The role of the interface in foam-bearing glass-epoxy composites subjected to impact loading

foam, either stacked together as three layers (MC) or inserted at three different positions (3L) while arranging the stacking sequence during the fabrication of glass fiber-epoxy composites, form the subject of investigation. This stacking variation resulted in a different interfacial area between these foam materials and the glass-epoxy regions in the laminates. This area in designed to be maximum for the 3L variety. The energy of impact being high enough to cause development of the crack in the samples, how the change in interfacial area affects the traverse of the crack front and the failure feature of the laminated composite are reported in the form of photomacrographs in this work. The results point to significant changes for the impact data, like for instance the peak load attained by the different samples, through thickness crack propagation and tensile fracture features on the non-impacted end for the plain variety, separation about the mid-zone for the MC laminates and two or more layer separations for the 3L variety. The separation for the foam-bearing systems occur invariably at the interface and here again one of the (two identical) interfaces only is chosen for the separation.

Modelling of a patch repair to a thin cracked sheet

Integrity enhancement of damaged or design deficient structures through repairs is attracting considerable engineering attention. Bonded composite patch repairs to cracked metallic sheets offer various advantages over riveted doubler type, particularly for airframe applications. This paper first reviews the R&D activity in the area of structural repairs. It then approaches the problem of a composite patch repair to a cracked aluminium sheet with different finite element modelling strategies and compares their outcome. The efficient finite element modelling approach thus established is used to study the effect of patch material, patch size, patch symmetry and adhesive thickness on repair performance as the crack grows in the repair configuration. (C) 1999 Elsevier Science Ltd. All rights reserved.

Numerical simulations of fracture initiation in ductile solids under mode I, dynamic loading

In this paper, an overview of some recent computational studies by the authors on ductile crack initiation under mode I, dynamic loading is presented. In these studies, a large deformation finite element procedure is employed along with the viscoplastic version of the Gurson constitutive model that accounts for the micro-mechanical processes of void nucleation, growth and coalescence. A three-point bend fracture specimen subjected to impact, and a single edge notched specimen loaded by a tensile stress pulse are analysed. Several loading rates are simulated by varying the impact speed or the rise time and magnitude of the stress pulse. A simple model involving a semi-circular notch with a pre-nucleated circular hole situated ahead of it is considered. The growth of the hole and its interaction with the notch tip, which leads to plastic strain and porosity localization in the ligament connecting them, is simulated. The role of strain-rate dependence on ductile crack initiation at high loading rates, and the specimen geometry effect on the variation of dynamic fracture toughness with loading rate are Investigated.

On the characterisation of syntactic foam core sandwich composites for compressive properties

Sandwich structures, especially those with honeycomb and grid structures as the core material, are very commonly employed in aircraft structures. There is an increasing use of closed-pore rigid syntactic foams as core materials in sandwich constructions because they possess a number of favourable properties. The syntactic foams, owing to their structure and formation, behave differently under compression compared to other traditionally used core materials. In the present study, therefore, syntactic foam core sandwich constructions are evaluated for their behaviour under compression in both edgewise and flatwise orientations. Further, the work characterises the relative performance of two sets of sandwich materials, one containing glass-epoxy and the other, glass/carbon hybrid-epoxy skins. As non-standard geometry test specimens were involved, only a comparative evaluation was contemplated in this approach. The experiments indicate that the nature of the reinforcement fabric in the skin has a bearing on the test results in edgewise orientation. Thus, the tendency towards initiation of vertical crack in the central plane of the core material, which is a typical fracture event in this kind of material, was found to occur after a delay for the specimens containing the glass fabric in the skin. Attempts are made to establish the correlation between observations made on the test specimen visually during the course of testing and the post-compression microscopic examinations of the fracture features.

