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Three tests are described which evaluate the oxygen compatibility characteristics of multiple composite materials: 1) Mechanical Impact Bruceton 'Up and Down' Method; 2) Promoted Combustion; 3) Electrostatic Discharge.
Fiber push-out tests have been performed on a ceramic matrix composite consisting of carborundum-sintered SiC fibers, with a BN coating, embedded in a reaction-bonded SiC matrix. Analysis of the push-out data, utilizing the most complete theory presently available, shows that one of the fiber/coating/matrix interfaces has a low fracture energy (one-tenth that of the fiber) and a moderate sliding resistance of about 8 MPa. The debonded sliding interface shows some continuous but minor abrasion, which appears to increase the sliding resistance, but overall the system exhibits very clean smooth sliding. The tensile response of a full-scale composite is then modeled using data obtained here and known fiber strengths to demonstrate the good composite behavior predicted for this material.
An investigation was conducted to characterize and model the fatigue crack growth (FCG) behavior of a SCS-6/Ti-15-3 metal matrix composite. Part of the study was conducted using a fatigue loading stage mounted inside a scanning electron microscope (SEM). This unique facility allowed high magnification viewing of the composite fatigue processes and measurement of the near crack tip displacements. The unidirectional composite was tested in the (0)8 (i.e., longitudinal) and (90)8 (i.e., transverse) orientations. For comparison purposes unreinforced matrix material produced by the identical process as the reinforced material was also tested. The results of the study reveal that the fatigue crack growth behavior of the composite is a function of specimen geometry, fiber orientation and the interaction of local stress fields with the highly anisotropic composite. In the case of (0)8 oriented single edge notch (SEN) specimens and (90)8 oriented compact tension (CT) specimens, the crack growth was normal to the loading direction. However, for the (0)8 CT specimens the crack grew mostly parallel to the loading and the fiber direction. The unusual fatigue behavior of the (0)8 CT specimens was attributed to the specimen geometry and the associated high tensile bending stresses perpendicular to the fiber direction. These stresses resulted in preferential cracking in the weak interface region perpendicular to the fiber direction. The interface region, and in particular the carbon coating surrounding the fiber proved to be the composites weakest link. In the (0)8 SEN the crack growth was confined to the matrix leaving behind unbroken fibers which bridged the cracked surfaces. As the crack grew longer, more fibers bridged the crack resulting in a progressive decrease in the crack growth rates and eventual crack arrest. The actual near crack tip displacement measurements were used in a proposed formulation for a bridging-corrected effective crack driving force, delta K(sub eff). This parameter was able to account for most of the experienced bridging and correlated the (0)8 SEN fatigue crack growth data reasonably well.
The experimental characterization for composite materials is generally more complicated than for ordinary homogeneous, isotropic materials because composites behave in a much more complex fashion, due to macroscopic anisotropic effects and lamination effects. Problems concerning the static uniaxial tension test for composite materials are considered along with approaches for conducting static uniaxial compression tests and static uniaxial bending tests. Studies of static shear properties are discussed, taking into account in-plane shear, twisting shear, and thickness shear. Attention is given to static multiaxial loading, systematized experimental programs for the complete characterization of static properties, and dynamic properties.
Standard single lap, double lap and symmetric step lap bonded joints of Celion 3000/PMR-15 graphite/polyimide composite were evaluated. Composite to composite and composite to titanium joints were tested at 116 K (-250 F), 294 K (70 F) and 561 K (550 F). Joint parameters evaluated are lap length, adherend thickness, adherend axial stiffness, lamina stacking sequence and adherend tapering. Advanced joint concepts were examined to establish the change in performance of preformed adherends, scalloped adherends and hybrid systems. The material properties of the high temperature adhesive, designated A7F, used for bonding were established. The bonded joint tests resulted in interlaminar shear or peel failures of the composite and there were very few adhesive failures. Average test results agree with expected performance trends for the various test parameters. Results of finite element analyses and of test/analysis correlations are also presented.
Due to a unique combination of properties including high hardness, low density, chemical and thermal stability, semi-conductivity, and high neutron absorption, boron carbide (B4C) is a potential candidate for various applications involving extreme environment. However, B4C’s current application is limited because of its low fracture toughness. In this study, a hierarchical microstructure design with features including TiB2 grains and graphite platelets was used to toughen B4C by simultaneously utilizing multiple toughening mechanisms including crack deflection, bridging, and micro-crack toughening. Using field-assisted sintering technology (FAST), B4C composites with dense and hierarchical microstructure were fabricated. Previously, the fracture toughness of fabricated B4C composites was measured at micro-scale using micro-indentation to have up to 56% improvement. In this work, the B4C composites’ fracture toughness was characterized at macro-scale using four-point bending methods and compared with previous results obtained at micro-scale. Micromechanics modeling of fracture behaviors for B4C-TiB2 composites was also performed to evaluate the contributions from experimentally observed toughening mechanisms. From four-point bending tests, B4C composites reinforced with both TiB2 grains (~15 vol%) and graphite platelets (~8.7 vol%) exhibited the highest fracture toughness enhancement from 2.38 to 3.65 MPa∙m^(1/2). The measured values were lower than those obtained using micro-indentation but maintained the general trends. The discrepancy between the indentation and four-point bending test results originated from the complex deformation behaviors triggered by the high contact load during indentation tests. Through micromechanics modeling, introduced thermal residual stress due to thermal expansion mismatch between B4C and TiB2, and weak interphases at B4C-TiB2 boundaries were identified as the main causes for experimentally observed toughness enhancement. These results proved the effectiveness of hierarchical microstructure designs for B4C toughening and can provide reference for the future design of B4C composites with optimized microstructures for further fracture toughness enhancement.
