Mechanical Behavior of Composite

8-1. Tensile Strength of Unidirectional Fiber Reinforced Composite

Isostrain Condition : loading parallel to fiber direction

Fiber & Matrix elastic case
Modulus Ec Ef V f Em Vm : works reasonably well
Strength c f V f m Vm : does not work well
Why?
Ec : intrinsic property (microstructure insensitive)
c : extrinsic property (microstructure sensitive)

Factors sensitive on strength of composite

- Fabrication condition determining microstructure of matrix
- Residual stress
- Work hardening of matrix
- Phase transformation of constituents

1
Analysis of Tensile Stress and Modulus of Unidirectional FRC
Assumption : Fiber : elastic & plastic
Matrix : elastic & plastic

Stress-Strain Curve of FRC - divided into 3 stages

Stage I : fiber & matrix - elastic
Rule of Mixtures
Strength c f V f m Vm
Modulus Ec Ef V f Em Vm
Stage II : fiber - elastic, matrix - plastic
Strength c f V f m Vm
m : flow stress of matrix at a given strain
dm
E E V V m Ef V f
Modulus c f f
d m
d m
: slope of the stress - strain curve of the matrix at a given strain
d m

2
Stage III : fiber & matrix plastic
Strength c f V f m Vm

d f d m
Modulus Ec V f Vm
d f d m

UTS cu fu V f m Vm
fu : ultimate tensile strength of fiber
m : flow stress of matrix at the fracture strain of fiber

3
Effect of Fiber Volume Fraction on Tensile Strength
(Kelly and Davies, 1965)
Assumption : Ductile matrix ( f ,fiber f ,matrix ) work hardens.
All fibers are identical and uniform. same UTS

If the fibers are fractured, a work hardenable matrix counterbalances the loss
of load-carrying capacity.
In order to have composite strengthening from the fibers,
cu fu V f m (1 Vf ) mu (1 Vf )
UTS of composite UTS of matrix after fiber fracture

Minimum Fiber Volume Fraction

Vf V min mu m
fu mu m
As fu , Vmin .
As mu m , Vmin .
degree of work hardening

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In order to be the strength of composite higher than that of monolithic matrix,
cu fu V f m (1 Vf ) mu
UTS of pure matrix

Critical Fiber Volume Fraction

mu m
Vf V crit
fu m

As fu , Vcrit .
As mu m , Vcrit .
degree of work hardening

Note that V crit V min always! ( mu 0 )

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6
8-2. Compressive Strength of Unidirectional Fiber Reinforced Composites
Compression of Fiber Reinforced Composite
Fibers - respond as elastic columns in compression.
Failure of composite occurs by the buckling of fibers.

Buckling occurs when a slender column under compression becomes unstable

against lateral movement of the central portion.
Critical stress corresponding to failure by buckling,

2
2E d
where dc is diameter,

16 l l is length of column.

7
2 Types of Compressive Deformation
1) In-phase Buckling : involves shear deformation of matrix
Gm Em
c Gm (or Em)
Vm 2(1
m ) Vm
for isostropic matrix, Gm Em
2(1 m )
predominant at high fiber volume fraction

2) Out-of-phase Buckling : involves transverse compression and tension of

matrix and fiber
1/ 2
V f Em E f
c 2 V f Em Ef 1/ 2
3Vm
pre-dominant at low fiber volume fraction
Factors influencing the compressive strength :
Gm , Em
Ef
Vf
Interfacial Bond Strength : poor bonding easy buckling
8
8-3. Fracture Modes in Composites
1. Single and Multiple Fracture
Generally, f ,fiber f ,matrix
When more brittle component fractured, the load carried by the brittle
component is thrown to the ductile component.
If the ductile component cannot bear this additional load Single Fracture
If the ductile component can bear this additional load Multiple Fracture

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1) Single Fracture
- predominant at high fiber volume fraction
- all fibers and matrix are fractured in same plane
- condition for single fracture
fu V f mu Vm m Vm

stress beared by fiber additional stress which can be supported by matrix

where m : matrix stress corresponding to the fiber fracture strain

2) Multiple Fracture
- predominant at low fiber volume fraction
- fibers and matrix are fractured in different planes
- condition for multiple fracture
fu V f mu Vm m Vm

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2. Debonding, Fiber Pullout and Delamination Fracture
Fracture Process : crack propagation

Discontinuous Fiber Reinforced Composite

( lc : critical length )
If distance from crack plane to fiber end lc
Debond & Pullout 2
Good for toughness

If distance from crack plane to fiber end lc

Fiber Fracture 2
Good for strength

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Fracture of Continuous Fiber Reinforced Composite

Fracture of fibers at crack plane or other position depending on the position

of flaw

Pullout of fibers

For max. fiber strengthening fiber fracture is desired.

