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Procedia Materials Science 3 (2014) 2134 2141

20th European Conference on Fracture (ECF20)

Size scale effects on post-impact residual strength of hybrid

glass/carbon/epoxy Nano-composites.
Kavitha N.S1 and Raghu.V.Prakash1, *
1

Machine Design Section, Department of Mechanical Engineering

Indian Institute of Technology Madras, Chennai-600036, INDIA

Abstract
Understanding the material response to macroscopic scaling along the thickness direction in fiber-reinforced composite materials
is important to reduce the effects of scaling-up during design. This paper presents the effect of size-scale of composites obtained
through two methods of scaling: a) ply-level (0gn/90cn)s and b) sub-laminate level (0g/90c)ns where, (n= 2,3,4), on the residual
strength and post-impact response. The strength parameters were determined with and without nano-clay addition (Nanomer
1.30E, clay surface modified with 25-30 wt% octa-decylamine). The hybrid glass/carbon/epoxy composite and nano-composite
(1.5% nano-clay of weight of epoxy) specimens were prepared using compression molding technique. The ultimate tensile
strength of thickness scaled composite and nano-composite specimen was examined. Impact tests were done at two velocities,
viz., 4.49 m/s and 3.78 m/s for both thickness scaled composite specimens with and without nano-composite addition. It was
observed that ply-level scaled laminates absorbs more impact energy compared to sub-laminate level scaled specimens. The
residual tensile strength was found out by conducting tensile test on the impacted specimens. The reduction in residual strength is
more in nano-composite specimens compared to plain-composite material. The damage developed in the ply-level scaled
specimen is more compared to sub-laminate level scaled specimens.
2014
Ltd. Open
access under
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2014Elsevier
The Authors.
Published
by CC
Elsevier
Ltd. license.
Selection and
under
responsibility
of the
University
of Science
and Technology
(NTNU), (NTNU),
DepartmentDepartment of
Selection
andpeer-review
peer-review
under
responsibility
ofNorwegian
the Norwegian
University
of Science
and Technology
of
Structural
Engineering
Structural Engineering.
Keywords:Hybrid composite, post-impact residual strength, ply-level scaling, sub-laminate level scaling, Nanoclay;

*
Corresponding author, Tel: +91-44-2257 4694, Fax:+91-44-2257 4652
E-mail address:raghuprakash@iitm.ac.in

2211-8128 2014 Elsevier Ltd. Open access under CC BY-NC-ND license.

Selection and peer-review under responsibility of the Norwegian University of Science and Technology (NTNU), Department of Structural Engineering
doi:10.1016/j.mspro.2014.06.345

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1. Introduction
Fiber reinforced plastic (FRP) composite materials are widely used in load bearing, light-weight structures in view
of their superior mechanical properties compared to metals. These light-weight structures experience high or low
velocity impact loading during fabrication, assembly or maintenance operation due to accidental drop of tool,
runway debris and hailstones. Some of the damages are difficult to detect with bare eyes and pose a threat during
dynamic loading. The energy absorbed during impact is mainly dissipated by a combination of matrix damage,
fiber-matrix debonding and fiber fracture that results in catastrophic failure of the structure if proper design
precautions are not taken. In order to avoid this, there is a need to test the large scale structure to ensure that there is
adequate residual strength of a damaged structure until the damage is detected. The effect of impact damage is
studied through: a) Impact damage resistance, which deals with the response and damage caused by a certain
impact, and b) Impact damage tolerance, which deals with the reduced strength and stability of the structure due to
damage (Fig 1) [1].
Testing large scale structure is an expensive, time consuming and difficult affair, hence small scale specimens are
used to predict the behavior of large scale structure. Change in mechanical properties while scaling from small scale
specimen data to large scale structure is referred to as size-scale effect. The specimen thickness and the stacking
sequence of the plies play an important role in damage modes. Ply level and sub-laminate scaling are two techniques
used for constructing scale model composite structure at the macrostructure level scaling. In ply-level scaling, the
baseline or laminate stacking sequence is "scaled-down" by simply decreasing the number of layers for each angular
ply orientation. In sub-laminate level scaling, the laminate thickness is scaled by reducing the repeating baseline
stacking sequence as a sub-laminate group (Fig 2).

