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Composites Part B 99 (2016) 162e172

Contents lists available at ScienceDirect

Composites Part B
journal homepage: www.elsevier.com/locate/compositesb

Review article

A study on the failure behavior and mechanical properties of


unidirectional fiber reinforced thermosetting and thermoplastic
composites
Yan Ma a, Yuqiu Yang b, c, *, Toshi Sugahara d, Hiroyuki Hamada a
a
Advanced Fibro-Science, Kyoto Institute of Technology, Kyoto 6068585, Japan
b
College of Textiles, Donghua University, Shanghai 201620, PR China
c
Engineering Research Center of Technical Textiles, Ministry of Education, Shanghai 201620, PR China
d
Maruhachi Corporation, Fukui 910-0276, Japan

a r t i c l e i n f o a b s t r a c t

Article history: Failure behavior and mechanical properties of unidirectional (UD) carbon fiber reinforced polyamide 6
Received 3 September 2015 (CF/PA6) and epoxy resin (CF/Epoxy) laminates were investigated through tensile tests in this study. The
Received in revised form fracture modes of both CF/PA6 and CF/Epoxy were discussed based on the fiber orientation, interfacial
28 May 2016
properties, Mode II interlaminar fracture toughness and the brush width. Meanwhile, Global load sharing
Accepted 2 June 2016
Available online 4 June 2016
(GLS) model was employed to compare with the experimental mechanical properties and corresponding
fracture mechanics model was employed to analyze the fracture behavior. The results showed that UD
CF/PA6 laminates with weak interface but high Mode II interlaminalr fracture toughness mainly
Keywords:
Polymer-matrix composites (PMCs)
exhibited step-like fracture modes (77%) in interfacial fracture mode (Adhesive failure), while CF/Epoxy
Failure behavior laminates with stronger interface but lower Mode II interlaminalr fracture toughness mostly showed
Damage mechanics splitting fracture mode (69%) in matrix fracture mode (Cohesive failure).
Prepreg © 2016 Published by Elsevier Ltd.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2. Experimental methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.1. Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.2. Experimental procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.2.1. Tensile tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.2.2. End notched flexure test (ENF test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.2.3. Microscope observation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.2.4. Scanning electron microscope (SEM) observation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3. Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.1. model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.2. Fracture mechanics model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4. Results and discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.1. Fundamental properties of composite laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.1.1. Fiber orientation and interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.1.2. Fiber volume fraction, Vf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.2. Mechanical properties of 0 laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.3. Interfacial shear strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.4. Mode II interlaminar fracture toughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

* Corresponding author. College of Textiles, Donghua University, Shanghai


201620, PR China.
E-mail address: amy_yuqiu_yang@dhu.edu.cn (Y. Yang).

http://dx.doi.org/10.1016/j.compositesb.2016.06.005
1359-8368/© 2016 Published by Elsevier Ltd.
Y. Ma et al. / Composites Part B 99 (2016) 162e172 163

4.5. Fracture behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169


4.6. The brushy width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.7. SEM observation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5. Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

