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MEMORANDUM

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(NASA-TM-X-73545) HYBRID COMPOSITES,

STATE-OF-THE-ART REVIEW: ANALYSIS, DESIGN,
APPLICATION AND FABRICATION {NASA) 54 p HC
CSCL 11D
A04/MF A01

N77-18215
Unclas
G3/24 172.05.

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HYBRID COMROSITES -STATE-OF-THE-ART REVIEW: ANALYSIS;

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DESIGN, APPLICATION AND FABRICATION

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by C. C. Chamis and R. F, Lark
Lewis Research Center
C1.eveland, Ohio 441.35

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S^1 FA^11.1ZY ;J

TECHNICAL. PAPER to be presented at the

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Eighteenth Annual Structural Dynamics and Materl^^^ti ,

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Conference cosponsored bythe American Institute of
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Aeronautics and Astronautics, the American Society of

1V^echanical Engineers, and the Society of Automotive Engineers
San Diego, California,_ . . March 21-25, 1977
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CONTENTS
Page

INTRODUCTION

. .

. .

CONSTITUENT MATERIALS AND TYPES OF HYBRID COMPOSITES

Fibers
Resins

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Unidirectional-Composites .
Type s ^f ^iybrids
,

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...,

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ANALYTICAL METHODS FOR HYBRIDS
,
.
^
Mechanical Behavior of Hybrids
. . . .
Mechanical behavior of unidirectional hybrids...
Mechanical behavior of off-axis hybrids
.
.
. . a
Angleplied hybrids
.
.
Restrained strains.. in angleplied hybrids . .
.
.
Stress .Analysis of Hybrids
e
.
.Composite mechanics
. p
.
.
. . .
Combined Stress Failure Criteria

. .

Rule..: of . mixtures
^
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Stress concentrations . in hybrids

Fracture. mechanics of hybrids
Fatigue in hybrids. ,
Structural Analysis of Hybrids
_<
Classical methods
Finite-Element methods
Summary
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APPLICATION OF HYBRID COMPOSITES

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. .
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. .
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. 0
. .

DESIGN METHODS
^ a
.
.
Design Data for .Hybrid Composites . .
Special Design Requirements
. _o . . 4 . e
. . .- ^
.
Summary of Specific Designs Using Hybrid Compos es .

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23

FABRICATION PROCEDURES FOR HYBRID COMPOSITES

AREAS FOR FURTHER RESEARCH

CONCLUDING REP2ARKS

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REFERENCES

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.HYBRID COMPOSITES -STATE-OF-THE-ART REVIEW:.

ANALYSIS, .DESIGN, APPLICATION AND FABRICATION

by C, C. Charms and R. F. Lark.

Lewis Research Center.
ABSTRACT
Astate-of-the-art review is presented for hybrid composites that
covers the areas of constituents and .types of hybrids, analytical methods.,

design methods , apps.cations, and fabrication procedures . The review

....^.

summarizes significant contributions in each area a,nd points out areas fore
further. research.- The description of each significant contribution ._s

`"

supplemented with pertinent illustrations and references.

Key Words:

hybrid composites, interply, intraply, superhybrids, constt-

uents,, mechanical behavior, composite mechanics , .stress analysis , stru^s

aural analysis, design, design data, application,- fabrication.

'I
l

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^
w

INTRODUCTION
Hybrid. composites. have. more than one kindof'fiber embedded in the

':.

matrix. They have been developed as a structuralmateral as a logical

sequel to conventional composites, which .have only one kind of fiber,

'

Hybrid composites have unique features that can be used to meet diverse
and competing design requirements in a morecost-effective way than either

j
i

-advanced or,00nventional composites. Some of the specific advantages of

hybrids over conventional composites are-balanced strength and stiffness,`

balanced. bending and membrane mechanical properties, balanced thermal

distortion stability, reduced weght`and/or cost, improved fatigue resistante , .reduced notch sensitivity, improved fracture toughness and/or crackarresting properties, and improved impact resistance. By using hybrids,

it is-possible to obtain a-viable compromise between mechanical properties

and cost to meet specified design requirements.

Considerable data have been generated for hybrid composites in 'the

areas of analysis., design `applications, and fabricationprocedures, These

,y

data suggest that research in these areas has matured to the point where '

astate-of-the-art review wi11 provide a valuable source of information

-for the composites community. It is the objective of this report to'provide such a review.

-- -

_,^

This review covers those hybrid composites that consist of two or more
different types of fibers (or fiber composites) in a frequently repeated
pattern in a laminate. Structural parts that have composites in strategically selected locations or composites thathavea few different lamina
in strategically selected locations are classified as selectively,reinforced components. These types of components are not. covered in this

review.

^^

The state-of-the-art review presented herein covers constituents and

types of hybrids, analytical methods, design .methods, applications, and

fabrication procedures. Significant contributions in each of these areas

.are . .descrbed and are supplemented by pertinent illustrations and references, Oven 100 documents were examined.. Wehad to be selective in the inelusion of significant points, illustrations, and references... The .amount
of ..material included in `the review for each area reflects, to a large extent,. the amount of data available in that area. Areas needingfurther
rese-arch. are pointed out..

We assumed that the reader is familiar . with some composite ferminology. The few symbols. that are used are mostly self- . evident and are
also defined when they first appear.
CONSTITUENT. MATERIALS AND TYPES OF HYBRID COMPOSITES
Fibers
Boron., various. types of graphite, .glass, and,Kevlar fibers are used

',

in hybrid composites. Cloth and .fabric woven from these fibers. are also
used. Typical stress-strain diagrams of some of these fibers are shown

in 'figure h As. shown in tY!is..figure, fibers ,are available with th,e fo1lowing typical ranges of mechanicalproperties: tensile strength, 25'0 to

500 ksi (10 3 psi) ; fracture strain, 0.4 to ^+.0 percent;` and 'tensile modelus 10 to 60 msi (10 6 psi) . Fibers are- available' to meet a variety of

diverse or competing design requirements for strength, stiffness, and

elongation to fracture.

'Resins:.,
The resins used in hybrid composites include mostly structural,..epoxi.es,:;
Thermoplastics are now beginning to; be used for their improved impact and

_.. _ __

^'
i
i

moisture-degrad^^.ton resi stance, and polyimides for their elevatedtemperature cap^^,ba.lity atxd moisture-degradation resistance. The typical
stress-strain diagrams oi' struc'bural epoxies shown, in figure 2 1 indicate
that epoxies are ava^.lab e with a wide range of properties . However, the

intermediate-modulus epoxy is _used in most hybrids..

^'

Unidirectional Composites

r^.

.Unidirectional composites (UDC's) made. from preimpregnated fibrous

mater`ia,l in tape foxmm (prepreg tape) can be prepared fromany of the

fibers and theeintermediate-modulus epoxies mentioned previously. The

UDC's and their mechanical properties, physicalpropertes, and costs ase

summarized in table l Table l includes fiber voltune ratio, ,longitudinal.
(0) properties (tension and compression) , transverse (g0) properties

(tension), interlaminar (short beam) shear strength, in-plane (ntralami-

nar) shear properties, flexural properties, ply thickness, and: cost in

dollars per pound of prepreg tape 2 . Thermal expansion coefficients {TEC)
for these . UDC's range from slightly negative to about . 3x106 in./in./F
along the fiber direction and from 15x10 6 to about 30x106 in./in./F

^;
'^

transverse to the fiber direction.. For thermal expansion coefficients

of specific UDC's and the: effect of temperature on their mechanical.
j

.:properties:, see_referenee 3. Examining the 0 tension properties in

table 1 shows that UDC tensile .strengths range from . 85 to 230 ksi and
their moduli range from 5 to 40 msi. Therefore, suitable combinations of

'.

`:.

these UDC's may be selected to meet diverse or competing design requrements, as i discussed later.

',

Types of Hybxds

This review is limited o four general categories of hybrid com-

I
^

posites: (1) intrrply (interspersed or core/shell); (2) intraply;

(3)

inteaply/intraply;.. and {^+) superhybrid.

Cross sections of typical h;^brids are shown in figures

and ^+.

Briefly, the interply hybrids consist of plies from two or more. different

UDC's stacked, in 'a specified sequence (fig. 3(a)) . Several inteaply

hybrids that were studied by Hoggatt 2 are listed in table 2. This table
also shows a notation '.convention that may be used to define or specify

i
i
i
1

-- --

^F

hybrids.

in the

Tntraply hybrids consist. of

ame ply (fig. . 3(b)).

two or more different fibers mixed

Interply/intraply hybrids consist of plies

of int^^aply and Interply hybrids stacked in a specified sequence (fig. 3(c)).

Super);iybrids consist . of resin composite plies , metal . composite plies , and

metal foils stacked in a specified sequence {fig. ^+).
The Interply and intraply hybrids generally have the same matrix, and
th.e laminate is fabricated by the cocuring procedure according to specifications provided by the prepreg tape supplier'.

If the plies: for these

hybrids. are made from different matrices , the hybrid is fabricated by a

curing procedure that is compatible with .both systems^ 2'' S . 'The superhybrid is fabrcated 6 by adhesively bonding metal foils, boron/aluminum

'j'

(or other metal matrix) UDC plies, anal resin/fiber prepreg UDC with an ad-

hesive that has the same-curing cycle as the prepreg tape 6.

ANALYTICAL METHODS FOR HYBRIDS

The mechanical behavior of hybrid composites is reviewed with respect
to stress-strain. or Toad deformation, in-plane. and bending (flexural) xesponse,.failure modes., falurecritera, and restrained strains,

The

review of stress analysis covers. methods for determining stress at a point

^`

,,

(ply stress) and for determining. stress concentrations and also methods.

''

associated with fracture mechanics and'the-postulation of failure criteria.

'

The review of structural analysis summarizes those methods that have been
6!

used to .predict the structural response of hybrid cQmpositecomponents to

`'

':

static,_ dynamic, or impact loadings.- The,'environmental, cyclic, and

fatigue load effects on the mechanical behavior:. of hybrids are reviewed
iri thesection_DESTGN METHODS.

^;

Mechanical Behavior of,Hybrids

-

Mechanical behavior of unidirectional hybrids. -The observed mechan-

ical behavior of hybrids (as_of other structural materals)_is fundamental

in determining which existing methods for predicting mechanical behavior

are applicable an;d in postulating hypotheses for deriving new analytical

methods .
Stress-strain:.diagrams'along the fiber (O) direction for Interply
unidirectional hybrids are shown irk figure
,^

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G:
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F..
v

,+

5`^; those

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transverse to the

^9

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_.

``
f_

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_.

fiber (90 ) direction are shown in figure 6^. These hybrids consist of
three different hybridization. (volume) ratios of Modmor II (MOD II).graphite
'

and S-glass (S-GL) fibers in PR-286 epoxy (E). The important observations
from figures. 5 anal

are as fo^lows.

1. Thestress-strain behavior is linear in both directions.

w,. ,

2. The 0.stress-strain curves of the hybrids lie between the two

`

constituents anal. are proportional to the amount-of constituents (MOD II/

S-GL hybridization ratio).
3. The-O'fracture stresses of the hybrids arE less than those of

the constituents,
^+. The . fracture strains of the hybrids appear to be limited to the
:fracture strain of the graphite (MOD II/E) composite, which is the more
brittle constituent in this hybrid.
5. The 90 fracture stress of the hybrids appears to be independent

':

of the hybridization ratio., but `the fracture strain. decreases proportionatelywith the. hybridization ratio.

