Stress Failure Modes Notes

Marine
Composites
Failure Modes
Marine Composites
Webb Ins1tute
Senior Elec1ve
Spring, 2013
Failure Modes
Eric Greene, Naval Architect

EGAssoc@aol.com
410.263.1348
410.703.3025 (cell)
hMp://ericgreeneassociates.com/webbins1tute.html
Webb Ins1tute
Senior Elec1ve – Spring 2013 page 0
Marine Composites
Bending Stresses in Panels Failure Modes
Maximum In-‐Plane Stress in Beams

Subject to Bending
Stresses and Deflec1ons due to Membrane Effects
Maximum Shear Stress in Beams Subject

to Bending
Webb Ins1tute
Marine Composites
Transversely-‐S1ffened Panels in Failure Modes
Compression
Transversely S1ffened Panel

(above) and Buckling Modes
(below) [Smith, Buckling
Problems in the Design of
Fiberglass Reinforced Plas9c
Ships]
Webb Ins1tute
Marine Composites
First Ply Failure based on Cri1cal Strain Failure Modes
First Ply Failure Based on First Play Cri1cal Strain Limits from the ABS Guide for Building and Classing High-‐Speed CraA
Webb Ins1tute
Marine Composites
Micro-‐buckling Failure Modes
Schema1cs of micro-‐buckling
The schema1c diagram showing the forma1on of kinking failure mode and its geometry: (a) in-‐plane buckling of
0° fibers with an ini1al fiber misalignment ϕo, (b) deforma1on of 0° fibers via fiber microbuckling mechanism
when it is loaded in compression σ∞ and (c) fibres kinking phenomena causing catastrophic fracture of the UD
laminate. The kink band geometry: w = kink band width, β = boundary orienta1on and ϕ = ϕo + γ = inclina1on
angle. [A. Jumahata, C. Sou1sa, F.R. Jonesb, and A. Hodzica, “Fracture mechanisms and failure analysis of carbon
fiber/toughened epoxy composites subjected to compressive loading,” Composite Structures, Jan 2010.
Webb Ins1tute
Marine Composites
Fa1gue Failure Modes
Webb Ins1tute
Marine Composites
S-‐N Curves for Composite Laminates Failure Modes
Composite & Metal S-‐N Curves S1ffness S-‐N Curves
Comparison of Fa1gue Strengths S1ffness S-‐N Curve for J/24 Sailboat Sandwich Laminate from
of Graphite/Epoxy, Steel, Fiberglass/ Paul Miller’s “Fa9gue Predic9on Verifica9on of Fiberglass Hulls”
Epoxy and Aluminum [Hercules]
Webb Ins1tute
Marine Composites
S-‐N Curves Comparing Failure Modes
Material Systems
Fiber Architecture Comparison S-‐N Curves Resin Comparison S-‐N Curves
Compara1ve Fa1gue Strengths of Nonwoven Unidirec1onal Comparison of Fa1gue Behavior of Epoxy
Glass Fiber Reinforced Plas1c Laminates [ASM Engineers’ and Polyester Resin
Guide to Composite Materials]
Webb Ins1tute
Marine Composites
Design for Fa1gue Failure Modes
•  Composite materials generally are less subject

to fa1gue damage because fiber architecture
inhibits crack growth
•  Fa1gue loading sources include main hull girder
bending for larger ships; slamming loads for
high-‐speed cras; rota1ng machinery; and road
transport for smaller boats
S-‐N Curves for various Resin
Systems [Konur & MaMhews
•  Avoid structural natural frequencies coincident “Effect of the proper1es of the
cons1tuents on the fa1gue
with loading performance of composites: a
review,” Composites, vol 20, no 4,
July, 1989]
•  Joints are more suscep1ble to fa1gue damage
than panels
•  Inadequate laminate s1ffness can contribute to composite laminate
fa1gue damage
Webb Ins1tute
Marine Composites
Types of Point Impact Load Damage Failure Modes
Face Crushing Face Shear Failure In-‐Plane Failure of Faces

