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Effects of layer waviness on the compression

fatigue performance of thermoplastic


composite laminates
Daniel O'Hare Adams* and M. W. Hyert
*Department of Aerospace Engineering and Engineering Mechanics, Iowa State
University, Ames, Iowa 50011, USA
tDepartment of Engineering Science and Mechanics, Virginia Polytechnic Institute
and State University, Blacksburg, Virginia 24061, USA
(Received 14 May 1993; revised 9 July 1993)
The influence of layer waviness on the compression fatigue response of carbon/polysulphone composite
laminates was studied. Specimens with a moderate level of layer waviness as well as wave-free
control specimens were cycled to failure at a variety of maximum stress levels to establish S - N curves.
A one and a half decade loss of compression fatigue life was observed for moderate layer wave
specimens as compared with the control specimens. Brooming failure, characterized by through-thethickness splaying of the layers and by numerous delaminations, was the common failure mode. The
stress level corresponding to the 106 cycle run-out for these layer wave specimens was reduced to
approximately 45% of the static compression strength of the wave-free laminate, as compared with a
reduction to 75% for the control specimens. Moderate layer wave specimens cycled to the 106 cycle
run-out showed no evidence of delamination in the vicinity of the layer wave. Specimens with a mild
layer wave failed in the grips away from the wave and exhibited fatigue life comparable to the wavefree specimens.
(Keywords: defects; compression; thermoplastic)

Layer waviness is a manufacturing imperfection most


commonly observed in thick-section composite laminates. This imperfection is characterized by the outof-plane undulation of a layer or a group of layers within
a multidirectional laminate. While most commonly
observed in cylindrical structures, layer waviness has
also been found in thick, flat laminates. The causes
of layer waviness have in some cases been identified,
and the degree of waviness reduced by altering the
manufacturing process. However, in many applications,
some degree of layer waviness remains and must be
tolerated within the composite structure.
Layer waviness has been shown to reduce significantly the static compression strength of composite
laminates. Garala 1 tested 15 mm (0.6 in) thick carbon/
epoxy cylinders under external hydrostatic pressure
loading. In some cases failures well below the design
pressure were believed to be due to layer waviness.
Abdallah et aL E tested 25 mm (1.0 in) wide composite
tings under external hydrostatic pressure loading. The
lowest failure pressures and strains were associated
with rings containing the greatest degree of layer
waviness. Failure in these rings occurred at locations
of severe layer waviness. Gascoigne and Abdallah 3
further investigated the strain fields in the vicinity of
layer waviness using moir6 interferometry. Large
interlaminar shear strains, nonexistent in a wave-free
ring, were found near the layer wave inflection points.
Several investigators have accounted for waviness

in models for static compression strength. A majority


of the modelling efforts have focused on fibre waviness
in unidirectional composites 4-1. Swanson 11 modelled
inplane fibre waviness in multidirectional laminates by
including the lateral support offered by adjacent plies
in the laminate. Shuart 12'13 incorporated layer waviness
into a microbuckling model for multidirectional laminates. Both inplane and out-of-plane waviness was
considered. Peel et al. 14 extended this study to consider
additional out-of-plane layer wave configurations. Bogetti et al. 15.16 developed a laminated plate theory based
model to predict stiffness and strength reductions due
to layer waviness. Hyer and Brown 17 and Telegadas
and Hyer ls,19 investigated layer waviness effects in
thick crossply composite cylinders using finite element
analysis.
Although layer waviness effects on static compression
strength have received considerable attention, the
effects on compression fatigue performance have
not. However, compression fatigue testing has been
performed on composite laminates with other types of
stress concentrations, including ply drop-offs 2, impact
damage 21-23, and open holes 24-27. Slaughter and
FleckES developed microbuckling models for compression fatigue loading which include initial fibre
misalignment.
In a related publication, Adams and Hyer 29 reported
on the static compression testing of thermoplastic
composite laminates with an intentionally fabricated,