1. Introduction fiber to other fibers and to the matrix in its vicinity. On the other
hand, in order to predict the strength and other properties of
Near-term developments in processing and manufacturing composites, a number of mathematical models of deformation,
technology of fiber reinforced plastics (FRPs) have given rise to an damage and failure of fiber reinforced composites have been
extensive range of engineering applications of types of materials to developed.
various application areas including aerospace and aircraft struc- The shear lag model, developed by Cox [22] is one of most often
ture, yachts as well as wind generator blades and other products on used approaches in the analysis of strength and damage of fiber
the account of their outstanding mechanical properties, light- reinforced composites. This model is often employed to analyze the
weight and longer service life [1e5]. Therefore, lots of traditional load redistribution in composites, resulting from failure of one or
materials, metal for instance, were gradually substituted by brand several fibers. This redistribution is described in the framework of
new replacements such as carbon fiber reinforced plastics (CFRPs) various load sharing models. Two limiting cases including global
[6e9]. Mechanical properties of CFRPs are affected by a lot of factors load sharing (GLS) [22e36] and local load sharing (LLS) [21,37e39]
including properties of raw materials, fiber orientation, are often considered. For GLS, load from a broken reinforcement
manufacturing processes and compatibility between fiber and is shed equally to all remaining intact reinforcements across the
resin. Therefore, one of the most efficient methods to ameliorate cross section of the composites. For LLS, one broken fiber sheds all
the capability of composites is to select a reasonable combination of the loads it carried before fracture to its immediate neighbors only.
reinforcement and matrix. Hedgepeth [23] applied the shear lag model to model the multifiber
Because reinforcements and matrices are chemically different, system for studying the stress distribution around broken fibers in
firm adhesion at their interfaces is necessary for an efficient 2D unidirectional composites with infinite array of fibers. Hedge-
transfer of stress and bond distribution throughout an interface peth and Van Dyke [24] generalized the elastic model to 3D case
[10]. Diverse raw materials including fibers and resins and various and included the elastic-plastic matrix into the model. Wagner and
interfaces contribute to all sorts of fracture modes, which bring Eitan [25] employed the shear lag model to investigate the stress
about different mechanical properties of CFRPs [11e15]. redistribution from a failed fiber to its neighbors. The effects of fi-
The tensile fracture mechanism of unidirectional (UD) CFRP has ber/matrix debonding and fiber/matrix interfacial friction were
not been completely understood because the fracture speed of UD incorporated in the model of stress redistribution after the fiber
CFRP is quite fast (Over 500 m/sec [16]). Failure of FRPs often occurs failure proposed by Zhou and Wagner [26]. Problem of independent
abruptly without any symptom or visible signs of damage serving and successive fiber fractures under GLS condition is reduced to the
as an alarm. This characteristic is caused by the progressively problem of failure of single fiber in the matrix by Curtin [27]. He
development of microscopic damages. Such damage prediction is estimated the ultimate strength of the composite as a function of
interesting and challenging, particularly in multidirectional CFRP the sliding resistance, and parameters of the Weibull distribution of
composites. In many cases, however, the failure of multidirectional the fiber strengths based on the assumption that the cumulative
composites was simultaneous with the failure of reinforced fibers number of defects in fibers from the Weibull distribution of fiber
oriented in the loading direction. Hence, understanding the strengths. Using Monte-Carlo method and shear lag-based models,
0 tensile failure behavior of UD composite is vital. Beyerlein et al. [28] and Beyerlein and Phoenix [29] investigated the
There are some proposed theories to figure out the tensile effects of the statistics of fiber strengths (Weibull distribution) on
fracture of UD CFRPs by using numerical calculation methods the fracture process. It was found that variability in fiber strength
[17,18] and numerical simulation methods [19] based on compu- can lead to a nonlinear deformation mechanism of the composites.
tational micromechanics, which were not experimentally verified. Landis et al. [30,31] developed a three-dimensional shear lag model
On the other hand, H.Kusano et al. introduced high-speed video combining with the Weibull fiber statistics and the influence su-
cameras to observe the destruction in detail of CFRPs from images perposition technique, and applied it to analyze the effect of sta-
[16]. O.Siron et al. investigated the mechanical behavior of UD tistical strength distribution and size effects on the strength of
CFRPs by using acoustic emission to detect physical damage composites. Curtin and colleagues [32e35] proposed an approach
occurring within the specimens [20]. to the analysis of the interaction between multiple breaks in fibers,
In a UD composites loaded along its fibers, unless the matrix is based on the Green’s functional model. Then Curtin and colleagues
brittle, internal damage is in the form of individual broken fibers [32,33] employed the 3D lattice Green’s functional model to
[21]. The tendency of one broken carbon fiber to cause neighboring determine the stress distribution and to simulate damage accu-
carbon fibers break determines the fracture behavior and me- mulation. Xia and Curtin [34], and Xia et al. [35] employed 3D FE
chanical properties like tensile strength. This tendency, in turn, is micro-mechanical analysis to investigate the deformation and
dominated by basic parameters of composites such as the fiber and stress transfer in fiber reinforced composites. However, most of
matrix properties, interfacial properties, fiber volume fraction (Vf) above existing related studies [22e39] mainly focused on the me-
and fiber distributions/arrangements in the matrix. Many authors chanical behaviors, their influence factors and mechanisms, while
have researched various combinations of matrix, fiber and inter- ignored the interesting fracture modes, which closely related to
facial properties to investigate the load transfer from one broken fracture mechanisms.
164 Y. Ma et al. / Composites Part B 99 (2016) 162e172

Table 1
Mechanical properties of raw materials.