The face fails in through-‐ The face fails locally in The face fails in local in-‐plane
thickness compression under interlaminar shear near the tension or compression near the
the impactor 1p sides of the impactor sides of the impactor
Flexural Failure Core Crushing Core Shear Failure Delamina1on

of Faces The core is locally crushed, The core fails in shear near the between Outer
The face fails locally in bending which manifests as buckling with impactor. With briMle cores, the
Face & Core
near the sides of the impactor honeycomb cores shear failure can spread over a
Typical failure mode with s1ffer
wide area
cores, such as balsa.
reported by Mar1n Hildebrand in VTT pub 281, “A comparison of FRP-‐sandwich penetra1ng impact test methods”
Webb Ins1tute
Marine Composites
Impact Damage Failure Modes
Damage to Viking 60 from

Front-Face (left) and Back-Face (right) Damage Collision with Whale
M. Gower
Blunt Object Impact
D. Zenkert Team Bad Company
Webb Ins1tute
Marine Composites
Hull Skin Delamina1on Failure Modes
Tony Guild
Webb Ins1tute YachtForums.com

Marine Composites
Sandwich Laminate Failure Modes
Failure Modes
(a) face/core yielding/fracture (e) general buckling

(b) core shear (f) buckling -‐ shear crimping
(c) buckling -‐ face wrinkling (g) buckling -‐ face dimpling
(d) delamina1on (h) core indenta1on -‐ core yield
Det Norske Veritas Offshore Standard DNV-‐OS-‐C501, Composite Components, January 2003.
Webb Ins1tute
Marine Composites
Summary of Sandwich Failure Loads Failure Modes
Failure Mode Failure Load
Face Yielding
Face Wrinkling
Core Shear
Core Fracture Core Fracture
Bond Failure
Sandwich failure presenta1on developed by Dr. John Pilling, Technical Director
of Electric Park Research [hMp://home.comcast.net/~brandihampson/ep.html]
Webb Ins1tute
Marine Composites
Core Failure Failure Modes
Shear Failure Skin-to-Core Debond
D. Roosen M. Gower
Crushing
Fatigue Skin-to-
Core Debond
D. Zenkert C. Berggreen
Webb Ins1tute
Marine Composites
Core Shear Failure Failure Modes
“EGB-‐150” Balsa Core Material, Vacuum-‐ “SAN-‐95” Foam Core Material, Vacuum-‐
Infusion (top), Hand Lay-‐up (boYom) Infusion (top), Hand Lay-‐up (boYom)
“PUR-‐130” Foam Core Material, Vacuum-‐ “PPHC-‐100” Polypropylene Honeycomb

Infusion (top), Hand Lay-‐up (boYom) Core Material, Hand Lay-‐up
Kurt Feich1nger, Wenguang Ma and Russell Elkin, “Proper1es of Structural Sandwich Core Materials: Hand Lay-‐
up vs. Vacuum-‐Infusion Processing,” COMPOSITES 2006
Webb Ins1tute
Marine Composites
Honeycomb & Foam Core Failures Failure Modes
Digital photograph of impact delamina1ons Digital photograph of skin to-‐core de-‐bond in a
in top skin of a sandwich construc1on GRP skin, PU foam sandwich
Digital photographs showing core crushing in (le\) GRP-‐high density

Nomex and (right) CFRP-‐medium density Nomex sandwich construc1ons
Gower, M., Sims, G., Lee, R., Frost, S. and Wall, M., “Assessment and Cri1cality of Defects and Damage In Material
Systems," Na1onal Physical Laboratory, Teddington, Middlesex, United Kingdom, June 2005
Webb Ins1tute
Marine Composites
Honeycomb Core Failures Failure Modes
Adhesive bond failure modes for honeycomb sandwich panels Flatwise tension failure of a
sandwich panel
Core (le\) and adhesive (right) surfaces a\er

