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COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Methodology for Characterization of Internal Structure of NCF Composite and Its Influence on
Mechanical Properties
Roberts Joffe and David MattssonDivision of Polymer EngineeringLuleå University of Technology
S-971 87, Luleå, Sweden
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Where is Luleå?
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
• Introduction
• Objectives
• Structure-properties relation
• Characterization of structure
CONTENTS
• Results
• Summary
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
INTRODUCTION: What is NCF?
Non-crimp fabrics - NCF
a
bVariable parameters:
a) Gauge stitching
b) Stitch length
c) Stitch pattern
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
INTRODUCTION: applications of NCF composites
NCF composites are used in large ship structures (72m long corvette Visby in SWEDEN)
Glass fiber (and lately also carbon fiber) NCF is used in wind generator blade and recreation boats
Lately there is interest from aircraft manufacturers to use NCF
However, due to complicated internal structure performance in connection with internal geometry must be studied
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
INTRODUCTION: NCF - multi-scale material
V fφ
NCF composite - inherently multi-scale material.
On the microscale each bundle with orientation φ is a UD composite with a certain fiber content ( ) and the homogenized bundle properties may be calculated using micromechanics expressions for long fiber composites.
On the mesoscale the bundle is considered as homogeneous transversely isotropic material surrounded by matrix and other bundles of the same or different orientation. A mesoscalecharacteristic of the composite is bundle content ( ) in the composite. V b
φ
The geometrical shape of bundles (cross-section and axial alignment) is complex and depends on bundle orientation in the blanket, surface compression during production, resin pockets etc. The described mesoscale configuration determines the NCF composite properties on macroscale and is typically used in simulations of macro behaviour.
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
INTRODUCTION: NCF - multi-scale material
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
OBJECTIVES
Main objective is to identify and characterize critical parameters of internal structure of NCF composites which are important for certain in-plane mechanical properties
This work is focused on structural parameters and, therefore, the role of fiber and matrix properties is not analyzed, although it is certainly of great importance.
The stitching effect on the material performance is not discussed
Quasi-isotropic [(45/0/-45/90)2, (90/45/0/-45)2] and cross-ply [0/90/0/90]S laminates are studied
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Structure-Properties Relation: stiffness
The stiffness of a multidirectional NCF composite is strongly dependent on the contribution of fibers.
The main parameter characterizing fiber contribution is the average fiber content of a certain orientation φ in the composite - V fa
φ
Detailed mesoscale description: volume content of bundles with a certain orientation –fiber volume fraction inside a bundle of each orientation –shape of the cross-section of bundles
V bφ
V fφ
However, it has been shown that the effect of mesoscale details on the NCF laminate stiffness may be neglected and a “smearing out“ routine leads to high accuracy of the determined stiffness matrix.
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Structure-Properties Relation: stiffness
Waviness of the bundles will have strong effect on the stiffness of the NCF composites, therefore such mesoscale parameters as wavelength and amplitudeof imperfection have to be characterized.
x
z
Gap Wavelength, λ
90° bundle width, w
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Structure-Properties Relation: damage, tensile loadingDamage in tensile loading can be analyzed as 2-step process: 1) intrabundle cracks in layers with off-axis orientation with
respect to the load; 2) failure of longitudinal bundles.
Intrabundle cracks: bundle cross-section (height to width ratio), the ratio of the bundle width and the matrix channel size, elastic modulus of the matrix and the longitudinal and transverse modulus of the bundle.
Failure of longitudinal bundles : out-of plane waviness
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Structure-Properties Relation: compressive failure
Two failure mechanisms are considered: 1) interbundle splitting; 2) kink-band formation in the longitudinal bundle.
