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Mode I Delamination Fracture Characterization of Polymeric Composites Under Elevated Temperature

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Mode I Delamination Fracture Characterization of Polymeric Composites Under Elevated Temperature Syracuse University SURFACE Mechanical and Aerospace Engineering - Dissertations College of Engineering and Computer Science 2011 Mode I Delamination Fracture Characterization of Polymeric Composites under Elevated Temperature Wenming Zhao Syracuse University Follow this and additional works at: https://surface.syr.edu/mae_etd Part of the Engineering Commons Recommended Citation Zhao, Wenming, "Mode I Delamination Fracture Characterization of Polymeric Composites under Elevated Temperature" (2011). Mechanical and Aerospace Engineering - Dissertations. 59. https://surface.syr.edu/mae_etd/59 This Dissertation is brought to you for free and open access by the College of Engineering and Computer Science at SURFACE. It has been accepted for inclusion in Mechanical and Aerospace Engineering - Dissertations by an authorized administrator of SURFACE. For more information, please contact [email protected]. ABSTRACT Mode I Delamination Fracture Characterization of Polymeric Composites under Elevated Temperature (May 2011) Wenming Zhao, M.S., Clarkson University Delamination is one of the major failure modes seen in the laminated polymeric matrix composite (PMC). Accurate prediction of delamination initiation and propagation is important for the design and analysis of robust composite structures. Existing experimental methodologies that are based on linear elastic fracture mechanics are inadequate to characterize delamination fracture properties under elevated temperature when PMC properties become time-, loading-history, and rate-dependent. A new experimental methodology based on linear viscoelastic fracture theory is developed and verified through finite element analysis and experiments. This new technique determines crack growth curves, such as stress intensity factor vs. crack growth speed and fracture initiation energy vs. crack initiation time, through the experimentally determined J- integral, Js, for a linear viscoelastic double cantilever beam (DCB) specimen. Special test setup is designed and validated for determining accurate Js using just the applied load and the load end rotation angles. This new methodology is then applied to measure the mode I fracture properties of a highly toughened graphite/epoxy composite under various environmental conditions. Mode I Delamination Fracture Characterization of Polymeric Composites under Elevated Temperature By Wenming Zhao M.S., Clarkson University, 2003 DISSERTATION Submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy in Mechanical Engineering in the Graduate School of Syracuse University May, 2011 2 Copyright 2011 Wenming Zhao All rights Reserved 3 Table of Contents List of Tables vii List of Figures viii Acknowledgement xii 1. INTRODUCTION 1 1.1.Problem overview 1 1.2.Objectives 3 1.3.Study overview 3 2. USE OF LINEAR ELASTIC FRACTURE MECHANICS IN DELAMINATION GROWTH PREDICTION 5 1.4. Introduction 5 1.5. Fracture parameters in LEFM 6 2.5.1.The mode I energy release rate, GI 6 2.5.2.The mode I stress intensity factor, KI 8 2.5.3.The J-integral 9 2.5.4.Fracture parameters in delamination prediction 10 1.6. The mode I double cantilever beam (DCB) test 11 2.6.1.Introduction 11 2.6.2.LEFM-based data reduction techniques 11 2.6.3.Use of LEFM in delamination toughness measurements 17 1.7. Conclusion 21 3. USE OF VISCOELASTIC FRACTURE MECHANICS IN DELAMINATION GROWTH PREDICTION 23 3.1.Introduction 23 3.2.Linear viscoelastic fracture analysis and characterization 24 3.2.1.Viscoelastic fracture mechanics overview 24 3.2.2.Requirements for application of VEFM to PMCs 25 3.2.3.Previous work 26 3.2.4.Most promising approaches 28 3.3.Schapery’s linear viscoelastic fracture theory 29 3.3.1.Fracture energy 29 3.3.2.Stress intensity factor method 30 3.3.3.Generalized J-integral method 39 3.3.4.Summary 46 3.4.Conclusion 46 4. COMPOSITE MATERIAL CONSIDERED 47 4.1.Introduction 47 4.2.Prior work on T800H/3900-2 Laminates 50 4.2.1.Mechanical properties 50 iv 4.2.2. Fracture properties under various environments 51 4.2.3. Summary 52 4.3.Measurement of linear viscoelastic properties 52 4.3.1.Experimental procedures 53 4.3.2.Test results 57 4.4.Conclusion 61 5. FRACTURE CHARACTERIZATION METHODOLOGY 63 5.1. Introduction 63 5.2.Linear viscoelastic DCB specimen 64 5.3.Analysis of crack growth 67 5.3.1.Crack initiation 67 5.3.2.Steady crack propagation 70 5.4.Experimental technique 71 5.5.Roadmap 74 5.6.Conclusion 76 6. MODELING AND VALIDATION 77 6.1.Introduction 77 6.2.Finite element modeling of the DCB test 77 6.2.1.Finite element model 78 6.2.2.Linear