adhesion fillet bond failure. Note the minimal Disbonded sandwich panel: core (le\) and skin (right)
amount of cohesion fillet bond damage to the
adhesive (right).
Davis, M.J. and Bond, D.A., “ The Importance of Failure Mode Iden1fica1on on Adhesive Bonded Aircras Structures
and Repairs,,” Royal Australian Air Force, Melbourne, Australia, Sep 2008.
Webb Ins1tute
Marine Composites
Adhesive Failure Modes Failure Modes
Adhesive bond failure modes for honeycomb sandwich panels
M.J. Davis and D.A. Bond, “ The Importance of Failure Mode Iden1fica1on in Adhesive Bonded Aircras
Structures and Repairs,” Royal Australian Air Force
Webb Ins1tute
Marine Composites
Bonded Joint Failures Failure Modes
Adhesive Failure: Failure of a bonded joint between the adhesive and
the substrate
•  Primarily due to a lack of chemical bonding between the adhesive
and the bonding substrate
•  Can be indica1ve of poor surface prepara1on or contamina1on
•  Or, incorrect adhesive selec1on for the substrate materials
Cohesive failure: Failure of an adhesive joint occurring primarily in
the adhesive layer
•  Op1mum type of failure in an adhesive bonded joint when failure
occurs at predicted loads
•  Lower failure loads are indica1ve of poorly cured adhesive or
moisture or other contaminants present in the adhesive
Webb Ins1tute
Marine Composites
Bolted Connec1on Failure Modes Failure Modes
Webb Ins1tute
Marine Composites
Visible Surface Damage Failure Modes
Air bubbles, voids Air entrapment in and between plies; Blisters Rounded, some1mes sharply defined eleva1ons of
noninterconnected spherical voids laminate surface resembling blisters.
Impact cracks Separa1on of material through en1re thickness Crazing PaYern of fine cracks on or
and visible on surfaces. beneath surface.
Dow Chemical Company
Webb Ins1tute
Marine Composites
Pit or pinhole Small regular or irregular Resin pocket Apparent accumula1on of
crater on surface, usually with excess resin in a small localized area
nearly equal width and depth
Worm hole Elongated void in surface or covered by Wrinkle Crease or wrinkle-‐like surface
thin film of cured resin. imperfec1on in one or more
plies of molded-‐in reinforcement.
Webb Ins1tute Dow Chemical Company

Marine Composites
Delamina1on Separa1on of layers Fisheye Small globular mass that has not blended into
surrounding material. Par1cularly evident in
transparent or translucent materials
Dry Spots Area of reinforcement that was not weYed Pimple Small sharp or conical pimple-‐like
with resin. Usually at laminate edge. eleva1on on surface. Usually resin-‐rich.
Webb Ins1tute Dow Chemical Company
Marine Composites
Gel Coat Cracking Failure Modes
Gougeon Brothers Inc., “WEST System Fiberglass Boat Repair & Maintenance,” 15th Edi1on, April 2011
Webb Ins1tute
Marine Composites
Gelcoat Cracking Failure Modes
photo credit: Tony Guild
www.walshsurveyor.com
Secondary cracks Adjacent stress Type I Radial or Divergent

diverge to less density fields Configuration
influence
pattern
Type III Cracks at Hole of Other Stress

Type II Randomly Spaced Parallel and Concentration
Vertical Fractures
illustration credit: J.W. Smith www.cautionwater.com
Webb Ins1tute
Marine Composites
Voids Failure Modes
Micrographs of voids in (le\) unidirec1onal pre-‐preg

and (right) filament wound CFRP materials
Gower, M., Sims, G., Lee, R., Frost, S. and Wall, M., Measurement Good Prac1ce Guide No. 78 “Assessment
and Cri1cality of Defects and Damage In Material Systems," Na1onal Physical Laboratory, Teddington,
Middlesex, United Kingdom, June 2005
Webb Ins1tute
Marine Composites
Lightning Damage Failure Modes
Lightning damage to wind

turbine blades Lightning damage to carbon fiber yacht mast
Kithil, R., Knight & Carver, “Case Study of Lightning showing discharge path
Damage to Wind Turbine Blade,” Na1onal Lightning Safety
Ins1tute (NLSI), June 2008. Eric Greene Associates, Inc. survey of Santa Cruz 72, July 2002.
Webb Ins1tute
Marine Composites
Lightning Damage Failure Modes
Micrographs of (le\) resin burn-‐off and matrix micro-‐cracking in

