Composites Testing:

Challenges & Solutions

JEC Europe - March 2015
Ian McEnteggart
 Challenges
• Testing Productivity given the large number of
test setups and standards
• Flexible testing equipment
• Easy change over
• Standard test methods
• Achieving and maintaining accurate Alignment
• Need for accurate alignment
• Nadcap alignment criteria
• Measuring Strain
• Standardized testing
• Non-uniform strain fields

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 Composites Require
Various Tests to Characterize
Tension: Fiber-dominant property. Dependant
on the tensile stiffness and strength of the fiber.

Compression: Matrix-dominant property.

Dependant on the stiffness and adhesion
qualities of the resin being able to maintain the
fibers as straight columns and not buckle.

Shear: Matrix-dominant property, transferring

stresses across the composite.

Flexure: Combination of above three: upper

=compression; lower = tension; middle = shear

Also a range of “structural tests” on coupons; e.g. open-hole tension &

compression, bearing load, compression after impact (CAI)
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 Challenge 1:
Managing a Wide Range of Test Types
and Standards
 Compression Testing Configurations

Unsupported Gauge Section

• Unsupported Gauge length (Short)
• ISO 14126
• ASTM D3410 (ITTRI)
• Celanese
• ASTM D6641 (CLC)
• AITM 1-0008 (Hydraulic Grips)
• Supported Gauge Length (Anti-Buckling)
• ISO 14126
Supported Gauge Section • Modified ASTM D695
5 • ASTM D6484
(Anti-Buckling)
 Flexible Modular System for Range of Tests
Over a Range of Temperatures
Alignment Load Cell with 1000:1 Precise
Fixture Range Grip
Alignment
Compression
to ASTM
D695, etc.
Temperature
Chamber

“Piggy back”
Compression CAI
Platens with
Spherical seats

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 Bluehill® 3 Composites Test Methods
• Range of Testing Modes
• Tension
• Compression
• Shear
• Flex
• Fracture toughness
• Special, e.g. bearing
• Range of Standards
• ASTM, ISO, EN, Pr-EN…
• AITM, BSS…..
• Methods include example data
and report
• Flexible software easy to
create new tests and/or modify
existing tests.

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Challenge 2:
Alignment
 What is Alignment?

9 IV
 Why is Alignment so Important for
Composites Testing?
Ductile Metal Test Fiber Composite Test
Piece Piece
• Misalignment • Misalignment
introduces uneven introduces uneven
stress distribution stress distribution
• Metal yields in high • Fibers in high-stress
stress region, but region fail
continue to carry load • Stress in remaining
• Stress redistributes fibers increases
reducing the effect of causing rapid failure
misalignment on test • Misalignment has a
results significant effect on
test results

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 Grip Design for Repeatable Alignment

• Moving body provides

repeatable jaw engagement
• Side-to-Side symmetrical
wedge “pocket” ensures
accurate alignment
• Front-Back symmetrical
body maintains accurate
alignment under load
• Specimen stops ensure
accurate specimen location
NOTE: Design principles apply to
both Manual and Hydraulic grips

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 Measuring Alignment - Typical Alignment
Specimens & Electronics

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 Alignment Fixtures
 Allow small adjustments of angularity and concentricity position to
optimize alignment between upper and lower grip on a testing
machine
 Fixtures designed to allow adjustment under load are much easier to
adjust as the effects of adjustments can be seen immediately

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 Compression Alignment
• Spherical Seated
• Hydraulic Wedge Grips
• Shear loading
• High lateral stiffness to
maintain alignment under
load
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Compression Platens
• Quick and easy mounting on to
fixed grips
• Center of rotation located in the
center of the platen surface
• Lockable
• Meet Nadcap compression
alignment requirements
 Nadcap - Tensile Alignment Requirements
• Alignment measured under load using strain gauged specimens* that are
representative of the specimens being tested
• For AC7101 (Metals)
• The alignment specimen shall produce ~1,000 µstrain at the lowest
yield strength of the weakest material being tested.
• The acceptable bending (PBS) is as follows:
• Static tests: 10%
• Cyclic tests: 5%
• For AC7122 (Composites)
• Typical alignment specimen designs are shown in the Nadcap
document.
• The acceptable bending (PBS) is as follows.
• Static tests: 8%
• Cyclic tests: 5%
• ASTM E1012 standard is cross-referenced by Nadcap and other
standards.
• Contains detailed procedures
• Latest version (E1012-12) includes classifications at 5%, 8% and 10% PBS.
*NOTE: Nadcap procedures for verifying alignment are more demanding than those
described in E1012 and they do not allow “alignment cell compensation”; this means that
very accurate alignment cells are needed to perform these verifications.

