Craze Initiation in Glassy Polymer Systems
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Craze initiation in glassy polymer systems MT02.002 O.F.J.T Bressers Master report Supervisors: dr. ir. J.M.J. den Toonder Philips Research ir. H.G.H. van Melick TU/e dr. ir. L.E. Govaert TU/e prof. dr. ir. H.E.H. Meijer TU/e Summary This report deals with the numerical simulation of craze initiation in amorphous polymer systems. The approach is based on the view that the development of a craze is preceded by de formation of a localised plastic deformation zone. As this zone develops, the hydrostatic stress increases, and, when exceeding a critical stress level, cavitation will take place leading to local development of voids. The voids grow, coalesce and the ligaments between the voids are subsequently super-drawn leading to the typical structure of a craze: a crack-like defect bridged by highly drawn filaments. In Part 1 a critical hydrostatic stress is examined as a cavitation criterion for polymers in a well-defined experiment. A micro indenter with a 150 m sapphire sphere produces reproducible indents, which are later examined with an optical microscope. These observations lead to a critical force where crazes are initiated in polystyrene (PS). Combination of these experiments with a numerical study using the compressible Leonov-model showed that the loading part of the indentation can be accurately predicted. A critical hydrostatic stress of 39MPa is extracted from the numerical model by analysis of the local stress field at the moment the indentation force reaches the experimentally determined force level at which crazes were found to initiate. This criterion is validated by application of the model to indentations on samples with different thermal histories, and at various loading rates. Varying the network density of the polymer showed that the incline of hydrostatic stress during indentation is not influenced. At higher network density, the samples started to craze at higher forces and the corresponding hydrostatic stress is higher. The cavitation criterion, validated in Part 1, is subsequently applied in Part 2 to analyse the temperature dependence of the deformation behaviour of a heterogeneous Polystyrene/void structure. The material parameters are extracted from compression tests at different temperatures and then applied to the numerical model, the RVE. Firstly, it is shown that at low temperatures the deformation of the RVE is more local whereas at high temperatures the deformation is more global. This is rationalised by the decrease of the strain softening with increasing temperature. Secondly, it is shown that application of the cavitation criterion yields a macroscopic brittle-to-ductile transition at a temperature between the 333K and 353K. The indentation on thin PS films is described in Part 3. Thin films are made on a glass plate using a spin coat device. The layer thickness varies from 20nm up to 28 m, the solvent of the thick films is eliminated in three days in the oven. The films are indented with a micro indenter and a nano indenter. Small differences occurred between both indenters. The indentations are also simulated with a numerical model. The thick films are simulated well. The experiments on the small films however showed a difference with the simulations. Especially the first tenth of nanometers of the indentation deviate strongly. The deviation appears to be related to the boundary conditions on the polystyrene/glass interface. ii iii Contents General introduction 1 Part 1 : Cavitation initiation of amorphous polymers 3 Abstract 3 Introduction 4 Experimental 7 Materials 7 Experimental set-up 7 Numerical methods 8 Material model 8 FEM model 10 Material characterisation 11 Identification of a cavitation initiation criterion 14 Annealed reference sample 14 Thermal history 17 Influence of the loading rate 18 Network density 19 Conclusions 20 References 21 Part 2 : Numerical prediction of a temperature-induced brittle-to- ductile transition in polystyrene 23 Abstract 23 Introduction 24 Experimental and numerical methods 25 Results 28 Uniaxial tensile tests 28 Large strain deformation of a RVE 29 Conclusion 32 References 33 Part 3 : Indentation on thin films 35 Introduction 35 Experimental and numerical modelling 36 Experimental 36 Numerical modelling 38 Results 39 Conclusion 41 References 41 Appendix A 43 Appendix B 45 iv v General introduction This report deals with the numerical simulation of craze initiation in amorphous polymer systems. The approach is based on the view that the development of a craze is preceded by de formation of a localised plastic deformation zone. As this zone develops, the hydrostatic stress increases, and, when exceeding a critical stress level, cavitation will take place leading to local development of voids. The voids grow, coalesce and the ligaments between the voids are subsequently super-drawn leading to the typical structure of a craze, a crack-like defect bridged by highly drawn filaments. It is well known that the initiation and development of a localised plastic zone is dominated by the