For max. fiber toughening fiber pullout is desired.

Analysis of Fiber Pullout

Assumption : Single fiber in matrix
rf : fiber radius
l : fiber length in matrix
f : tensile stress on fiber
i : interfacial shear strength

i
f

12
Force Equilibrium
rf2 f 2rf il
rf2 fu 2rf ilc ( lc : critical length of fiber )
fu lc
2i r f
fu lc lc
4i 2r f d

1) Condition for fiber fracture,

rf2 f 2rf il
fu l 1
If l lc
4i d 2rf

2) Condition for fiber pullout,

rf2 f 2rf il
fu l 1
If l lc
4i d 2rf

13
Fracture Process of Fiber Reinforced Composites
Real fibers - non-uniform properties
3 steps of fracture process
1) Fracture of fibers at weak points near fracture plane :
Wd
2) Debonding of fibers :
3) Pullout of fibers : W p

Load
W fracture W d W p
Outwater and Murphy
WP

Displacement
Wd
14
Energy Required for Fracture & Debonding
2fu d2
Wd x x : debond length
Ef 24
elastic strain E. volume

Energy Required for Pullout

lc
Let k : embedded distance of a broken fiber from crack plane 0 k
x : pullout distance at a certain moment 2
i : interfacial shear strength

Force to resist the pullout = i d(k x )

fiber contact area

Energy to pullout a distance dx id(k x )dx

Total energy(work) to pullout a fiber for distance k
k idk 2

W p id(k x )dx
0 2
lc
Average energy to pullout per fiber(considering all fibers with different k, 0 k )
lc
2
2
i dk 2 idlc
1

2

W p,ave 0
dk
lc 2 2 24

15
Fracture of Discontinuous Fiber Reinforced Composite
l
If a fiber is located within a distance, c , from crack plane, pullout
2
Probability for pullout of a fiber with length, l lc
l
Average energy to pullout per fiber with length, l
2
lc idlc
Wp,ave
l 24
probability for pullout energy required for pullout
Energy for Fiber Pullout vs Fiber Length(l)

If l lc , fiber pullout distance increases with increasing length l.

Wp increases, with increasing length l. W p l2
If l lc , fiber fracture tendency increases with increasing length l.
1
Wp decreases, with increasing length l. W p lc constant
l
Wp becomes maximum, when l lc .
16
As Wd << Wp
Wfracture Wd Wp Wp

Advantage of Composite Material:

can obtain strengthening & toughening at the same time
Toughening Mechanism in Fiber Reinforced Composite
1) Plastic deformation of matrix - metal 2
matrix composite

Energy of fracture d Vm d : fiber diameter
Vf
2) Fiber pullout
d
Energy of fracture
i
3) Crack deflection (or Delamination) - ceramic matrix composite
Cook and Gordon, Stresses distribution near crack tip

yy

xx

17
If xx > interfacial tensile strength delamination
crack deflection

Delamination Fracture in Laminate Composite

Fatigue debonding at interface
Fracture repeated crack initiation & propagation

18
8-4. Statistical Analysis of Fiber Strength
Real fiber : nonuniform properties need statistical approach
Brittle fiber (ex. ceramic fibers) - nonuniform strength
Ductile fiber (ex. metal fibers) - relatively uniform strength

Strength of Brittle Fiber

dependent on the presence of flaws
dependent on the fiber length : "Size Effect

Weibull Statistical Distribution Function

: probability density
f Lthat
Probability
1function
the fiber
L is between
exp strength and .
f
: statistical parameters
L : fiber length d
,

19

Let, Mk 0
k f ()d Mk : kth moment of statistical distribution function

Mean Strength of Fibers

f d M
0
1

Standard Deviation for Strength of Fibers

S M2 M12
1/ 2

Substituting f
1
L
1/
1

1/ 2
1 / 2 1
S L 1 2 1


where n 0
exp( x )xn1dx : gamma function

Coefficient of Variation
S 1 2 / 2 11/
1/ 2

1 1/
1
( f() only, for 0.05 0.5 )
- 0.92

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 1
(L )1/ (1 ) 1/ vs L plot

As L , . "Size Effect
As , . is less dependent on L.