Material Manufacturer Type E (GPa) s (MPa) d (%) r (g cm3)


CF Toray T700SC 12k 230 4900 2.1 1.8
PA6 Mitsubishi Gas Chemical Company MXD-PA 2.4 82 4.0 1.1
Epoxy Maruhachi Corp. MCP1110 3.2 80.6 5.4 1.2

E: Tensile modulus;s: Tensile strength;d: Elongation;r: Density.

properties based on the fiber orientation, interfacial properties,


Mode II interlaminar fracture toughness and the brush width using
a range of experimental techniques including tensile tests, end
notched flexure (ENF) tests, optical microscopy and scanning
electron microscopy (SEM). Meanwhile, GLS model was employed
to compare with the experimental mechanical properties and cor-
responding fracture mechanics model was employed to analyze the
fracture behavior.

2. Experimental methods

2.1. Materials

These CFRPs were manufactured from a unidirectional rein-


Fig. 1. CFRP plates (a) with thickness of 1 mm were fabricated by laminating 10 plies of
prepreg sheets (b) with stacking sequences of [0]10 for tensile tests and curing at forced prepreg make of reinforcing carbon fiber grade T700SC 12K
280  C for 3.5 min under compression pressure 4 kg/cm2 and curing at 130  C for supplied from Toray and PA6 (Type:MXD-PA) and epoxy
50 min under compression pressure 25 kg/cm2 for CF/PA6 and CF/Epoxy laminates, (Type:MCP939) supplied from Mitsubishi Gas Chemical Company
respectively. and Maruhachi Corporation, respectively. Mechanical properties of
raw materials were shown in Table 1. Mechanical properties
including tensile modulus, tensile strength and density of PA6 and
In this study, typical thermoplastic resin polyamide 6 (PA6) and
epoxy resin were similar. The thickness of a single ply lamina was
thermosetting epoxy resin were used as matrices to manufacture
0.1 mm. CFRP laminates with thickness of 1 mm were fabricated by
UD carbon fiber reinforced PA6 resin laminates (CF/PA6) and epoxy
laminating 10 plies of prepreg sheets with stacking sequences of
resin laminates (CF/Epoxy) laminates through hot compression
[0]10 for tensile tests and cured at 280 C for 3.5 min under
molding to investigate their failure behavior and mechanical
compression pressure 4 kg/cm2 and 130 C for 50 min under

Fig. 2. Appearances of specimens before and after polishing.

Fig. 3. Specimen for tensile tests based on JIS K7165.


Y. Ma et al. / Composites Part B 99 (2016) 162e172 165

Fig. 4. Specimen for end notched flexure test based on JIS K 7086.

compression pressure 25 kg/cm2 for CF/PA6 and CF/Epoxy lami- 2.2.2. End notched flexure test (ENF test)
nates, respectively. CFRP laminate and prepreg sheet are shown in Five specimens of both CF/PA6 and CF/Epoxy 0 laminates were
Fig. 1(a) and (b), respectively. manufactured to standard specimens according to JIS K 7086
The specimens of both CF/PA6 and CF/Epoxy composite lami- standard [41]. Three-point flexure test with the span length 2L of
nates were cut with a size of 25  250  1 100 mm is used as schematized in Fig. 4. The ENF tests were con-
(Width  Length  Thickness:mm) for tensile tests. The fiber di- ducted under a displacement controlled condition with the
rection of both CF/PA6 and CF/Epoxy composite laminates were 0 . displacement rate of 1 mm/min. According to JIS K 7086, the
For specimens of compact tension tests, the fiber direction was 90 . interlaminar fracture toughness in mode II GIIc was evaluated using
the Eqs. (1) and (2) based on beam theory in reference to JIS K 7086
standard [41]:
2.2. Experimental procedures
9a2 P 2 C1
GIIC ¼  1 C  (1)
The tensile tests and compact tension tests were performed in 2B 2L3 þ 3a31
room temperature and relative humidity controlled laboratory
(23 ± 0.5  C, 48 ± 2% RH). Before testing, two edges of the speci-    1
mens were polished by polishing machine in order to eliminate the C1 3 2 C1 3
a1 ¼ a0 þ  1 L3 (2)
defects which formed during cutting process. The appearances of C0 3 C0
specimens before and after polishing were showed in Fig. 2. Where PC is the critical load at the onset of crack growth, a0 and
C0 are the initial crack length and load point compliance of the
specimen. a1 and C1 are the crack length and load point compliance
2.2.1. Tensile tests at P ¼ PC.
78 pieces of CF/PA6 and 52 pieces of CF/Epoxy 0 laminates were
cut into standard sizes for tensile tests as shown in Fig. 3. The
tensile tests were based on the JIS K 7165 standard [40]. Aluminum 2.2.3. Microscope observation
sheets were attached at the two grip sections of the specimens to The fiber orientation was analyzed on a polished surface part of
increase the friction between specimen and collet. The tensile tests cross section of the laminates (roughly over 1000 fibers). Each
were carried out on a computer-controlled Instron 55R4206 screw- micrograph contained typically 100 fully visible fibers. The fiber
driven universal testing machine equipped with a 100 kN load cell orientation for a given fiber was determined as follows: (i) Images
at a speed of 1 mm/min. taken in optical microscopy (VHX-500F CCD camera, which has a