CFRP panel containing lightning strike protec1on and
(right) large scale delamina1ons in unprotected panel
Gower, M., Sims, G., Lee, R., Frost, S. and Wall, M., Measurement Good Prac1ce Guide No. 78 “Assessment
and Cri1cality of Defects and Damage In Material Systems," Na1onal Physical Laboratory, Teddington,
Middlesex, United Kingdom, June 2005
Webb Ins1tute
Marine Composites
Damage in Foil Spar Structures Failure Modes
Types 1 (skin/adhesive debonding) and 2 (adhesive Damage types 4 (delamina1on driven by buckling
joint failure between skins) at the leading as well load) in upper flange and 5 (fiber failure in tension;
as the trailing edge. Types 4 (delamina1on driven laminate failure in compression) in the web
by a buckling load), 5 (laminate failure in
compression) and 7 (gel-‐coat cracking and gel-‐
coat/skin debonding)
Sørensen, B.F., Jørgensen, E, Debe, C.P., Jensen, F.M., Jensen, H.M., Jacobsen, T.K.and Halling, K.J., “Improved design
of large wind turbine blade of fibre composites based on studies of scale effects (Phase 1) -‐ Summary Report,” Risø
Na1onal Laboratory, Roskilde, Denmark, September 2004.
Webb Ins1tute
Marine Composites
Ship Structural Failures Failure Modes
Indonesian Trimaran Fire Bulbous Bow
High-‐speed Catamaran Bow
Webb Ins1tute

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Marine

Eric Greene, Naval Architect

Maximum In-­‐Plane Stress in Beams

Stresses and Deﬂec1ons due to Membrane Eﬀects

Maximum Shear Stress in Beams Subject

Transversely S1ﬀened Panel

Schema1cs of micro-­‐buckling

Composite & Metal S-­‐N Curves S1ﬀness S-­‐N Curves

• Composite materials generally are less subject

Face Crushing Face Shear Failure In-­‐Plane Failure of Faces

Flexural Failure Core Crushing Core Shear Failure Delamina1on

Damage to Viking 60 from

Blunt Object Impact

D. Zenkert Team Bad Company

Webb Ins1tute YachtForums.com

(a) face/core yielding/fracture (e) general buckling

Failure Mode Failure Load

Core Fracture Core Fracture

Shear Failure Skin-to-Core Debond

“PUR-­‐130” Foam Core Material, Vacuum-­‐ “PPHC-­‐100” Polypropylene Honeycomb

Digital photographs showing core crushing in (le\) GRP-­‐high density

Core (le\) and adhesive (right) surfaces a\er

Adhesive bond failure modes for honeycomb sandwich panels

Webb Ins1tute Dow Chemical Company

photo credit: Tony Guild

Secondary cracks Adjacent stress Type I Radial or Divergent

Type III Cracks at Hole of Other Stress

Micrographs of voids in (le\) unidirec1onal pre-­‐preg

Lightning damage to wind

Micrographs of (le\) resin burn-­‐oﬀ and matrix micro-­‐cracking in

Indonesian Trimaran Fire Bulbous Bow

High-­‐speed Catamaran Bow

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Maximum In-‐Plane Stress in Beams

Schema1cs of micro-‐buckling

Composite & Metal S-‐N Curves S1ﬀness S-‐N Curves

•  Composite materials generally are less subject

Face Crushing Face Shear Failure In-‐Plane Failure of Faces

“PUR-‐130” Foam Core Material, Vacuum-‐ “PPHC-‐100” Polypropylene Honeycomb

Digital photographs showing core crushing in (le\) GRP-‐high density

Micrographs of voids in (le\) unidirec1onal pre-‐preg

Micrographs of (le\) resin burn-‐oﬀ and matrix micro-‐cracking in

High-‐speed Catamaran Bow