Fracture stress variations with the .volume percent of graphite in a,

GY -70- graphite/S-glass hybrid are shown in figure 77. There-is an initial

rapid drop in ,both longitudinal fracture stresses (figs. 7(a) and (c)) and
then a linear increase with . increasing volume. percent of graphite fiber.
"

The corresponding moduli increase nonlinearly and lie above the straight

"

dine.. connecting the moduli. of the constituents (end. points). Thus apparent "synergistic effect" is the result of stacking the stiffer. plies furthey away from the neutralplane. The transverse tensile strength 'and

';

modulus (x'g. 7(b)) decrease linearly with increasing volume percent of

'_graphite fiber. The shear strength and modulus (fig. 7(dJ) decrease-

,.
t

approximately linearly with increasing volume. percent of graphi e fiber.'

Interesting points to be noted from the curves. in figure 7 are (1) the
^

difference 'in the shear strength and.. modulus in the two dfferent ` drec-tions for the graphite composite; and (2) the difference in the shear
strength between the short-beam and orlon values for the S-glass. compolite.
;The flexural (bending) strengt:a'varatiom of several interply hybrids,

^
^

^,

^'

6
AS/5-GL and HMS/S-GL, with varying volurle percent of S-glass is shown in
figure

8 5 .

Note (1) the.. rapid linear dr^^p of the flexura3 strength of the

type AS graphite/S-glass (AS/S-GL) hybrid, with increasing . volume percent of

S-glass; and (2) the approximate linear increase in flexural . strength of
the high-modulus graphite/S-glass (HMS/S-Gh) hybrid with increasing volume.
percent of S-glass.

Observed flexural fraciure modes for the HMS/S-GL

interply hybrid are illustrated schematically in figure

95.

,,.^,_

As shown, the

interply hybrids may exhibit several peak stresses before fracture and
'
;,

thereby provide increased energy absorption capability of

he more brittle

constituent..
Flexural strengthsfor several hybrids are shown in figure 10 5 .

j{

The

flexural .strength data fall below the straight line connecting the .strengths
of the constituents (end .points).

Also, the flexural strength of the HMS/

S-GL intraply'hybrds appears to be independent of (or at most slightly

dependent. on) the volume . percent of S-glass.

Photomicrographs of fracture

surfaces showing . .flexural fracture modes. for .interply andintraply hybzids

?^

are. presented in figure 115..

Note the .staggered . fracture surface in the

interply hybrids and the relatively flat fracture ` urface in -the interply

hybrid.

'^

increased load-carrying capacity of the hybrid.

,^
j

^'

The staggered fracture surface usually is associated with an

j

'.

The variation
of the flexural moduli of various `hybrids with the vo1-
ume percent of S-glass is shown in figure 125. Here too, the data fall

'

below the straight' ine connecting the moduli of the constituents..:{end

points)
Longitudinal and transverse tensile stress-strain diagrams for super-

`I

hybrids and their constituents are . hown in _figure 13 6 Figure 13 indicates

,r

fj

(1) that the stress-strain diagrams of the superhybrids are linear . along the
boron/aluminum (B/Al) composite and (2) that the corresponding stress-strain
diagrams in the transverse direction are nonlinear, with transverse fracturestrains approaching'1 percent.

Far--

fiber direction and fracture is limited by the fracture strain of the

^E

{}g

^,

In summary, the previous observations and discussion on the meth an-

^'

ical behavior of unidirectional hybrids lead to the following important.

i
t

7
conclusions:
1. The in-plane stress-strain behavior to fracture is approximately
linear in general.

2. The data for fracture stresses , .for both in-plane and flexure,
fall below the straight line. connecting the . corresponding strengths of the
e

constituents (end points). This indicatessome loss in efficiency of

property translation relative to the constituent composites.
3. The flexural moduli of interply hybrids . depend on the Stacking
sequence of the constituents.
Mechanical behavior of off-axis hybrids. - We are not aware that . any

^
^

data have been reported. on off-axis (unidirect^,onal hybrids loaded other

than O o to the fiber direction)_properties of hybrids. These data would
be useful in two important respects: (1) to .verify the transformation
equations for e elastic constants (normal moduli, Poisson's ratio, and shear
moduli.). of hybrids-and (2) to determine the applicability of the available
failgure criteria for combined-stress states in hybrids. Judiciously
selected data for .off-axis hybrids need to be generated.
Angleplied hybrids. - A large amount df data for angleplied hybrids
(hybrid composite laminates made of alternating plies oriented at plus

',

and minus angles to the load. direction) has been generated and reported,'
The reason for .this large.. amount of data is that many of the angleplied
.hybrids have been made,to simulate composite components for specific appl-.

cations.
Stress-strain diagrams for some typical. angleplied hybrids are shown..

in figures 1^+' to 168 and figure 17 9 . The corresponding Poisson^s strains

are'also,shown in these figures. In figures'l^+ to 17, the stress-strain
curves are approximately linear to fracture. This observation .leads to
the important conclusion that .linear laminate theoryshould be:.applicable
to angleplied hybrids.
_

Restrained strains in angleplied hybrids. -Thermally induced, restrained

3

the. use temperature and the lamination temperature. Restrained strains have

been measured in some angleplied nterply hybridsby the embedded `strain

,;

gage technique. Some typical results of ply .restrained strains are shown

in -figures 18 to 2010.
r
^. _

strains are present in angleplied, hybrids as a result of differences between

_+

The important points to beobserved in figures

18

to 20 are (1) that

the restrained strains are approximate^.y linear in the temperature range

`fi0 to 340 F and (2) that the transverse restrained strains (e 90 ) are of
considerably higher magnitude than the other .restrained strains
Lamination residual straihs are equal in magnitude to restrained
strains but of opposite sign. Therefore, the curves in figures

'

1.8

^"^

to 20

can be used to determine the lamination residual strains in the anglepl:iel

'

hybrids shown in these figures... Fox example,,referrng to figure 18, the..

transverse lamination residual strain (e90 ) in the Kevlar

49

plies of the
i

'

(0 Kev /^+5 Gr/0 Gr) s composite is about 9000 uin./in. (opposa..te sign
of _9x10 3 )... This is a very large strain when compared with the transverse
`

tensile fracture strain of Kevlar 49, about 5000 . uino/ino The important
conclusion from this discussion is that transverse lamination residual
strains in angleplied interply hybrids may be greater than the fracture.
strain of the constituent plies,

Stress Analysis of Hybrids

Stress analysis methods that have been used for hybrids are summarized with respect to composite mechancs,,stress concentrations, fracture

mechanics ,..anal fatigue o

Composite mechanics, -Composite mechanics has been the principal

stress analysis tool for hybrids. By far the majority of the hybrid
analyses reported employ linear laminate theory (LLT)

2^h^fi^11.-13

. Lam-

nate theory has been used in- . one of two ways; (1) to predict secetion
properties for structural analysis and . . (2) to predict ply stresses having
given the resultant forces at the .section...
The influence of the constituent plies on the section properties and
thermal forces of the hybrid<is best illustrated_,by briefly ..examining the
general LLT equations for determining thesepropertieso
N k

Zi

[A] ^[C],[D^ _ ^
i =1

(1)

(l,z,z2)CR]TLE^-1[RJ d^
Zi-1

^.

9
NQ

{NT },{M,f } _ ^
=1

{{

Zi

(2.)

(l,Z) QT [R][E]-^"{a} dZ
Z-1

^-

The notation in equations (1) and (2) is as follows: jA^, [C], anal [D]
.."

denote membrane, coupling. and flexural (benang) stiffness matrices, re-

spectively; these matrices are [3 x 3] for plane problems anal [5 x 5] in

cases where the transverse (through the thickness) shear deformations .axe
taken into account.. The term Z denotes the laminate thickness coordinate
_referred to some convenient plane; the . index is denotes the th ply in
the stacking sequence of the ,laminate; [R] i denotes the transfcxmation
matrix locating the th ply material axes (parallel to anal transverse to

the fiber direction) from the ,laminate structural axes lcoinc^ident with. +,he
ith
ply stress-strain rela..principal : load. direction); [E] i denotes the
tions; {NT} and {M,f } denote the thermal forces; OT1 denotes the difference
between ply and reference temperature; and {a} i denotes the ply thermal

expansion coeY'ficents . For extensive- discussions on th.e application of

equations (l) and {2) to composites and their limitations and use,.see

references l^+ to 16.

Referring to equation (1), it is seen that the .constituent plies in.fluence the hybrid section properties (1).through,theply stress-attain

relations [E], (2) the ply orientation relative to th.e hybrid structural,..

'

axes ` [R]
: , and (3) the ply location in the stacking sequence Z. ^^ Laminate
i
configuration concepts such as the core/shell hybrid and the-super-hybrid
.

are readily deduced from equation (1). The ply properties used s.n equa-

tion (1) for interply hybrids are obtained either by measurer^ient ^tabl.e 1,)
or by the use of micromechanics. The ply properties for in`^raply hybrids
-are obtained by measurement. Composite micromechancs concepts in predict.

ng intraply hybrid stress:-strain relations were not reported;'in the liter-

-ature summarized in. this review:.

Application of equation (1) to hybrids is valid if the hybrids have.
;^

^^ _, x,._-

linear, or reasonably linear, stress-strain curves.to fracture anti if +';hey

;have in situ ply stress-strain relations that are identical with. those

measured in characterizing the; ply material. It will be- recaaled from ^:he

-.

^ ---._

.... K. ^

_-^3

10

previous section that resin matrix hybrids and suT^erhybrids satisfy th.e first
criterion; the second criterion may not always be satisfied; Far example,
predicted properties that are not coincident with the major fiber direction

are not in good agreement . with measured data^`^a

.,.,, ,

Applying equation (2) to hybrids depends on whether the hybrid ^trcas-

strain-temperature relations are approximately linear in ^fh,e temperature

range of interest. The temperature effects on these relations for some...
`

interply hybrids were investigated2 . The results showed ^th,at these relat^.ons .are linear in the - ^5 to 250 F temperature range, with some degradaton in the 250 to 350 F temperature range, We have aaso seen (figs, 18

to 20) that . the thermally .induced. restrained si^rai.ns are approxi,ma^tely

linear in the-same. temperature range. It may be concluded from this d,scussion that hLT appears tc be adequate for predicting section. properties
and thermal forces. in hybrids.

Applicationa^ nonlinear laminate ana]^yss to hybrids has nc;t been

reported in thelterature summarized in this re.riewo We expectthat

available nonlinear laminae analysis will be applicable to hybrids,

provided that the appropriate, ply stress-straa.n-temperature relations are
.used.
The LLT equation that has -been used to predict ply st^^ans in: hybxids
may be expressed. in matrix form as follows":
{e} i - [^]i{^[A)!1 - Z i [C1 1 1 } ^{N C } + {NT}^

+ ^[c)il - Z i [D^ i 1

^^{M C } + { ' M,^}^?

(3a

where {e}^ denotes: the strains in-the th ply; {NC} and {MC } denote re-

su^_^a,nt mechanical- load forces and moments at the ection; and {NT} and
{MT} denote the correspo^iding thermal forces 2nd moments . '1'h.e other symboll have been-defined previously.
The,equa^ion to predict ply stress in hybrids is obtained by multiplying equation (3) with t11e ply stress-strain relations and aGCOUnti.ng for the
free thermal strains. The resulting matrix _equation matiy be expressed as
follows:
i

y
,^

_
_

,.
.

_ ____

11

{cs} i =

^T i {a } i ^
[E]i\ {E}i

where {a} i denotes the stresses in the i th'

(4)

ply of the hybrid; . {e} i is

determined from. equation (3); and the other symbols have been defined previously.
The strain predicted by equation (3) may be used in conjunction with
the first ply-strain failure criterion to predict hybrid initial,. or final,
damage. Similarly, the stresses predicted by equation (^+) may be used in
conjunction with the. first ply-stress failure criterion. In general, however, the stresses predicted by equation (^+) have been used in conjunction
with combined-stress failure criteria to predict hybrid failure, as is discussed later.