Fig. 5. Cross section observation of CF/PA6 plates (a) and CF/Epoxy plates (b) after binarization and schematic diagram of cross section of the ith carbon fiber (c).
166 Y. Ma et al. / Composites Part B 99 (2016) 162e172

resolution of 1600  1200 pixels in size) were preprocessed by the approximation [42].
aid of the ImageJ software. (ii) Functions in ImageJ software “Make
Binary” and “Watershed” used to get binary photos, then function sf r f
of “Noise / Remove outlier” [21] employed to get clear boundary
d¼ (3)
2ty
carbon fiber images of CF/PA6 and CF/Epoxy laminates as shown in
Fig. 5(a) and (b), respectively. (iii) Four directions (0 , þ45 , 90 and Where, sf is the stress in intact fiber, rf is the radium of radius of
45 ) diameters of the ith carbon fiber were measured by ImageJ fiber, ty is the interfacial shear strength. The predicted composite
software (Functions in ImageJ software “Measure”) and recorded as strength can be predicted as shown in Eq. (4) [43].
Li1, Li2, Li3 and Li4 respectively, which were shown in Fig. 5(c).
  !
The fiber volume fraction, Vf, was measured in a similar way as
5 sf mþ1
above fiber orientation described on a polished surface of the whole sL ¼ sf Vf 1 (4)
12 s1
cross section of both CF/PA6 and CF/Epoxy laminates. The Vf for a
given laminates could be measured as above steps (i) and (ii) then
function in ImageJ software “Analyze/Analyze Particles” could be Where,
P 
Fiber cross section
used to calculate the area ratio cross section of CFRP , which is clearly ! 1
sm
0 L0 ty
mþ1

related to the Vf owing to the unidirectional characteristics. s1 ¼ (5)


rf

2.2.4. Scanning electron microscope (SEM) observation   1


All fracture specimens were observed under the optical micro- 12 mþ1
sf ¼ s1 (6)
scope, and then selected samples were coated with an AuePd layer 5m þ 10
and examined in more detail in a SEM Jelo JSM 5200.
Where m and s0 are the Weibull modulus and the scaling param-
eter, respectively. L0 is the span length at determining Weibull
3. Theory
parameters.
Then, maximizing with respect to the strain yields the ultimate
3.1. model
tensile strength
Rosen [36] introduced the weakest-link theory into the pre-   1  
diction of the unidirectional composite strength s*L , namely the 12 mþ1 mþ1
s*L ¼ Vf s1 (7)
“chain of bundles” model. He presented the UD composite as a 5m þ 10 mþ2
chain of bundles in series; once one of the unit bundles is broken,
To construct a stress-strain curve, a linear relation between fiber
the UD composite would be immediately fractured. Based on Cox’s
stress and composite strain shown in Eq. (8) can be substitute into
shear-lag model [22] and Kelly and Tyson’s model [42], Curtin [27]
above equations, where Ef is fiber modulus.
proposed a global load sharing (GLS) model in which the stress
released from a broken fiber is equally sustained by the remaining
unbroken fibers. Following Rosen’s chain of bundle concept,
sf ¼ Ef εf (8)
important characteristic of the Curtin’s model is that it takes
loading contributions of broken fibers and matrix shear loading
recovers away from the fiber breakage into consideration.
Rosen [36] considers the sustained load inside a bundle with
length 2d, double ineffective length as the working section. The
ineffective length d is defined as Eq. (3) according to the Kelly-Tyson 3.2. Fracture mechanics model

Criteria of splitting are deduced using a fracture mechanics


approach [43]. A model with length L includes a fiber breakage
cluster with length l, which defined as the representative length as
schematized in Fig. 6. In this model, a unidirectional composite was
divided into two parts: I) with cluster with a length l and II) without
cluster with length L-l. A is the composite cross section, a is the
cluster cross section area, s is the circumference of cluster, F is the
tensile load and EL is the composite modulus in the intact part.
The energy release rate (G) related to splitting at the edge of the
cluster could be deduced according to the strain energy in region I
(UI) and II (UII) as in Eq. (9).