0142-1123/94/060385-07
1994 Butterworth-Heinemann Ltd

Fatigue, 1994, Vol 16, A u g u s t

385

Thermoplastic composite laminates: D. O'Hare Adams and M. W. Hyer


isolated layer wave. The laminate chosen was a 22 ply
[902/02/902/02/902/02w]S laminate with the layer wave
fabricated into the central 0 layer. The wavy layer is
designated as 02w, the overbar indicating this layer is
not repeated in the symmetric stacking sequence. A
three-step procedure was used to fabricate the isolated
layer wave into the composite laminates. Layer wave
geometries up to 1.5 layer thicknesses in amplitude
and as short as 9 layer thicknesses in length were
tested. The more severe wave geometries were shown
to produce reductions in static compression strength
as high as 35%, although the wavy 0 layer accounts
for only 20% of the load carrying capacity of the
laminate.
In the present study a similar methodology was
used to investigate the effects of layer waviness
on compression fatigue response. Specimens with a
moderate layer wave geometry were cycled to failure
at a variety of maximum stress levels to establish an
S-N curve for this particular level of layer waviness.
In addition, wave-free control specimens were used to
develop an S-N curve corresponding to the case of
no layer waviness. Thus, the reductions in compression
fatigue life associated with a specific layer wave
geometry were established. An overview of the results
of this study follows.
COMPRESSION FATIGUE TESTING
The wavy layer specimens were fabricated by the
method described in ref. 29. The fabrication of
specimens with a known and controlled level of
waviness is an interesting issue in its own right. The
reader is encouraged to consult ref. 29 for details.

Experimental setup
Compression fatigue testing on the wavy layer
was performed using a test fixture designed and
manufactured at NASA Langley Research Center 3.
This fixture, shown in Figure 1, consists of two massive
steel blocks with U-shaped cavities and which are
aligned by four rods and linear bearings. The compression fatigue specimen is placed between end
loading plates within the cavity of each block. The
thickness of each end loading plate is machined to be
slightly less than the specimen thickness. Gripping
surfaces on the rear of the cavities and on the two
cover plates are lightly serrated. Four bolts are used
to secure each cover plate. Thus, the ends of the
specimens are supported along a portion of their

AhgmHeli{t~)(ls

f
I.

100 mm

Figure 2 Compression fatigue test specimen configuration

length and loaded through the end loading plates. The


serrated gripping surfaces allow for limited load transfer
through shear-loading of the supported portions of the
specimen faces. In Figure 1 the top cover plate is in
place whereas the bottom cover plate is removed,
revealing the bottom end loading plate.
The specimen configuration used in compression
fatigue testing is shown in Figure 2. The 102 mm (4.0
in.) long by 25 mm (1.0 in.) wide specimens were cut
using a water-cooled diamond saw. Specimen ends
were cut as fiat and parallel as possible to ensure that
the compression load was introduced uniformly. The
layer wave was centred along the length of each
specimen. Use of 102 mm (4 in) long specimens
resulted in an unsupported gage length of 25 mm (1.0
in). With specimen thicknesses of approximately 4.3
mm (0.17 in), the length-to-thickness ratio for the
gauge section was less than 6. As a result buckling
was not an issue.
A total of nine 152 mm (6 in) square T300/P1700
laminates were fabricated, all of which were 22 ply
[902/02/902/02/902/02w]S laminates. Six laminates were
fabricated with layer waviness and three were fabricated
wave-free. All laminates were ultrasonically C-scanned
to ensure laminate quality prior to cutting into test
specimens.
The layer wave geometry was characterized separately for each specimen. The wavy region of each
specimen was photographed under a microscope at
low magnification. From photographic enlargements,
the wavelength, h, and wave amplitude, B, were
measured as shown in Figure 3. In this figure, t
denotes the thickness of the two-ply wavy layer (ca.
0.4 mm, 0.016 in). The layer wave 'severity' parameter
B/h was calculated for each specimen. Intuitively, a
more 'severe' wave implies a shorter wavelength, h,
coupled with a larger wave amplitude, B, and thus a
larger value of B/X.
The variation in wave geometries among the six
laminates was less than the variation obtained in the
laminates used for the static tests 29. In fact, layer
wave geometries with B/h ratios between 0.05 and
0.06, namely moderate waves, were produced in five
of the six laminates. A representative layer wave