_3

Experimental and predicted results for hybrid mo^.uli and fracture

stresses based o^ the maximum strain fracture criterion are compared in

table 312,18, The experimental . data used in Kulkani 12 werE obtained from

'

Hoggatt 2 . The .predicted. values for. the moduli for the . hybrids in table 3

are in fair agreement withthe experimental data. However, in the case of

superhybrids 6 -the predicted values for normal and flexural moduli and. the

; ;'

Poisson'-s ratios {longitudinal: and transverse) agree very well with the experimentaldata. As shown. in table 3, the . comparison fcr fracture stresses is
poor... This may be attributed in part to differences in situ ply properties
as compared with those used in the computations.
The maximum-strain criterion in conjunction with LLT has been: used,by

1'^cKague^' 9 to generate,,interaction diagrams (failure envelopes) for a variety

of'hypothetcal nterply hybrids. Atypical diagram is shown in figure 211'9.

The approach` used by IcKague1 9 has been used extensively in designing composite _structu r al _components .
Combined-stress failure criteria. -Several combined-stress failure
20,21 . The most ccmmc+nly used is
criteria have been.. proposed for compostes

^'

.the von Mises-Hill criterion. In equation form, using the.:presentnotation,

this criterion is2:

s1a

s la

2
+

2a
s2(3

61a62R +

612

slas2a

5.12

_ l

(7)

..

.. ...

..

..^

.'

..._..^_^^....^

_..._......

_.._ .._..T

-- +e

I
I.
!

`;
FE

t![

F^

^..

12
where Q denotes-ply stress predicted from equation (4);

S i^enotes the

corresponding fracture stress measured under uniaxial loading; the

numerical subscripts denote direction with 1 taken along the fiber direction;
:and the subscripts . a and. $ denote tension andcompression, respectively.
Equation

^-

(5) was used in reference 2 for co;nparisons with the exper-

.^.,.

mental data. Some typical comparison results for the hybrids described
in table ^2 are. shown in table 5 2 . Shown also in table 5 are values pre-

dieted by equation (5) when the plyfracture stresses S 2T and S 12 ..are

arbitrarily increased, as is indicated in footnote (c and d) to this table. Ply

fracture stress was increased to account for possible differences in the

in situ'ply fracture stresses. In addition, the fracture stresses predicted.

by using the maximum stress (with ann without increases in

S2T an'd S12)

-and the maximum stxain critexia are shown in the last three column of
f

table 5.
The predicted values `(with and without, in situ ply strength modifications)
..shown: in table 5 agree poorly with. the . data. The correlation was improved

'

for the. compression data when specimens. that were suspected to have failed
by Euler buckling ,were exclude d 2 .

_ _

'i'he conclusion, therefore, is that com-

posite strength theories do not appear to be adequate-for predicting the

tensile fracture stress in hybrids.

-^

Rule of mixtures...- The rule of mixtures (ROM) has been used to predict

in-plane mechanical properties of nterply unidirectional hybrids from con5, 7, 22-21+ Reasonab e agreement-betweenpredicted
stituent_ply properties
and experimental results. were reported by Kalnin7 for several in-plane
properties, ncludingtransverse tensile strength.
Predicted and experimental results for longitudinal tensile fracture
'

stress are compared. in figure 222 for several interply,Kevlar/graphite

hybrids, Note the rapid. initial drop (at low graphite fiber volume ratio)

'

fQ:?lowedby a, linear increase; this is consistent with what`was described

previously. Beyond the initial. drop the predicted resultsagree well with
3

the measured data.

The ROM has also been used to`predict flexural properties of interply

^.

unidirectional hybrids

5,7

Reasonable agreement with measured data was..

found when the moduli of the constituent plies were weghted'according to

t

. ^ _.

__

13

the ply's location in the stacking sequence as shown in ^th.e fallowing

'..equation
_,

i
where Ems,

EHF^

3t

+l _

Z i )^E i ^

(6)

..,.

denotes the flexural modulus of the hybr^_d; t H deno+es the

hybrid's thickness; Z. is the distance from the reference plane to the

i

bottom of the i th ..ply; and Zi+l , is the distance from the reference plane
to the top of the i th ply.
i

From the. foregoing, it appears that 'the RGM predicts mechanical proper-

ties of interply unidirectional. hybrids that ire in reasonable agreement with

experimental 'data. However, no unified and integrated theory especially
derived for hybrids has been reported in the literature summarized in this
'

review...
Stress concentrations in hybrids, - T^e

.:analytical methodsfordetermin-

ing stress concentrations in hybrids. are . the same as those used in conven-

tional composites, Usually, these method^ inchzde orthotropic or a_nisotropic

plate theory, and general or special-purposefinite-element analytical
methods. Results obtained from such ana j yses are subsequently compared with

,"

measured 'data either at the ply . level. through LLT er at the hybrid level.

It was- found by Fogg' 25 that LLT underestimates the strength of hybrids .with
^

holes because of the nonlinearities present in the hole vicinity. Inter-

laminar stresses near the, free surfaces of holes -and diseont . i.nuties may be

:_.

treated by using finite-element and finite-difference methods ^6,

Fracture: mechanics of hybrids. - the methods of analysis used are

directed coward determining the stress sfi^te at the crack t^.p ` and its i.mmedi ate ` vicinity. Tnthis sense, orthotropic and anisotropic elasticity..

.:^

'!

theories are used, as well as special and general-purpose finite-element

.

methods . A recent symposum 27 examined the aspects of fracture mech , arics

in composites in considerable depth. A current controversy i:i the field
focuses on the difficulty .n defining what material. properties. govern un-

stable crack growth caused` by the multitude of possible failure modes in "

^
J

fiber composites:.

,^

l^+
'

It appears that linear elastic .fracture mechanics (ZEFF) concepts of

metals may not be applicable to composites . The ^ieterminati.on of fracture

'

toughness properties of hybrids based on one configuration is not directly

generalized to other configurations. It would seem, then, that more basic
material properties probably govern the unstable crack growth,

.....

One advantage of the hybrid concept mentioned previously is _its. irxherent notch insensitivity or the existence of crack-arresting mechanisms that

are derivable .from ,the differences in stiffness and fracture strains of the
^

different fibers used in the hybrid. An approximate method has been proposed

to determine the'sze., spacing, and material of crack-arresting strips^8.

An ap^;licaton of this approach to large components is described by Huang29e

Fatigue in hybrids, - An analytical, method for . predicting fatigue in

a,nterply unidirectional hybrids based on ROM concepts is described by

Skudru^^. .However, as is the casefor conventional composites,.description
of fatigue in hybrid laminates is empirical.

Structural Analysis of Hybrids.

The structural analysis .methods that have been usedi:n hybrids are
^,

^.

summarized with respect to classical methods and finite-element methods.

'

Classical `methods. '- .All classical methods of analyzing the structures

that the force de-
of com P osites^ 30 - 32 axe aPP licable to hY brids^ rovided

P
formation. relations are appropriately modified.

The torsional and bending stiffness 'requirements. in hybrid circular

shafts (golf club shafts,) were. n^restigated by using slender-shaft structural

`analysis concepts ll . The stability of hybrid - composite columns and plates

was .investigated ,by using Euler buck.lingtheoryacid classical platebuckling theory, respectively3 ^ The strength. and stability of hybrid com.

i
^,
^

posite sandwich beams, plates, and shells were investigated by using strut-

tural andwich theory12

Finite-element methods. -Finite=element methods. that have. been used in

analyzing conventional composite componentw 3^ are suitable. for analyzing hy-

brid composite components as well. The appropriate force deformation relabons are required, as was the case for the classical methods. Practically

all major .composite components .include some form of hybrid, This may be-

^
:;

j
i

_.__,

15

nterply hybrid (or intraply) . throughoutthe component, .crack arresters,

..and/or local reinforcement for openings. In the majority. of these cases,
finite element :analytical .methods are used to determine the structural re_-

spouse of the components'29 ^35.

.^,.

Summary

The literature review of analytical methods led to the following observations

1. Large amounts of data have . been. generated on the mechanical behavior
of hybrids. In general, these data appear to be linear.. Data for transverse
compression, off-axis , and combined stress have not been reportedo
-

2. Composite mecY^ancs (LLT} appears to be adequate in predicting stiffness of hybrids in the linear range. Reasonable fracture stress correlation
has ,been _obtained in interply unidirectional composteso The correlation for

anglepled hybrids is poor. A unified and integrated theory especially

derved^for e hybridcompostes appears to be needed.

3 Failure modes in hybrids under combined stress .need to be quantified.

Fracture stress predictions under . combined stress using available criteria

are inadequate and in stu_ply properties need be quantified.
^+. Structural analysis methods used in composite components appear to

be adequate.-.for Y^ybrds, provided the force deformation relations have been

appropriately modified.

DESIGN METHODS
The methodsthat have been used. in the design of hybrid composite components are .the same as those-usedfor conventional composites;. Design
methods for composites in flight-structures,,includng hybrids, have been
^

the subject-of three recent specialty conferences 36-^$ Composite design

methods, in general, `and examples for basic structural . cpmponents are de-

+'

scribed by;Chamis^ 9 . The review in this section is limited to pertinent

design- data of hybrids, some special design requirements that hybrids may.:
satisfy effectively, and a summary'of specific designs where advantage has
.been taken of one or more of thespecial features of hybrid composites.

'

^;

^^
r
r
,,

.;
m_

`
_

Design Data fox F^ybrid Composites

Design data usually consist of mechanical and thermal material propex'

ties and environmental effects on these properties . . Typical mechanical

'

properties data for hybrids have.. been discussed in previous sections. Available data for environmental effects on these properties are reviewed herein.

The. environmental effects include temperature, moisture, mechanical load

fatigue, thermal fatigue, and thermal shock. Also, limited data on the re-

'

^,,,,

sistaneE of hybrids to high-velocity .impact: are included.

r

The effects of temperature for short-time-exposures on t:^e mechanical

'

properties- of hybrid composites were reported'by Hoggatt 2 and- are shown in

figures-23 to

27,

Curves are shown .for three dfferentload directions 0,

^+5 ,.and 90 .

mhe 0 direction coincides with the largest number of 0

'.

plies. The temperature effects'on the. tensile fracture. stress are shown in
figure 23 for the temperature range-- 65 to 350 F. Two important points to

be observers from figure 23 axe

1. The temperature. effects. on .the tensile fracture stress. are negligible
/

in the 0' to 250 F range forall three load-directions:

2, !'^ small degradation in tensiae fracture. stress occurs :.from 0 to

-65 F and from 25.0 to 350 F.

The-effects of temperatureon_the compressive fracture stress of hybrids

are. shown in figure 2 1+. Theecompxessve fracture stress is sensitive to

,,_

- temperatures , in general, from -room emperature to 350 ' F,.

i

The effects of temperature on tensile modulus are ..shown in fguxe_25.

The temperature effects on the tensile modulus.. in the 0 ply direction are

-'

-negligible. Some degradation occurs in the other two-load directions in thee.

room-temperature to'350 F range. An increase in modulus occurs in the g0
j

`,

-ply direction in the room-temperature to -65 F range.

1

The temperature effects on the Poisson's ratio of hybrids are shown in

figure 26. Poisson's ratio appear to be sensitive to temperature and, also, to load direction at temperature.
The temperature effects on the in-plane (intralamirrar):shear:fracture

stress and. shear modulus of hybrids -are shown,in figure 27. These properties
exhibit erratic-behavior with decrease or increase in temperature. The
^

^;

thermal expansion coefficients. (TEC), as shown in table 6, are. not affected

by changes in temperature in the -100 to 300 F range2.
Thee effects of moisture on the flexural strength and flexural modulus.