Table 2
kI value calculation.

Type Modulus (GPa) kI

CF Vf Matrix VR Calculated Tested

CF/PA6 230 51.3% 3.0 48.7% 119.46 102.31 0.856


CF/Epoxy 230 59.3% 3.2 40.7% 137.78 133.83 0.971

* Calculation was based on the consideration that carbon fiber orientation of both
Fig. 6. Schematic of fracture mechanics model for splitting initiation [31]. CF/PA6 and CF/Epoxy plates both were UD).
Y. Ma et al. / Composites Part B 99 (2016) 162e172 167

 
1 dUI dUII ð1  lÞaF 2
G¼ þ ¼
s dl dl 2EL AfA  ð1  lÞags
ð1  lÞAas2L
¼ (9)
2EL fA  ð1  lÞags
Where l is effective rate of composite modulus inside the
cluster. If A is large enough compare to a, G could be approximated
as in Eq. (10).

ð1  lÞAas2L ð1  lÞs2L a
G ¼ lim ¼ (10)
A/∞ 2EL fA  ð1  lÞags 2EL s

a/s represents the geometry of the cluster. By submitting shear


fracture toughness against splitting Gc into G in Eq. (11).
a * 2Gc Ef
c≡ ¼ (11)
s ð1  lÞVf s2f
Fig. 7. Typical tensile stress-strain curves between experiments and predictions from
Finally the critical cluster geometry c is linked to the shear GLS model.
fracture toughness Gc, fiber volume fraction (Vf) and intact fiber
stress (sf).
Table 4
Material constants used in the present calculation.
4. Results and discussion
Material constants CF/PA6 CF/Epoxy
4.1. Fundamental properties of composite laminates Young’s modulus of fiber (Ef) 230 GPaa 230 GPaa
Diameter of fiber (rf) 7 mma 7 mma
4.1.1. Fiber orientation and interface Fiber gage length (L0) 25 mm 25 mm
Weibull scale factor (s0) 2426 MPab 2426 MPab
The modulus of UD composite laminates could be calculated by
Weibull shape factor (m) 5.48 4.22b
the Rule of Mixtures equation as shown in Eq. (12). Interfacial shear strength (t0) 53.8 MPab 49.9 MPab
  Fiber volume fraction (Vf) 0.513 0.593
EC ¼ kFO  kI  Ef  Vf þ Em  1  Vf (12) a
From Tory Corp.
b
Cited from Ref. [31].
Where EC is calculated modulus, kFO is fiber orientation factor, kI
is interface factor, Ef is fiber modulus, Vf is fiber volume fraction, Em
is matrix modulus. Table 5
The calculated modulus and strength from GLS model.
For investigating the fiber orientation of the i th carbon fiber,
parameter Di was chosen as the evaluation index. Material constants CF/PA6 CF/Epoxy

Modulus (GPa) 117.43 1776.26


Limin
Di ¼ (13) Strength (MPa) 136.02 2291.27
Limax

Limin ¼ minfLi1 ; Li2 ; Li3 ; Li4 g (14) fiber orientation of both CF/PA6 and CF/Epoxy laminates both were
almost unidirectional oriented. In this case, fiber orientation factor,
Limax ¼ maxfLi1 ; Li2 ; Li3 ; Li4 g (15) kFO, of both CF/PA6 and CF/Epoxy is considered 100% at current
study to simply the calculation, interface factor, kI, was calculated
For both CF/PA6 and CF/Epoxy laminates, more than 1000 car-
and listed in Table 2. Even a rough calculation, the values of kI-CF/PA6
bon fibers (n > 1000) were measured and tested for investigating
and kI-CF/Epoxy were 0.856 and 0.971 respectively, which show that
the direction of all carbon fibers based on Eq. (16):
the interface of CF/Epoxy laminates seems better than CF/PA6
Pi¼n laminates.
i¼1 Di
d¼ (16)
n
4.1.2. Fiber volume fraction, Vf
Where d and n are direction parameter and tested number of all Owing to their UD character, fiber volume fraction (Vf) of CF/PA6
carbon fiber in CFRPs respectively. and CF/Epoxy composites were calculated according to their cross
The calculating results showed that dCF/PA6 and dCF/Epoxy were section ratio (as shown in Fig. 5(a) and (b)) between fibers and
0.921 and 0.946 respectively, it could be considered that carbon laminates, which could be measured by image analysis software

Table 3
Mechanical properties of 0 composite boards.