SerrateO

gtlppmg
stlrface ,,

End

loading
plales

Cover
D~ates

Figure 1 Compression fatigue test fixture

386 Fatigue, 1994, Vol 16, August

jv
Figure 3 Definition of layer-wave geometry parameters

Thermoplastic composite laminates: D. O'Hare Adams and M. W. Hyer


Table 1 Compression fatigue test results from control specimens

Laminate Specimen

Figure

Cycles to
failure

Failure
location

1
2
3
4

552/80
552/80
586/85
586/85

297 886
183 507
18 734
1 846

Grip
Grip
Grip
Grip

1
2
3
4
5

586/85
483/70
517/75
483/70
448/65

448
372 009
9075
429 864
574091

Gauge section
Grip
Grip
Grip
Grip

1
2
3
4
5

552/80
483/70
414/60
517/75
448/65

18 248
19 783
1000 000
14784
43 285

Moderate layer-wave geometry

geometry from this group is shown in Figure 4. The


specimens from these laminates became the primary
group for the purpose of generating fatigue life (SN) data. The layer wave geometry in the remaining
laminate was much less severe, with a G/h ratio of
approximately 0.02. This layer wave geometry, referred
to as a mild wave, is shown in Figure 5. The specimens
from this laminate became the secondary group for
fatigue testing.
Testing was performed under load control using an
Instron servo-hydraulic load frame. Specimens were
placed in the fatigue fixture and preloaded with a
small compression load prior to installing the cover
plates. The four inner bolts were tightened to 81 N
m (60 ft lbs) whereas the outer bolts were tightened
to 41 N m (30 ft lbs). Displacement limits on the
actuator stroke of the test machine were set as tightly
as possible to avoid post-failure crushing of specimens.
All fatigue testing was performed with a stress ratio,
R, of 10. Thus, the maximum compression stress
during each loading cycle was 10 times the minimum
compression stress. Specimens were cycled at a frequency of 5 Hz using a sinusoidal waveform. This
cycling frequency resulted in only a 2C (4F) increase
in surface temperature of the specimen. All specimens
were cycled either to failure, or to 106 cycles, a value
which was considered a run-out in this study.
The static compression strength of the 22 ply [902/
02/902/02/902/02w]s laminate with no waves was determined using the IITRI compression test 29. Specimens
were cut from two additional laminates to the same
dimensions as those for compression fatigue testing.
However, glass/epoxy tabs were bonded to the IITRI
test specimens, resulting in a 25 mm (1.0 in) guage
length. Based on nine tests, the static compression
strength was determined to be 608 MPa (88.2 ksi).

Max. stress
(MPa/ksi)

Grip
Grip
Grip
Grip

each control specimen is presented in Table 1. These


results are presented as an S-N diagram in Figure 6.
The maximum applied stress, trmax, shown in Figure 6
is nondimensionalized by dividing by the average static
compression strength of laminates with no waves,
namely -608 MPa (-88.2 ksi). The numbers shown
with the data in Figure 6 correspond to the laminate
number from which the specimens were cut. Results
indicate a 106 cycle run-out strength of approximately
75% of the average static compression strength. As
can be seen, considerable scatter was present in the
data, partly due to laminate-to-laminate variations.
For example, specimens from laminate 1 showed
consistently better fatigue resistance than specimens
from laminates 2 and 3. Failures within a grip occurred
in all but one of the control specimens cycled to
failure.
Specimens with layer waviness were separated into
two groups for testing. The primary group, totalling
24 specimens from laminates 1 to 5, had G/h ratios
ranging from 0.05 to 0.06, the moderate wave geometry.
These specimens were cycled at maximum stress levels
ranging from -552 MPa ( - 8 0 ksi) to -276 MPa ( - 4 0
ksi) in an effort to produce failures in the range of
103 to 106 cycles. The secondary group, consisting of