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 … Not Just about Alignment …
• Adherence to Nadcap procedures mean:
• Alignment in accordance with Nadcap
• Alignment specimens are representative of materials being tested
• Calibration frequency is adhered to and calibrated to ISO/ASTM
standards for load cells, extensometers, displacement,
crosshead/speed, etc….
• Preventive maintenance plan is followed
• Training is recorded … operators shall be trained to recognize
proper operation of equipment

• … Services provided by Instron

• Alignment, Gauged Alignment Cells, Calibration, PPM, Training,
Advice

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 Challenge 3:
Strain Measurement
 Strain Products for Composites Testing
Non-Contact Automatic

DIC Replay
SVE/AVE 2

Clip-On & Strain Gauges

Biaxial Clip-Ons
Static Clip-Ons

Strain Gauges AutoX750

Dynamic Clip-Ons

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 Clip-On Biaxial Extensometer
 Main applications in composites
testing
 Tensile (including Poisson's ratio)
 In Plane Shear (IPS)
 Key Features:
 Covers a wide range of test
standards
 Wide temperature range (-200 to
+200 °C /-328 to +392 °F)
 Single-handed attachment
 Versions with independent axial
output options (allows
simultaneous monitoring of total *PBS (Percentage Bending Strain)*
average strain and PBS*) ∈𝑓 −∈𝑏
𝑃𝐵𝑆 = × 100
 Compatible with all current
∈𝑓 +∈𝑏
Where ∈𝑓 and ∈𝑏 are the strains on
/existing Instron® Systems either side of the specimen

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 Biaxial Extensometer
• Averaging Axial
• Corrects for specimen bending
• Versions with independent axial
outputs allow for measurement
of average and PBS
(Percentage Bending Strain)*
∈𝑓 −∈𝑏
𝑃𝐵𝑆 = × 100
∈𝑓 +∈𝑏

Where ∈𝑓 and ∈𝑏 are the strains on

either side of the specimen.
• Versions with Transverse Strain
measurement allow for
determination of Poisson’s ratio
• 𝑃𝑜𝑖𝑠𝑠𝑜𝑛𝑠 𝑅𝑎𝑡𝑖𝑜 𝜈 = ∈𝑇 ∈𝐴
Where ∈𝐴 is the Axial strain and ∈ 𝑇 is
the Transverse strain

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 Automatic Extensometer

• Automatic contacting
extensometer
• 1 micron accuracy
• Capable of testing
multiple gauge lengths
• Suitable for tension
and compression
• Measures strain
through failure
• Automatically closes
on specimen to test

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 AutoX750 for Composites Testing
Tow – Tensile Laminate – Tensile Laminate Laminate
ASTM D4018 ASTM D3039 & Compression Flexure
ISO527-4/5 ASTM D695 ASTM D790/7264
EN2562/2746
ISO178/14125

• 1µm accuracy • 1µm accuracy. • 1 um accuracy • 1 um accuracy

• Low clamping • Robust - arms • Less expensive • Robust - arms
force does not can be left on than strain can be left on
damage until failure gauges until failure
specimen • Repeatable • Robust - arms • Easy to use
• Low drag force positioning and can be left on
minimizes attachment until failure
specimen ensures • Easy to use
bending consistent
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results
Advanced Video Extensometer 2
 Accurate and Consistent
• High-accuracy strain measurement
meets most composites standards
• The 1 micron accuracy allows
measuring modulus to ISO 527-4/5
• 490 Hz frame rate prevents missing
fast events such as break
• Patented LED lighting and fan
system prevents environmental
influences
• Doesn’t require operator to attach
extensometer, reducing operator
influence and increasing consistency
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 Versatile and Capable
• Can be used to measure both tensile and
compressive strain
• Can be used on chambers for cold and hot
tensile tests
• Can be used with any testing machine with a
+/- 10V input
• Can be used for full field strain
measurement using Digital Image
Correlation software

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 What is Digital Image Correlation?
An optical method to measure deformation on an object surface.

Images Displacement Strain

Analysis of image Use of cross correlation to Strain calculated

surface over time determine displacement from displacement

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 DIC Example 1 - Vee-Notch Shear
• Test to determine shear properties ASTM D5379
• Vee–notched specimen
• Approximately uniform shear stress distribution in notch ASTM D7078
• Traditional approach is to use strain gauges mounted at +/-
45º required to measure shear strain (see below)
• DIC allows determination of actual strain distribution and can
be used to validate measurements from gauges

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 DIC Example 2 – Open-Hole Tension

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 Why Instron® DIC?

Integrated camera and Only 1 PC

lighting unit sits on the
frame, out of the way of
testing area. Polarized
light is used so ambient
light doesn’t matter.

Integrated
and Users can focus
synchronous on analyzing
collection of and
all data from understanding
testing their results
machine, e.g. rather than
Force, and assembling test
camera. rigs.

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~Thank you for your attention~
Any Questions?