28/06/2012

Kunststofftechnik an der Montanuniversitt Leoben 1

Damage Tolerance and Fatigue
Behaviour of Composites
Otto Glckel-Strae 2, A-8700 Leoben, Tel.: +43 3842 402 2100
wpk@unileoben.ac.at
www.kunststofftechnik.at
Behaviour of Composites
Univ.-Prof. Dr. mont. Gerald Pinter
Chair of Materials Science and Testing of Polymers, Montanuniversitaet Leoben
FACC Technical Colloquium Advances in Composites
Salzburg, July 5-6, 2012
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 2
Scope and Content
Introduction:
Why is fatigue and fatigue damage tolerance
of importance?
Topics covered
g Approaches to fatigue of composites
www.kunststofftechnik.at 2 FACC Colloquium 2012, gPinter
Approaches to fatigue of composites
- stress/strain based
- fracture mechanics concepts
g Outlook:
Methodology and testing concept for fatigue life assessment
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 3
Topics of Interest and Open Issues
Are we using composites to the best of their
performance capacity?
Key Questions in dealing with composite fatigue problems
Over- vs.
Under-Design
What is the residual lifetime or residual loading capacity
(strength) if damage occurs or is present?
Fatigue Damage
Tolerance
www.kunststofftechnik.at 3 FACC Colloquium 2012, gPinter
How do current design concepts/methods deal with these
issues?
Applicability &
Limitations
of Current
Fatigue Design
Methodologies
Do we have the proper knowledge and adequate test
concepts and design tools to answer these questions?
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 4
Stress/Strain Based Approach
Methodology
Concepts for the characterization of the fatigue
behavior of engineering plastics
Fracture Mechanics Approach
www.kunststofftechnik.at 4 FACC Colloquium 2012, gPinter
Stress/Strain Based Approach
S-N curves
Hysteresis measurements
Isocyclic stress-strain
diagrams
Fracture Mechanics Approach
Fatigue crack propagation
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 5
Stress/strain based approach
S-N diagram (Whler)
www.kunststofftechnik.at 5 FACC Colloquium 2012, gPinter
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 6
Stress/strain based approach
S-N diagram (Whler)
Laminate with foil defects
(6.35 6.35 mm)
Specimen with notch
(diameter: 6.35 mm)
Artificial defects in woven carbon fabric RTM laminates
www.kunststofftechnik.at 6 FACC Colloquium 2012, gPinter
Two layers of teflon foil sealed with an
adhesive tape in order to entrap air
(Felber, 2006)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 7
Stress/strain based approach
S-N diagram (Whler)
500
600
700

Effect of artificial defects on S/N curves
of woven carbon fabric RTM laminates
www.kunststofftechnik.at 7 FACC Colloquium 2012, gPinter
10
0
10
1
10
2
10
3
10
4
10
5
10
6
10
7
100
200
300
400

,

M
P
a
N , 1
CF-EP qi
CF-EP qi-foil defect
CF-EP qi-notch
23 C, 10 Hz, R=0.1
(Felber, 2006)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 8
Stress/strain based approach
S-N diagram (Whler)
Residual stress after fatigue for differently
compacted RTM laminates
1,000
INJW
1,000
INJW
After 10
6
cycles at 60% of
tensile strength
After 10
6
at 70% of
tensile strength
www.kunststofftechnik.at 8 FACC Colloquium 2012, gPinter
23 C, 10 Hz, R=0,1
0
100
200
300
400
500
600
700
800
900
1,000
INJW
INJBC1
INJST1x8
INJST2x4
INJST4x2

z
B
,

6
0
%

o
f

t
e
n
s
i
l
e

s
t
r
e
n
g
t
h

[
M
P
a
]
0
100
200
300
400
500
600
700
800
900
1,000
INJW
INJBC1
INJST1x8
INJST2x4
INJST4x2

z
B
,

7
0
%

o
f

t
e
n
s
i
l
e

s
t
r
e
n
g
t
h

[
M
P
a
]
(Painold, 2003)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 9
Stress/strain based approach
Hysteresis measurements
Data Acquisition
s
t
r
e
s
s