The characterization of triaxially braided composite is complicate due to the nonuniformity of deformation within the unit cell as well as the possibility of the freeedge effect related to the large size of the unit cell. Extensive experimental investigation has been conducted to develop more accurate test approaches in characterizing the actual mechanical properties of the material we are studying. In this work, a meso-scale finite element model is utilized to simulate two complex specimens: notched tensile specimen and tube tensile specimen, which are designed to avoid the free-edge effect and free-edge effect induced premature edge damage. The full field strain data is predicted numerically and compared with experimental data obtained by Digit Image Correlation. The numerically predicted tensile strength values are compared with experimentally measured results. The discrepancy between numerically predicted and experimentally measured data, the capability of different test approaches are analyzed and discussed. The presented numerical model could serve as assistance to the evaluation of different test methods, and is especially useful in identifying potential local damage events.
Ambient temperature hydrostatic pressurization tests were conducted on a composite overwrapped pressure vessel (COPV) to understand the fiber stresses in COPV components. Two three-dimensional digital image correlation systems with high speed cameras were used in the evaluation to provide full field displacement and strain data for each pressurization test. A few of the key findings will be discussed including how the principal strains provided better insight into system behavior than traditional gauges, a high localized strain that was measured where gages were not present and the challenges of measuring curved surfaces with the use of a 1.25 in. thick layered polycarbonate panel that protected the cameras.
Quasi-static tests have been performed on triaxially braided carbon fiber composite materials with large unit cell sizes. The effects of different fibers and matrix materials on the failure mode were investigated. Simulations of the tests have been performed using the transient dynamic finite element code, LS-DYNA. However, the wide range of failure modes observed for the triaxial braided carbon fiber composites during tests could not be simulated using composite material models currently available within LS-DYNA. A macroscopic approach has been developed that provides better simulation of the material response in these materials. This approach uses full-field optical measurement techniques to measure local failures during quasi-static testing. Information from these experiments is then used along with the current material models available in LS-DYNA to simulate the influence of the braided architecture on the failure process. This method uses two-dimensional shell elements with integration points through the thickness of the elements to represent the different layers of braid along with a new analytical method for the import of material stiffness and failure data directly. The present method is being used to examine the effect of material properties on the failure process. The experimental approaches used to obtain the required data will be described, and preliminary results of the numerical analysis will be presented.
Quasi-static tests have been performed on triaxially braided carbon fiber composite materials with large unit cell sizes. The effects of different fibers and matrix materials on the failure mode were investigated. Simulations of the tests have been performed using the transient dynamic finite element code, LS-DYNA. However, the wide range of failure modes observed for the triaxial braided carbon fiber composites during tests could not be simulated using composite material models currently available within LS-DYNA. A macroscopic approach has been developed that provides better simulation of the material response in these materials. This approach uses full-field optical measurement techniques to measure local failures during quasi-static testing. Information from these experiments is then used along with the current material models available in LS-DYNA to simulate the influence of the braided architecture on the failure process. This method uses two-dimensional shell elements with integration points through the thickness of the elements to represent the different layers of braid along with a new analytical method for the import of material stiffness and failure data directly. The present method is being used to examine the effect of material properties on the failure process. The experimental approaches used to obtain the required data will be described, and preliminary results of the numerical analysis will be presented.
Difunctional and trifunctional arylacetylenes were used as monomers to form thermoset matrix resin composites. Composites can be hot pressed at 180 C to react 80 percent of the acetylene groups. Crosslinking is completed by postcuring at 350 C. The postcured resins are thermally stable to nominally 460 C in air. As a result of their high crosslink density, the matrix exhibits brittle failure when unaxial composites are tested in tension. Failure of both uniaxial tensile and flexural specimens occurs in shear at the fiber matrix interface. Tensile fracture stresses for 0 deg composites fabricated with 60 v/o Celion 6K graphite fiber were 827 MPa. The strain to failure was 0.5 percent. Composites fabricated with 8 harness satin Celion cloth (Fiberite 1133) and tested in tension also failed in shear at tensile stresses of 413 MPa.