Fig 1:Impact damage divided into two sub problems [1]

Fig 2:General methods of thickness scaling in FRP composite[2]

The thickness of the laminate is more sensitive to damage due to impact and static loads. Varying the scaling
method changes the ability of laminate to store energy and impact resistance[3]. The delamination area and back face
cracking decreases with increase in specimens area. Increase in panel size does not affect the maximum static force
but has an influence on damage [4]. The scaling effects have been studied by many researchers when the specimen is
subjected to tensile, compression, flexural etc.A three dimensional analysis was used to develop the scaling laws for
impact of marine composites. The elastic response was noted to scale well, whereas, size effect was observed in
damage response. The similitude law is used to predict the elastic scaled structures [5]. The load carrying capacity of

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hybrid composite increases compared to neat carbon/epoxy laminate with slight reduction in stiffness. The matrix
toughness reduces the scaling effects. The material with the tougher resin suffers less impact damage and has better
strength.
Polymer matrix can be toughened with the addition of functionalised Nanoclay[6], as it increases the interfacial
shear strength between fibre and matrix and improvement in the mechanical properties [7]. The type of fibre and
orientation plays an important role in mechanical properties. The fibre failure was found to occur at relatively low
load and in thinner woven roving at high strain rate [8]. The level of impact energy, number of impacts, and the mass
of the impactor significantly influences the residual strength degradation [9].
The residual strength has a significant effect with low temperature.The residual strength decreases with low
temperature in tape carbon epoxy laminate; woven laminate has greater strength [10]. The preload increases the
compression residual strength if the load actually approaches the initial buckling value, since the plate loses its
stiffness [11]. It is noted that while scaling effects and scaling laws of different fibre composites have been studied,
scaling effects of hybrid composites and residual strength are not studied, which is very important for structural
integrity. The objective of this paper is to study the impact response, damage and residual tensile strength for two
types of scaled composites and nano-composite.
2. Experimental
2.1 Material and fabrication technique
In this study, uni-directional glass and carbon fibre matt of 0.25 mm thickness were used as reinforcement materials,
epoxy (LY556) as matrix material and hardener as curing agent. The hybrid laminates were fabricated according to
Figure 2 by keeping glass fibre at 0 degree and carbon fibre at 90 degree orientation; compression molding was used
for specimen preparation by applying pressure at 20 bars and temperature at 80 degree centigrade. The matrices for
the nano-composites were prepared by mixing 0.5, 1, 1.5, 2, and 2.5 % of Nanoclay (Nanomer 1.30E, clay surface
modified with 25-30 wt% octa-decylamine) to the epoxy resin by an electrical stirrer for 3 hours. During electric
stir, shear force is applied on the clay particles during mixing; these dispersed nanoclay particles and exfoliated
nano-composite gives good mechanical properties [12].
Standard specimens of size 25 mm x 250 mm x 4mm (Sub-4 and Ply -4) were prepared according to ASTM-D
3039standards (Fig 3b), and other specimens were scaled down from the baseline specimen thickness of 4 mm to 3
mm (Sub-3 and Ply-3) and 3 mm to 2 mm (Sub-2 and Ply-2). The laminates were cut according to the dimension by
using vertical saw cutting machine for tensile and impact test.
2.2 Tensile testing:
Tensile test was done at a displacement rate of 1 mm/min using a MTS 810 servo hydraulic machine (Fig 3a) for
both nanocomposite and composite specimens. The ultimate tensile strength was obtained from tensile test, which is
useful to know the change in residual strength after impact. Tensile tests were done on specimens prepared with
different percentages of nano-clay addition to understand the effect on tensile strength. It was observed that addition
of 1.5% of Nanoclay provides the highest tensile strength and Youngs modulus.
a)

b)

Fig 3: a) MTS 810 Servo hydraulic machine, b) tensile test specimens

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Fig 4: Stress-strain curve for different percentage of Nanoclay added specimens