If , spike distribution function (dirac delta function)
uniform strength independent on L
Glass fiber
Boron, SiC fibers 0.1, 11
0.2 0.4, 2.7 5.8
21
Strength of Fiber Bundle
Bundle strength Average strength of fiber n
# of fibers
<
Assumption : Fibers - same cross-sectional area
- same stress-strain curve
- different strain-to-fracture
Let F() : The probability that a fiber will break before a certain value of is
attained.
Cummulative Strength Distribution Function

F() f () d
0

Mean Fiber Strength of Bundle

B fu [1 F( fu )] (L e)1/

Mean Fiber Strength of Unit Fiber

1
(L )1/ (1 )

22
Comparison of B and

B
As , . ( : coefficien t of variation)
( )

B
0.1 0.8


0.25 B 0.6

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8-5. Failure Criteria of an Orthotropic Lamina
Assumption : Fiber reinforced lamina - homogeneous, orthotropic
Failure Criterion of Lamina
1. Maximum Stress Criterion
Failure occurs when any one of the stress components is equal to or greater
than its ultimate strength.
Interaction between stresses is not considered.

Failure Condition
1 X1T or 1 X1C
or 2 XT2 or 2 XC2
or 6 S or 6 S
where XT : ultimate uniaxial tensile strength in fiber direction (>0)
1
: ultimate
X1C uniaxial compressive strength in fiber direction (<0)
: ultimate
XT2 uniaxial tensile strength in transverse direction
: ultimate
XC2 uniaxial compressive strength in transverse direction
S : ultimate planar shear strength

24
ex) If uniaxial tensile stress x is given in a direction at an angle with the fiber axis.
1 x x
[T] 0
2 1
6 0

m2 n2 2mn

[ T ] n 2 m2 2mn
2
2
mn mn m 2
n
Failure occurs when,
1 x m2 X1T
or 2 x n2 XT2
or 6 x mn S

Failure Criterion
X1T
x 2 longitudin al tensile failure
m
X1T Failure occurs by a criteria, which
or x 2 transverse tensile failure
n is satisfied earlier.
S
or x planar shear failure
mn
25
26
2. Maximum Strain Criterion
Failure occurs when any one of the strain components is equal to or greater
than its corresponding allowable strain.

Failure Condition
1 1T or 1 1C
or 2 T2 or 2 C2
or 6 S6 or 6 S6

where 1
T
: ultimate tensile strain in fiber direction
1 : ultimate compressive strain in fiber direction
C

T2 : ultimate tensile strain in transverse direction

C2 : ultimate compressive strain in transverse direction
S6 : ultimate planar shear strain

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3. Maximum Work Criterion
Failure criterion under general stress state
Tsai-Hill
12 12 22 12
2 2 1
X12
X1 X2 S 2

where X1 : ultimate tensile (or compressive) strength in fiber direction

X2 : ultimate tensile (or compressive) strength in transverse direction
S : ultimate planar shear strength

ex) For uniaxial stress x , having angle with the fiber axis
1 x m2
2 x n2 substituting
6 x mn

Failure criterion
m4 n4 2 2 1 1

X2 X2 m n 2
2x 1
S X
2
1 2

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4. Quadratic Interaction Criterion

Consider stress interaction effect

Tsai-Hahn
Stress Function
f () Fi i Fi j i j 1
stress term 1st interaction term
Thin Orthotropic Lamina
i, j = 1, 2, 6 (plane stress)
: strength parameters
Fi , Fi j

Failure occurs when,

F11 F22 F6 6 F1112 F22 22 F66 26 2F121 2 2F16 16 2F26 26 1

need to know 9 strength parameters

For the shear stress components, the reverse sign of shear stress should
give the same criterion.