Experimental results
A total of 44 specimens were tested in fatigue; 14
control specimens with no layer waviness and 30
specimens with layer waviness. The 14 control specimens were tested at maximum stress levels ranging
from -586 MPa ( - 8 5 ksi) to -414 MPa ( - 6 0 ksi) in
an effort to produce failures in the range of 103 to
106 cycles. The maximum applied compression stress
and the corresponding number of cycles to failure for

1 1

2 03
003

2W2
20
3 .-~-

033

0.8

.6

tatic/0.4

0.2
(Numbers: Laminate Number, Bracket: Range of Static Data)
. . . . . . . .

101

. . . . . . . .

102

. . . . . . . .

103

. . . . . . . .

. . . . . . . .

104

10 s

. . . . . . . .

10 s

. . . . . . .

107

N, number of cycles

Figure 5

Mild layer-wave geometry

Figure 6

Compression fatigue results of control specimens

Fatigue, 1994, Vol 16, August 387

Thermoplastic composite laminates: D. O'Hare Adams and M. W. Hyer


five specimens from laminate 6, had ~/h ratios of
approximately 0.02, the mild wave geometry. These
specimens were cycled at maximum stress levels ranging
from -552 MPa ( - 8 0 ksi) to -448 MPa ( - 6 0 ksi).
Results of compression fatigue testing for specimens
with layer waviness are presented in Table 2. The
layer wave severity parameter g/h, the maximum
compression stress, number of cycles to failure, and
location of failure is presented for each specimen. A
'wave' failure location refers to a failure within the
actual layer wave, whereas a 'grip' failure refers to a
failure beyond the gauge section, within the gripped
portions of the specimen. Generally, these grip failures
occurred within a short distance beyond the ends of
the gauge section. All but one specimen from the
primary group with moderate layer wave geometries
(specimens from laminates 1-5) failed at the location
of the layer wave. Four of the five specimens from
the secondary group with mild layer wave geometries
(specimens from laminate 6) failed in the grip. The
latter result indicates that this mild level of waviness was
of equal or less severity than the stress concentration
produced by the grips. Thus, the secondary group of
specimens was of limited use for assessing the effects
of the mild layer wave geometry (8/h = 0.02) on
compression fatigue life.
Results from the primary group of specimens with
moderate layer wave geometries are presented as an
S-N diagram in Figure 7. Once again, the number of
the laminate from which each specimen was cut is