Residual strength and fatigue life assessment of composite patch repaired specimens

Design, analysis and technology for the integrity enhancement of damaged or underdesigned structures continues to be an engineering challenge. Bonded composite patch repairs to metallic structures is receiving increased attention in the recent years. It offers various advantages over rivetted doubler, particularly for airframe repairs. This paper presents an experimental investigation of residual strength and fatigue crack-growth life of an edge-cracked aluminium specimen repaired using glass epoxy composite patch. The investigation begins with the evaluation of three different surface treatments from bond strength viewpoint. A simple thumb rule formula is employed to estimate the patch size. Cracked and repaired specimens are tested under static and fatigue loading. The patch appears to restore the original strength of the undamaged specimen and enhance the fatigue crack growth life by an order of magnitude. (C) 1999 Elsevier Science Ltd. All rights reserved.

Sliding wear of copper against alumina

OFHC copper pins with 10 ppm oxygen were slid against alumina at a load of 50 N and sliding speeds of 0.1 ms(-1) to 4.0 ms(-1) The wear characteristics of copper were related to the strain rate response of copper under uniaxial compression between strain rates of 0.1 s(-1) and 100 s(-1) and temperatures in the range of 298 K to 673 K. It is seen that copper undergoes flow banding at strain rates of 1 s(-1) up to a temperature of 523 K, which is the major instability in the region tested. These flow bands are regions of crack nucleation. The strain rates and temperatures existing in the subsurface of copper slid against alumina are estimated and superimposed on the strain rate response map of copper. The superposition shows that the subsurface of copper slid at low velocities is likely to exhibit flow band instability induced cracking. It is suggested that this is the,reason for the observed high wear rate at low velocities. The subsurface deformation with increasing velocity becomes more homogeneous. This reduces the wear rate. At velocities >2 ms(-1) there is homogenous flow and extrusion of thin (10 mu m) bands of material out of the trailing edge. This results in the gradual increase of wear rate with increasing velocity above 2.0 ms(-1).

Studies on indentation fracture toughness on ceramic and ceramic composite using acoustic emission technique

This paper is aimed at investigating the acoustic emission activities during indentation toughness tests on an alumina based wear resistant ceramic and 25 wt% silicon carbide whisker (SIC,) reinforced alumina composite. It has been shown that the emitted acoustic emission signals characterize the crack growth during loading. and unloading cycles in an indentation test. The acoustic emission results indicate that in the case of the composite the amount of crack growth during unloading is higher than that of loading, while the reverse is true in case of the wear resistant ceramics. Acoustic emission activity observed in wear resistant ceramic is less than that in the case of composite. An attempt has been made to correlate the acoustic emission signals with crack growth during indentation test.

Influence of interface properties on fracture behaviour of concrete

Hardened concrete is a three-phase composite consisting of cement paste, aggregate and interface between cement paste and aggregate. The interface in concrete plays a key role on the overall performance of concrete. The interface properties such as deformation, strength, fracture energy, stress intensity and its influence on stiffness and ductility of concrete have been investigated. The effect of composition of cement, surface characteristics of aggregate and type of loading have been studied. The load-deflection response is linear showing that the linear elastic fracture mechanics (LEFM) is applicable to characterize interface. The crack deformation increases with large rough aggregate surfaces. The strength of interface increases with the richness of concrete mix. The interface fracture energy increases as the roughness of the aggregate surface increases. The interface energy under mode II loading increases with the orientation of aggregate surface with the direction of loading. The chemical reaction between smooth aggregate surface and the cement paste seems to improve the interface energy. The ductility of concrete decreases as the surface area of the strong interface increases. The fracture toughness (stress intensity factor) of the interface seems to be very low, compared with hardened cement paste, mortar and concrete.