max

E
www.kunststofftechnik.at 9 FACC Colloquium 2012, gPinter
strain
cycles

min

max

min

E
dyn
E
S
E
S
= Secant Modulus
E
dyn
= Dynamic Modulus
Viscoelastic effects and material damage
Material damage
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 10
Stress/strain based approach
Hysteresis measurements
Data Presentation
r
e
l
a
t
i
v
e

m
o
d
u
l
u
s
cyclic creep
damage
accumulation
E
S
E
dyn
www.kunststofftechnik.at 10 FACC Colloquium 2012, gPinter
Evaluation of the stiffness decrease as a result of viscoelastic effects
and material damage
No deformation analysis
Restricted use as a material law
log (N)
r
e
l
a
t
i
v
e

m
o
d
u
l
u
s
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 11
Stress/strain based approach
Hysteresis measurements
Evaluation of cyclic stiffness for differently
compacted RTM laminates
Dynamic Modulus
1.0
1.1
Secant Modulus
1.0
1.1
www.kunststofftechnik.at 11 FACC Colloquium 2012, gPinter
10
2
10
3
10
4
10
5
10
6
0.5
0.6
0.7
0.8
0.9
E
d
y
n
,
r
e
l


[

]
N [ ]
70% of
ts
INJW
INJBC1
INJST1x8
INJST2x4
INJST4x2
PRIW
10
2
10
3
10
4
10
5
10
6
0.5
0.6
0.7
0.8
0.9
E
S
,
r
e
l


[

]
N [ ]
70% of
ts
INJW
INJBC1
INJST1x8
INJST2x4
INJST4x2
PRIW
23 C, 10 Hz, R=0,1
(Painold, 2003)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 12

m
a
x
10
3
Isocyclic
max
-
max
diagram

max, 1

max, 2

max, 4

m
a
x

max, 3

max

max, 1

max, 2

max, 3

max, 4
N
Stress/strain based approach
Isocyclic stress-strain diagram
www.kunststofftechnik.at 12 FACC Colloquium 2012, gPinter

max
Isocyclic - diagram
log N
10
3
log N

1

2

3

4
10
3

1

2

3

4
10
3
N
(Zahnt ,2003)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 13
Stress/strain based approach
Isocyclic stress-strain diagram
Isocyclic
max
-
max
diagram
accumulative material reaction up to the specified cycle
number
- Viscoelastic effects
- Material damage
Isocyclic - diagram
www.kunststofftechnik.at 13 FACC Colloquium 2012, gPinter
instantaneous material reaction at a specified cycle number
- Only material damage
Assessment and comparison of the resulting deformation contribution
of viscoelastic effects and of cumulated damage
Deformation analysis as a function of cycle number with the potential to be used
as a material law for component design
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 14
PP-SGF30
0
20
40
60

[
M
P
a
]
[1]
23 C
10 Hz
R = 0,1 (tension)
R = 10 (compression)
PP-SGF30
longitudinal
40
60

m
a
x

[
M
P
a
]
23 C
10 Hz
R = 0,1 (tension)
PP-SGF30
longitudinal
40
60

m
a
x

[
M
P
a
]
23 C
10 Hz
R = 0,1 (tension)
PP-SGF30
longitudinal
Stress/strain based approach
Isocyclic stress-strain diagram
www.kunststofftechnik.at 14 FACC Colloquium 2012, gPinter
-0,015 -0,010 -0,005 0,000 0,005 0,010 0,015
-80
-60
-40
-20
cycle N [1]:
10
1
10
2
10
3
10
4
10
5
10
6
cyclic
damage
-0,015 -0,010 -0,005 0,000 0,005 0,010 0,015
-80
-60
-40
-20
0
20