'

of a hybrid are shown in figure 282. The presence of moisture increases

the room-temperature properties but produces a small reduction in the 350 F

^.

fracture. stress. Though data are not available in the review summarized
i

herein, it is generally known that the fracture modes may change. with in-

creases in 'temperature, moisture, or both..

:Fatigue .strength. data of hybrids have been reported in references 2,
?+,.and 8. Selected Fatigue data on ir^terply unidirectional hybrids and.
'

their .constituents are shown in figure 29^. The fatigue data for .the. hybrid

^-

'

lie between its two constituents. It can be seen in .figure 29 that the
:fatigue life of the S-glass (S-GL) composite decreases nonlinearly with he

;;

log of the namber of-cycles t^ failure in the range shown,.while the fatigue
lives of Modmor II and all. the hybrids plotted decrease .linearly ... These
^

observations appear to lend. some :support to the use of the rule of mixtures

to predict the fatigue life of unidirectional hybrids by using the fatigue

'

lives of the constituents?2.

_1

Selected fatigue data of anglepled nterply hybrids and their consti-

tuents are. shown in figure 30 8 . The fatigue lives of the hybrids lie between.

'

those of the constituents, as was the case for the unidirectional hybrids,

Thee temperature of the hybrid specimen rises during fatigue testing:

This rise depends. on _the .constituent composites ,and the cyclic load fre-

^ -

quency. 'Temperature `increases of 130 F have been measured :Phis Lem-

perature increase may change the fracture mode and, therefore, should be an
important consideration in studying fatigue fracture modes..
Thermal fatigue (500 cycles, -65 to 3D0 F over a 30 -min :period) has

^,

^ ""

negligible effect on the tensile fatigue life of hybrds 2 . Interlaminar - shear,

`^

thermal fatigue ,data are shown in figure 31 2 , and the effect is'negligible.

Thermal fatigue :(1000 cycles , -100 to 300 F) has negligible effect on the
-room-temperature: longitudinal and transverse flexural_strength'of super-

_.

hybrids^0.

_^ r
j
"^

...,s.,...^"

`_

13

Thermal shock (100 cycle:, -65 to 300 F by immediate immersion) has

no effect on the room-temperature tensile . strength. and tensile modulus of

anglepled interply hybrids2 . However, some hybrids containing S-GL de!

laminated during thermal shock cycling. Some delamnation also occurred

'during thermal. fatigue of angleplied hybrids with S -GL constituents 2 .

r,,

""`

The impact resistance of hybrid composites has been investigated

!
f

-extensively. Hybridization with high-strength fibers considerably improves

the impact resistance of relatively brittle composites 5' 13 , 21+, ^+1^+3

^`

The

data in these references . are useful in designing for impact resistance;

selected samples are included herein. Izod impact resistance of graphite/
Kevlar hybrids improved with increased content of Kevlar fibers (fig. 3220.
9

^!

The addition-of 20-vo1/ Kevlar almost. doubled the impact resistance of the

HMS grapk^te composites .

'i Data that may be useful in trading off. between
^

flexural modulus

and

impact resistance. are :shown in figure 335 . The approximate lower bound
requiredon the flexural modulus (19 x 10 6 psi.) is shown by the dashed line
in figure 33. This bound was selected to satisfy vbrationrequirements'
in laminate configurations for engine. fan blade applications. As shown,

^
^

a design condition requiring a flexural modulus of 19 msi and an impact

resistance of .120 -ft-lb/n.2 or greater can only be satisfied by hybridnation. The impact resistance of some superhybrids is shown in tab le:7^0.

The impact resistances- of B/A1 composites are, also shown for comparison.
The longitudinal impact resistance-of superhybrids is shown to be about
twice that of B/Al.

Special. Design Requirements

It was mentioned previously that hybrids have been developed to meet

diverse competing designregizirements. An example of these competing requirements is ;the high flexural modulus and high impact-resistance illus-

^i
^

trated in fi^ ure 33. Another exam P le is flexural modulus and cost^ illus-

trated in' figure 3^+ 5 , which indicates that a high flexural modulus: can be

J_

achieved at lower cost by hybridization.

These examples axe -from parametric and/or trade-off studies.' Datafrom a large number of hybrids that can be used for these studies. are

rY

i
19
,.

available12.
'

Amore direct.. approach for a specific design is automated

design and optimization by mathematical programming.

This .approach was

used to identify hybrids for optimum. cost 2 and to design structural components such as sandwich beams, plates. ,. and. shells for minimum . cos t. or
''
'
i
^

minimum weight
^

12.

Examples of specific. designs may be found in :the section

^"

APPLICATION OF HYBRID COMPOSITES.

Summary of Specific Designs using Hybrid Composites

The special features of hybrids have been used advantageously in the

followin6 designs; . mechanical fatigue imrrovement of helicopter rotor

blades^^;survivability of helicopter rotor blades when subjected to large-

29 ;
damage tolerance by means of softening strip. in spar caps 25; minimization
of wing-box-face waviness, which had caused premature falures^ 5; stiffness
Iimprovement in stiffness-critical designs of thin tubes 1 ^` ; stiffness imcaliber ground fire; . damage tolerance:in`.-fuselage-like

structures

provement and damage tolerance in vertical stabilizers' and in'horizontal.

stabilizers^;,and impact improvement in'compressor bla3es^6 ^8.

,^

'

fAPPLICATION OF HYBRID COMPOSITES

Specific applications of hybrid composites reported in the literature
#

reviewed were as follows;

fi
i
'

^_

a 10-foot-long outboard section of a helicopter

rotor 2; helicopter rotors aircraft components ,such as upper and lower

wing surfaces, shear web, and fuselage. upper crown^^; fuselage component
(25 -in di am by ^+l in. long)^ 9 ;:upper and lower skins of the outer wing
section for A70 aircraft 35; sporting goods such as golf club shafts ,
bicycle frames, and tennis racquets 1+9; box beam^^; inboard aileron of the
L-1011..:aircraft 25. , aircraft fuselage panels , bows., .goof shafts :2^+,, space
shuttle thrust truss stapport' S0; vertical stabilizer for the B-1';' compressor fan blades for aircraft . eng' ines^6 ^8 ; theoretical-studies for heli-

copter aft fuselage tail boom; and a horizontal.:stabih.zer51.

^

^
^:

Two hybrid composite .compressor blades, are shown in figure 35 (inter-

ply) and figure 36 (intraply)'^6. ` As can be deduced from this list, the

,`

application of hybrid composites has been mainly in the aircraft and sporting industries.

is
^ ....

-:

2D
FABRICATION PROCEDURES. FOR HYBRID COMPOSITES
^

The fabrication. procedures used for hybrid composites are the same
as those used ,for conventional composites. A comprehensiYe review of the

fabrication methods ^'or composites is compiled in reference 3. Additional

'i

emphasis is placed on low-cost fabrication procedures and field repairs^^

i'

Some typical fabrication costs are summarized in table 8 2 .

,,,,,,

The cocurzng process may be unique to hybrids . since eachcomp,;,s.ite

within the hybrid has been optimized with respect to a fbP-r/matrxcombination. The cocuring process for hybrids has been. inrestigated 2 .and the
':

optimum cure cycle was 'shown to be a compromise between the cure-cycles of

`.

the individual composites. Typical mechanical properties ds,ta from this

'

cocuring study are summarized in table 92. The cocuring process appears
i

to improve the mechanical-properties. A variety of fabrication procedures

^

including the use of polyimides and PPQ (polyphenylquinoxalr^e) resins for

making interply and ntraply hybrids are described by Pikes.

!,

.^
`

Fabrication procedures fora specific hybrids are described in,the literature reviewed as follows: : Kevlar/graphitehybrids2,1+,5,8,9,2+,42,
2^4^5^ 8 ^9, 1+2, boron/gra hi;e 7h brads
S-^ lass or E-g lass./gra
p hate^Y brads
^
Y
P
'boron/S-glass hybrids 2 , boron/glass/graphite/Kevlar hybrids 46 ^ thermo2

v
I

plastic resins

,
,

52,53_ , 6,40,53
superhybrids

Nondestructive evaluation methods (NDE) and inspection techniques that

j -

have been used .in quality assurance for conventional composites are applcable to hybrid composites as well. Assuring the quality of components.

`^
^

made from hybrid composites was not `identified as a special problem for
.,

-Y^ybrds in the literature reviewed and summarized herein.

From our literature review, we conclude that fabrication procedures for

the various hybrids are well in hand.

AREAS FOR FURTHER RESEARCH
Lased on the data reviewed, the following areas (not prioritized) need

'; ;-
^,
,'

further research:

:,
..

1. Experimental.
a. Evaluation of the transverse compression properties of interply

^F

unidirectional hybrids

,^
:i,t

^_
_.

._ . __. __.

,.:^

N.r .

21

b. .Complete characterization. of intraply hybrids

,^

c. Evaluation of off-axes properties of hybrids

1(

d. Evaluation. ofcombined-stress fracture in hybrids

' I
^

e. Identification and quantification of fracture . modes in hybrids

f. Assessment of 'in situ ply properties relative to unidirectional
material

^^

g. Additional fatigue data - compression stress reversal and shear

r. Effects of . temperature and/or moisture on fatigue life..
'

i. Evaluation of thermal properties--.thermal coefficients of

expansion, heat conductivity, heat capacity

^, Design data generated-from generally accepted test methods
i

2. Theoretical
a, Compositemechanies for intraply hybrids
b. Nonlinear laminate-theory for hybrids
c. Strength .theory for

anglepliedinterply and intraply hybrids.

d, Unified. and integrated theory . for .hybrid composites

e. Theoretical description of fatigue. of hybrids.

f, Life prediction in controlled .and service environments

CONCLUDING REMARKS

4
i

The Significant findings and conclusions from astate-of-the-art review

`

on the analysis,"design, application, and fabrication of hybrid composites

is

are as follows:
i

1. Considerable data have been generated for the tensile strength

}

properties,,as well as 'the tensile and thermal fatigue, of interply hybrids,

^,

2. Limited data have been generated on the thermal properties, moisture

-j
l

effects., an d effects of residual strains in:'interply hybrids.

^i

3. '.Considerable data have been generated. for impact resistance of inter-

1^ -

^"
,

........J,..-...

ply and intraply hybrids.

^+. The rule of mixtures appears to be -adequate for predicting longitudinal, and .transverse mechanical properties of unidirectional interply

hybrids..

..

S., Linear

elastic

laminate theory appears to be adequate for predicting;-the

response of hybrids,

ry,.,.^;;._^,,,^,,^,.;

^-

22

6.

Stress and structural analysis methods, design procedures, fabrm-

cation methods, and quality assurance technmques that are used for conven-

tmonal composites are also suitable for hybrids.

7. Structural. components can be designed to meet diverse and competing

design requirements .

,.,,, .

8. Ax eas that need. further research are complete characterization of

mntraply hybrmds, off-axes and combined stresses, compressive and reverse.

fatigue, quantification of fracture modes. and . in situ ply properties, ten-

perature and moisture effects, thermal properties, strength prediction

i

theory, nonlinear lammnate theory for . hybrids, theoretical description of

'

fatigue, and development of a unified and integrated theory . for hybrid

.composites.
REFERENCES
1. Charms, C. C., Hanson, M. P., and Serafmni, T. T., "Cri^t;eria for
Selecting Resin Matrices .for Improved Composite Strength," Pro',

ceedmn^s of the: Twenty-Eighth Annual Conference on Reinforced ^

`'

Plastics -Ever New, Society of the Plastics Industry, Snc., 1973,

pP. 12-C, 1 to 12-C, 12.

2. Hoggatt, J. T., and R. G. Cheatham. "Evaluation of Hybrid Composites."

''

June 197+- Oct._1 975, Boeing Aerospace Co.