post-yield characteristics of the material. In the case of amorphous glasses, the post-yield behaviour is governed by two phenomena: 1) strain softening, leading to the initiation of strain localisation, and 2) strain hardening, which stabilises the growth of the localised plastic zone. Subtle variations in the amount of strain softening or strain hardening can lead to extreme changes in the macroscopic deformation behaviour, changing the failure mode from tough to brittle. Over the past 15 years several constitutive models were developed that are able to describe this complex post-yield behaviour, enabling us to numerically simulate localisation phenomena in glassy polymers. Up till now, however, two factors hamper the adequate analysis of the stability of the deformation zone: 1) the absence of a validated criterion that can be used to detect incipient cavitation, and 2) the limited knowledge of the influence of ligament size on the intrinsic material properties. It are exactly these problems that are addressed in the present work. The study consists of three parts. In Part 1 an approach with indentation is used to find, and validate, a cavitation criterion for polystyrene. Subsequently the influence of network density on the resistance against cavitation is investigated. The cavitation criterion, validated in Part 1, is subsequently applied in Part 2 to analyse the temperature dependence of the deformation behaviour of a heterogeneous polystyrene/void structure. In addition, indentation is used to investigate the mechanical behaviour of thin PS films. The results are presented in Part 3. At low layer thickness of films the material behaviour is different from bulk material. The layers are spin-coated on glass and then indented with a micro indenter and a nano indenter. Experimental results are compared to results from numerical models. 1 2 Part 1 Craze initiation in glassy polymers: Influence of thermal history, loading rate and network density O.F.J.T. Bressers 1,2, H.G.H van Melick 1, L.E. Govaert 1, J.M.J. den Toonder 2, H.E.H. Meijer 1 1 Dutch Polymer Institute (DPI), Materials Technology (MaTe), Eindhoven University of Technology, P.O. Box 513, 5600 MB Eindhoven, The Netherlands 2 Philips Research Laboratories Eindhoven, Prof. Holstlaan 4, 5656 AA Eindhoven, The Netherlands Abstract In this work a method is presented that can be used to predict craze initiation in glassy polymers. The approach is based on the view that the development of a craze is preceded by de formation of a localised plastic deformation zone. As this zone develops, the hydrostatic stress increases, and, when exceeding a critical stress level, cavitation will take place, leading to local development of voids. The initiation of a localised plastic zone is numerically simulated using a constitutive model that incorporates an accurate description of the post-yield behaviour with the important phenomena of strain softening and strain hardening. Subsequent cavitation of the deformation zone is detected using a hydrostatic stress criterion. This criterion is identified and validated by confronting numerical simulations to experimental results of indentation experiments on polystyrene. A micro-indenter with a sapphire sphere of 150 m radius is used to produce indents that are later examined with an optical microscope. These observations lead to a critical force where crazes are initiated in polystyrene (PS). Combination of these experiments with a numerical study using the numerical model shows that the loading part of the indentation can be accurately predicted. A critical hydrostatic stress of 39MPa is extracted from the numerical model by analysis of the local stress field at the moment the indentation force reaches the experimentally determined force level at which crazes were found to initiate. This criterion is validated by application of the model to indentations on samples with different thermal histories, and at various loading rates. The influence of network on the value of the hydrostatic stress criterion is investigated by indentation of blends of polystyrene and poly(2,6-dimethyl-1,4-phenylene-oxide). It is shown that the critical hydrostatic stress increases with network density. 3 Introduction Macroscopic brittle fracture of glassy polymers is normally preceded by the formation of crazes, small crack-like defects, bridged by super-drawn fibrils. As a result of these fibrils, crazes have, unlike real cracks, a considerable load-bearing capacity and when viewed on a microscopic level, they display large plastic deformations. For this reason, crazes are the most important source of fracture toughness in brittle glassy polymers, even though the volume fraction crazes during fracture is generally low. It is, therefore, not surprising that a vast amount of research has been done on all aspects of crazing: craze nucleation, growth and failure, the micro-structure of crazes, the influence of molecular parameters, etc., and a number of excellent reviews are available [1-3]. Figure 1 depicts some of the microscopic events that are likely to be involved in craze nucleation [1].