max
[1]
min
[1]

m
i
n

[
M
P
a
]
R = 0,1 (tension)
R = 10 (compression)
cycle N [1]:
10
2
10
1
10
3
10
4
10
5
10
6
cyclic
creep + damage
-0,015 -0,010 -0,005 0,000 0,005 0,010 0,015
-80
-60
-40
-20
0
20

max
[1]
min
[1]

m
i
n

[
M
P
a
]
R = 0,1 (tension)
R = 10 (compression)
cycle N [1]:
10
2
10
1
10
3
10
4
10
5
10
6
cyclic
creep + damage
(Zahnt, 2003)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 15
30
40
50
60
N [1] PP-SGF30 PP-LGF30
10
1
10
2

10
3

10
4

10
5

10
6

[
M
P
a
]
longitudinal
cyclic
damage
50
60
cyclic
creep + damage
50
60
cyclic
creep + damage
50
60
50
60
cyclic
creep + damage
Stress/strain based approach
Isocyclic stress-strain diagram
www.kunststofftechnik.at 15 FACC Colloquium 2012, gPinter
Effect of fiber length
in PP-GF30
0,000 0,002 0,004 0,006 0,008 0,010 0,012 0,014 0,016
0
10
20
23 C
10 Hz
R = 0.1

[1]
0,000 0,002 0,004 0,006 0,008 0,010 0,012 0,014 0,016
0
10
20
30
40
23 C
10 Hz
R = 0.1

m
a
x
[
M
P
a
]

max
[1]
N [1] PP-SGF30 PP-LGF30
10
1
10
2
10
3
10
4
10
5
10
6
longitudinal
0,000 0,002 0,004 0,006 0,008 0,010 0,012 0,014 0,016
0
10
20
30
40
23 C
10 Hz
R = 0.1

m
a
x
[
M
P
a
]

max
[1]
N [1] PP-SGF30 PP-LGF30
10
1
10
2
10
3
10
4
10
5
10
6
longitudinal
0,000 0,002 0,004 0,006 0,008 0,010 0,012 0,014 0,016
0
10
20
30
40
0,000 0,002 0,004 0,006 0,008 0,010 0,012 0,014 0,016
0
10
20
30
40
23 C
10 Hz
R = 0.1

m
a
x
[
M
P
a
]

max
[1]
N [1] PP-SGF30 PP-LGF30
10
1
10
2
10
3
10
4
10
5
10
6
longitudinal
(Zahnt, 2003)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 16
0
100
200
300
400
500
600
-0,01 -0,0075 -0,005 -0,0025 0 0,0025 0,005 0,0075 0,01 0,0125

[
M
P
a
]
10
2
10
3
10
4
10
5
10
6
N [1] 23 C
10 Hz
R = 0,1 (tension)
R = 10 (comp.)
cyclic
damage
RTM
Laminates
500
600
N [1] 23 C
500
600
N [1] 23 C
500
600
N [1] 23 C
Stress/strain based approach
Isocyclic stress-strain diagram
www.kunststofftechnik.at 16 FACC Colloquium 2012, gPinter
-400
-300
-200
-100
-0,01 -0,0075 -0,005 -0,0025 0 0,0025 0,005 0,0075 0,01 0,0125



[ ]
-400
-300
-200
-100
0
100
200
300
400
500
-0,01 -0,0075 -0,005 -0,0025 0 0,0025 0,005 0,0075 0,01 0,0125

max
[ ]

m
a
x
[
M
P
a
]
10
2
10
3
10
4
10
5
10
6
N [1]
10 Hz
R = 0,1 (tension)
R = 10 (comp.)
cyclic
creep + damage
-400
-300
-200
-100
0
100
200
300
400
500
-0,01 -0,0075 -0,005 -0,0025 0 0,0025 0,005 0,0075 0,01 0,0125

max
[ ]