3.`"Structural Desmgn Guide for Advanced: Composite ,Applications," 3rd ed.,
Lab., Wra.ght-Patterson AFB, Ohio, 1973,
^o Rao, Nagara^a,.and Hofer, K. E., Jr., "Fatigue Behavior of Graphmte/
G1,ass/Epoxy.Composites," Proceedings of the International Conference
on Carbon Fibers, Their Place in Modern Technology, Plastics In'
stitute, 197^+^

5. Pike, R. A. and-Novak, R.-C., "Design, Fabrication and Test of MultiFiber Laminates," R75-911.730 -15, Jan. 1975, United..Aircraft: Cor-

;:

poration; also NASA CR-13+763

6. Charms, C. C., Lark, R'. F. and Sullivan, T. L. "Boron/AluminumGraphite/Resmn Advanced Fiber Composite Hybrids," NASA TN D-7879,
1975

,.

_
; _-

r,

^
r^
^!
r,

23

7, Kalnin, I. L., "Evaluation of Unidirectional Glass -Graphite. Fiber/

Epoxy Resin Composites," Proceedings of the Second Conference on
i

Composite Materials. Testing &Design, STR x+97, American Society

'

for Testing and Materials, 197 2 e Pp 551 -5^3,

^^, !
8

Liber, T., and Daniel, I. M., "Evaluation of Hybrid Composite Materials

in Cylindrical Specimen Geometries,"` TTTRI= D6089, Mar. 1976, LIT
Research Institute; also NASA CR-1+5006.

^. Daniel, I, M., and Liber, T., "Lamination Residual Strains and Stresses
in Hybrid Laminates," presented at the ASTM Fourth Conference on
Composite Materials; Testing and Design, Valley Forge, Pa., May 3-^+,
X976

10. Daniel, I. M., and Liber, T., "Lammnation Residual Stresses in Hybrid
Composites." Part L. (Illinois Tnst. Teck^., NAS3-16766) CR- 13548 >,
1976,. NASA.
llo Kliger, H. 5., "Ultra-High Modulus Graphite Hybrids for ..Combined 'Torsion
and Extensional. Rigidity," 3lst Annual`SPI Conference, Society of the

Plastics Industry, Inc . ,, 7.976, Paper 12A.,

12o Kulkarn, S. V., Rosen, B. W., and Boehm,. H. C., ".Evaluation of Hybrmd

Composite Materials." MSC/TFR/507, June :1.975, Materials Science

'

Corporation (AFML-TR- 75 - 92 ^ AD A027.688).

'

13o Charms, C. C., Hanson, M P., and Serafini, T. T., "Design. for Impact
Resistance with Unidirectional .Fiber Composites,".NASA TN D -663, 1971..
l^+Q Ashton, J. E., Halpin,.J> C., ar_d'Pellit, P. H., "Prirex on Composite

^
,.
,.

Materials: Analysis," 1969, Technommc.

15. Sendec^y^, G. P., ed.,: Mechanics .of Composmte Materials, AGademic.Press,

1971 '_

,.
^-

i ^

'

16. Jones, R. M., Mechanics of Composite Materials, McGraw-Hm11,

17

1975

Charms, C. C. and Sullivan, T. L, "Combined-Load Stress-Strain<Rela

t3onshmps fgr Advanced. Fiber Composites," NASA TMX-71825, 1976.

2^+

186

Itulkarn, S. V., Rosen, B. W., and Boehm, H. C., "Cost-Performance

Evaluation of Hybrid Composite Materials." Pr ^ceedings of the 31st
Annual SPT conference, Society of the Plastics Industry, Inc., 1.976.,
Paper 17A.

19. McKague, E. h., Jr., "Hybrid Laminate Analysis," ERR-FW-1 398, Dec.

..,^

1972, General Dynamics.

20. Wu, E. M., "Phenomenological Ani otropic Failure .Criterion," C^osite

Materials. Volume 2: Mechanics of Composite Materials, G. P,
Sendeckyj, ed., Academic Press,. 197+, pp. 353-x+31.
21. Vicario, A. A., Jr,, and Toland, R. H., "Failure Critcri,a and Failure
Analysis of Composite Structural Components," Com,^osite Materials.
Volume 7: Structural Design and Analysis, Part I, C. C. Charms,
ed., Academic Press, 1975 pP

51-97.

22. Skudra, A. M,, et al., "Properties of Fiberglass-Plastics Reinforced

with High-Modulus. Fibers." Mechika Polimerov, Jan.-Feb. 1972,

pp.

68-7^+.

23. Bunseh, A. R., and Harris,. Bo, "Hybrid Carbon and Glass Fibre. Compos-
ites^ n Composites, Vol. 5, June 1974, Pp 157 -161+,

,^
^
3

24. Reewald, P. G., and Zweeben; ^,., "Kevlar 49 Hybrid Composites for
Commercial and Aerospace Applica.tians." Proceedings . of the 30th

Annual SPI Conference, Society ^f the, Plastics . Industry, Inc.,

1975e Paper 14B.

25. Private commr^.nication on hybrid composite design. .for damage olerance

I

from.: L. D._ Fogg of Lockheed Aircraft Co., Burbank, Calif..:

7a

26, Grimes, G. C., and Greimann, L. F., "Analysis of Discontinuities

Edge Effects, and Joints," Composite Materials. Volume 8c Struc^

aural. Design and Analysis, Part TT, C. C. Ghams, ed., Academic

Press, 1 976 Pp .135-230.
27. Fracture Mechanics of Composite, STP 593, American Society. for

Testing and Materials, 1975=

^__

25

28. Sendec'ky^, G. P., "Concepts for Crack ArrestTnen^ in Composites,"

Fracture Mechanics of Composites, STP -593, American Society for
Testing and Materials, 1975, ppo 21^-226,

29. Huang., S. La , and Hess, T, E "A Hybrid Composite Fuselage Design with
Integral Crack Arresters." Third Conference on Fibrous Composites
in Flight Vehicle Design, NASA TM X- 3377 -Pt-2,

1976,

'^"

pp. 737-758>

30. Knoe11, A. Co, and Robinson, E. Y,, "Analysis Truss, Beam, Frame,
and Membrane Components," C omp osite Materials. Volume 7: .Structural
Design and Analysis, Part T, C. C. Charms, ed., Academic.. Press,...
3

1975

pP o

99 - 1^+8.

31. Bert, C. W., "Analysis of Plates," Composite Materials. Volume 7:

',

Structural Design and Analysis, Part T, C. C. Charms, ed., Academic

.Press,. 1975 PP= 1^+9-206..
32. Bert, C. We, "Analysis of Shells," Composite Materials., Volume 7^
Structural Design and Analysis, Part I, C. C, Chatnis, ed., Academic
Press 1975 Pp. 207-258.
33a Berg, K. R. j "GraFhite Reinforcing of Glass Composite Structures,"
Proceedings of the 27th Annual SPI Conference, Society o^ the
I^lastics Industry, Inc. ,

1 97 2 s Pp ^

17-E,1 to 17-E',^+.

3^+. Purdy, D. M., "Discrete Element. Analysis of Composite Structures,"

Composite Materials. Volume 8: Structural Design and Analysis,
Part I, Ce C. Charms, eda, Academic

Press, 1975,

pP- 1-31.
3

35. Foreman, Ce R., and Tanis, Ca, "Development of-an A-7D Advanced
Composite-Outer'Wingfor Production and Tn-Service Experience,"

Third Conference on Fibrous Composites in Flight Vehicle Design,

NASA_TM X -3377 -Pt-1, 197 6 , Pp.

1^+3 -16^+.

36. Proceedings of the.. Conference on Fibrous Composites in Flight Vehicle

Desi n, AFFDL-TR-72-130, Dec. 1972, Wright-Patterson AFB:
37. Proceedings cf the Second Conference on Fibrous Composites in Flight.::
Vehicle Design:, AFFDL-TR -7^+ -103, Sept. 1g71+, Wright.-Patterson AFB,
,^

38. "Thixd Conference on Fibrous Composites. in Flight Vehicle Design,

NASA TM X-3377, pts. 1 and 2,

1976.

^.

r
C

26

3q,

Charms, C. C., "Desa.gn of Composite Structural Components," Composite

Materials. Volume 8: Structural Design and Analysis, Part: I, '
CP C. Charms, ed., Academic Press, 1975 pP 231-.280.

1+0^ Charms, G. Co, .Lark, R4 Fo, a'nd Sullivan, Ta L., "Super--Hybrid Composites An Emerging Structural M^.terialo" Third Conference on Fibrous Com-

~"^

posites in Flight Vehicle Design, NASA TM X-3377-Pt. 2,-1976, pp."851877,

1+1a Novak, R. C., and Dec^escente, M^. A., "Impact . Behavior of Unidirectional
Resa.n Matrix Composites Tested in the Fiber Direction," Proceedings
of the Second Conference on Composite Materials; Testing and Design,
STP - 1+97, American Society for. Testing . and Material, .197.2, pp. 311- 323. `

1}2. Frizdreh, L. A., and. Preston, L. Jo,, "impact Resistance of Fiber Com--
posite Blades Used in Aircraft Turbine Engines," PWA- 1+727, May 1873,
Putt &Whitney Airc^aft; also NASA CR-131+502a
1+3,

'

^^'--^,,,`

Simon, R. A., ":"Cznpact:Strength of Carbon Fiber .Composites." Proceedings

of the Twent,^-Eighth Annual Confe^ence on Reinforced Plastics. Ever
New, Society of the Plastics Industry, Tnce, 1973,. pp. 17 -B,1 to^17-B, 8.
,a

_1+1+o Salkind, M. J. , "New Composite Helieop^er Rotor, Concepts `," Proceeding

of the..Conftrence of Fibrous Gomposites in Flight Vehicle_Design,'
AFFDL-TR-72-130. , Deco 1972, Wr^^.ght-Patterson AFB, po^57.
'

'+jo Hadcock, R,-N., et a1,, "Design-_and. Fabrication of aMixed-:Composite

Wing Box," presented.;at SAMPE`5th National Symposium,. October. 9-11,

1973.0.
1+60

"impact Resistance of Go^^nposite Fan Blades," R71+AEG320, Dec. 1871+,

..General. Electric Co, a1s^Ci NASA CR- 131+707.

47. 011er, Tq L., "Fiber Composite Fan Blade .impact Improvement Program.:"

(General Electric; NAS3-17836), NASA CR-135078., 1976.

1+$0 "Low Cost FOD Resistant Organic Matrix Fan Blades." ^Oontract F- 33615
71+ -C-5072,,
490

AFML, Wright-P^^,tterson AFB, Ohio, Final report, 1977.

Private communication on^^.applicat^on of 1.hybrids'^^bo;^sg^nrtzng_goads::frora

P. R. Hoffman of Avco, :Lowell, Mass.., 1975

.^.

^_.^t`

^^^

i
50. Corvelli, N., and Carr R., "Evaluation of Bornn- Epoxy-Reinforced
Titanium Tubular Truss for . Application to a Space Shuttle Booster
Thrust Structure," NASA TN D-677$, 1972
51. Hadcock, R H., "The Application of Mixed Fiber Composites to Mili-

'"'"

tart' Aircraft," presented at the 10th National State- of-the-Art

Sylaposium, American Chemical Society, June 10-12, 1.97+.

',

52. Long, W. G., "Reinforced Thermoplastics." Apr.. 197+, Babcock and

Wilcox. Corporation (AD-782760; AMMRC-CTR- 71+-32; TRG- 71+ -10).
53. Novak, R. C., ."Multi-fiber Composites," R76- 912098-11,

Apr. 1976,

United Technologies Research Center, also NASA.CR-135062

-^___

~^__.
^^^_

^..
v

^'^`^

.^..^"'^^.

j_

'
!

^
'

a
i

^
f

^.

'.d

.^

_.
^y.

t.
i^
!'.