Let F6 = F16 = F26 = 0

F11 F2 2 F1112 F22 22 F66 26 2F1212 1
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Calculation of Strength Parameters by Simple Tests
1) Longitudinal uniaxial tensile and compressive tests,
1
If XT , f () 1 F XT F ( XT )2 1 F11
1 1 1 1 11 1 X1T X1C
1 1
If 1 X1C , f () 1 F1 X1C F11 ( X1C )2 1 F1 T C
X1 X1
X1T : longitudinal tensile strength
X1C : longitudinal compressive strength

2) Transverse uniaxial tensile and compressive tests, 1

If 2 X2 , f 1 F2 X2 F22 (X2 ) 1
T T T 2 F 22
XT2 XC2
1 1
If 2 X2 , f 1 F2 X2 F22 (X2 ) 1
C C C 2
F2
XT2 XC2
3) Longitudinal shear test
1
If 6 S, f () 1 F66S2 1 F66
S2
4) In the absence of other data,
F12 0.5 F11 F22

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Boron/Epoxy composite
Intrinsic properties
X1T 27.3 MPa, XT2 1.3 MPa, S 1.4 MPa
X1C 52.4 MPa, XC2 6.5 MPa

31
32
8-6. Fatigue of Composite Materials

Fatigue Failure in Homogeneous Monolithic Materials

Initiation and growth of a single crack perpendicular to loading axis.

Fatigue Failure in Fiber Reinforced Laminate Composites

Pile-up of damages - matrix cracking, fiber fracture, fiber/matrix debonding,
ply cracking, delamination
Crack deflection (or Blunting)
Reduction of stress concentration
A variety of subcritical damage mechanisms lead to a highly diffuse damage
zone.

33
Constant-stress-amplitude Fatigue Test
Damage Accumulation vs Cycles

Crack length in homogeneous material - accelerate

( increase of stress concentration)
Damage (crack density) in composites - accelerate and decelerate
( reduction of stress concentration)

34
S-N Curves of Unreinforced Plolysulfone vs Glassf/Polysulfone, Carbonf/Polysulfone

Carbon Fibers : higher stiffness & thermal conductivity

higher fatigue resistance

S-N Curves of Unidirectional Fiber Reinforced Composites (B/Al, Al2O3/Al, Al2O3/Mg)

35
Fatigue of Particle and Whisker Reinforced Composites

For stress-controlled cyclic fatigue or high cycle fatigue, particle or whisker

reinforced Al matrix composites show improved fatigue resistance compared to
Al alloy, which is attributed to the higher stiffness of the composites.

For strain-controlled cyclic fatigue or low cycle fatigue, the composites show
lower fatigue resistance compared to Al alloy, which is attributed to the lower
ductility of the composites.

Particle or short fibers can provide easy crack initiation sites. The detailed
behavior can vary depending on the volume fraction, shape, size of
reinforcement and mostly on the reinforcement/matrix bond strength.

36
Fatigue of Laminated Composites
Crack Density, Delamination, Modulus vs Cycles
i) Ply cracking
ii) Delamination
iii) Fiber fatigue

37
Modulus Reduction during Fatigue
Ogin et al.
Modulus Reduction Rate max
n
1 dE max
2
m
A 2
E0 dN E0 (1 E / E0 ) time
min
where E : current modulus
E0 : initial modulus N : number of cycles
max : peak fatigue stress A, n : constants
1 dE max
2

log vs log 2 plot linear fitting
E0 dN E
0 (1 E / E )
0

38
Integrate the equation to obtain a diagram relating modulus reduction to number
of cycles for different stress levels.
used for material design

39
8-7. Thermal Fatigue of Composite Materials
Thermal Stress
Thermal stresses arise in composite materials due to the generally large
differences in thermal expansion coefficients() of the reinforcement and matrix.
It should be emphasized that thermal stresses in composites will arise even if
the temperature change is uniform throughout the volume of composite.
T

Thermal Fatigue
When the temperature is repeatedly changed, the thermal stress results in the
thermal fatigue, because the cyclic stress is thermal in origin. Thermal fatigue
can cause cracking of brittle matrix or plastic deformation of ductile matrix.
Cavitation in the matrix and fiber/matrix debonding are the other forms of
damage observed due to thermal fatigue of composites. Thermal fatigue in
matrix can be reduced by choosing a matrix that has a high yield strength
and a large strain-to-failure. The fiber/matrix debonding can only be avoided
by choosing the constituents such that the difference in the thermal expansion
coefficients of the reinforcement and the matrix is low.

40