Parameters affecting compressive failure:
fiber distribution in the composite
in-plane and out-of-plane waviness
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Property V fa
φ V b
φ V f
φ Shape of the cross-section
Waviness
Stiffness 5 1 1 1 5 Failure in tension 1 3 3 3 5 Failure in compression 2 3 3 1 5
Influence of mesostructural parameters on different mechanical properties of the NCF composite
Structure-Properties Relation: summary
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Classification of bundles by their shape
Characterization of structure: bundle shape
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Classification of “unusual” bundles
Characterization of structure: bundle shape
Shape of bundle is assumed to be “half-ellipse”
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Characterization of structure: volume fraction
A
AAAV l
rli
heik
ektottotb
∑+∑+∑==
φφφφφ v/v
Volume fraction of a bundle with 90º, ±45º or 0ºorientation in the composite
90450bbb
totb VVVV ++= ±The total volume fraction of
bundles in the composite
Ellipse Rectangle
We
He
Wr
Hr
The volume fraction of bundles is defined as the cross section area fraction of bundles in each layer
4
eee
WHA π=4
WHAhehe
heπ= rr
r WHA =
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Characterization of structure: volume fraction
Volume fraction of fibers in the bundle ( ) is obtained from image analysis as ratio between the area were measurements are performed and area occupied by fibers
φfV
The average volume fraction of fibers with the same orientation φ in the composite
φφφfbfa VVV =
90450fafafa
lamf VVVV ++= ±
The total average volume fraction of fibersin the composite, where
0faV 45±
faV 90faV, and are average volume
fractions of fibers (in the laminate) with corresponding orientations
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Characterization of structure: resin channels
LCH
Matrixarea
Bundle Bundle
Matrixarea
Bundle Bundle
Matrixarea
Bundle Bundle
Matrixarea
BundleBundle
LCH
Bundle
Bundle
Matrix area
1)
2)
3)
4)
5)
6)
Matrixarea
Bundle Bundle
channelsofNr
WWL
totbundle
tot
CH−
=
The average linear size of the resin channel between the bundles in a layer
Where is the total width of the bundles in the layer in the window of observation and is the total width of the window
totbundleW
totW
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Characterization of structure: waviness
x
z
Gap Wavelength, λ
90° bundle width, w
In ideal case waviness can be assumed of periodic nature and described by sinus function. In this case wavelength and amplitude are sufficient characteristics of the misalignment of the 0°-bundles. The amplitude of the wave in the 0°-bundles can be determined from the measured standard deviation with respect to the theoretical horizontal direction of the bundles (and it is called SDO).
However, If the waviness is not periodic, another parameter of imperfection should be used instead of wavelength and amplitude, for example, the maximum inclination angle.
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Characterization of structure: waviness
Quasi-isotropic laminate
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Stitches inducing small scale waviness.
Characterization of structure: waviness
Cross-ply laminate
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Size and shape of the bundles with indicated standard deviation for NCF quasi-isotropic composites produced with base configuration and high stitch tension fabrics.
a) Bundle width b) Bundle thickness
0
1
2
3
4
5
6
0° 90° ±45° 0° 90° ±45°
Base configuration High stitch tension
Bun
dle
wid
th (m
m)
Half ellipsEllipsRectangle
(a)
0,0
0,2
0,4
0,6
0,8
1,0
1,2
0° 90° ±45° 0° 90° ±45°
Base configuration High stitch tension
Bun
dle
thic
knes
s (m
m) Half ellips
EllipsRectangle
(b)
RESULTS: size and shape of bundles
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Size and shape of the bundles with indicated standard deviation for NCF quasi-isotropic composites produced with base configuration and high stitch tension fabrics.
c) Bundle area d) Frequency of particular bundle shape
0,00,20,40,60,81,01,21,41,6
0° 90° ±45° 0° 90° ±45°
Base configuration High stitch tension
Bun
dle
area
(mm
^2)
Half ellipsEllipsRectangle
(c)
0
20
40
60
80
100
0° 90° ±45° 0° 90° ±45°
Base configuration High stich tension
Bun
dle
shap
e (%
)
Half ellipseEllipsRectangle
(d)
RESULTS: size and shape of bundles
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
totbV
Volume fractions in quasi-isotropic composites produced with base configuration and high stitch tension; a) Volume fraction of bundles with certain orientation in the laminate, b) Volume fraction of fibers within the bundles with certain orientation.