It was observed that the ply-level scaled baseline specimen had an ultimate tensile strength of 302.96 MPa; when the
thickness was scaled down from 4 mm to 3 mm, the UTS increased by 12 to 14%, but when thickness was reduced
from 4 mm to 2 mm, the UTS decreases by 7 to 13% in sub-laminate level scaling (Fig 5). The thinner specimens of
sub-laminate scaling had higher tensile strength compared to thinner specimens in ply-level scaled laminate; hence,
one could infer that there is scale effect as the thickness is reduced. Sub-laminate level scaled specimen had 16%
higher tensile strength compared to ply-level scaled laminate. In [0/90]ns laminate, the 90 degree plies share the
damage from 0 degree plies.
b)

Fig 5: Stress-strain curve for scaled a) composite specimens and b) nanocomposite. Ply-x indicates ply level scaled specimen, and Sub-x
represents sub-laminate level scaled specimen.

Sub-laminate level nano-composite does not show any change in tensile strength compared to plain composite
laminate; however, there is 36 % reduction in tensile strength in ply-level nanocomposite (Fig 5). In both types of
scaled nanocomposites, thin specimen had less strength compared to thicker specimens, whereas failure strains are
different with thickness.
2.3 Impact testing:
Impact tests were conducted at room temperature using a single impact drop weight impact machine, which consists
of drop tower equipped with an impactor and a variable crosshead weight arrangement, a high speed data acquisition
system, and a load transducer mounted in the impactor (Figure 6). The crosshead/ impactor weight was kept
constant at 5.2 kg for all tests. Impact energy was varied by changing the drop height. The specimen support fixture
is at the bottom of impact testing system; a stopper is provided at the bottom of the machine to stop the impactor
after single impact. The shape of the impactor was semi-hemispherical with a diameter of 16 mm; the falling weight

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is guided by two fricition less columns. A LVDT is placed at the bottom of the specimen to measure the deflection
during impact. The impact tests were done at two velocities of 3.78 m/s and 4.49 m/s on both scaled nano-composite
and plain-composite specimens.Transient response data during impact test, such as, velocity, deflection, load and
energy as function of time is recorded for all specimens.

Figure 6: Low velocity impact test setup

The load-displacement response of the scaled sublaminate level and ply-level scaled nano-composite varied with
thickness.When an impact load is applied to the composite plate, it absorbs the impact energy by elastic deformation
(rebound of impactor) and plastic deformation. The energy absorbed energy by the plastic deformation remains as
damage in the specimen. The load-displacement response for a specimen thickness of 3 mm sub-laminate level
scaled nanocomposite specimens shows closed loop response. The area under the load-displacement curve
represents the deformation energy that is initially transferred from the impactor to the specimen surface. The area
included inside the loop refers to the energy absorbed during the impact. The maximum peak load is achieved in
case of 3 mm thickness specimen at 3.78 m/s velocity in sub-laminate level scaled nano-composite. The maximum
peak load for ply-level and sub-laminate level scaled nano-composite specimens are the same; however, the peak
load decreases with increase in velocity (Figure 7(a), (b)). For thinner specimens, the load-displacement response is
different and indicates penetration of impactor inside the specimen. The glass fiber has lower stiffness than carbon
fiber, hence for thin specimen penetration of impactor may be taking place.
The peak load for specimens without addition of Nanoclay is different for both scaled composites; it is higher for
ply-level scaled specimens compared to sub-laminate level scaled specimens. As the impact velocity increases, the
peak load decreases with thickness (Figure 7(c), (d)). Rebouncing of load can be observed for 3 mm thickness and
high velocity for both types of scaled composites. The thicker nano-composite specimen has more rebouncing but
peak loads are same for two scaled specimens.
The damage in the specimen due to impact suggests that intra-ply matrix splitting cracks are created first,
followed by de-lamination growth from these cracks. This delamination initiates at almost every interface through
the specimen thickness, propagating from the cracks in the back plies of the interface. The delamination in the 45
interface follows the matrix split in the +45 direction as shown in (Figure 8(a)). The impact damage mechanism in
ply-level and sub-laminate scaled specimens is different at same velocity. The failure mode in hybrid composite is
different from glass/epoxy or carbon /epoxy laminate. De-lamination failure was observed in glass/epoxy laminates
while fibre fracture was observed in carbon/epoxy laminate. Combination of these two fibres results in change in
failure mode and is based on the stacking sequence. The stacking plies of same fibre orientation increases the stress
concentration at the adjacent interface, due to increase bending stiffness within that plies, which leads to
delamination, hence delamination failure mode can be observed in ply-level scaled specimens (Figure 8(b)). The
shape of the damage is circular in ply-level scaled specimens. If the fibre orientation is different between the
adjoining plies, delamination occurs at the interface and will not propagate, and leads to fibre fracture. The
delamination initiates when the transverse shear stress exceeds the critical value. The impact damage is found to be