Tabk 2 Compression fatigue test results ~om layer-waviness


specimens

Laminate Specimen

8/h

Max. stress Cycles to


(MPa ksi)
failure

Failure
location

1
2
3
4
5

0.051
0.053
0.054
0.052
0.053

552/55
552/60
586/50
586/70
547/79

241603
34907
199856
14605
1

Wave
Wave
Wave
Wave
Wave

1
2
3
4
5

0.054
0.053
0.053
0.055
0.051

586/40
483/70
517/80
483/60
448/70

1000000
67946
444
96641
551

Grip
Wave
Wave
Wave

1
2
3
4
5

0.055
0.055
0.054
0.053
0.050

552/50
483/60
414/80
517/65
448/60

219081
35812
33
14172
46068

Wave
Wave
Wave
Wave
Wave

1
2
3
4
5

0.053
0.058
0.059
0.054
0.051

552/60
483/40
414/60
517/50
448/70

316814
1000000
164323
762264
40556

Wave
Wave
Wave
Wave

1
2
3
4
5

0.044
0.052
0.055
0.056
0.056

552/70
483/50
414/80
517/70
448/60

20736
321993
120
5258
10367

Wave
Wave
Wave
Wave
Wave

1
2
3
4
5

0.020
0.019
0.018
0.020
0.022

552/80
483/70
414/75
517/70
448/60

52
494 792
288 086
147 963
925 664

Wave
Grip
Grip
Grip
Grip

388

Fatigue, 1994, Vol 16, August

3zxr-i5Z~ 2~.
2
,0,

0.8

0 0

3,~

0244

133

(.%~_, o 6

1A

laave I

\static/0. 4

Mild
Layer
Wave
10.05
<8/)~<
0.06 IJ Layer
~ Wave
=0.0~

24

Moderate

0.2

Fatiguel
Static (ave.) I

z~

I
I

I C7

rol

(NumbersIndicateLaminateNumber)
......

_1

101

......

.i

102

......

_1

103

. . . . .

..i

......

_1

104
105
N, number of cycles

ml ...-I

10 s

Ill''"

107

Figure 7 Compression fatigue results of control and layer-wave


specimens

indicated. Results from the control specimens and the


secondary group of specimens with mild layer wave
geometries are presented for comparison. The average
static compression strength from two specimens with
values of 8/h between 0.05 and 0.06 that failed at the
layer wave is also shown on the diagram (solid
triangle). Results clearly show a reduction in the
compression fatigue life due to the moderate layer
wave. Relative to the control specimens, a one and a
half decade loss of fatigue life was observed in the
range of 103 to 106 cycles. The 106 cycle strength of
the specimens with moderate layer waviness was
reduced to approximately 45 % of the static compression
strength of the control specimens. Once again, a
considerable amount of scatter was seen in the data,
due in part to laminate-to-laminate variations. The
greatest fatigue life was associated with specimens
from laminate 4, whereas specimens from laminate 1
exhibited below average fatigue life. The secondary
group of layer wave specimens with mild layer wave
geometries experienced fatigue life comparable to the
control specimens. Again, this result suggests that the
presence of the mild layer wave was no worse than
the influence of the grips.
Two failure modes were observed in the compression
fatigue specimens, each mode corresponding to a
different failure location. Specimens failing at the
location of the layer wave experienced a brooming
mode, as shown in Figure 8. These failures were
characterized by through-the-thickness splaying of the
layers and numerous delaminations. The actual degree
of out-of-plane brooming varied greatly among specimens, and was believed to be dependent on the
amount of post-failure actuator motion of the load
frame and subsequent crushing of the specimen prior
to stoppage. An angled fracture surface through the
thickness was observed in nearly all of the failed
specimens. These fracture surfaces were found to have
preferred orientations, passing through an inflection
point of the wavy layer and angling away from the
central wave trough, as illustrated in Figure 9. In most
specimens, each 0 layer was fractured in only one
location. Specimen failure at the location of the layer
wave was sudden and catastrophic. In no instance was

Thermoplastic composite laminates: D. O'Hare Adams and M. W. Hyer

Figure 8 Post-test condition of moderate layer-wave specimen

Figure 9 Preferred angular orientations of failure planes in layer-

wave specimens

the initiation of failure detected audibly, visually, or


by actuator stroke or load limits such that testing
could be stopped and the specimen examined for
failure initiation. Therefore, the sequence of events
leading to final failure could not be readily determined.
Only inferences were possible based on post-failure
observation of specimens, particularly those specimens
displaying a minimal degree of brooming. However,
no consistent similarities in delamination patterns
existed among the relatively few specimens which
experienced limited brooming.
The remaining layer wave specimens, and all but
one control specimen, failed within the grip and
experienced a failure mode consisting of localized
buckling of each of the 0 layers. The buckled 0
layers formed angled fracture bands through the
thickness of the specimen, as shown in Figure 10. In
some instances, a single fracture band (Figure lOa)
within the grip produced a detectable increase in the
actuator stroke during testing, exceeding the stroke
limit and stopping the test. In other specimens,
subsequent fracture bands appear to have formed
within the grip region (Figure lOb). If loading was
not stopped prior to the fracture bands reaching the
unsupported gauge section, a brooming failure occurred
at the edge of the grip, as shown in Figure 10c.
Six specimens failing within the grip, three layer
wave specimens and three control specimens, and the
three I06 cycle run-out specimens were subsequently
X-rayed to investigate the extent of damage. These
specimens were treated with a zinc iodide penetrant
prior to X-ray to enhance damage detection. Internal
damage regions reached by the penetrant produced
dark regions in the photographs. Results from Xraying the six specimens failing within the grip are