Materal.

Form Fitter
EpoMY
volume
matrix.
xatio
resin=.

Boron

5505

Graphite:.
A-5
3501
f8+15
934.
HT5 ^ .5208
1-3oa
cY-7o

Density:
g/om3

3
lb tin.,

Tape

Tension

Transverse (90)
tension

0.50

1.99

. 0.60

HOD-I 5208 '

MO7T-IT 5208

1..63

D.055
.059.

1,6g

.061.

1.54

S208
934-

0.072 "

L95 ...056

.060 >

1.67
1.54

.050

230

210.
120

u5

210
85-

16.0

19.0

.0.93

0.21

5.2

150

8.7
10.4

D.83
.85

0.25.

5-8
7-8

45
75

ksi

2.7

alas,
msi

ksi

32

170
90.

16
25

9.0
12.5

1.3
2.0

225
150

17
28

14
.10.5

20
ao

210
75

20
38

6.5
6.0

1.5
l.z

260

20

14

38

12.0
9.7

2.0
1.9

135

186
210

29
23

4.1
4.1

0,8

90

ll.

.7

90

----

----

bl4

b0.7

120 ^
186. ^

31
24

I55

loo
100

24,

29
2^
1l

Kevlar-k9
Kevlar-29

-------

Tape
Tape

0.60
. 60

1.38
1.:38

0.050
.050

200
200,.

11.0
5.:0

40

Nomex

----

Tape

. 0.60

---

----

---

----

---

----

1002
10025

Tape
Tape

0.60

L80
1.82

0.065
.066

160 ^
21^

90
120

6.0

10025- Tae

:6q

4U..

5.0

13

1.3

'245

16.5

23

Strength,

52-5

.60

1.82

`:066

18ri

5..7
6,3

6.3

]10

4.6

6.0

Modulus,

ksimsi

10.5

.85

.zo

.0

7-8

65

9.D

.95

.21

5-7

7.S

14.0

.60

.25

6- 8

60

10
14.9

10.4
15.8

.85

. 22

6- 8
6-8..

75
65

7..0
6.0

8.7

S.D

8.7

D.3
.3

0.34
.34

5-7
5-7

45
20

---

----

----

----

---

-----

---

55

165
200

5.3
6.0

10.0.
11.2

12_0
12.0

b0. . 7

b0.3

10
10

Glass:
E
901-5

f?repreg
cost,
$/lb

'Strength,

ulus,
msi

360..

^ 25

Ply
thickHess,
mils

---

t9ba-

ksi

9.1.'

Poisson^s
ratio

Hod-

Strength;

l
118 :5
^ 30.

X30

In-piane (intralamsuar)
shear pro p erties

Interleminar
{short beam l;
shear
strength,

Flexural
properties

Compression

'

Strength, Mtd- Strength , Dtodu_us,

ksi
alas,
ksi
;Hsi
^csi

Tape

Longitudir.'^`(0) properties

170

6.0

10.5

12.0

72.

.38

10

45

2_35
17.60

6.20

i
i
M

TABLE 2. - INTERPLY HYBRID DESCRIPTIONa

.laminate

Material

Configuration

S-GL/T-.300/S-GL

^0^/+1+5 /9^ ^s

T-300/B/T-30o
B/T-3o0/T-300

^+

S-GL/B/S-GL

^o^/^+5/gU^s
^S^/^+5/90^
(off/+^+5/90 ^ss

Kev 1+9 /T-300/Kev

T-300/HMS/T-3oo

xTS /B/T- 3oo

(off/ ^+5/90) s

S-GL/HMS/S-GL

(0^/^50/9^0 ^s

S-GL/G-181/S-GL

(0/45 /90

to

s-l8l /G-18i

(0/45 ^S

11

S-GL/Kev 49- .328/S-GL

T-300/G-181

(0/45 /90 ^s
(0/45 /90 ^S

13

AS/Kev 49-.181

(0/45/90^

14

G-248 /G-181/G- 248..

(02/45 /90 ^S

15

HTS /G- 181 /xTS

(0/45/90^

1(^

Kev 49 /G -181F/Kev 49 (0/45/90^ s -

^+9

^04/ +^+5/90 ^s
_(off / ^+5/90

^S

Material

Configuration

Tensile failure
stress,
ksi'
Test

Theoryb

Compressive failure stress,

ksi
Test

Theoryb

Modulus.
(transverse),
msi

Modulus
(longitudin^:1),
msi
Test
Tension

Test

Theory

ComAres-,

Tension

- (0^/45 2)S

141.5"

(31,0)

96.5

(31.0)

ComAres-

Sion

sion
S -GL/T -300

Theory

6.9

5.7

5.3

3.1

3.3

2.5

81.0

.141.0

T-3oo/B

(0^ /+1+5)s

157.5

167.2

g8.7

(104..7)
157.0..

21. 4

17..0

15..9

4.4

2.6

3.2

B/T-/T-300
.300

{03/ 45 /90 )s

124..2'

127..3.

95.0

(182.3)

22.0

3.5

17...4

8.4

2.2

4.2

7.2

7.1

6.0

4.3

3.4

1.9

7.0

5.7

6.0

4.0

3.0

3.9

s-GL/B

(05/45)s

241.5

(81.5)

75.1

185.9
(78..3)

25.5

108.0
29.8

Kev 49/T- 300 /Kev 49

(0 2 /.452/90) s

72.0

189.0
(33.9)

T-300 /HMS

(0^/453)5

92.0:

(97.0)

79.1

(56.2)
84.0

10.8

10.4

9.9

3.6

3.1

4.4

HrS/B

(05/_+;45 )s`

116.0

160.2

90.7

211.9

10. 8

12.8

17.2

3.6

2.5

3.1

s- GL /HMS

(0^/45)s

109.0

(47..3)

57.9:.

(47.3)

2.8

5.3

4.8

1.1

2.7

3.0

114.0

65.0

TABLE 4. -HYBRID COb11'OSITES TESTED IN REFERENCE 2

^..

.Laminate
(0 /45 /90)

Material

S-GL/T-300/S-GL

T-300/B/T-300

B/T-300fT-300

S-GL/B /s -GL

Kev 49/T- 300/Kev 49

T-300 /RMS /T-300:

xT5 /B/T-300`..

S-GL/HMS/S - GL

Panel

Longitudinal (0) tension,

compression., and
shear coupons

(0^/45/90)

(0/452/90)S

(04/ 452)S

(0^/45^/g0)s

(D/452/90)S

(04/45 /90

)s

(04/+45/90)s

(0/t45/90)s

(05/45)s

(p^/49 0/90)S

(o/x-.452/99)5

(02/452/90)S

(04/t45/90)s

( G /{452/90)5

(04/453)S

(04/45/90)5

(0/+452/:90)S

(04/45 /90 )5

(0/+452190)s

Material

:Laminate

S-GL/T-300/S-GL

1
2

3 , ^

T- 3o0 /B/T-300

B/T-3oo/T-3oo

S-GL/B/S-GL

5
6

Kev 49/T-3oo/Kev 49

T-3oo/xMS /T-3oo

1
2
3
1
2
3
1

.stress,
average
ksi

Von.MisesHill

122.x+
53. 4

32.9

48,4

22.8

33.7

141:'5

29.7

44.4

150.5

31.1.

1+6.6

1.1.7.5

128: 4

63.3

92.7

140:7

64.7

97.0

37.0

39.9

58..2

88.1

40.9

61.3

157.5
95.6
48.1

11+1.4
89.1
35 .1
147..5-

147.2
132.:7.
51.3
177.7
62.8
53..3.

147.2
151.6
57.0
177.7

155.5
89.5
35.9
172.5

ll6.6

58.4

97.7

51..1

155..5
134.3
`53.8
180.8
87.2
76.7

68.1
ls2. 7
139.8
98.9
37.7

124.2
133.2.

xTS /B /z -3oo

S--GL/HMS/S-GL

43.7

Von MisesHilly

Maximum
stress

Maximum
stress c

Maximum
strain

137.8

39.4
26.0

59.1
39.0

20.9

101.1

Von MisesHil1d

14.5

152-.F

21.1
16.0

2
3

53.6

36.7

24L 5

56.3.

8i. 9

149. `4

74.5

111.8

.131..1

116.2

4g.3

58.6

71..0

60.4

77-5

63.6

57.2

29..5..

34.2

40.0

36.6

43.1

39.9

72.0

36.9

41.4

46.2

47..1

49.2

51+,1

1_
2
3

1.05.0
40.5

60.8

89.2

135.8

62.0
30.9

65.5
32.3
101.0
74.8
36.3

92.0

Predicted tensile . fracture stresses , Sxj, , ksi

Panelb Fracture

>_
2
3
1

77.0
26.6
116>5
117.8

2
3

42.3
log .6

30.2

72.4
69.7
34.0
165:2

44.0

104..9..
ioi.9
49.5

104.9

75.3

132.9

71.2.
35.0

93.0
46. 4
112.4
106.9
52.5

66.5

1.65.2

64.4
165.2

36.3

1+9...6

80.4

43.0.

64.5

27.0'

38.5:

75.1

29..4

44.2

15.5.

28.6

42. 1

107.7

29.3

44.0

71.9

169.1+

1.69:.4

160.0

20.8

baF'rom ref . '2.

Refersand
to hybrid.
configuration shown in table ^+.
cciS2T
S
12 are 1.5 times the values shown in-table 1.
5 2T and 12 - 50 ksi.
S

^.,,
i

r'

_..^

_ ^ w .,_

w.

^.
_

THERMAL EXPANSION MEASUREMENTS (-100 F TO +300 F)a

T^

'

Thermal expansion
coefficient,
in./in./F

Configuration

Material

Longitudinal

Kev

49/T - Soo /Ke v 49

(04/45/90) s

- 0.76x10

Transverse

-6

3.oxlo - 6
3.8

T-300/HMS/T-300

(04/ 45/90)S

5-181/G-181

(04/45)s

3.3

^+0

(04/45 /90 )5

-.6k

3.1

Kev

^+9 /G-181E/Kev

49

3.4

j
r'rom ref. 2.
^i

TABLE

7. -

SUPERHYBRID TRIP-SPECIMEN IZOD IMPACT STREYGTHa

Test
direction

Constituents

Izod impact strength

in-lb/in2
^

.Low
^B/A1 (5:6-mil-di an fiber) b
^

Number of
specimens

High

f--- --Longitudinal
Transv2r_e

135

331 +^
^

335
167

3
2

Longitudinal
Transverse

319
129

338.
147

32

Ti, B/A1,

Longitudinal.

634

720

^r/Ep, d Ti

Transverse

186

j(

202.

Ti, Gr/Ep

Longitudinal
Transverse

573

734
171

3
3

Longitudinal

454

658
143

6
2

B/A1

(8.0 -mil-diam

Ti, B/A1,
Gr/Ep

fiber) b

142

Transverse - ^ 129

aFrom ref. 40.

b Diffusion-bonded, 1100 aluminum alloy,
Adhesive bonded.
aGraphite/epoxy.