Composites Vf (%) Test Number Modulus Strength

Mean (GPa) C.V. (%) Mean (MPa) C.V. (%)

CF/PA6 51.3 Tensile 78 102.3 10.5 1660 16.2


CF/Epoxy 59.3 Tensile 52 133.8 10.5 2428 18.3
168 Y. Ma et al. / Composites Part B 99 (2016) 162e172

Table 4. Results indicate the GLS and experimental results exhibited


a good agreement especially for CF/PA6 laminates. Although the
load carried by broken fibers is locally distributed in the actual
composites (LLS), the difference in the stress-strain relation and
fiber breakage between GLS and LLS are very small until just before
failure [44]. At the same time, Kamoshida et al. [45] used a 3D shear
lag model for more realistic calculations of the fiber damage and
point out that the local strain concentration around a cluster of
fiber breaks can be neglected before failure. According to the
experimental and calculated stress-strain curve from Eq. (4), it is
shown that the GLS model is valid and useful to evaluate the me-
chanical damage except for the final failure strength and strain (see
Table 5).
The relationship between modulus and strength of tensile tests
together with results from GLS model (Different Vf) were shown in
Fig. 8. The calculated modulus and strength by using GLS model of
CF/PA6 and CF/Epoxy laminates is shown in Fig. 8 as closed triangle
and circle, respectively. Experimental results (Open triangle and
Fig. 8. Relationship between modulus and strength of tensile tests. circle in Fig. 8) indicate that mechanical properties of CF/PA6
composites exhibited more concentrated behavior than CF/Epoxy
composites. However, CF/PA6 laminates exhibited lower modulus
(ImageJ software) as explained in Section 2.2.3. The results of five than GLS model calculated modulus. According to the strain-stress
specimens showed the Vf of CF/PA6 and CF/Epoxy laminates were curves of CF/PA6 laminates as shown in Fig. 7, it is clear that the
51.3% (±2.4%) and 59.3% (±4.1%), respectively. modulus calculated from initial part of stress-strain curves is
smaller than the part of strain over 0.5%, which could be explained
by the difference of fiber orientation.
4.2. Mechanical properties of 0 laminates The results shown in Table 3 clearly indicate that there is an
appreciable scattering of tensile strength. The statistical distribu-
Mechanical properties of 0 CF/PA6 and CF/Epoxy laminates tion of composite strengths is usually described by means of the
were summarized in Table 3. Coefficient of variation (C.V.) value was Weibull equation [46]. The Weibull distribution is given by
calculated by the following Eq. (17) to indicate the stability of
tensile properties of the CFRP and CFRTP composites.

s   a 
C:V: ¼  100 (17) sf
m PF ¼ 1  exp  (18)
s0
Where s is standard deviation and m is mean value of all data.
Calculated stress-strain curves from the modified Curtin’s model where PF is the cumulative probability of failure of composite at
and typical experimental stress-strain curves (CF/PA6: Vf z 0.5, CF/ applied tensile strength sf, a is the Weibull modulus (Weibull shape
Epoxy: Vf z 0.6) are compared in Fig. 7. The basic parameters parameter) of the composite, s0 a Weibull scale parameter (char-
including young’s modulus, diameter and fiber gage length of fiber, acteristic stress). Taking the logarithm of both sides of Eq. (18),
Weibull scale and shape factors, interfacial shear strength and fiber rearrangement of the two-parameter Weibull statistical distribu-
volume fraction used in the present calculation are shown in tion expression gives the following:

Fig. 10. Effect of interfacial shear strength on tensile strength of both CF/PA6 and CF/
Fig. 9. Weibull distribution of tensile strength (s) for unidirectional CF/PA6 and CF/ Epoxy based on GLS model. (Material constants except interfacial shear strength used
Epoxy laminates. in this calculation as shown in Table 4).
Y. Ma et al. / Composites Part B 99 (2016) 162e172 169

Fig. 11. Representative load-deflection curves (a) and fracture toughness results (b) of both 0 unidirectional CF/PA6 and CF/Epoxy composites based on End Notched Flexure tests.