Figure 10 Post-testcondition of specimens failing at the grip: (a)


single failure band; (b) multiple failure bands; (c) multiple failure
bonds, brooming failure

presented in Figure 11. The grip region failures,


characterized by dark bands extending across the width
of the specimen, are clearly visible in each specimen.
Each distinct band corresponded to a localized buckling
failure within one of the 0 layers. For the three wavy
layer specimens which failed at the grip, there was no
evidence of damage in the gauge section as a result
of the layer wave. Thus it would appear that failure
in the wavy region, when it does occur, is sudden and
is not preceded by damage accumulation. Results from
X-raying the three 106 cycle run-out specimens, two
layer wave specimens and one control specimen, are
presented in Figure 12. No evidence of failure initiation
was seen in any of these three specimens either. The
two layer wave specimens showed no visual evidence
of delamination or other damage in the vicinity of the
layer wave.
In all nine of the specimens X-rayed, sets of thin
parallel lines were observed both perpendicular and
parallel to the loading direction. These lines were
subsequently determined to be transverse cracks within
the individual layers of the laminate. Transverse crack
densities in the 90 layers (perpendicular to the loading
direction) were noticeably higher than in the 0 layers
(parallel to the loading direction). The presence of
the layer wave did not appear to affect the crack
density.

Fatigue, 1994, Vol 16, August 389

Thermoplastic composite laminates: D. O'Hare Adams and M. W. Hyer

Grip region

Gauge section

Grip region

372 009

19 783

14 784

Control specimens

.... - ~

67 946
~

5258

I 0 367

Layer wave specimens

Numbers indicate cycles to failure


Figure 11 X-ray results for specimens exhibiting grip failure

on the results of the study, the reader is referred to


ref. 31.
~:~, Grip region

ACKNOWLEDGEMENTS

Gauge section

This work was supported by the Virginia Institute for


Material Systems, the Cunningham Fellowship Program
at Virginia Tech, and Office of Naval Research Grant
N00614-90-J-1688, the University Research Initiative
Program. The financial support of these sources is
appreciated.

Grip region

REFERENCES
1

Control
specimen

Layer wave specimens

Figure 12 X-ray results for run-out specimens (10~ cycles)

CONCLUSIONS
Compression fatigue specimens fabricated from T300/
P1700 and with moderate layer waves (8/k ratios
between 0.05 and 0.06) exhibited a one and a half
decade loss of compression fatigue life as compared
with specimens without layer waviness. The stress
level corresponding to the 106 cycle run-out for these
layer wave specimens was reduced to approximately
45% of the static compression strength of the wavefree laminate. Compression fatigue specimens with
moderate layer waves failed at the location of the
layer wave in a sudden, undetected manner. Brooming
failure, characterized by through-the-thickness splaying
of the layers and by numerous delaminations, was the
common failure mode. Specimens with a mild layer
wave (8/k = 0.02) failed in the grips and exhibited
fatigue life comparable to the control specimens. Layer
wave specimens cycled to the 106 cycle run-out showed
no evidence of damage accumulation or delamination
in the vicinity of the layer wave. For more information

390 Fatigue, 1994, Vol 16, August

4
5
6

8
9
10
11
12

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Fatigue, 1994, Vol 16, August 391

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