TABLE 8. -SUMMARY OF-FABRICATION COSTS FOR

1
i

ALL HYBRIDS SHOWN IN TABLE 4a

Forme

Method

Hand layup
Machine assist
Automatic machine
12-Inch tape Hand layup
Machine assist
2^+-Inch fabric Hand layup
36-Inch fabric Hand: ayup

3-Inch tape

Fabrication
rate,
lb/hr
2.5 5 -

3.5

4 - 5
4 - 5
8 - 10
7.5 -`8.5

8 - 10

Fabrication
cost,
$/lb
6.00
2. 50 - 3.00

x+.25 -

3.00 - 3.75'

3,00 - 3...75
1.90"
1.75 - 2.00
1.50 - 1.90
1.50 -

^'

Material

Resin
content,'
wt^

Specific
gravity

AS/5208

29.3

1.59

209.5

200.3'
22.4. 5
211.4
30.9

As/934

AS/3501'

28.0

1...56

1.59

Shear,
ksi

Cure

18.7
17.9
18. 8
18.4

10.7

Cure. at room temperature (275 F) at ^+ to 6 F per min

at 'vacuum pressure; hold for 1 hour at 275 F; apply
85 to 100. psig and vent; 275 to 355Fat ^+ to 6 I'
per min; .hold for 2 hr at 355 F; cool to 140 F under
pressure-

18.9

12.5
11.1

Flexural Flexural
stress,
modulus,
ksi
msi

11.2
10.0

10.6

254.3
250.3
224; 5

20.2
18.:9

11.0

2 ^

19.3

11.5

244.3
256.0

18.4

21.4

257.9

22.2

14.8
15.3
15.4

252.7

20.7

15..2

271.1

Gure at room temperature (250 F) at 1 to 5 F per min

at vacuum pressure;'hold for 15 min at 250 F; apply
100 psig and vent; hold for. 45 min at 250 F; 250 to
350Fat l to 5 F pex min; hold for 2 hr at 350 F;
cool to , 140 F underpressure
Cure at room temperature (225 F) at 2 to 3 F per min
at vacuumpressure; apply 85 to 100 psig at 225 F and
hold vacuum pressure; continue temperature rise to 350 F;
hold at 350 F for 1/2 hr at 85 to 100 psig and vacuum;
cool under pressure and vacuum to 140 F.

b
AS 5208

28.6

93^

5208b

3501

30.5

1.61

1. bl

259.8
2+4,8

20.6
20.5

17.3.
17.8.

19.8

15.4

25$.6_

20.8

16.8

249.4.
21+1.1
242.1

21.0

17. ^+

22.2
19.3

16.1
16.4

2^E.2

2d.8

1b.6

Cure at room. temperature (250 F) at 3 F per min at

vacuum pressure; . hold for 45 min at 250 F; apply 100 psig;'
vent then :hold for 2 hr at 355 F:and 100 psi; cool under
pressure and vacuum

^ 3501

29. 6

1.60

260.1

20.0

15.6

255.1

19.6

14,6.

253.4

19.8

17.2

256.2

19.8

15.8

;^` >
^ Via:

^.'

brom reE. 3._

Alternating plies of each system.

``

,:

^''^"^^^

Kevlar 49 or S-glass leverywherel

S-glass

AS or HMS graphite

HMS graphite

Kevlar 49 or S-glass

HMS graphite

AS or HMS graphite

HMS graphite

S-glass
AS graphite
HMS graphite
AS graphite

Kevlar 49 or S-glass

S-glass

S-glass
1a-21 Corelshell.

la-lllnterspersed.

lal Interply.

0 0 0 0
I
I

^ S-glass
Kev!ar 49

00 0 0 0

AS or HMS graphite
0
O o
AS or HMS graphite
0Q o O o

HMS graphite

oQ
AS or HMS graphite

O O

Ic-11 Interspersed.

lbllntraply.

Ic-21 Corelshell.

0
o^

Icl Interplylintraply.

Figure 3. -Cross sections of typical hybrid composites.

_ _.._ Ti
FM 1000

^Ti IADHESIVEI

^ oo ^^

^ FM 1000

`^^ BIAI
`_ ^FM 1000
_`^-- ASIEPDXY
^^ FM 1000
`

i
:.

^,

Ti

-^

^^

C S -75035
Figure 4. -Cross section of superhybrid composite (from ref.
61. X50.

i
I

^
^

'.i

FIBER
VOLUME
RATIO

'

,N 150
,^

^
f

i
i

^
;
^

^^

3:1 ^^ ^ ^2:1

it
^ 100
^

/^^:1
/^/
,
/^/

/%
^,
^^0:11S-GLASS)
^
^ `^
^^-1.0 (GRAPHITE)

50

i
5

I
^
^

I^

ZO

15

10

25x10-3

STRAIN, inlin

^
^

Figure 5. -Summary of tensile (0) stress-strain diagrams

for PR-2861Modmor II graphitelS-glass. composites having
various fiber volume ratios, compared with conventional
glass and graphite composites with epoxy resin. (From.

ref. 4.

+I
I
^

10

^3:

FIBER
VOLUME
g

RATIO.

i
'^
Y

vi

va

W
^

is

2:1

3:1

^
a

i
i

I^

2
e

6x10-3

STRAIN, inlin

'

Figure 6. -Summary of tensile f90) stress-strain diagrams-for PR-286/Modmor IIgraphite/5-glass com=

posites of various fiber volume ratios. 1From ref. 4.)

^
'
I

;'

. .
.^

,.

-^

E-8y^0

120

40

STRENGTH

O
?'

.200

q0

W .N

^ y, ^
^n
N .^ N
^W E

_^ Z0
ZJ
^
o
o^ 10

W
^

W
J

^ ^

15O

^ _

tW.Y

Z^ 100 1
oz
^
_
'_ ^
N

^._

STRENGTH

^^
,o

MODULUS

10

=v
^
0

.^
W
^

W ^,;
v,^ 3

^"
W ^=
Nom,

>

1
a^
^

>

^
^

40

^^^^

^ ^^

^ ^^

^
,^

O
^'`^

^^

60

.x

2.0

1.5

a^.

10

z^

10
0

2.5

2D

(c) LONGITUDINAL COMPRESSIVE STRENGTH

AND MODULUS.
STRENGTH
---- MODULUS
O
LONGITUDlNALTORSION
^
TRANSVERSE TORSION
12
SHORT BEAM
O

O STRENGTH MATETI
D MODULUS STRAIN
^ STRENGTH AT 0.4
PERCENT STRAIN

it

40

fa) LONGITUDINAL TENSILE STRENGTH AND

MODULUS.

W
_,

on.

100
N
Y

Qz

5U

,^

^ MODULUS

>

cn

RELATNE GRAPHITE FIBER CONTENT, VOL%

(b) TRANSVERSE TENSILE STRENGTH AND

MODULUS.

a
^-

Z0

40

60

80

Figure 7. -Fracture stresses (strengths) of hybrid iGY-70

graphitelS-glassl. (From ref. 7.)

100

\^^^

^^^^
^^^^^^.^^^

`^

T---^A

0
20
80
100
60
^
RELATIVE GRA'PHIT^ FIBER CONTENT, VOL%
(d) SHEAR STRENGTH AND MODULUS.
Figure 7. -Concluded.

j'^

AS AS GRAPHITE CONVENTIONAL
COMPOSITES
S S-GLASS
(UNIDIRECM HMS GRAPHITE TIONAU

Y 300

^,

250.
^

^ ASIS-GLASS ^ HYBRID
HMSlS-GLASS COMPOSITES ^^ "
^

AS

.^,.

^/ /^

of

200

/O

Q.

^.

LL 150
0

10

20

30- 40

50

60

70

80

90 100..

GLASS FIBER VOLUME RATIO

I
^,
rn

Figure8. -Flexural strength of hybrid (AS/S-glass and.

HMS/S-glass) interply composites as function of glass
fiber volume ratio. Span to depth ratio, SID, 32. (From
ref. 5. )

I
W

'

HMS
- HMSIS-GL .HMS/S-GL HMS/S=GL
(45 VOL %
GRAPHITE (10 VOL %
(23 VOL %
GLASS)

,^

GLASS).

GLASS)

^
Figure 9. `- Interply load deflection cure and flexural fail
^ ure modes for HMS graphite and. HMS graphite/S-glass.
with various glass contents. Span to depth .ratio, SID,
32. (From ref.. 5. )

DEFORPJIATION
.-

F -^'iii0

!^

00
^^
b^

AS

^a

AS GRAPHITE
CONVENTIONAL
COMPOSITES
IUNIDIRECTIONALI

SO S-GLASS
^M HMS GRArHITE
O
^
q
O
^
Y

CORElS HELL
INTRAPLY
INTERPLY
INTER PLY/INTRAPLY

HYBRID
COMPOSITES

^^

^ S

^ c"40
c^
z

^ 160 ^

/^
V

l^
rye_,

120 ^
0
10 20

30 40

50

60

I
70 80

^^
90 100

GLASS FIBER VOLUME PERCENT

Figure 10. -Flexural strength of hybrid IASIS-glass - HMSI
S-glass) core/shell, interply, and intraply composites as
function of glass fiber volume ratio. Span to depth ratio,
SID, 32. (From ref. 5.1
la) INTEkPLY INTERSPERSED.

Ibl INTRAPLY.

Figure ll. -Fracture modes of HMSIS-glass interply and intraply hybrids

Ifrom ref. 51.

.+..

CONVENTIONAL
COM POS ITE,S
(UNIDIRECTIONAU

S-GLASS
HMS GRAPHITE

COREIS HELL
HYBRID..
4` INTRAPLY
_COMPOSITES
q INTERPLY
INTERIINTRAPLY

35

^^ ^
J
0

25

lS^
^

20

^p

o ^^
;,

15

x_

10

\^

S
5
0

10

20

30

40

50

b0

70

80

90

lU0

GLASS f:16ER VOLUME PERCENT

Figure 12._-Flexural-modulus of hybrid {HMSlS-glass) com-

posites as function of glass fiber volume ratio. -(From
ref. 5.)

`'
)

,'
!
^,
r, .
i

9
_

^,

7
`

'
j

ia

_
7

-J
#

,7

+I
L
3

^^ ^ 1

I
I

^-- GRAPHITEI
f PDXY (ASIE)
---- .BIAI (DIFFUSION CONSTITUENTS
BONDED)
-- BIAI (ADHESIVE
BONDED)

,'
^

Ti, BIAI
^SUPERNYBRIOS
- -- Ti, BIAI, GrlEp

240.

200

^^

160

1Z0

^ %/

so

^,,^^ ^^

^^ /

'

a
^^ ^/
^
,

._
^{

40

Y _
N
N

^^^
, ;
/5
,^
^

(a! LOADING PARALLEL TO FIBERS.

5C

,.

.^

40

' /'

30

^^

^.^

i
^//

20

/ ^'
1

^^/
'^
.'/

i^

'

^.

l0

^^'^'
a

--. _ _

--

_.

r'-^98^
140

^,

^ _FRACTURE-^^
120

80

100
70

60

,N

Y 50
N

^
t

STRESS

^ ^ POISSON'S STRAIN
^

^o

20

10

^i ;

'

FRACTURE,,`

90

80

w_

^
^

0 POISSON'S STRAIN

60

STRESS

+ ^^--POISSON'S STRAIN
I i
^^
,--AXIAL STRAIN
^^ (

^i

^^

i'

I ^/
I ^/
15
10
STRAIN, inlin

^
20

25x10-3

Figure 14. - Stress-strain diagrams for uniaxially loaded.

angleplied graphitelS-glasslepoxy hybrid composite
(t4510)s. LoadparalleLto0o .direction. lFrom ref. 8.)

I^^ POISSON'S STRAIN

^ ^
i

, i^^ ^ ^

^^ AXIAL STRAIN

10

20
STRAIN, iNin

30

40x10-3

Figure 15. -Stress-strain diagrams for uniaxially load angleplied Kevlar 4915-glasslepoxy .hybrid composite ^45104 .
s
(From ref. 8.)

100

\FRACTURE-.^`

FRACTUR^.T,
}

_50
80

^
M

40

60

^
^

N.

(^

,
)

v;
,N 30
N

O ,STRESS
D POISSON'S STRAIN

O
h

I
^

_'.

20

_
^;

20

I
,

I
^
r-POISSON'S STRAIN
^i ^
^^-AXIAL STRAIN

f`

I
,^
..,

^..