The difference in Weibull modulus, a can be attributed to the


   
1 nature and distribution of the flaws which are existed in the
ln ln ¼ a ln sf  alnðs0 Þ (19)
1  Fi composites. It is well know that many defects in the composites
were formed during precursor manufacturing and subsequent
Hence the Weibull modulus, a, can be obtained by linear various treatments. In present study, these include defects in car-
regression from a Weibull plot of Eq. (19). The probability of failure, bon fiber (misalignment, ultramicropores, etc.), carbon fiber
Fi, at the ith ranked specimen from a total of N specimens is ob- misalignment, bubble, dry carbon fiber bundle (not good impreg-
tained from the symmetric rank method as nation), etc. The existence of these defects in unidirectional com-
posites results in scattering of tensile strength. As a result, the
i  0:5 Weibull modulus a can be regarded as a defect frequency distri-
Fi ¼ (20)
N bution factor [46]. High values of a indicates the defects are evenly
distributed throughout the material. Low values of a indicated that
where i is rank of the specimen from lowest strength to highest defects are fewer and less evenly distributed, causing greater
strength. scatter in strength [47].
The Weibull plots of tensile strength for 0 unidirectional CF/
PA6 and CF/Epoxy laminates are shown in Fig. 9. The Weibull 4.3. Interfacial shear strength
modulus, a, for CF/PA6 and CF/Epoxy laminates were calculated to
be 7.04 and 6.48, respectively. In GLS model used in this study, the value of interfacial shear
strength is cited from Ref. [43]. The effect of interfacial shear
strength on tensile strength of unidirectional CF/PA6 and CF/Epoxy
laminates is shown in Fig. 10. It is clear that the tensile strength
increased in similar Cube Root Function way with the improvement
of interfacial shear strength. To investigate the relatively interfacial
shear strength of CF/PA6 and CF/Epoxy laminates, experimental
tensile strength of both CFRPs were employed to look for the cor-
responding interfacial shear strength as shown in Fig. 10. In detail,
the corresponding interfacial shear strengths of CF/PA6 and CF/
Epoxy laminates are z44 MPa and z68 MPa, respectively, which
means CF/Epoxy laminates possessed stronger interfacial shear
strength than CF/PA6 laminates.

4.4. Mode II interlaminar fracture toughness

The representative load-displacement curves of the ENF tests for


both CF/PA6 and CF/Epoxy laminates were shown in Fig. 11(a). The
calculated mode II fracture toughness of both CFRPs is depicted in
Fig. 11(b). It is clear that the mode II interlaminar fracture toughness
of CF/PA6 laminates (GIIc-CF/PA6 ¼ 2.60 J/m2) was better than CF/
Epoxy CFRP laminates (GIIc-CF/Epoxy ¼ 1.89 J/m2), which means the
ability of CF/PA6 CFRP composites containing a crack to resist
fracture was more excellent than CF/Epoxy ones under the shearing
loading.

Fig. 12. Two typical fracture modes of both CF/PA6 and CF/Epoxy specimens; (a)
Splitting fracture mode of CF/PA6 CFRP composite, (b) Step-like fracture mode of CF/
4.5. Fracture behavior
PA6 CFRP composite, (c) Splitting fracture mode of CF/Epoxy CFRP composite, (d) Step-
like fracture mode of CF/Epoxy CFRP composite. After tensile tests, two typical fracture modes including splitting
170 Y. Ma et al. / Composites Part B 99 (2016) 162e172

Fig. 13. Example of brush width measurement (a) and brush width distribution (b) of whole data.

Fig. 14. SEM observation of fractured area of CF/PA6 and CF/Epoxy composites.