A finite element assessment of flexural strength of prestressed concrete beams with fiber reinforcement

This paper presents an assessment of the flexural behavior of 15 fully/partially prestressed high strength concrete beams containing steel fibers investigated using three-dimensional nonlinear finite elemental analysis. The experimental results consisted of eight fully and seven partially prestressed beams, which were designed to be flexure dominant in the absence of fibers. The main parameters varied in the tests were: the levels of prestressing force (i.e, in partially prestressed beams 50% of the prestress was reduced with the introduction of two high strength deformed bars instead), fiber volume fractions (0%, 0.5%, 1.0% and 1.5%), fiber location (full depth and partial depth over full length and half the depth over the shear span only). A three-dimensional nonlinear finite element analysis was conducted using ANSYS 5.5 [Theory Reference Manual. In: Kohnke P, editor. Elements Reference Manual. 8th ed. September 1998] general purpose finite element software to study the flexural behavior of both fully and partially prestressed fiber reinforced concrete beams. Influence of fibers on the concrete failure surface and stress-strain response of high strength concrete and the nonlinear stress-strain curves of prestressing wire and deformed bar were considered in the present analysis. In the finite element model. tension stiffening and bond slip between concrete and reinforcement (fibers., prestressing wire, and conventional reinforcing steel bar) have also been considered explicitly. The fraction of the entire volume of the fiber present along the longitudinal axis of the prestressed beams alone has been modeled explicitly as it is expected that these fibers would contribute to the mobilization of forces required to sustain the applied loads across the crack interfaces through their bridging action. A comparison of results from both tests and analysis on all 15 specimens confirm that, inclusion of fibers over a partial depth in the tensile side of the prestressed flexural structural members was economical and led to considerable cost saving without sacrificing on the desired performance. However. beams having fibers over half the depth in only the shear span, did not show any increase in the ultimate load or deformational characteristics when compared to plain concrete beams. (C) 2002 Published by Elsevier Science Ltd.

Constraint loss under dynamic loading in rate independent plastic solids

The objectives of this paper are to examine the loss of crack tip constraint in dynamically loaded fracture specimens and to assess whether it can lead to enhancement in the fracture toughness at high loading rates which has been observed in several experimental studies. To this end, 2-D plane strain finite element analyses of single edge notched (tension) specimen and three point bend specimen subjected to time varying loads are performed. The material is assumed to obey the small strain J(2) flow theory of plasticity with rate independent behaviour. The results demonstrate that a valid J-Q field exists under dynamic loading irrespective of the crack length and specimen geometry. Further, the constraint parameter Q becomes strongly negative at high loading rates, particularly in deeply cracked specimens. The variation of dynamic fracture toughness K-dc with stress intensity rate K for cleavage cracking is predicted using a simple critical stress criterion. It is found that inertia-driven constraint loss can substantially enhance K-dc for (K) over dot > 10(5) MPa rootm/s.

Critical stress intensity factors for cracked hollow pipes under transient thermal loads

Finite element analyses of a long hollow cylinder having an axisymmetric circumferential internal edge crack, subjected to convective cooling on the inner surface are performed. The transient thermal stress intensity factor is estimated using a domain version of the J-integral method. The effect of the thickness of the cylinder, crack length, and heat transfer coefficient on the stress intensity factor history are studied. The variations of critical normalized stress intensity factor with crack length-to-thickness ratio for different parameters are presented. The results show that if a small inner surface crack begins to grow, its stress intensity factor will increase with increase in crack length, reach a maximum, and then begin to drop. Based on the results, a fracture-based design methodology for cracked hollow pipes under transient thermal loads is discussed.

Modeling of concrete cracking-A hybrid technique of using displacement discontinuity element method and direct boundary element method

This paper presents a new approach by making use of a hybrid method of using the displacement discontinuity element method and direct boundary element method to model concrete cracking by incorporating fictitious crack model. Fracture mechanics approach is followed using the Hillerborg's fictitious crack model. A boundary element based substructure method and a hybrid technique of using displacement discontinuity element method and direct boundary element method are compared in this paper. In order to represent the process zone ahead of the crack, closing forces are assumed to act in such a way that they obey a linear normal stress-crack opening displacement law. Plain concrete beams with and without initial crack under three-point loading were analyzed by both the methods. The numerical results obtained were shown to agree well with the results from existing finite element method. The model is capable of reproducing the whole range of load-deflection response including strain-softening and snap-back behavior as illustrated in the numerical examples. (C) 2011 Elsevier Ltd. All rights reserved.