Experimental study addresses related topics of thermo-oxidative aging of PMR-15 (polyimide matrix/graphite-fiber composite materials) strengths of interfacial bonds, effects of various surface treatments, and relative merits of mechanical tests yielding measures of strengths of materials.
Unidirectionally reinforced A1203 matrix composites have been fabricated by hot pressing. Approximately 30 volume % of either coated or uncoated sapphire fiber was used as reinforcement. Unstabilized ZrO2 was applied as the fiber coating. Composite mechanical behavior was analyzed both after fabrication and after additional heat treatment. The results of composite tensile tests were correlated with fiber-matrix interfacial shear strengths determined from fiber push-out tests. Substantially higher strength and greater fiber pull-out were observed for the coated fiber composites for all processing conditions studied. The coated fiber composites retained up to 95% and 87% of their as-fabricated strength when heat treated at 14000C for 8 or 24 hours, respectively. Electron microscopy analysis of the fracture surfaces revealed extensive fiber pull-out both before and after heat treatment.
The crushing response and the energy absorption capacity of a quasi-isotropic C-shaped composite panel is presented to simulate the progressive damage and failure mechanisms involved in the component testing. Crushable composite structures are widely used for impact applications, as because of their great high-energy absorption capability and lower weight. Simulating the crush characteristics of composite structures is challenging, as the conventional tools fail to accurately represent the failure mechanisms at the component level. Here, a cost-effective predictive tool ‘CZone’ is applied for simulating the crushing response of composite materials. CZone for Abaqus (CZA) is an add-on capability for Abaqus/Explicit and combines with the commercially available impact modeling capabilities included within the Abaqus finite element software package.
Difunctional and trifunctional arylacetylenes were used as monomers to form thermoset matrix resin composites. Composites can be hot-pressed at 180 C to react 80 percent of the acetylene groups. Crosslinking is completed by postcuring at 350 C. The postcured resins are thermally stable to nominally 460 C in air. As a result of their high crosslink density, the matrix exhibits brittle failure when uniaxial composites are tested in tension. Failure of both uniaixial tensile and flexural specimens occurs in shear at the fiber-matrix interface. Tensile fracture stresses for 0-deg composites fabricated with 60 v/o Celion 6K graphite fiber were 827 MPa. The strain to failure was 0.5 percent. Composites fabricated with 8 harness satin Celion cloth (Fiberite 1133) and tested in tension also failed in shear at tensile stresses of 413 MPa.
The edge crack torsion (ECT) test is reexamined to address two primary concerns with this method. The first of these relates to inconsistencies in the data reduction procedure that was originally proposed and is most commonly used to compute the mode III interlaminar fracture toughness, G(sub IIIc), from the experimental data. The second relates to the observation that plies neighboring the preimplanted insert in the standard ECT layup are unable to contain initiation and growth of intralaminar cracks, and that growth of these cracks contributes to errors in the apparent values of G(sub IIIc). To address these issues, an alternative data reduction technique, which uses a polynomial expression to represent the ECT specimen’s compliance versus crack length relation, is proposed. The accuracy and potential drawbacks of this expression are investigated using FE simulations. Next, seven groups of ECT specimens are fabricated and tested. Each of these groups contains specimens with preimplanted inserts that are bounded by plies at different +q and -q orientations. The seven groups consist of values of q that vary from 0° to 90° in 15° increments. Tests on these specimens show that intralaminar cracking occurs in specimens from all batches except those for which q equals 15° or 30°. However, values of G(sub IIIc) measured using specimens with these two ply orientations were not equal and, for q = 30°, the values of G(sub IIIc) that were obtained were not completely independent of initial starter crack length. Potential issues accounting for these observations and other challenges associated with measuring G(sub IIIc) using the ECT test are discussed.
The usefulness of the end-notched flexure (ENF) test for measuring G(IIc) for toughened composites was evaluated. Calculations were made using the measured flexural compliance from the ENF test and the measured axial modulus. Tests were conducted on three different composite materials, using laminates with two different span lengths and insert sizes. The error associated with neglecting nonlinear terms in the displacement-curvature relationship was analyzed to demonstrate the influence of specimen geometry on G(IIc) measurement. It is concluded that G(IIc) measurement may vary with the method of calculation, span length, or insert thickness, but these effects are minor compared to the large differences in measurements obtained for different materials. Hence, the ENF test is a valid one for screening materials for improvements in interlaminar shear fracture toughness.
Technical problems associated with fuel containment and damage tolerance of composite material wings for transport aircraft were identified. The major tasks are the following: (1) the preliminary design of damage tolerant wing surface using composite materials; (2) the evaluation of fuel sealing and lightning protection methods for a composite material wing; and (3) an experimental investigation of the damage tolerant characteristics of toughened resin graphite/epoxy materials. The test results, the test techniques, and the test data are presented.