(a) (b)
RESULTS: volume fraction
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
totbV
Volume fractions in quasi-isotropic composites produced with base configuration and high stitch tension; c) Average volume fraction of fiber in layers with a certain orientation, d) Total volume fraction of bundle and total average volume fraction of fibers in the composite .
totbV
lamfV
(c) (d)
RESULTS: volume fraction
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0° 90° ±45°
Dis
tanc
e be
twee
n bu
ndle
s (m
m)
Base configurationHigh stitch tension
Average distance between bundles (mm)
RESULTS: resin channels
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Result from the measurements of waviness in 0°-bundles. The normalization of the coordinates is performed with respect to the thickness and observation length of the composite; a) Cross-ply laminate with base configuration; b) Quasi-isotropic laminate with base configuration.
RESULTS: wavinessB-C [0, 90, 0, 90]s
0,0
0,2
0,4
0,6
0,8
1,0
0,0 0,2 0,4 0,6 0,8 1,0Normalized x-coordinate
Nor
mal
ized
z-c
oord
inat
e
Upper 0º-bundle
Second 0º-bundle
Third 0º-bundle
Lower 0º-bundle
(a)
B-C [ (45, 0, -45, 90)2, (90, 45, 0, -45)2 ]
0,0
0,2
0,4
0,6
0,8
1,0
0 0,2 0,4 0,6 0,8 1Normalized x-coordinate
Nor
mal
ized
z-c
oord
inat
e Upper 0º-bundle
Second 0º-bundle
Third 0º-bundle
Lower 0º-bundle
(b)
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Result from the measurements of waviness in 0°-bundles. The normalization of the coordinates is performed with respect to the thickness and observation length of the composite; c) Cross-ply laminate with high stitch tension; d) Quasi-isotropic laminate with high stitch tension.
RESULTS: wavinessH-S [0, 90, 0, 90]s
0,0
0,2
0,4
0,6
0,8
1,0
0,0 0,2 0,4 0,6 0,8 1,0Normalized x-coordinate
Nor
mal
ized
z-c
oord
inat
e
Upper 0º-bundle
Second 0º-bundle
Third 0º-bundle
Lower 0º-bundle
(c)
H-S [ (45, 0, -45, 90)2, (90, 45, 0, -45)2 ]
0,0
0,2
0,4
0,6
0,8
1,0
0 0,2 0,4 0,6 0,8 1Normalized x-coordinate
Nor
mal
ized
z-c
oord
inat
e Upper 0º-bundle
Second 0º-bundle
Third 0º-bundle
Lower 0º-bundle
(d)
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Cross-ply Laminate SDO (µm) Base configuration 27 High stitch tension 22
Quasi-isotropic Laminate Base configuration 71 High stitch tension 86
RESULTS: waviness
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
“Global wave”“Local wave”
RESULTS: wavinessIt can be seen that the waviness of the 0°-bundles is rather disordered, which complicates the definition of a characteristic wavelength.
It seems that waviness of bundles is on two scales: “global” wave with large wavelength and amplitude and “local” waviness (small wavelength and amplitude) most probably related to the mesoscale characteristic dimension which is superposed to the global wave and “hidden” in it.
However, “local” waviness is of such small amplitude that effect of it might be negligible. Unfortunately none of the waves (either local or global) has an obvious periodicity.
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
SUMMARY
• Mechanical performance of NCF composites in contrast to prepreg tape composite laminates is not uniquely determined by fiber volume fraction in layers and by volume fraction of layers of different orientation. In addition to above parameters the mesoscale internal structure is as important.
• The main mesoscale parameter is related to imperfect bundle out-of-plane orientation which affects the compressive strength, the longitudinal bundle breaks in tension and composite stiffness.
• The structural parameters characterizing composite layer in the cross-section transverse to the bundle axis are of major importance analyzing matrix dominated damage mechanisms like intrabundle cracks. Intrabundle cracks and the imperfect mesoscale bundle structure are responsible for the most of secondary damage mechanisms serving as initiators for more severe damage modes.
• Consistent methodology is suggested to determine the identified basic parameters governing performance of NCF composites by optical microscopy investigation.
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Acknowledgements
Authors would like to thank Mr Clement Touron for his help with the microscopy.
Part of this study has been carried out with financial support from the Commission of the EC granted to
the Project G4RD-CT-2001-00604 "FALCOM". The study does not necessarily reflect the views of the
European Commission.
COMPTEST2006, 10th-12th April, 2006Faculdade de Engenharia da Universidade do Porto
Thank you very much for your attention!
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