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more in thin specimens than in thick specimens. The damage is detected over the entire thickness whereas in thick
specimens damage is restricted to top three or four layers. This impact damage reduces the impact force. In the sublaminate level specimens (Figure 8(c)), line damage can be observed along the width of the specimen, which failed
by fibre failure because of shear stress between two dispersed plies. In sub laminate scaled specimen, the carbon and
glass plies are dispersed, the carbon plies are more brittle and stronger; as a result, the fibre fracture happened when
the specimens are subjected to impact load. The damage increases with increasing impact load, decreases with
increase in specimen thickness.

a)

b)

c)

d)

Figure 7 : Load displacement curve for: a) nanoclay added sub-laminate level scaled specimens, b) nanoclay added plylevel scaled
specimens,c) sub-laminate level scaled specimens and d) ply-level scaled specimens.

Figure 8: a) Delamination orientation on laminate interfaces as observed by the de-ply technique.[6], b) sublaminate level scaled impact damaged
specimen c) ply-level scaled impact damaged specimen.

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The size of the damage depends on the impact energy absorbed by the specimens. In sub-laminate level scaled
specimen, the impact energy absorbed by the speciemn is high for 3.78 m/s velocity for 2 mm and 3 mm thick
specimens compared to 4.49 m/s velocity (Fig. 9). Nanoply in the figure legend represents laminates with nano-clay
addition prepared by ply-level stacking while nanosub indicates samples with nano-clay addition prepared by sublaminate level stacking. As the thickness increases, the energy absorbed by the speciemn increases for 4.49 m/s
velocity. In both types of scaled nano-composites, the impact energy decreases with thickness for 4.49 m/s velocity
and increases for 3.78 m/s velocity. In ply-level scaled specimen, the energy absorption for 3 mm and 4 mm
specimen has no effect on impact velocity and decreases with thickness. Thin specimen (2mm) has no effect on
velocity in ply-level nancomposite specimen.

Fig 9 : Impact energy verses thickness of the specimens.

2.4 Residual strength

The tensile test was done on the impacted specimens to understand strength reduction after impact damage. Tensile
test were done using MTS 810 servohydraulic machine of load rate of 1 mm/sec for all specimens.The reduction in
residual strength for ply-level scaled laminate is 37 to 47%; as the thickness increases, residual strength decreases
by 17 to 22%. In ply-level nancomposites the residual strength decreases by 40-60% (Figure 10 a-c). In sublaminate
level scaled specimen, the decrease in residual strength is almost constant (50%) for different thickness of the
specimen. Higher residual strengh variation (30-60%) was observed in sub-laminate scaled nano-composites.
3

Conclusions:

The behaviour of two types of scaling, viz., ply-level and sub-laminate scaled hybrid composite and nano-composite
were examined. The following observations were made:
In ply-level scaling, tensile strength decreases with thickness of the specimen, whereas it increases in sublaminate level scaled specimens.
The tensile strength decreases with addition of nano-clay.
The ply-level scaled specimen absorbs more impact energy compared to sub-laminate scaled specimen.
The impact damage shape of the ply-level scaled specimen is circular and in sub-laminate specimen
occurred along the width in the form of line.
Reduction in residual strength is more in nano-clay added composite.
Acknowledgments:
The first author thanks the Dean, Office of International Relations, IIT Madras for providing the Boeing travel grant
to present this work at ECF-20.

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a)

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b)

c)

Fig 10:Residual strength variation with impact velocity for a) 2 mm,b) 3mm and c) 4mm thick specimen.

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