elastic analyses 78 6.2.3.Linear viscoelastic analyses 79 6.2.4.Js from finite element model 81 6.2.5.Mesh refinement study 82 6.3.Results and discussion 82 6.3.1.Linear elastic analyses 82 6.3.2.Linear viscoelastic analyses 87 6.3.3.Specimen dimension 87 6.4.Conclusion 88 7. ROOM TEMPERATURE DELAMINATION TOUGHNESS TESTING 89 7.1.Introduction 89 7.2.Specimen preparation and experimental setup 90 7.3.DCB Data reduction and experimental procedure 92 7.4.Results and discussion 95 7.5.Conclusion 99 8. ELEVATED TEMPERATURE AND MOISTURE TESTING 100 8.1.Introduction 100 8.2.Moisture conditioning chamber and high temperature furnace 100 8.3.DCB testing procedures 102 8.4.Results and discussion 104 8.4.1.Dry DCB tests at 98C 104 8.4.2.Moisture saturated tests at 98C 107 8.4.3.Dry DCB tests at 125C 110 v 8.4.4.Discussion 112 8.5.Conclusion 118 9. CONCLUSIONS AND RECOMMENDATIONS 120 9.1.Conclusion 120 9.2.Recommendation and future work 123 10. REFERENCES 125 11. APPENDICES 138 TABLES AND FIGURES 149 VITA 229 vi List of Tables Table 4.1 Typical elastic properties for unidirectional T800H/3900-2 graphite/epoxy laminate Table 4.2 Constant load level in creep tests Table 4.3 Linear viscoelastic properties of T800H/3900-2 at each condition Table 6.1. Material properties for elastic analyses Table 6.2. Material properties for viscoelastic analyses Table 8.1. DCB test matrix under high temperature Table A.1. Material properties in numerical simulation Table B.1. Geometries considered vii List of Figures Figure 2.1 Basic delamination modes. Figure 2.2 Schematic of the double cantilever beam (DCB) test. Figure 2.3 Definition of coordinate axes for a unidirectional specimen. Figure 3.1 Typical KI vs. a curve from a viscoelastic facture test. Figure 3.2 Schematic of crack geometry and cohesive zone. Figure 4.1 Cross-sectional view showing interlayer of a cured composite at (a) low magnification and (b) high magnification. Figure 4.2 4-point bending tests schematic drawing and test setup. Figure 4.3 Iosipescu in-plane shear test setup. Figure 4.4 Verification of linear viscoelasticity from creep-recovery tests. Figure 4.5 Storage modulus vs. temperature from DMA tests of dry T800H/3900-2: (a) DMA-dry1; (b) DMA-dry2. Figure 4.6 Storage modulus vs. temperature from DMA tests of wet T800H/3900-2: (a) DMA-wet1; (b) DMA-wet2. Figure 4.7 Shear strain from two stress levels at T=208F of wet T800H/3900-2 specimen. Figure 4.8 S22(t) of T800H/3900-2 at different conditions. Figure 4.9 S66(t) of T800H/3900-2 at different conditions. Figure 5.1 (a) Experimental indirect angle measurement (b) geometry of “L” shape loading blocks. Figure 6.1 Typical FE mesh for DCB analyses. Figure 6.2 Percent error of Js to J vs. end rotation angle for the Gr/Ep DCB specimen with various thicknesses and crack lengths. Figure 6.3 Percent error of Js to J vs. end rotation angle for the Gl/Ep and the isotropic DCB specimen with various crack lengths and thickness of 4mm. Figure 6.4 Evaluation of Js for models with adhesive. Figure 6.5 Evaluation of Js for models with different size of loading blocks. Figure 6.6 Comparison of J between proposed material model and ABAQUS default material model for isotropic materials. viii Figure 6.7 Evaluation of Js for orthotropic linear viscoelastic materials. Figure 7.1 Electrical circuits of crack propagation gage. Figure 7.2 DCB test setup. Figure 7.3 Typical load-deflection curve for a DCB test of T800H/3900-2 at room temperature. Figure 7.4 Delamination mechanism of T800H/3900-2 at room temperature (a) fracture surface view; (b) Schematic of crack growth path. Figure 7.5 Critical Js of T800H/3900-2 at room temperature from multiple specimens. Figure 7.6 Fracture toughness by CC method of T800H/3900-2 at room temperature. Figure 7.7 Fracture toughness by MWLO method of T800H/3900-2 at room temperature. CC MWLO Figure 7.8 Comparison of Js, GIC and GIC of T800H/3900-2 at room temperature. MWLO CC Figure 7.9 Percent error of GIC to GIC of T800H/3900-2 at room temperature. CC Figure 7.10 Percent error of Js to GIC of T800H/3900-2 at room temperature. MWLO Figure 7.11 Percent error of Js to GIC of T800H/3900-2 at room temperature. Figure 7.12 Typical load-deflection curve of IM7/8551-7 DCB test at room temperature. CC MWLO Figure 7.13 Js, GIC , and GIC of IM7/8551-7 DCB specimens. Figure 7.14 Percent error of fracture toughness from different methods for IM7/8551-7 DCB specimens. Figure 8.1 Humidity system setup and schematic of flow cycles. Figure 8.2 Typical moisture content with time for T800H/3900-2 specimens. Figure 8.3 Typical output from one crack gage: (a) voltage output (b) crack speed. Figure 8.4 Tele-Microscope System (TMS) and a sample image. Figure 8.5 Typical load-deflection curve of T800H/3900-2 dry DCB specimen at 98C.
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