m
a
x
[
M
P
a
]
10
2
10
3
10
4
10
5
10
6
N [1]
10 Hz
R = 0,1 (tension)
R = 10 (comp.)
cyclic
creep + damage
-400
-300
-200
-100
0
100
200
300
400
500
-0,01 -0,0075 -0,005 -0,0025 0 0,0025 0,005 0,0075 0,01 0,0125

max
[ ]

m
a
x
[
M
P
a
]
10
2
10
3
10
4
10
5
10
6
N [1]
10 Hz
R = 0,1 (tension)
R = 10 (comp.)
cyclic
creep + damage
(Lintschinger, 2003)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 17
Stress/Strain Based Approach
Methodology
Concepts for the characterization of the fatigue
behavior of engineering plastics
Fracture Mechanics Approach
www.kunststofftechnik.at 17 FACC Colloquium 2012, gPinter
Stress/Strain Based Approach
Generation of S-N curves
Hysteresis measurements
Isocyclic stress-strain
diagrams
Fracture Mechanics Approach
Fatigue crack propagation
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 18
Fracture mechanics approach
Fatigue crack propagation
www.kunststofftechnik.at 18 FACC Colloquium 2012, gPinter
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 19
Fracture mechanics approach
Fatigue crack propagation
Fatigue delamination growth in polymer matrix composites
Effect of polymer matrix in UD-CF Laminates
10
-3
10
-2
CF-EP1
CF-EP1
CF-PEEK
CF-PEEK
CF-EP2

d
a
/
d
N
,

m
m
/
c
y
c
l
e
23 C
f=5 Hz
R=0,1
www.kunststofftechnik.at 19 FACC Colloquium 2012, gPinter
10
10
-6
10
-5
10
-4
1000
CF-EP2
CF-EP2

d
a
/
d
N
,

m
m
/
c
y
c
l
e
G
Imax,
J/m
2
100
(Stelzer, 2009)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 20
Fracture mechanics approach
Fatigue crack propagation
Fatigue delamination growth in polymer matrix composites
Effect of textile technology
10
-3
10
-2
10
-1
triaxial braid - Epoxy
45/0/-45
UD - Epoxy
5276
UD - PEEK

d
a
/
d
N
,

m
m
/
c
y
c
l
e
www.kunststofftechnik.at 20 FACC Colloquium 2012, gPinter
10
1
10
2
10
3
10
4
10
-8
10
-7
10
-6
10
-5
10
-4
23C
f=5Hz
R=0,1
UD - PEEK
PEEK