and step-like mode of both CF/PA6 and CF/Epoxy laminates were width of each brush through ImageJ software. All data of every
observed as shown in Fig. 12. Specimens fractured in splitting mode specimen was summarized as shown in Fig. 13(b). The results
exhibited broom-like head (Fig. 12(a) and (c)) while specimens showed that CF/PA6 laminates had more brush with width below
fractured in step-like mode showed more smooth fracture surface 0.5 mm than CF/Epoxy laminates.
(Fig. 12(b) and (d)). The big difference was that 0 CF/Epoxy com-
posite laminates mostly (69%) showed splitting fracture mode after
tensile tests, while CF/PA6 composite laminates mainly (77%) 4.7. SEM observation
exhibited step-like fracture modes.
According to the observing results of CF/PA6 and CF/Epoxy
4.6. The brushy width laminates after tensile tests as shown in Fig. 14, it was found that
lots of PA6 resins surround carbon fibers were torn from fibers
The brushy width distribution of brush-shape fractured lami- which could be directly observed in CF/PA6 laminates. While for CF/
nates in splitting fracture modes of CF/PA6 and CF/Epoxy laminates Epoxy laminates, lots of crack propagated in epoxy matrices and
was investigated in this study. Example of brushy width measure- carbon fibers were hard to be imaged directly. These representative
ment was shown in Fig. 13(a). In detail, the broken specimens after characteristics indicate the fracture modes of CF/PA6 and CF/Epoxy
tensile test were taken photos by microscopy and measured the laminates belong to adhesive and cohesive failure, respectively.
Y. Ma et al. / Composites Part B 99 (2016) 162e172 171

Fig. 15. Schematic diagram of tensile fracture modes of CF/PA6 and CF/Epoxy composite boards.

5. Discussion different fracture behavior, various propagation forms of cracks


related to the fractured brush width after tensile tests. Crack
According to above investigation, it was found that CF/PA6 propagating in the inside of matrices contributed to attach more
laminates with interface fracture form (Adhesive failure) have matrices around fibers after fracture.
unidirectional fiber orientation, a relative weaker interface but high Tensile fracture modes of CF/PA6 laminates with lower tensile
Mode II interlaminar fracture toughness, while CF/Epoxy laminates strength variation (16.2%) and lower Vf (51.3%) mainly exhibited
with matrix fracture form (Cohesive failure) have unidirectional step-like mode (77%). CF/Epoxy CFRP laminates with higher tensile
fiber orientation, stronger interface but low Mode II interlaminar strength variation (18.3%) higher Vf (59.3%) mostly showed splitting
fracture toughness. mode (69%). The lower variation, the more concentrated fracture
Schematic diagram of typical tensile fracture modes is shown in mode was. Based on the research of Cook and Gordon [48], Ger-
Fig. 15. For CFRP laminates, fiber breakage occurred at stresses berich [49] calculated the stress distribution ahead of a crack in an
exceeding the strength of the weakest fiber. An isolated fiber break all-brittle system and found that the tensile stress in transverse
caused stress concentration on the interface around the tip of the direction reaches a maximum valure which is about one-fifth of the
broken fiber. If the interface between fiber and resin was not strong tensile stress in the longtitudinal direction. According to this
enough, the crack in specimens propagated along the interface. mechanism, splitting occurs if
Otherwise, cracks in laminates with very strong interfaces propa-
gated in vertical direction firstly. After the first fiber breakage, CF/
PA6 laminates with weak interfaces mainly exhibited interfacial sc;T
fracture mode as shown in Fig. 15(b), while CF/Epoxy laminates < 0:2;
sc;L
with stronger interfaces mostly showed matrix fracture mode as
shown in Fig. 15(c). In macroscopic view, both CF/PA6 laminates
where sc,T and sc,T are the transverse and the longtitudinal strength
and CF/Epoxy laminates showed two fracture modes including
of composites, respectively. According to Gerberich [49], sc,T
splitting fracture mode (see Fig. 15(d) and (f)) and step-like fracture
decreased but sc,L increased with increasing volume fraction of fi-
mode (see Fig. 15(e) and (g)) after tensile tests.
ber Vf, leading to the occurrence of splitting at high Vf. This is also
In splitting fracture mode, cracks, parallel to the fiber orienta-
approved by Eq. (11), which indicates the fracture bundle sizes
tion, propagated in the inner of matrices of CF/Epoxy laminates
related to the interlaminar shear fracture toughness GII and Vf
owing to their strong interface and low fracture toughness, while it
because same carbon fibers (same Ef, l and sf) are used in present
was harder for CF/PA6 laminates to fracture in matrices easily
study. Therefore, CF/PA6 laminates with higher Vf possessed higher
owing to their high fracture toughness. On the other hand, the weak
fracture toughness than CF/Epoxy laminates with lower Vf, which
interface properties of CF/PA6 laminates led to the inner cracks
indicates that fiber bundles are easier to fracture in small size than
propagate along the interfaces. Different fracture mode led to
CF/Epoxy laminates.
172 Y. Ma et al. / Composites Part B 99 (2016) 162e172

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