Influence of martensite content and morphology on the toughness and fatigue behavior of high-martensite dual-phase steels

A series of high-martensite dual-phase (HMDP) steels exhibiting a 0.3 to 0.8 volume fraction of martensite (V m ), produced by intermediate quenching (IQ) of a vanadium and boron-containing microalloyed steel, have been studied for toughness and fatigue behavior to supplement the contents of a recent report by the present authors on the unusual tensile behavior of these steels. The studies included assessment of the quasi-static and dynamic fracture toughness and fatigue-crack growth (FCG) behavior of the developed steels. The experimental results show that the quasi-static fracturetoughness (K ICV ) increases with increasing V m in the range between V m =0.3 and 0.6 and then decreases, whereas the dynamic fracture-toughness parameters (K ID , K D , and J ID ) exhibit a significant increase in their magnitudes for steels containing 0.45 to 0.60 V m before achieving a saturation plateau. Both the quasi-static and dynamic fracture-toughness values exhibit the best range of toughnesses for specimens containing approximately equal amounts of precipitate-free ferrite and martensite in a refined microstructural state. The magnitudes of the fatigue threshold in HMDP steels, for V m between 0.55 and 0.60, appear to be superior to those of structural steels of a similar strength level. The Paris-law exponents (m) for the developed HMDP steels increase with increasing V m , with an attendant decrease in the pre-exponential factor (C).

Influence of matrix characteristics on fracture toughness of high volume fraction Al2O3/Al–AlN composites

The role of matrix microstructure on the fracture of Al-alloy composites with 60 vol% alumina particulates was studied. The matrix composition and microstructure were systematically varied by changing the infiltration temperature and heat treatment. Characterization was carried out by a combination of metallography, hardness measurements, and fracture studies conducted on compact tension specimens to study the fracture toughness and crack growth in the composites. The composites showed a rise in crack resistance with crack extension (R curves) due to bridges of intact matrix ligaments formed in the crack wake. The steady-state or plateau toughness reached upon stable crack growth was observed to be more sensitive to the process temperature rather than to the heat treatment. Fracture in the composites was predominantly by particle fracture, extensive deformation, and void nucleation in the matrix. Void nucleation occurred in the matrix in the as-solutionized and peak-aged conditions and preferentially near the interface in the underaged and overaged conditions. Micromechanical models based on crack bridging by intact ductile ligaments were modified by a plastic constraint factor from estimates of the plastic zone formed under indentations, and are shown to be adequate in predicting the steady-state toughness of the composite.

Fracture and R-curves in high volume fraction Al2O3/Al composites

Fracture toughness and fracture mechanisms in Al2O3/Al composites are described. The unique flexibility offered by pressureless infiltration of molten Al alloys into porous alumina preforms was utilized to investigate the effect of microstructural scale and matrix properties on the fracture toughness and the shape of the crack resistance curves (R-curves). The results indicate that the observed increment in toughness is due to crack bridging by intact matrix ligaments behind the crack tip. The deformation behavior of the matrix, which is shown to be dependent on the microstructural constraints, is the key parameter that influences both the steady-state toughness and the shape of the R-curves. Previously proposed models based on crack bridging by intact ductile particles in a ceramic matrix have been modified by the inclusion of an experimentally determined plastic constraint factor (P) that determines the deformation of the ductile phase and are shown to be adequate in predicting the toughness increment in the composites. Micromechanical models to predict the crack tip profile and the bridge lengths (L) correlate well with the observed behavior and indicate that the composites can be classified as (i) short-range toughened and (ii) long-range toughened on the basis of their microstructural characteristics.