d
a
/
d
N
,

m
m
/
c
y
c
l
e
G
I,max
, J/m
2
(Stelzer, 2009)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 21
Scope and Content
Introduction:
Why is fatigue and fatigue damage tolerance
of importance?
Topics covered
g Approaches to fatigue of composites
www.kunststofftechnik.at 21 FACC Colloquium 2012, gPinter
Approaches to fatigue of composites
- stress/strain based
- fracture mechanics concepts
g Outlook:
Methodology and testing concept for fatigue life assessment
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 22
Damage modes during fatigue life
www.kunststofftechnik.at 22 FACC Colloquium 2012, gPinter
(Reifsnider, 1991)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 23
Stiffness reduction during fatigue life
Matrix
cracking
Long period of stiffness reduction caused by
additional matrix cracking in off-axis and on-axis
plies, crack coupling, internal delaminations
Delamination,
fibre fracture
www.kunststofftechnik.at 23 FACC Colloquium 2012, gPinter
Stages of stiffness reduction during fatigue life of a [0/90
2
]
s
graphite epoxy laminate (R=0.1)
(Reifsnider, 1991)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 24
Residual strength and stiffness during fatigue life
www.kunststofftechnik.at 24 FACC Colloquium 2012, gPinter
Schematic diagram of strength change during fatigue life of an unnotched laminate
(Reifsnider, 1991)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 25
Talreja (1987), Fatigue of Composite Materials
Chapter
Stiffness Based Fatigue Damage Characterisation of Fibrous Composites
2 approaches: Strength degradation and stiffness changes
Quote:
It is generally accepted now that the strength degradation does
not always reflect the fatigue damage
www.kunststofftechnik.at 25 FACC Colloquium 2012, gPinter
not always reflect the fatigue damage
Stiffness properties change continously with fatigue cycles and
could provide basis for nondestructive procedure for fatigue
damage characterization
A complete characterization of fatigue damage would require
measuring changes in all stiffness components relating to these
damage mechanics
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 26
1. Cyclic loading on-axis
2. Load axis with angle of
15 to longitudinal axis
3. Poissons ratio measured
with a vice
Talreja (1987) Stiffness Based Fatigue Damage Characterisation
of Fibrous Composites
Steel
Specimen
with Al-
tabs
Specimen
On-
axis
Off-
axis
www.kunststofftechnik.at 26 FACC Colloquium 2012, gPinter
E
11
, E
22
, G
12
,
12
,
21
for UD-ply
(Talreja, 1987)
Specimen
On-
axis
Off-
axis
(transverse isotropic)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 27
Leoben 2012: Extended test-set up for orthotropic materials
Steel
Specimen
with Al-
tabs
Specimen
On-
axis
Off-
axis
Off-
axis
Cycle dependent
determination of
stiffness components
with modern methods of
deformation analysis
(online optical)
www.kunststofftechnik.at 27 FACC Colloquium 2012, gPinter
E
11
, E
22
, E
33
G
12
, G
13
, G
23
,

12
,
13
,
23
(orthotropic)
Off-
axis
On-
axis
Off-
axis
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 28
Stiffness tensors
1. Correlation between
components of stiffness tensor
with failure mechanisms
2. Cycle-dependent stiffnesses
for law of elasticity (not
available up to now)
Strengths
Residual strengths
(single value)
Information about load
capacity of material
www.kunststofftechnik.at 28 FACC Colloquium 2012, gPinter
Complete material characterisation
3. Physically based stiffness
degradation model for
material/component simulation
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 29
Acknowledgements
Colleagues from the Leoben Composite Team
Markus Wolfahrt (PCCL)
Steffen Stelzer (WPK-MUL)
Julia Brunbauer (WPK-MUL)
Scientific Partners
Institute of Lightweight Design and Structural
Biomechanics, Technical University Vienna
www.kunststofftechnik.at 29 FACC Colloquium 2012, gPinter
Biomechanics, Technical University Vienna
Chair Carbon Composites, Technical University
Munich
Polymer Competence Center Leoben GmbH
Company Partners
FACC AG
Airbus Deutschland GmbH
Toho Tenax Europe GmbH
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 30
6 Chairs 6 Full Professors
From Molecules
over Processing Technology
to Polymer-based Materials
and Components and Products
Department Polymer Engineering and Science
Montanuniversitaet Leoben, A
www.kunststofftechnik.at 30 FACC Colloquium 2012, gPinter
and Components and Products
Polymer
Chemistry
Polymer
Processing
Materials Science
of Polymers
Designing of Plastics
& Composites
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 31
Polymer Competence Center Leoben, GmbH
founded in 2002
currently 85 employees
non-university research company
with two sites (Leoben und Graz)
scientific, pre-competitive and
LEOBEN
Graz
About us
www.kunststofftechnik.at 31 FACC Colloquium 2012, gPinter
scientific, pre-competitive and
applied research in polymer
engineering and science
project partner for the national and
international plastics industry
close cooperation with university
research and education (bachelor
and master theses, dissertations)
Headquarters of PCCL (Leoben, Austria)
28/06/2012
Kunststofftechnik an der Montanuniversitt Leoben 32
Polymer Center Leoben
Thank you
for
www.kunststofftechnik.at 32 FACC Colloquium 2012, gPinter
for
your attention