skip to main content
US FlagAn official website of the United States government
dot gov icon
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
https lock icon
Secure .gov websites use HTTPS
A lock ( lock ) or https:// means you've safely connected to the .gov website. Share sensitive information only on official, secure websites.


Title: Effect of nanoscale interface modification on residual stress evolution during composite processing
The interface characteristics of the matrix and fibers significantly influence the evolution of residual stress in composite materials. In this study, we provide a methodology for reducing the residual stress in laminated composites by modifying the thermomechanical properties at the fiber–matrix interface. A hydrothermal chemical growth method was used to grow Zinc Oxide nanowires on the carbon fibers. We then utilized a novel digital image correlation approach to evaluate strains and residual stresses, in situ, throughout the autoclave curing of composites. We find that interface modification results in the reduction of residual stress and an increase in laminate strength and stiffness. Upon growing ZnO NWs on the carbon fibers, the maximum in situ in-plane strain components were reduced by approximately 55% and 31%, respectively, while the corresponding maximum residual stresses were decreased by 50.8% and 49.33% for the cross-play laminate [0°/90°] layup in the x and y directions, respectively. For the [45°/-45°] angle ply layup in the x-direction, the strain was decreased by 27.3%, and the maximum residual stress was reduced by 41.5%, whereas in the y-direction, the strain was decreased by 166.3%, and the maximum residual stress was reduced by 17.8%. Furthermore, mechanical testing revealed that the tensile strength for the [45°/-45°] and [0°/90°] laminates increased by 130% and 20%, respectively, with the interface modification.  more » « less
Award ID(s):
2001038
PAR ID:
10426560
Author(s) / Creator(s):
; ; ;
Date Published:
Journal Name:
Journal of Composite Materials
ISSN:
0021-9983
Page Range / eLocation ID:
002199832311795
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. Residual stresses are detrimental to composite structures as they induce processing defects like debonding, delamination, and matrix cracking which significantly decrease their load-bearing capability. In this research, a new in-situ approach using digital image correlation is utilized to analyze the effect of the cure cycle modification on residual stress evolution during processing. It was found that the modified cure cycle comprising abrupt cooling after gelation reduces the residual stresses. Five different layup configurations are investigated to examine the effect of fiber direction. A maximum average residual stress reduction of 31.8% is observed for the balanced unsymmetric [30/-30/60/-60] laminate. The residual stress reduction results in an increase in failure strength between 4 and 12% in the different layups and can lead up to a 22% increase in first-ply failure strength. 
    more » « less
  2. null (Ed.)
    The effect of residual stress build-up on the transverse properties of thermoset composites is studied through direct and inverse process modeling approaches. Progressive damage analysis is implemented to characterize composite stiffness and strength of cured composites microstructures. A size effect study is proposed to define the appropriate dimensions of Representative Volume Elements (RVEs). A comparison between periodic (PBCs) and flat (FBCs) boundary conditions during curing is performed on converged RVEs to establish computationally efficient methodologies. Transverse properties are analyzed as a function of the fiber packing through the nearest fiber distance statistical descriptor. A reasonable mechanical equivalence is achieved for RVEs consisting of 40 fibers. It has been found that process-induced residual stresses and fiber packing significantly contribute to the scatter in composites transverse strength. Variation of ±5% in average strength and 18% in standard deviation are observed with respect to ideally cured RVEs that neglect residual stresses. It is established that process modeling is needed to optimize the residual stress state and improve composite performance. 
    more » « less
  3. 3D woven composites, in particular carbon/epoxy, are being increasingly adopted in aerospace, wind energy, transportation and other industries due to their high strength, lightweight, good dimensional stability and delamination resistance. They are often produced by resin transfer molding with epoxy cured at elevated temperature. This process can result in high level of residual stresses due to the mismatch in thermal expansion coefficients of carbon and epoxy. In this paper, a numerical modeling in combination with blind hole drilling experiments is utilized to determine processinginduced residual stresses in 3D woven composites using the example of orthogonal reinforcement. In particular, the individual contributions of residual stress in the weft and binder tows as well as resin-rich pockets to the entire residual stress distribution are evaluated. Our studies show that these contributions are determined by both arrangement and orientation of the tows. The developed numerical modeling tool can be used in the design of reinforcement architectures with reduced levels of residual stresses. 
    more » « less
  4. Chan, Edwin P. (Ed.)
    Stress concentrations in polymer matrix composites occur due to non-uniform loadings which develop near the interface between the matrix and reinforcement in a stressed composite. Methods to better understand the evolution of this stress concentration are required for the development of advanced composites. Mechanophores, which are stress responsive molecules, can be embedded into the polymer matrix and used to quantify the local stresses in a loaded composite. In this work, single particle model composites were fabricated by combining functionalized glass particles embedded into a silicone/mechanophore matrix. Confocal microscopy was then used to measure the mechanophore activationin situduring mechanical loading. The fluorescence intensity was correlated to maximum principal stress values obtained from a finite element analysis (FEA) model of the system utilizing an Ogden hyperelastic model to represent the elastomer. By calibrating stress to fluorescence intensity spatially, quantitative stress measurements can be obtained directly from fluorescent images. To validate this technique, calibrated stress values for a two-particle composite system were compared to a FEA model and good agreement was found. Further experiments were performed on silicone matrix composites containing short cylindrical particles oriented with their major axis parallel or perpendicular to the stretching direction. To demonstrate the versatility of the single particle intensity/stress calibration approach, maximum principal stress values were mapped on the fluorescence images of the cylindrical experiments. This technique has potential to quantify stress concentrations quickly and accurately in new composite designs without the use of FEA models or differential image correlation. 
    more » « less
  5. Uncontrolled curing-induced residual stress and strain are significant limitations to the efficient design of thermoset composites that compromise their structural durability and geometrical tolerance. Experimentally validated process modeling for the evaluation of processing parameter contributions to the residual stress build-up is crucial to identify residual stress mitigation strategies and enhance structural performance. This work presents an experimentally validated novel numerical approach based on higher-order finite elements for the process modeling of fiber-reinforced thermoset polymers across two composite characteristic length scales, the micro and macro-scale levels. The cure kinetics is described using an auto-catalytic phenomenological model. An instantaneous linear-elastic constitutive law, informed by time-dependent material characterization, is used to evaluate the stress state evolution as a function of the degree of cure and time. Micromechanical modeling is based on Representative Volume Elements (RVEs) that account for random fiber distribution verified against traditional 3D FE analysis. 0/90 laminate testing at the macroscale validates the proposed approach with an accuracy of 9%. 
    more » « less