominantly by matrix
cracking.
† In almost all the split-disk tests, failure occurred in the
gage section of the specimens. Fiber fracture and fiber-
matrix debonding was observed to be the dominant
failure mechanisms for specimens having 908 winding
angle. For specimens having G658 winding angle, in
addition to these mechanisms, delamination of layers
was also detected. For G458 filament-wound specimens,
fiber-matrix debonding was more dominant. For speci-
mens having G258 winding angle, fiber breakage was
very limited and the specimens failed with the rupture of
the matrix phase.
† Both hoop tensile strength and hoop tensile modulus of
elasticity depended strongly on the winding angle (fiber
direction) of specimens. Specimens having 908 and G
658 had much higher values compared to the ones having
G458, G258, and 08.
† Specimens produced using carbon fibers showed much
higher mechanical properties compared to the ones
produced with glass fibers for loading directions closer to
the direction of loading.
† The effect of epoxy resin system on the mechanical
performance was negligible, since the properties of
these systems were quite similar with a slight
difference in glass transition temperature and resin
viscosity.
† Split-disk tests are an effective method to determine
hoop tensile properties of filament-wound tubular
structures. Reliable results were obtained with low
standard deviations. Tests with carbon fiber reinforced
specimens resulted in relatively higher deviations.
655
Acknowledgements
This study was a part of a research program supported by
TUBITAK TIDEB (Turkish Scientific and Technical
Research Council) and Baris Electrical Industry, Co. The
authors would like to acknowledge their sincere thanks to
TUBITAK TIDEB and Baris Electrical Industry, Co. staff
for their help throughout the study.
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