/
^^

10
STRAIN, nlin

^
10

^
^

/^^

.^`

15

20x10_3

AXIAL STRAIN

^i
^

,POISSON S STRAIN

5x10-3

STRAIN, inlin

Figure 17. -Stress-strain diagrams for uniaxially loaded

HM graphitelKevlar 491epoxy angleplied hybrid composite
Figure 16. - Stress-strain diagrams for uniaxially loaded
anglepled HM graphite/Kevlar 491epoxy hybrid composite . (t 45IOIO)s. (From ref. 9. )
^45IOZ^ . (From ref. 8. )
s

'.
+.I

2x10-3

i
-2

.,.,.
-4
O

90

^ ,f45 DIRECTIONS

-6

100

140

-8

-10
60

180

22(1

260

300

340

380 ,

_.

TEMPERATURE, F

,^

Figure 18. -Restrained strains in )ongitudinal LO)

Kevlar 49 plies of (0 KevI45 GrlO Gr1 s and (t 45
Gr10 Kev10 Gris HM graphitelKevlar 491epoxy hybrid
composites. (From ref.. 10. i

^
oo

y
,

W
'a
Zx10`3

.c

z -2

I_,

90

d 45 DIRECTIONS.

-4

60

100

140

180

220..

260.

3(10

340

380

TEMPERATURE,. F
Figure. l9. -Restrained strain in longitudinal (01

graphite plies of (0 Kevl 45 Gr10 Gris and (t 45

Gr10 KevIO Gr)S HM graphitelKevlar 491epoxy hybritl
composites.. (From :ref. 10.1

i
i

==:.;% t

j
^,
i
i

_
1x10-3
^;

c ^
^^

z
^

_1 ",

p 900

^ f45 DIRECTIONS

-2

,,

0 0

-3
60

^`
i

100

140 _180

220

260 300

340 380

TEMPERATURE, F

Figure 20. -Restrained strains in longitudinal (0)

S-glass plies of (0 S-GLI45 Gr10 Gr) 'and (f 45
Gr10 S-GLIO Gr) s HM graphitelS-glassfepoxy hybrid
composites. (From ref. 10. )

0w

`;

^,

^
20

Y
N
0
N
,,,

N '^..
u.1 -

^.
i

W

Z

^^

_^

~ -60
^
'

-8O
-100 -80

-60

-40

-20

20

40

60

LONGITUDINAL STRESS, iai

Figure 21. -Interaction diagram for S-glasslboron hybrid
composite 03145^S. (From ref. 19.)

I
f
j

-:

200

I
4

KEVLAR 491GRAPHITE

160

^
O

^^-^'
Y

^^^

^^- KEVLAR 291GRAPHIIE

^^^

THEORY
-- YIELD

^
v,
j

^,

^
'

..,..

^^^

120
;)

`^

80

'

KEVLAR 291T-300 GRAPHITE

KEVLAR 491T-300 GRAPHITE
KEVLAR 491AS GRAPHITE

O
O
^

z
^

'!

i
i

I
0

20

40

80

60

100

GRAPHITE CONTENT, PERCENT OF TOTAL FIBER CONTENT

Figure 22. -Tensile strength of Kevlarlgraphite interply
un idirectional hybrid composites compared,with theoretical prediction.. Total fiber content, 60 vol %. (From
ref. 24.)

W
I
I

`LOAD ANGLE, A

LOAD

LOAD.

DIRECTION

ANGLE,....:

r S-GLASS

deg

S-GLASS ,,
j

45

90

125

^-
..
'

W
^^
^W
a - o
^ F-^

T-300 -'^
100

^ ROOM
^ %^ TEMPERATURE

WaW
^
N
^

75 100

100

200

300

TEMPERATURE,: F
Figure 23. -Tensile fracture stress of S-glasslT-3001
S-glasslS-glass hybrid,composite ^031t45190103
s
as function of temperature. (From ref. 2.)

^.

400

i
i

w
125
,,,,

^
t--

'

w 100
a
^

'

75

...
LOA D

0
^

it ^

ANGLE,
^

o
z

deg
0

q 90
45
^

50

,^-ROOM TEMPERATURE
V)i
,,,.,
v;

25

100

100

i
o

v^

400.

^:

LOAD
ANGLE,.

LaJ

o
^

deg

125

j
p
'.

q 45
90

^ ^

W,
(/')

'
di

^
J y^.1

300

Figure 24. Compression fracture stress of S-glass!

T-3001S-glasslS-glass. hybrid: composite ^031t45190IO^^
S
as function of ternperature. (From ref. 3.

150

200

TEMPERATURE,. F

^ 1 .100
o ^
^ o

ROOM TEMPERATURE -^,

75
_100

^
100

200'

300

400

TEMPERATURE, ^F
Figure 25. -'Tensile fracture modulus of S-glasslT=3001
S-glasslS-glass hybrid composite 03145190103 as
s
function of temperature. (From ref. 2.)

f.

150

oW
z
^
^ >

LOAD
ANGLE,.
deg

125

o a

,^

45

^ a

N
Z i

100

No

,^ ROOM TEMPERATURE

r^

75.
100

100

200

300

400

TEMPERATURE, F
Figure 26. -Poisson' s ratio of S-glasslT-3001S-glass(
S-glass hybrid composite ^031t 45I90103 as function
s
of temperature. (From ref. 2.)

150

c
z

W
^ _'
d J
Q

125

^ 100
>

_. ^.
^

'

^
G

____,___

0-- MODULUS

1
j
50

--0- .FRACTURE
SHEAR. STRESS

^
25

9
``^
`q

^0
m

75

g ]9

100

^, --.ROOM TEMPERATURE
0

Z00
100:
TEMPERATURE, F

300

Figure 27. -Fracture shear stress and. modulus for.

S-glasslT-30015-glasslS-glass hybrid composite
^031f45I90103 as function of temperature. Load
angle,' 0. (From ref: 2. )

400

___

-^ ;8J

^
O

^ GRAPHITE MOD II 11:0)

^,

^ 120
U
100
cam,

oW
^
s
?
#'

^ ^ :1110
W^
n.. ,j,
^ ^

^
Q

^j

^'
,^ MOD II1S-GL (3:1)
--- =^.^__

__

^,. ,
________ ,_
__ ^---,
"'
1-` ^
_
..,
'^ _____
^ ^'^
^'
MO II/S-GL ( li^^'`"^^

80

^X P

^
^

J Q
^
^ ^

50

,rR^DOM TEMPERATURE
100

200
100.
TEMPERATURE, F

300

Figure 28. '- Flexural fracture stress and modulus for

S-glasslT-300lS-glasslS-glass hybrid composite

031+_45190103 as function ' of temperature and
moisture conten^. .From ref.: 2. i

,^

S-GL^^'

20
0

400

;'

AVERAGE

I03 104.
..25

251S

W 75

rMOD IIlS-GL (2:1)

140

SOLID SYMBOLS DENOTE AGING

FOR 200 HR AT 100-PERCENT
ROOM NUMlDITY

125

MODULUS
FLEXURAL FRACTURESTRESS

^
105

1p6

107.

NUMBER OF CYCLES TO FAILURE

Figure 29. -Tensile fatigue lives of unidirectional
hybrid composites and constituents. Fiber orien-

Cation, 0; stress ratio, 0.1; cycling frequency,

1800 tiz; test femperafure, room temperature.

(From ref. 4.)

i

--___
_

__

^,

MATERIAL

CONFIGU- STATIC
RATION

STRENGTH

ksi

rt45IO}

'.
j '
I

100

s
---------
^t45102
s

--o--- KEVLAR 491

^f450102^
s
Ct 45^1Og}
s

S-GLASS
----- S -GLASS 1
S-GLASS
^- ^^ + ^^

^
z
it

KEVLAR 49
---- 10EVLAR 49
-^0-- HiS GRAPHITEI
S-GLASS

F-

o
^
W

w
,,,
f

T-3001Kev 49-1811T-3001T-300
^0^45^90 01021s

S-GUT-3001S-G LIS-GL

82

^0If
3 45019001003^s

96
91
92
124

LL;

OPEN SYMBOLS DENOTE NO AGING

125

SOLID SYMBOLS DENOTE AGING FOR

500 CYCLES AT 65TO 300 0 F

^ LL,
^ ^
^ >
^ ^

F 100
^ ^

^ ^

^\

N ' 60

NQ

U_

Gi

106

HTS GRAPHITE/
2s
HTS GRAPHITE `
HTS GRAPHITEI ^t45^102^

^^ ^```
40

75

a^

=
o
^^
o
z
_ F.-

^z

^ ^

;'

ROOM
TEMPERATURE

_,_. _
^
F
^[

z
N

-100

0
104

j
105
106
NUMBER OF CYCLES TO FAILURE

107

Figure 30. -Tensile fatigue lives of angleplied hybrid

composites and constituents_ Stress. ratio, 0. l; cycling frequency, 5 and 30 Hz; test temperature,
room temperature. (From ref._8. )

100

200

300

400

TEMPERATURE, 0F'
Figure 31. - Interlaminar shear stress at fracture (short
beam) for hybrid composites as function of thermal cycling and temperature. IFre;n .ref. 2. )

1'

100

U
O

KEIILAR 49 O
60

^
N

o
^'

40

MATERIAL
O
KEVLAR 49/T-30015208
^-^-- KEVLAR 291T-30016['-907
0 KEVLAR 49/T-30016 P-907
--+!^ KEVLAR 49/
AS GRAPHITEIFR-.286
-^Cl-- KEVLAR 491
HMS GRAPH11E1PR-286

INTERPLY (HMSIS- GU

INTRRPLY (ASIS-GL)
INTRAPLY tHIVIS/S-GL)
.INTRAPLY (ASIS-GL)
O' COREISHELL ('rIMSIS-GL)
CORELSHELL tHMSIKEV)
0 INTRRPLY (HMSIS-GU

KEVLAR 29

.a
w

80

J-I^LHJJ

ZO

40

60

80

100

__

HYBRID
COMPOSITES

INTERPLY (ASlKEV)

NUMBERS IN PARENTHESES DENOTE

HYBRID CONTENT IN VOL%
^

^ 20
o
o
^
a

KEVLAR CONTENT, PERCENT OF TOTAL FIBER CONTENT

Figure 32. - Izod impact strength of unidirectional

Kevlar hybrid composites. Total fiber content,
60 vol %. (From ref, 24.)

i10)?^
O (25)
^
; ^ (36)
^ 15
^ (10) 16.5) i16)O , ^ (10)
^ (25)
^-^-.------^
-- _O
(10)
AS 'TC)(50)
(25)
(50)C^
^t15)

10

Sam

0
40 60

342
FT-LBII^i2
80 100 120 140 160 180: 200 220 240. 260
IMPACT ENERGY, ft-lblin2

Figure 33. -Flexural: modulus as function of pendulum

impact per unit area for unidirectional hybrid fiber)
epoxy composites.. (From ref. 5. )

-----^---

AS GRAPHITE
O S-GLASS
O
O
0

INTER PLY
COREISIfLL
TOW-BY-TOW
INTRA PLY

vi

CONVENTIONAL
COMPOSITES
(UNIDIRECTIONALI

HYBRID
COMPOSITES

..^. ^

o I5
0
J
Q

10

J
LL.

0

55.0('

a^
^

10
15
25
ZO
HYBRID FIBER CONTENT, VOL ^

100

52.40 49.55 47.20 44.60 42.00

TOTAL FIBER COST PER POUND, DOLLARS

"3.50

Figure 34. -Flexural behaviorlcost trade-off for AS graphite)

S-glass composite. (From ref. 5.1

ou

Figure 35. - Interply hybrid composite compressor blade (from ref. 461.

-^-- ..

._
Figure 36. - Intraply hybrid composite compressor blade (from ref. 461.
NASALswis